JP7433115B2 - Sandwich panel and its manufacturing method - Google Patents

Description

The present disclosure relates to sandwich panels and methods of manufacturing the same.

Sandwich panels used in aircraft, satellites, vehicles, etc. are required to be lightweight. However, in the case of a sandwich panel having an insert structure, it is necessary to use a filler in order to firmly fix the insert to the panel, resulting in an increase in weight. Various techniques have been proposed to solve this problem. For example, Patent Document 1 discloses a method of fixing an insert by rotating the insert and positioning a portion of the insert under the skin of a sandwich panel.

JP2017-62030A

In the technique disclosed in Patent Document 1, the insert is fixed to the sandwich panel by being rotated. For this reason, in the sandwich panel disclosed in Patent Document 1, when rotational stress acts on the insert, there is a risk that the insert will fall off from the sandwich panel, and the insert cannot be stably held.

The present disclosure has been made in view of the above problems, and aims to be lightweight and stably hold an insert.

To achieve the above object, the sandwich panel of the present disclosure includes an insert, a panel material, and a fixing member. The panel material has mounting holes. An insert is placed in the mounting hole. The fixing member is disposed between the panel material and the insert in the mounting hole. The fixing member is fixed to the panel material and the insert, and is made of a porous resin composition. The insert includes an extension portion extending in the depth direction of the mounting hole, a first flange formed at one end of the extension portion in the depth direction, and a first flange formed at the other end of the extension portion in the depth direction. It has a second flange and a claw portion extending from the end of the second flange in a direction perpendicular to the depth direction toward the first flange. The insert is a housing space surrounded by the extension part, the second flange, and the claw part, and constitutes a housing space in which the resin composition is stored.

According to the present disclosure, the insert is fixed to the panel material by the fixing member. Further, the fixing member is made of a porous resin composition. Therefore, it is lightweight and the insert can be held more stably.

A perspective view showing a sandwich panel according to Embodiment 1 A partial cross-sectional view of the sandwich panel cut along the IB-IB line shown in FIG. 1A. Top view showing the panel material shown in Figure 1B A partial cross-sectional view of the panel material cut along the line IIB-IIB shown in FIG. 2A Diagram showing the insert shown in Figure 1B Flow diagram showing a method for manufacturing a sandwich panel according to Embodiment 1 Flowchart of preparation process according to Embodiment 1 A diagram for explaining the method for manufacturing a sandwich panel according to Embodiment 1 A diagram for explaining the method for manufacturing a sandwich panel according to Embodiment 1 A diagram for explaining the method for manufacturing a sandwich panel according to Embodiment 1 A diagram showing another example of the method for manufacturing the sandwich panel according to Embodiment 1 A diagram showing a first modification of the sandwich panel according to Embodiment 1 A diagram showing a second modification of the sandwich panel according to Embodiment 1 A diagram showing a third modification of the sandwich panel according to Embodiment 1 A diagram showing a fourth modification of the sandwich panel according to Embodiment 1 Diagram for explaining the method for manufacturing a sandwich panel according to Embodiment 2 Diagram for explaining the method for manufacturing a sandwich panel according to Embodiment 2 Diagram for explaining the method for manufacturing a sandwich panel according to Embodiment 2 Diagram for explaining the method for manufacturing a sandwich panel according to Embodiment 2 Flowchart of preparation process according to Embodiment 3 Diagram for explaining the method for manufacturing a sandwich panel according to Embodiment 3 Diagram for explaining the method for manufacturing a sandwich panel according to Embodiment 3 Diagram for explaining the method for manufacturing a sandwich panel according to Embodiment 3 Diagram for explaining the method for manufacturing a sandwich panel according to Embodiment 3 A diagram showing a modification of the insert according to Embodiment 3 Flowchart of preparation process according to Embodiment 4 Diagram for explaining the method for manufacturing a sandwich panel according to Embodiment 4 Diagram for explaining the method for manufacturing a sandwich panel according to Embodiment 4 Diagram for explaining the method for manufacturing a sandwich panel according to Embodiment 4 Diagram for explaining the method for manufacturing a sandwich panel according to Embodiment 4

DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments of a sandwich panel and a method for manufacturing the same according to the present disclosure will be described with reference to the drawings.

[Embodiment 1]
A sandwich panel 100 according to Embodiment 1 and a method for manufacturing the same will be described with reference to FIGS. 1A to 6C. In the following description, the embodiment will be described with the thickness direction of the sandwich panel 100 as the Z-axis direction, and the directions parallel to the main surface of the sandwich panel 100 as the X-axis direction and the Y-axis direction, respectively. Further, although the embodiment will be described with the +Z side as the upper side and the opposite side as the lower side, the orientation of the sandwich panel 100 during use is not limited by these regulations.

(Configuration of sandwich panel 100)
The sandwich panel 100 is a sandwich panel having an insert structure, and as shown in FIG. 1A, the sandwich panel 100 includes a panel material 10, a plurality of inserts 20 attached to the panel material 10, and a fixing member that fixes the inserts 20 to the panel material 10. 30 (see FIG. 1B). A cross-sectional view taken along line IB-IB in FIG. 1A is shown in FIG. 1B. As shown in FIG. 1B, the insert 20 is placed in a mounting hole 10h formed in the panel material 10, and is fixed to the panel material 10 by a fixing member 30. The fixing member 30 is made of a porous resin composition 31 such as expanded plastic or synthetic resin foam. The resin composition 31 will be described later with reference to FIG. 4.

The configuration of each part will be described below with reference to FIGS. 2A to 3. FIG. 2A is a top view of the panel material 10 shown in FIG. 1B, with part of the skin 12A peeled off. FIG. 2B is a partial cross-sectional view taken along line IIB-IIB in FIG. 2A.

(Panel material 10)
As shown in FIGS. 2A and 2B, the panel material 10 includes a honeycomb core 11 having a honeycomb structure, and a skin 12A and a skin 12B that face each other with the honeycomb core 11 in between. Note that the direction in which the skin 12A and the skin 12B are lined up coincides with the thickness direction of the sandwich panel 100.

As shown in FIG. 2A, the honeycomb core 11 is a core material having honeycomb-shaped holes in plan view, and is made of a hard foam. In this embodiment, the honeycomb core 11 is an aluminum honeycomb containing aluminum or an aluminum alloy as a material. Note that the honeycomb core 11 is not limited to an aluminum honeycomb, and may be, for example, a paper honeycomb, a cloth-based honeycomb, a metal honeycomb containing a metal other than aluminum as a material, or the like. Examples of paper honeycombs include cellulose honeycombs containing cellulose paper and aramid honeycombs containing aromatic polyamide fiber paper.

The skin 12A and the skin 12B are made of fiber-reinforced plastic such as glass fiber-reinforced plastic and carbon fiber-reinforced plastic.

A mounting hole 10h is provided in the panel material 10 at the mounting position of the insert 20. The mounting hole 10h has a circular shape in plan view. As shown in FIG. 2B, the mounting hole 10h penetrates the skin 12A and is provided in the honeycomb core 11 in a concave shape. The mounting hole 10h has a shape and size that can accommodate the insert 20 to be mounted.

(insert 20)
As shown in FIG. 3, the insert 20 has a cylindrical web 21 extending in the Z-axis direction and two flanges 22 formed at both ends of the web 21 in the Z-axis direction. Each flange 22 has a circular shape in a plan view with radial directions in the X-axis direction and the Y-axis direction, and is provided concentrically with the web 21 . The insert 20 includes, for example, aluminum or an aluminum alloy as a material. A fastener T such as a screw, pin, bolt, or joint hook is formed or attached to the insert 20. The fasteners T are used for fixing the sandwich panel 100 to another structure, connecting a plurality of sandwich panels 100 to each other, attaching other objects to the sandwich panel 100, and the like. In addition, in the example shown in FIG. 3, the fastener T is a female thread.

(Fixing member 30)
The fixing member 30 shown in FIG. 1B is filled between the panel material 10 and the insert 20. Specifically, the fixing member 30 is filled between the panel material 10 and the two flanges 22 of the insert 20. Note that in this specification, filling is not limited to filling a space without any gaps. That is, in this specification, filling includes cases where the filling rate is greater than 0% and less than or equal to 100%.

The fixing member 30 is filled between the panel material 10 and the insert 20 and is fixed to the panel material 10 and the insert 20, thereby fixing the insert 20 to the panel material 10. The fixing member 30 is composed of a porous resin composition 31 containing a large amount of micro-sized air bubbles 301 therein.

(Method for manufacturing sandwich panel 100)
Next, a method for manufacturing the sandwich panel 100 having the above-described configuration will be described with reference to FIGS. 4 to 6C. In addition, in the following figures, the fastener T formed on the insert 20 is omitted.

As shown in FIG. 4, in the method for manufacturing the sandwich panel 100, first, the insert 20 and the resin composition 31 are placed in the mounting hole 10h, and a preparation step is performed in which the panel material 10 and the insert 20 are prepared for adhesion. (Step S1).

In the preparation process, as shown in FIGS. 5 and 6A, an additional process of applying and adding the resin composition 31 constituting the fixing member 30 to the area between the two flanges 22 of the insert 20, that is, the web 21. (Step S111 in FIG. 5). The fixing member 30 is formed by foaming and expanding an uncured resin composition 31 to be filled between the panel material 10 and the insert 20 in the mounting hole 10h, and the resin composition 31 is cured. .

The resin composition 31 includes a base resin and a foaming material that is foamed by energy such as heat and vibration. Note that the resin composition 31 may further contain a cell regulator, an anti-shrinkage agent, and the like.

Base resins include thermosetting resins, thermoplastic resins, and the like. When the base resin is composed of a thermosetting resin, the resin composition 31 is cured by being heated. When the base resin is composed of a thermoplastic resin, the resin composition 31 is heated and then cooled to harden. Examples of the base resin include acrylic resin, epoxy resin, silicone resin, urethane resin, polyimide resin, and polysiloxane resin. In the following, embodiments will be described assuming that the base resin is composed of a thermosetting resin.

The foam material includes a conventional blowing agent and a thermoplastic resin covering the blowing agent. In this embodiment, the foam material is a thermally expandable microcapsule. The average particle size of the thermally expandable microcapsules is, for example, 5 μm or more and 50 μm or less. The amount of the foamed material is, for example, 0.01 or more and 30 or less parts by weight based on 100 parts by weight of the base resin. The foaming ratio of the foam material is, for example, 1.1 times or more and 10 times or less, preferably 1.5 times or more and 5 times or less.

The resin composition 31 has fluidity and has a viscosity in a standard state of, for example, 0.01 Pa·s or more and 1000 Pa·s or less, preferably 10 Pa·s or more and 1000 Pa·s or less. The viscosity is measured with an E-type viscometer manufactured by BROOKFIELD. In addition, below, standard conditions shall be 25 degreeC and 1 atmosphere.

After the insert 20 is prepared in the mounting hole 10h, the resin composition 31 is heated to cause the foaming agent to foam and expand. The resin composition 31 is filled between the panel material 10 and the insert 20 by expanding. The expansion rate of the resin composition 31 varies depending on the weight ratio of the foam material and the expansion ratio of the foam material, and is, for example, 1.1 times or more and 10 times or less, preferably 1.5 times or more and 5 times or less. be. The coating amount of the resin composition 31 is calculated based on the volume of the space between the panel material 10 and the insert 20, the expansion coefficient, and the target value of the adhesion strength between the panel material 10 and the insert 20. That is, the amount of the resin composition 31 applied is set to such an amount that the expanded resin composition 31 fills the space and the adhesion strength between the panel material 10 and the insert 20 reaches a target value.

Next, as shown in FIGS. 5, 6A, and 6B, the insert 20 coated with the unfoamed and uncured resin composition 31 is inserted and placed in the mounting hole 10h. That is, a first arrangement step is performed in which the insert 20 and the unfoamed, uncured resin composition 31 are arranged together in the mounting hole 10h (step S113 in FIG. 5). Note that the first placement process is an example of a placement process.

Next, as shown in FIGS. 4, 6B, and 6C, a filling process is performed in which the resin composition 31 is expanded and the space between the panel material 10 and the insert 20 is filled with the resin composition 31 (see FIG. 4). Step S3). In the filling step, the resin composition 31 is heated to a first temperature to foam the foaming agent contained in the resin composition 31 and expand the resin composition 31. The first temperature is set to a temperature at which the foaming agent foams and the resin composition 31 expands. The first temperature can be controlled by selecting the type of blowing agent, and is, for example, 80°C or more and 200°C or less, preferably 100°C or more and 180°C or less, and more preferably 120°C or more and 150°C or less. be. Note that the time required for foaming and expansion is, for example, 2 seconds or more and 3 hours or less.

Next, when the foaming of the resin composition 31 is completed and the expansion stops, a curing step is performed to harden the resin composition 31 (step S5). In the curing step, the resin composition 31 is cured by raising the temperature to a second temperature. The second temperature is higher than or equal to the temperature at which the base resin is cured, and higher than or equal to the first temperature, for example, 85°C or higher and 350°C or lower. Note that the filling process (step S3) and the curing process (step S5) constitute a fixing process.

The expanded and hardened resin composition 31 adheres to the panel material 10 and the insert 20, thereby forming a fixing member 30 that fixes the panel material 10 and the insert 20 together. Specifically, the fixing member 30 is formed by foaming the foaming agent of the foaming material contained in the resin composition 31, expanding the resin composition 31, and curing the resin composition 31. That is, the fixing member 30 includes a foamed material. By configuring the fixing member 30, the sandwich panel 100 is completed as shown in FIG. 6C.

According to the sandwich panel 100 according to the present embodiment described above, the fixing member 30 is composed of the porous resin composition 31. This makes them lighter than sandwich panels that use non-foamed fillers. Furthermore, by adjusting the coating amount of the resin composition 31 constituting the fixing member 30, sufficient strength for fixing the insert 20 to the panel material 10 can be obtained. Therefore, the sandwich panel 100 is lightweight and can hold the insert 20 more stably.

Further, according to the manufacturing method of the present embodiment, the resin composition 31 expands when heated and is filled between the panel material 10 and the insert 20. Therefore, compared to a configuration in which a non-foaming filler is filled between the panel material 10 and the insert 20, the resin composition 31 used for manufacturing the sandwich panel 100 can be suppressed to a small amount, and the sandwich panel 100 can have higher strength. is obtained.

Furthermore, in the method of manufacturing the sandwich panel 100 by injecting the filler through a minute injection hole provided in the panel material 10, insert 20, etc., it is necessary to inject the filler through the minute injection hole; According to the method for manufacturing the sandwich panel 100 according to the present embodiment, the resin composition 31 is placed in the mounting hole 10h together with the insert 20. Therefore, the work of injecting the resin composition 31 into the mounting hole 10h through a minute injection hole can be omitted, and the work of preparing the resin composition 31 into the mounting hole 10h can be simplified.

Further, when the filler is injected into the mounting hole 10h through a minute injection hole, since the injection hole is minute, it takes a long time to inject the filler into the mounting hole 10h. However, according to the present embodiment, since the resin composition 31 can be placed in the mounting hole 10h together with the insert 20, the time for preparing the resin composition 31 in the mounting hole 10h can be shortened, and the productivity of the sandwich panel 100 can be improved. do.

(Modified example of manufacturing method of sandwich panel 100)
In addition, in the first embodiment, as a method for adding the resin composition 31 to the insert 20, a case where the resin composition 31 is applied to the insert 20 has been described. The method is not particularly limited as long as it can be arranged. For example, the resin composition 31 may be cut into a shape that is easy to attach to the insert 20, such as a rectangular shape, and the cut resin composition 31 may be wound around the web 21 of the insert 20. Note that the resin composition 31 may be wound around the web 21 in a layered manner, that is, in multiple layers, as long as the outer diameter when wound around the web 21 is equal to or less than the inside diameter of the mounting hole 10h.

Since the resin composition 31 is wound around the web 21, it is desirable that the resin composition 31 has adhesive strength while not having fluidity. When wrapping the resin composition 31 around the insert 20, the resin composition 31 includes an adhesive having adhesive strength and a foam material. The adhesive can be selected from, for example, an acrylic adhesive, a silicone adhesive, a urethane adhesive, a rubber adhesive, and the like. Since the resin composition 31 has adhesive strength, the work of winding the resin composition 31 around the insert 20 becomes easier, and the productivity of the sandwich panel 100 improves.

Note that in this embodiment, a case has been described in which the base resin is made of a thermosetting resin, but the base resin may be made of a thermoplastic resin. When the base resin is composed of a thermoplastic resin, in the curing step (step S5) described with reference to FIG. 4, the resin composition 31 is heated to a third temperature and then cooled to a fourth temperature. By doing so, the resin composition 31 is cured. The third temperature is equal to or higher than the temperature at which the resin composition 31 has fluidity, and the fourth temperature is equal to or lower than the temperature at which the resin composition 31 hardens. The third temperature can be controlled by selecting the type of resin, blowing agent, etc., and can be controlled, for example, from 80°C to 350°C, preferably from 150°C to 300°C, more preferably from 180°C to 230°C. below ℃. The fourth temperature may be below the glass transition point of the resin used.

Moreover, in order to suppress the positional shift of the insert 20 when the resin composition 31 is cured, it is desirable to fix the insert 20 with a pressing member F such as an adhesive tape, as shown in FIG. In FIG. 7, the holding member F is shown by cross hatching. After the resin composition 31 is cured, if there is a gap between the panel material 10 and the insert 20, the sandwich panel 100 may deteriorate. However, by fixing the insert 20 with the presser member F, the sandwich panel Positioning of the insert 20 to prevent deterioration of the sandwich panel 100 can be simplified, and productivity of the sandwich panel 100 can be improved.

(Modified example of configuration)
The sandwich panel 100 also includes, for example, an outflow suppressing member disposed between the panel material 10 and the insert 20, as shown in FIG. 8A, in order to suppress the resin composition 31 from flowing out below the insert 20. 40 may further be provided. In addition, in FIG. 8A, the outflow suppressing member 40 is shown by dotted hatching. The outflow suppressing member 40 can be selected from elastic resins such as silicone resin, epoxy glass resin, fiber-reinforced plastic, and epoxy resin. The outflow suppressing member 40 preferably has elasticity in order to suppress the outflow of the resin composition 31 and the generation of a gap between the panel material 10 and the insert 20, and its elastic modulus is, for example, 10^2 Pa. It is desirable that the pressure is above 10^8 Pa or less. Note that the caret symbol "^" is an operator representing a power; for example, "10^2" means 10 squared. Elastic modulus is a value measured by a rheometer. The shape of the outflow suppressing member 40 may be, for example, a flat surface, an uneven shape, or the like.

Further, in the present embodiment, the upper surfaces of the panel material 10 and the insert 20 are flush with each other, that is, the same plane, but the positional relationship between the upper surface of the panel material 10 and the upper surface of the insert 20 is It can be arbitrarily changed depending on the shape of the panel 100, the shape of the fastener T, etc. For example, as shown in FIG. 8B, the top surface of the insert 20 may not be flush with the top surface of the panel material 10, and the insert 20 may protrude beyond the panel material 10.

Further, in the present embodiment, the mounting hole 10h of the panel material 10 is open on the upper side, but the mounting hole 10h may be opened on both the upper side and the lower side, as shown in FIG. 8C. That is, the mounting hole 10h may penetrate through the panel material 10. Alternatively, as shown in FIG. 8D, only the lower side of the mounting hole 10h may be open. Note that the insert 20 may be changed as appropriate depending on the shape of the mounting hole 10h, the shape of the sandwich panel 100, and the like.

Furthermore, during the manufacturing process, the sandwich panel 100 is often manufactured on a pedestal B, as shown in FIG. 8D. When the mounting hole 10h opens downward, the pedestal B can also serve as the holding member F. This reduces the number of parts required to manufacture the sandwich panel 100.

[Embodiment 2]
Next, the sandwich panel 100 according to the second embodiment will be described with reference to FIGS. 9A to 9C. Embodiment 2 differs from Embodiment 1 in the shape of insert 20 and in that insert 20 has accommodation space 23 in which resin composition 31 is accommodated. In the second embodiment, a configuration in which the lower side of the mounting hole 10h is open will be described as an example.

(Configuration of insert 20)
As shown in FIG. 9A, the flange 22 of the insert 20 according to the second embodiment includes a base portion 221 extending in the X-axis direction and the Y-axis direction, and a claw portion 222 extending upward from the tip of the base portion 221. have The accommodation space 23 is a space surrounded by the web 21, the base portion 221, and the claw portion 222.

The length of the claw portion 222 in the Z-axis direction is determined based on the amount of resin composition 31 accommodated in the accommodation space 23 . Note that the amount of resin composition 31 accommodated is determined in the same manner as the amount of application described in Embodiment 1. The claw portion 222 is made of the same material as the base portion 221, and in this embodiment, is made of a material containing aluminum, aluminum alloy, or the like. Note that in this embodiment, the thickness of the claw portion 222, that is, the length in the X-axis direction and the Y-axis direction, is constant.

(Method for manufacturing sandwich panel 100)
Next, a method for manufacturing the sandwich panel 100 according to the second embodiment will be described. In the second embodiment, in the additional step (step S111 in FIG. 5) of the method for manufacturing the sandwich panel 100, the resin composition 31 is accommodated in the accommodation space 23, as shown in FIGS. 9A and 9B. Specifically, the resin composition 31 is injected into the housing space 23 from above the housing space 23 . Therefore, the resin composition 31 desirably has fluidity before curing, and the viscosity of the resin composition 31 in a standard state is, for example, 0.01 Pa·s or more and 1000 Pa·s or less, preferably 10 Pa·s. It is above 1000 Pa·s. The method for measuring the viscosity of resin composition 31 is the same as in the first embodiment.

Next, as shown in FIGS. 9B and 9C, an arrangement step is performed in which the resin composition 31 and the insert 20 are inserted into the mounting hole 10h and arranged (step S113 in FIG. 5). That is, the insert 20 and the resin composition 31 are placed in the mounting hole 10h at the same time.

Next, in the same manner as in the manufacturing method described in Embodiment 1, a fixing step is performed in which the resin composition 31 is expanded and cured to fix the panel material 10 and the insert 20 (step S3 in FIG. 4). S5), as shown in FIG. 9D, the sandwich panel 100 is completed.

The second embodiment has been described above. According to this embodiment, since the insert 20 and the resin composition 31 can be placed in the mounting hole 10h at the same time, the work of preparing the resin composition 31 in the mounting hole 10h can be simplified. Moreover, the time required to prepare the resin composition 31 in the mounting hole 10h can be shortened. As a result, the productivity of the sandwich panel 100 is improved.

Furthermore, according to the present embodiment, the accommodation space 23 can be made smaller than when a non-foaming filler is used. That is, the length of the claw portion 222 in the Z-axis direction can be reduced. Therefore, the insert 20 can be made more compact than when a non-foaming filler is used.

Further, in the present embodiment, the claw portion 222 is made of the same material as the base portion 221, but the claw portion 222 may be made of a different material than the base portion 221, and the claw portion 222 may be made of, for example, It may also be an adhesive tape. Alternatively, the claw portion 222 may be made of resin such as epoxy resin, silicone resin, or urethane resin.

(Modified example of configuration of Embodiment 2)
In addition, although the thickness of the claw part 222 is constant in this embodiment, the thickness of the claw part 222 does not have to be constant. For example, the tip portion of the claw portion 222 may be made thin in order to function as a springback. Thereby, it is possible to more effectively prevent the insert 20 from falling off from the sandwich panel 100.

[Embodiment 3]
Next, a sandwich panel 100 according to a third embodiment will be described with reference to FIGS. 10 and 11A to 11C. Embodiment 3 differs from Embodiments 1 and 2 in the preparation step in the method for manufacturing sandwich panel 100, and differs from Embodiments 1 and 2 in the configuration of insert 20. In the third embodiment, a configuration in which the upper side of the mounting hole 10h is open will be described as an example.

(Method for manufacturing sandwich panel 100)
In the preparation step (step S1 in FIG. 4) according to the third embodiment, a first injection step is performed in which the resin composition 31 is injected into the mounting hole 10h, as shown in FIGS. 10, 11A, and 11B. (Step S121 in FIG. 10). Note that the first injection process is an example of an injection process. In this embodiment, the resin composition 31 is injected into the mounting hole 10h from above the panel material 10. That is, it is injected into the mounting hole 10h through the opening of the mounting hole 10h. Note that the resin composition 31 in this embodiment has fluidity before being cured. The viscosity of the resin composition 31 in a standard state is, for example, 0.01 Pa·s or more and 1000 Pa·s or less. The method for measuring the viscosity of resin composition 31 is the same as in the first embodiment.

Next, as shown in FIGS. 11B and 11C, a second placement step of placing the insert 20 in the mounting hole 10h is performed (step S123 in FIG. 10). In this embodiment, the insert 20 has a shape that allows the resin composition 31 to be easily dispersed uniformly around the insert 20 . Specifically, the insert 20 has only an upper flange 22, and the lower end of the insert 20 has a smaller diameter than the upper end. Note that the second placement process is an example of a placement process.

Next, in the same way as in the manufacturing method described in Embodiment 1, a fixing step is performed in which the resin composition 31 is expanded and cured to fix the panel material 10 and the insert 20 (Steps S3 and S5 in FIG. 4). ), the sandwich panel 100 is completed as shown in FIG. 11D.

The third embodiment has been described above. According to this embodiment, since the resin composition 31 is injected into the mounting hole 10h through the opening of the mounting hole 10h, the work of preparing the resin composition 31 in the mounting hole 10h can be simplified. Moreover, the time required to prepare the resin composition 31 in the mounting hole 10h can be shortened. As a result, the productivity of the sandwich panel 100 is improved.

(Modified example of configuration of Embodiment 3)
In this embodiment, the lower end of the insert 20 has a smaller diameter than the upper end, but the shape of the insert 20 is such that the resin composition 31 injected in advance into the mounting hole 10h is uniformly distributed around the insert 20. Any shape is sufficient as long as it can be easily dispersed, and the lower end and the upper end may have the same radius. Alternatively, as shown in FIG. 12, a notch may be formed at the lower end. Note that the lower end is the end that contacts the resin composition 31, and the upper end is the end that is opposite to the end that contacts the resin composition 31.

[Embodiment 4]
Next, a sandwich panel 100 according to a fourth embodiment will be described with reference to FIGS. 13 to 14B. Embodiment 4 differs from Embodiments 1 to 3 in the preparation process of the method for manufacturing sandwich panel 100. In the fourth embodiment, a configuration in which the lower side of the mounting hole 10h is open will be described as an example.

(Method for manufacturing sandwich panel 100)
In the preparation step (step S1 in FIG. 4) according to the fourth embodiment, a third placement step is performed in which the insert 20 is placed in the mounting hole 10h, as shown in FIGS. 13, 14A, and 14B. 13 step S131). Next, as shown in FIGS. 14B and 14C, a second injection step is performed in which the resin composition 31 is injected into the space SP between the panel material 10 and the insert 20 (step S133 in FIG. 13). In this embodiment, the resin composition 31 is injected by an injector C through an injection hole 20h provided at the bottom of the insert 20. Note that the second injection process is an example of an injection process, and the third placement process is an example of a placement process.

When the injection hole 20h is provided at the bottom of the insert 20, in order to prevent the resin composition 31 from flowing out from the injection hole 20h, the viscosity of the resin composition 31 in a standard state is, for example, 0.01 Pa·s or more and 1000 Pa. -s or less, preferably 0.1 Pa.s or more and 100 Pa.s or less, more preferably 1 Pa.s or more and 100 Pa.s or less. The method for measuring the viscosity of resin composition 31 is the same as in the first embodiment.

Further, the injection hole 20h may be closed using putty material, adhesive tape, etc. after the resin composition 31 is injected. The viscosity of the putty material is preferably, for example, 10^4 or more and 10^7 mPa·s or less in a standard state. The method for measuring the viscosity of the putty material is the same as the method for measuring the viscosity of the resin composition 31.

Next, in the same way as in the manufacturing method described in Embodiment 1, a fixing step is performed in which the resin composition 31 is expanded and cured to fix the panel material 10 and the insert 20 (Steps S3 and S5 in FIG. 4). ), the sandwich panel 100 is completed as shown in FIG. 14D.

The fourth embodiment has been described above. According to this embodiment, since the resin composition 31 foams and expands, the mounting hole of the resin composition 31 is smaller than the structure in which a non-foaming filler is filled between the panel material 10 and the insert 20. The amount of injection per 10 hours can be kept to a small amount. Therefore, even when the resin composition 31 is injected through the minute injection hole 20h, the time required to prepare the resin composition 31 in the mounting hole 10h can be shortened. As a result, the productivity of the sandwich panel 100 is improved.

Note that in the fourth embodiment, the injection hole 20h was provided at the bottom of the insert 20, but the injection hole 20h may be provided in the panel material 10.

Further, the injection hole 20h may be provided in the upper part of the insert 20 in order to cause the resin composition 31 to flow downward.

Note that the present disclosure is not limited to the examples of the embodiments described above, and can be implemented in other embodiments by adding appropriate changes.

For example, in the present embodiment, the resin composition 31 is foamed at a first temperature and cured at a second temperature, that is, the resin composition 31 is foamed and cured in stages. However, the resin composition 31 may be foamed and cured at the same temperature. That is, the resin composition 31 may be cured while being foamed.

Furthermore, the items described in Embodiments 1 to 4 can be combined as appropriate. Specifically, when injecting the resin composition 31 into the accommodation space 23 described in the second embodiment, the resin composition 31 is injected into the accommodation space 23 through the injection hole 20h described in the fourth embodiment. You can. Furthermore, in the method for manufacturing the sandwich panel 100 described in the second embodiment, the resin composition 31 may be injected into the accommodation space 23 through the injection hole 20h after the insert 20 is placed in the mounting hole 10h.

DESCRIPTION OF SYMBOLS 10... Panel material, 10h... Mounting hole, 20... Insert, 21... Web, 22... Flange, 23... Accommodation space, 30... Adhering member, 31... Resin composition, 100... Sandwich panel, 221... Base part, 222... Claw portion, 301... Air bubble, S1... Preparation process, S3... Filling process (fixing process), S5... Curing process (fixing process), S111... Addition process, S113... First placement process (placement process), S121... First Injection process (injection process), S123...second placement process (placement process), S131...third placement process (placement process), S133...second injection process (injection process).

Claims (4)

insert and
a panel material having a mounting hole, the insert being disposed in the mounting hole;
a fixing member disposed between the panel material and the insert in the mounting hole, fixed to the panel material and the insert, and made of a porous resin composition;
A sandwich panel comprising:
The insert is
an extending portion extending in the depth direction of the mounting hole;
a first flange formed at one end of the extending portion in the depth direction;
a second flange formed at the other end of the extending portion in the depth direction;
a claw portion extending from an end of the second flange in a direction perpendicular to the depth direction toward the first flange;
has
A housing space surrounded by the extension part, the second flange, and the claw part, and forming the housing space in which the resin composition is stored.
sandwich panel . The sandwich panel according to claim 1 , wherein the resin composition contains a foaming agent. The sandwich panel according to claim 1 or 2 , wherein the fixing member includes a foamed foam material. a preparation step of preparing an insert and a resin composition containing a foaming agent into a mounting hole provided in the panel material;
a fixing step of foaming the foaming agent to make the resin composition porous and expanding it, and curing the panel material and the insert;
A method for manufacturing a sandwich panel comprising:
The insert is
an extension portion extending in the Z-axis direction;
a first flange formed at one end of the extending portion in the Z-axis direction;
a second flange formed at the other end of the extending portion in the Z-axis direction;
a claw portion extending from an end of the second flange in a direction perpendicular to the Z-axis direction toward the first flange;
has
The preparation step includes:
an additional step of adding the resin composition to the insert by accommodating the resin composition in a housing space surrounded by the extension part, the second flange, and the claw part;
an arrangement step of inserting the insert to which the resin composition has been added into the mounting hole in the Z-axis direction;
A method of manufacturing a sandwich panel, including:

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