JP7498317B2 - Manufacturing method of honeycomb laminate, honeycomb laminate, laminate - Google Patents
Manufacturing method of honeycomb laminate, honeycomb laminate, laminate Download PDFInfo
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- JP7498317B2 JP7498317B2 JP2023002660A JP2023002660A JP7498317B2 JP 7498317 B2 JP7498317 B2 JP 7498317B2 JP 2023002660 A JP2023002660 A JP 2023002660A JP 2023002660 A JP2023002660 A JP 2023002660A JP 7498317 B2 JP7498317 B2 JP 7498317B2
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- porous sheet
- thermosetting resin
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- 238000004519 manufacturing process Methods 0.000 title claims description 18
- 239000000463 material Substances 0.000 claims description 97
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 72
- 239000004917 carbon fiber Substances 0.000 claims description 72
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 72
- 229920005989 resin Polymers 0.000 claims description 65
- 239000011347 resin Substances 0.000 claims description 65
- 229920001187 thermosetting polymer Polymers 0.000 claims description 64
- 239000004744 fabric Substances 0.000 claims description 40
- 239000002131 composite material Substances 0.000 claims description 31
- 238000010438 heat treatment Methods 0.000 claims description 26
- 238000007906 compression Methods 0.000 claims description 24
- 230000006835 compression Effects 0.000 claims description 24
- 238000005470 impregnation Methods 0.000 claims description 18
- 238000000034 method Methods 0.000 claims description 14
- 238000010030 laminating Methods 0.000 claims description 6
- 238000003475 lamination Methods 0.000 claims description 6
- 238000002360 preparation method Methods 0.000 claims 1
- 238000000465 moulding Methods 0.000 description 21
- 239000000853 adhesive Substances 0.000 description 14
- 230000001070 adhesive effect Effects 0.000 description 14
- 239000006260 foam Substances 0.000 description 13
- 239000004745 nonwoven fabric Substances 0.000 description 12
- 229910052782 aluminium Inorganic materials 0.000 description 11
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 11
- 230000000052 comparative effect Effects 0.000 description 11
- 239000005011 phenolic resin Substances 0.000 description 5
- 239000003822 epoxy resin Substances 0.000 description 4
- 238000011156 evaluation Methods 0.000 description 4
- 229920000647 polyepoxide Polymers 0.000 description 4
- 238000005452 bending Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- 239000004640 Melamine resin Substances 0.000 description 2
- 229920000877 Melamine resin Polymers 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 230000014759 maintenance of location Effects 0.000 description 2
- 229920001568 phenolic resin Polymers 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 125000006850 spacer group Chemical group 0.000 description 2
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 2
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- 229920001342 Bakelite® Polymers 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000004918 carbon fiber reinforced polymer Substances 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
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- Laminated Bodies (AREA)
Description
本発明は、ハニカムコアの両面に、熱硬化性樹脂が含浸硬化した表面材が積層されたハニカム積層体とその製造方法に関する。 The present invention relates to a honeycomb laminate in which a surface material impregnated with a thermosetting resin and cured is laminated on both sides of a honeycomb core, and to a method for manufacturing the same.
ハニカムコアの両面に、熱硬化性樹脂が含浸硬化した表面材が積層されたハニカム積層体は、軽量で高剛性のため、航空機、自動車、建築等の分野で用いられている。 Honeycomb laminates, which have a surface material impregnated with thermosetting resin and laminated on both sides of a honeycomb core, are lightweight and highly rigid, and are used in fields such as aircraft, automobiles, and construction.
ハニカム積層体の製造には、熱硬化性樹脂が含浸したプリプレグをハニカムコアの両面に配置し、プリプレグの熱硬化性樹脂を硬化させることにより、表面材の形成と、表面材（プリプレグ）とハニカムコアの接着とを同時に行うコキュア成形がある。 Honeycomb laminates are manufactured using a method called co-cure molding, in which prepregs impregnated with thermosetting resin are placed on both sides of a honeycomb core and the thermosetting resin in the prepregs is cured, simultaneously forming the surface material and bonding the surface material (prepregs) to the honeycomb core.
また、ハニカム積層体は、プリプレグの熱硬化性樹脂によってハニカムコアの壁の端部で表面材（プリプレグ）と接着し、ハニカムコアの壁で包囲されるセル内の部分（中空部分）では表面材と接着していないため、ハニカムコアと表面材との接着強度を高めるには、ハニカムコアの壁と表面材との間に形成されるフィレットを良好に形成することが重要である。フィレットは、表面材（プリプレグ）からハニカムコアの壁の端部を挟むように熱硬化性樹脂が盛り上がって形成されたものである。 In addition, the honeycomb laminate is bonded to the surface material (prepreg) at the ends of the honeycomb core walls by the thermosetting resin of the prepreg, but is not bonded to the surface material in the parts inside the cells (hollow parts) surrounded by the honeycomb core walls. Therefore, in order to increase the adhesive strength between the honeycomb core and the surface material, it is important to form a good fillet between the honeycomb core wall and the surface material. The fillet is formed by the thermosetting resin rising from the surface material (prepreg) to sandwich the end of the honeycomb core wall.
フィレットを良好に形成する方法として、プリプレグの熱硬化性樹脂に、粘度調整したエポキシ樹脂組成物を用いることが提案されている（特許文献１）。 As a method for forming good fillets, it has been proposed to use a viscosity-adjusted epoxy resin composition as the thermosetting resin for the prepreg (Patent Document 1).
しかし、粘度調整したエポキシ樹脂組成物をプリプレグの熱硬化性樹脂に用いてフィレットを形成する方法では、表面材から盛り上がったフィレットで、ハニカムコアの壁の端部を挟むだけであるため、表面材とハニカムコアとの接着強度が高いものではなかった。 However, in the method of forming fillets using a viscosity-adjusted epoxy resin composition as the thermosetting resin of the prepreg, the fillet that protrudes from the surface material simply sandwiches the end of the honeycomb core wall, and the adhesive strength between the surface material and the honeycomb core is not high.
本発明は前記の点に鑑みなされたものであって、表面材とハニカムコアとの接着強度が高く、表面材がハニカムコアから剥がれ難いハニカム積層体とその製造方法の提供を目的とする。 The present invention has been made in consideration of the above points, and aims to provide a honeycomb laminate in which the adhesive strength between the surface material and the honeycomb core is high and the surface material is not easily peeled off from the honeycomb core, and a method for manufacturing the same.
第１の発明の態様は、ハニカムコアの両面に表面材が積層されたハニカム積層体において、前記表面材は、炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたものに多孔質シートが積層された表面材用部材に熱硬化性樹脂が含浸硬化したものからなり、前記表面材と前記ハニカムコアは、前記多孔質シートと前記ハニカムコアが当接し、前記多孔質シートと前記ハニカムコアとの当接位置では、前記多孔質シート内に前記ハニカムコアが食い込んで前記多孔質シートから滲出した熱硬化性樹脂が硬化していることを特徴とする。
A first aspect of the invention is a honeycomb laminate in which surface materials are laminated on both sides of a honeycomb core, the surface materials being made of a surface material component in which a porous sheet is laminated onto a carbon fiber fabric, a unidirectional carbon fiber sheet, or a composite of these laminated together, and which is impregnated with and hardened by a thermosetting resin, and the surface material and the honeycomb core are in contact with each other, and at the position of contact between the porous sheet and the honeycomb core, the honeycomb core is embedded in the porous sheet and the thermosetting resin that has seeped out from the porous sheet is hardened.
第２の発明の態様は、第１の発明の態様において、前記多孔質シートの厚みが０．５～２ｍｍであることを特徴とする。
A second aspect of the present invention is the first aspect of the present invention , characterized in that the porous sheet has a thickness of 0.5 to 2 mm.
第３の発明の態様は、第１または第２の発明の態様において、前記多孔質シートは発泡体または不織布からなることを特徴とする。
A third aspect of the present invention is the first or second aspect of the present invention , characterized in that the porous sheet is made of a foam or a nonwoven fabric.
第４の発明の態様は、第３の発明の態様において、前記発泡体の密度が５～１００ｋｇ／ｍ３であり、前記不織布の目付が２～２００ｇ／ｍ２であることを特徴とする。
A fourth aspect of the invention is the third aspect of the invention , characterized in that the density of the foam is 5 to 100 kg/ m3 and the basis weight of the nonwoven fabric is 2 to 200 g/ m2 .
第５の発明の態様は、第１から第４の発明の態様の何れか一において、前記ハニカムコアのセルサイズが１／３２～１／１インチであることを特徴とする。 A fifth aspect of the present invention is characterized in that in any one of the first to fourth aspects of the present invention , the cell size of the honeycomb core is 1/32 to 1/1 inch.
第６の発明の態様は、ハニカムコアの両面に表面材が積層されたハニカム積層体の製造方法において、前記表面材は、炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたものに多孔質シートが積層された表面材用部材に熱硬化性樹脂が含浸硬化したものからなり、前記表面材用部材に熱硬化性樹脂を含浸させる含浸工程と、前記ハニカムコアの両面に、前記熱硬化性樹脂が含浸した表面材用部材を、前記多孔質シートが前記ハニカムコアと当接するように配置して圧縮加熱用積層体を得る積層工程と、前記圧縮加熱用積層体を圧縮及び加熱することにより、前記多孔質シートに前記ハニカムコアを食い込ませ、該食い込んだ部分で前記多孔質シートから前記熱硬化性樹脂を滲出させ、該滲出した前記熱硬化性樹脂及び前記表面材用部材内の前記熱硬化性樹脂を硬化させて、前記表面材と前記ハニカムコアを一体化する圧縮加熱工程と、を有することを特徴とする。
A sixth aspect of the invention is a manufacturing method for a honeycomb laminate in which a surface material is laminated on both sides of a honeycomb core, the surface material being made of a carbon fiber fabric, a unidirectional carbon fiber sheet, or a composite laminate of these laminated and a porous sheet laminated thereon, impregnated and cured with a thermosetting resin, the method comprising: an impregnation step for impregnating the surface material member with a thermosetting resin; a lamination step for arranging the surface material members impregnated with the thermosetting resin on both sides of the honeycomb core so that the porous sheet abuts against the honeycomb core to obtain a compression heating laminate; and a compression heating step for compressing and heating the compression heating laminate to cause the honeycomb core to bite into the porous sheet, causing the thermosetting resin to exude from the porous sheet at the bitten portion, and curing the exuded thermosetting resin and the thermosetting resin in the surface material member, thereby integrating the surface material and the honeycomb core.
第７の発明の態様は、第６の発明の態様において、前記多孔質シートの厚みが０．５～２ｍｍであることを特徴とする。
A seventh aspect of the present invention is the sixth aspect of the present invention , characterized in that the porous sheet has a thickness of 0.5 to 2 mm.
第８の発明の態様は、第６または第７の発明の態様において、前記多孔質シートは発泡体または不織布からなることを特徴とする。
An eighth aspect of the present invention is the sixth or seventh aspect of the present invention , characterized in that the porous sheet is made of a foam or a nonwoven fabric.
第９の発明の態様は、第８の発明の態様において、前記発泡体の密度が５～１００ｋｇ／ｍ３であり、前記不織布の目付が２～２００ｇ／ｍ２であることを特徴とする。
A ninth aspect of the invention is the eighth aspect of the invention , characterized in that the density of the foam is 5 to 100 kg/ m3 , and the basis weight of the nonwoven fabric is 2 to 200 g/m2.
第１０の発明の態様は、第６から第９の発明の態様の何れか一において、前記ハニカムコアのセルサイズが１／３２～１／１インチであることを特徴とする。
A tenth aspect of the present invention is characterized in that in any one of the sixth to ninth aspects of the present invention , the cell size of the honeycomb core is 1/32 to 1/1 inch.
本発明によれば、ハニカムコアの両面の表面材を、炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたものに多孔質シートが積層された表面材用部材に熱硬化性樹脂が含浸硬化したものとし、表面材の多孔質シートにハニカムコアが食い込んで、多孔質シートから滲出した熱硬化性樹脂が硬化しているため、ハニカムコアと表面材との接着強度が良好になる。 According to the present invention, the surface materials on both sides of the honeycomb core are made of carbon fiber fabric, unidirectional carbon fiber sheet, or a composite of these laminated together, on which a porous sheet is laminated, and the surface material components are impregnated and hardened with a thermosetting resin. The honeycomb core is embedded in the porous sheet of the surface material, and the thermosetting resin that seeps out from the porous sheet is hardened, resulting in good adhesive strength between the honeycomb core and the surface material.
さらに、ハニカム積層体の製造の際、ハニカムコアが多孔質シートに食い込むことにより、その部分で多孔質シートが圧縮されて熱硬化性樹脂が滲出し、その滲出した熱硬化性樹脂が、ハニカムコアの食い込んだ壁に沿って盛り上がった状態で硬化し、良好にフィレットを形成する。また、製造されたハニカム積層体は、表面材の多孔質シートにハニカムコアが食い込んでいることにより得られる接着強度増大効果と、フィレットにより得られる接着強度増大との両方の効果により、ハニカムコアと表面材との接着が強固（表面材の剥離強度が大）になる。 Furthermore, when manufacturing the honeycomb laminate, the honeycomb core bites into the porous sheet, compressing the porous sheet at that point and causing the thermosetting resin to seep out. The exuded thermosetting resin hardens in a raised state along the wall where the honeycomb core has bitten into, forming a good fillet. In addition, the manufactured honeycomb laminate has strong adhesion between the honeycomb core and the surface material (high peel strength of the surface material) due to both the effect of increased adhesive strength obtained by the honeycomb core biting into the porous sheet of the surface material and the effect of increased adhesive strength obtained by the fillet.
以下、本発明のハニカム積層体及びその製造方法について図面を用いて説明する。
図１及び図２に示す本発明の一実施形態に係るハニカム積層体１０は、ハニカムコア１１と、ハニカムコア１１の両面に積層一体化された表面材２１とからなり、ハニカムコア１１と表面材２１との接着強度（表面材の剥離強度）が高いものである。
Hereinafter, the honeycomb laminate and the manufacturing method thereof according to the present invention will be described with reference to the drawings.
The honeycomb laminate 10 according to one embodiment of the present invention shown in Figures 1 and 2 comprises a honeycomb core 11 and surface materials 21 laminated and integrated onto both sides of the honeycomb core 11, and has a high adhesive strength between the honeycomb core 11 and the surface materials 21 (peel strength of the surface materials).
ハニカムコア１１は、壁１３によって区画されたセル１５を複数有する。ハニカムコア１１は、セル１５の平面形状が本実施形態のような六角形（ハニカム）からなるものの他に、四角形、三角形、五角形、八角形、フルート形（波形）、円形等からなるものがあり、限定されない。ハニカムコア１１の強度や製造のし易さからは、セルの平面形状が六角形のものが好ましい。 The honeycomb core 11 has a plurality of cells 15 partitioned by walls 13. In addition to the honeycomb core 11 in which the planar shape of the cells 15 is hexagonal (honeycomb) as in this embodiment, the honeycomb core 11 may be rectangular, triangular, pentagonal, octagonal, fluted (wave-shaped), circular, or other shapes, and is not limited thereto. In terms of the strength and ease of manufacture of the honeycomb core 11, a hexagonal planar cell shape is preferred.
ハニカムコア１１の材質としては、紙、金属、樹脂、セラミック、アラミド繊維シート等を挙げることができるが、特に軽量性及び不燃性に優れるアルミニウム（アルミハニカムコア）が好ましい。また、ハニカムコア１１のセルサイズ（目開き）ｄは、小さすぎるとハニカムコア１１の重量が増大してハニカム積層体１０が重くなり、一方、大きすぎるとハニカム積層体１０の強度低下や表面材２１の窪みの原因となるため、１／３２～１／１インチの範囲が好ましく、１／３２～１／２インチがより好ましい。また、ハニカムコア１１の高さ（厚み）は、低すぎると嵩の割りに重くなり、高すぎるとハニカムコア１１の強度低下を生じることから、２～１５０ｍｍの範囲が好ましい。 Materials for the honeycomb core 11 include paper, metal, resin, ceramic, aramid fiber sheet, etc., but aluminum (aluminum honeycomb core) is particularly preferred because of its light weight and non-flammability. If the cell size (opening) d of the honeycomb core 11 is too small, the weight of the honeycomb core 11 increases and the honeycomb laminate 10 becomes heavy, while if it is too large, it can cause a decrease in the strength of the honeycomb laminate 10 and dents in the surface material 21, so it is preferably in the range of 1/32 to 1/1 inch, and more preferably 1/32 to 1/2 inch. If the height (thickness) of the honeycomb core 11 is too low, it becomes too heavy for its bulk, and if it is too high, it can cause a decrease in the strength of the honeycomb core 11, so it is preferably in the range of 2 to 150 mm.
表面材２１は、炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３に多孔質シート２５が積層された表面材用部材２７に熱硬化性樹脂が含浸硬化したものからなる。
表面材２１の厚みは、窪みなどの自然変形を防ぐため及び軽量性のため、各側で０．２～３．０ｍｍが好ましい。
The surface material 21 is made of a surface material member 27 having a porous sheet 25 laminated on a carbon fiber fabric, a unidirectional carbon fiber sheet, or a composite laminate 23 of these, which is impregnated with a thermosetting resin and hardened.
The thickness of the surface material 21 is preferably 0.2 to 3.0 mm on each side in order to prevent natural deformation such as depressions and to ensure light weight.
炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３は、ハニカムコア１１の各側において一層に限られず、複数層の積層（複層）で構成してもよい。
炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３は、軽量及び高剛性に優れるものである。炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたものは、特に、繊維が一方向のみではない織り方のもの（織物）が好ましく、例えば、縦糸と横糸で構成される平織、綾織、朱子織及び３方向の糸で構成される三軸織などが好適である。また、炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３は、熱硬化性樹脂の含浸及び剛性の点から、繊維重さが９０～４００ｇ／ｍ２のものが好ましい。
The carbon fiber fabric, unidirectional carbon fiber sheet, or a composite laminate thereof 23 is not limited to a single layer on each side of the honeycomb core 11, but may be a laminate of multiple layers (multiple layers).
The carbon fiber fabric, the unidirectional carbon fiber sheet, or the composite laminate thereof 23 is excellent in light weight and high rigidity. The carbon fiber fabric, the unidirectional carbon fiber sheet, or the composite laminate thereof is preferably a weave (woven fabric) in which the fibers are not only in one direction, for example, a plain weave, a twill weave, a satin weave, which are composed of warp and weft threads, and a triaxial weave, which are composed of threads in three directions, are suitable. In addition, the carbon fiber fabric, the unidirectional carbon fiber sheet, or the composite laminate thereof 23 is preferably one having a fiber weight of 90 to 400 g/ m2 from the viewpoint of impregnation with a thermosetting resin and rigidity.
多孔質シート２５は、発泡体または不織布からなり、ハニカムコア１１が当接して該当接位置でハニカムコア１１が多孔質シート２５内に食い込んでいる。
多孔質シートの厚みは、薄すぎるとハニカムコア１１の食い込みできなくなる。一方、厚すぎると重くなり、また熱硬化性樹脂のハニカムコア１１への染み出しが不十分となり、接着強度の増大が効果的でなくなるため、０．５～２ｍｍが好ましい。
The porous sheet 25 is made of a foam or nonwoven fabric, and when the honeycomb core 11 abuts against it, the honeycomb core 11 is embedded in the porous sheet 25 at the contact position.
If the thickness of the porous sheet is too thin, it will not be able to bite into the honeycomb core 11. On the other hand, if the thickness is too thick, it will be heavy, and the thermosetting resin will not seep into the honeycomb core 11 sufficiently, making it difficult to effectively increase the adhesive strength. Therefore, the thickness is preferably 0.5 to 2 mm.
発泡体としては、熱硬化性樹脂の含浸を可能にするために連続気泡構造の発泡体が好ましく、例えば、ウレタン樹脂発泡体又はメラミン樹脂発泡体を挙げることができる。また、メラミン樹脂発泡体は良好な難燃性を有するため、ハニカム積層体１０に難燃性が求められる場合に好適なものである。発泡体の密度（ＪＩＳ Ｋ ７２２２）は、低すぎると熱硬化性樹脂の含浸性及び保持性が悪くなり、一方、高すぎるとハニカムコアが食い込めなくなるため、５～１００ｋｇ／ｍ３が好ましく、より好ましくは２０～８０ｋｇ／ｍ３である。 The foam is preferably a foam with an open cell structure to enable impregnation with a thermosetting resin, and examples of the foam include a urethane resin foam and a melamine resin foam. In addition, since a melamine resin foam has good flame retardancy, it is suitable when flame retardancy is required for the honeycomb laminate 10. The density of the foam (JIS K 7222) is preferably 5 to 100 kg/ m3 , more preferably 20 to 80 kg/m3, because if the density is too low, the impregnation and retention of the thermosetting resin are poor, while if the density is too high, the honeycomb core cannot be embedded .
不織布としては炭素繊維不織布、ガラス不織布、ナイロン不織布、ＰＥＴ不織布等を挙げることができる。また不織布の目付量は小さすぎると含浸性及び保持性が悪くなり、一方、大きすぎるとハニカムコアが食い込めなくなるため、２～２００ｇ／ｍ２が好ましい。 Examples of nonwoven fabrics include carbon fiber nonwoven fabrics, glass nonwoven fabrics, nylon nonwoven fabrics, PET nonwoven fabrics, etc. If the weight of the nonwoven fabric is too small, impregnation and retention will be poor, while if it is too large, the honeycomb core will not be able to be embedded in it, so a weight of 2 to 200 g/ m2 is preferable.
また、図２に示すように、ハニカムコア１１が多孔質シート２５内に食い込んでいる位置では、多孔質シート２５が圧縮されて熱硬化性樹脂が滲出し、その滲出した熱硬化性樹脂が、ハニカムコア１１の食い込んだ壁１３に沿って盛り上がり、該壁１３の端部を挟んだ状態となって硬化し、フィレット１７を形成している。 Also, as shown in FIG. 2, at the positions where the honeycomb core 11 is embedded in the porous sheet 25, the porous sheet 25 is compressed, causing the thermosetting resin to seep out, and the exuded thermosetting resin rises along the wall 13 into which the honeycomb core 11 is embedded, clamps the end of the wall 13, and hardens to form a fillet 17.
熱硬化性樹脂は、特に限定されないが、ハニカム積層体１０の剛性を高めるためには、熱硬化性樹脂自体がある程度の剛性を有する必要があり、エポキシ樹脂、フェノール樹脂、エポキシ樹脂とフェノール樹脂の混合物、ウレタン樹脂からなる群より選択することができる。また、ハニカム積層体１０に難燃性が求められる場合、熱硬化性樹脂は難燃性のものが好ましい。フェノール樹脂は良好な難燃性を有するために好適である。熱硬化性樹脂の含浸量は、含浸後の表面材用部材に対して５０～８０重量％が好ましい。 The thermosetting resin is not particularly limited, but in order to increase the rigidity of the honeycomb laminate 10, the thermosetting resin itself must have a certain degree of rigidity, and can be selected from the group consisting of epoxy resin, phenol resin, a mixture of epoxy resin and phenol resin, and urethane resin. In addition, if flame retardancy is required for the honeycomb laminate 10, the thermosetting resin is preferably flame retardant. Phenol resin is suitable because it has good flame retardancy. The amount of thermosetting resin impregnated is preferably 50 to 80% by weight of the surface material member after impregnation.
ハニカムコア１１と表面材２１の一体化は、表面材用部材２７に含浸している熱硬化性樹脂が、ハニカム積層体１０の製造時に多孔質シート２５から滲出してハニカムコア１１と接触し、さらに前記フィレット１７を形成して硬化することにより行われる。 The honeycomb core 11 and the surface material 21 are integrated by the thermosetting resin impregnated in the surface material member 27 seeping out of the porous sheet 25 during the manufacture of the honeycomb laminate 10, coming into contact with the honeycomb core 11, and then forming the fillet 17 and hardening.
次に、本発明のハニカム積層体１０の製造方法について説明する。
発明のハニカム積層体１０の製造方法は、含浸工程、積層工程、圧縮加熱工程とからなる。
含浸工程では、炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたものに多孔質シートが積層された表面材用部材に熱硬化性樹脂を含浸させて含浸済み表面材用部材を作製する。含浸工程の一例を次に示す。
図３の例では、まず図３の（３－１）に示すように、炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３Ａに熱硬化性樹脂Ｆを含浸させて含浸済み炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３Ｂを形成する。炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３Ａ及び熱硬化性樹脂Ｆは、前記ハニカム積層体１０において説明した炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの及び熱硬化性樹脂と同じである。含浸時に用いる熱硬化性樹脂Ｆは、未硬化の液状からなる。
Next, a method for manufacturing the honeycomb laminate 10 of the present invention will be described.
The method for manufacturing the honeycomb laminate 10 of the present invention includes an impregnation step, a lamination step, and a compression and heating step.
In the impregnation step, a surface member, which is a carbon fiber fabric, a unidirectional carbon fiber sheet, or a composite laminate of these laminated with a porous sheet, is impregnated with a thermosetting resin to produce an impregnated surface member. An example of the impregnation step is shown below.
In the example of Fig. 3, first, as shown in Fig. 3 (3-1), a carbon fiber fabric, a unidirectional carbon fiber sheet, or a composite laminate thereof 23A is impregnated with a thermosetting resin F to form an impregnated carbon fiber fabric, a unidirectional carbon fiber sheet, or a composite laminate thereof 23B. The carbon fiber fabric, the unidirectional carbon fiber sheet, or a composite laminate thereof 23A and the thermosetting resin F are the same as the carbon fiber fabric, the unidirectional carbon fiber sheet, or a composite laminate thereof, and the thermosetting resin explained in the honeycomb laminate 10. The thermosetting resin F used during impregnation is in an uncured liquid state.
次に図３の（３－２）に示すように、含浸済み炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３Ｂの片面に多孔質シート２５Ａを積層し、含浸済み表面材用部材２７Ａを形成する。その際、含浸済み炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３Ｂの表面に付着している熱硬化性樹脂のタック性（粘着性）により、多孔質シート２５Ａを含浸済み炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３Ｂの片面に貼り付けることができる。含浸済み炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３Ｂに積層された多孔質シート２５Ａは、多孔質シート２５Ａと接する含浸済み炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３Ｂの表面に付着している熱硬化性樹脂が含浸する。多孔質シート２５Ａは、前記ハニカム積層体１０において説明した多孔質シートと同じである。 Next, as shown in FIG. 3 (3-2), a porous sheet 25A is laminated on one side of the impregnated carbon fiber fabric, unidirectional carbon fiber sheet, or laminated composite thereof 23B to form an impregnated surface material member 27A. At this time, the tackiness (adhesiveness) of the thermosetting resin attached to the surface of the impregnated carbon fiber fabric, unidirectional carbon fiber sheet, or laminated composite thereof 23B allows the porous sheet 25A to be attached to one side of the impregnated carbon fiber fabric, unidirectional carbon fiber sheet, or laminated composite thereof 23B. The porous sheet 25A laminated on the impregnated carbon fiber fabric, unidirectional carbon fiber sheet, or laminated composite thereof 23B is impregnated with the thermosetting resin attached to the surface of the impregnated carbon fiber fabric, unidirectional carbon fiber sheet, or laminated composite thereof 23B that is in contact with the porous sheet 25A. The porous sheet 25A is the same as the porous sheet described in the honeycomb laminate 10.
熱硬化性樹脂Ｆは、含浸を容易にするため、溶剤に溶かしたものが好ましく、含浸後に、含浸済み表面材用部材２７Ａを、熱硬化性樹脂Ｆの硬化反応を生じない低い温度で乾燥させることにより、溶剤を除去する。 The thermosetting resin F is preferably dissolved in a solvent to facilitate impregnation, and after impregnation, the impregnated surface material component 27A is dried at a low temperature that does not cause a curing reaction of the thermosetting resin F to remove the solvent.
含浸手段は、液状の熱硬化性樹脂Ｆを収容した槽に炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３Ａを浸ける方法、スプレーにより行う方法、ロールコータにより行う方法等、適宜の方法により行うことができる。 The impregnation can be performed by any suitable method, such as immersing the carbon fiber fabric, unidirectional carbon fiber sheet, or a composite laminate of these 23A in a tank containing liquid thermosetting resin F, spraying, or using a roll coater.
なお、前記ハニカム積層体１０における表面材２１の炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３を複数層とする場合、前記含浸済み炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３Ｂを複数枚積層した後に前記多孔質シート２５Ａを積層することにより、前記含浸済み表面材用部材２７Ａを形成する。 When the carbon fiber fabric, unidirectional carbon fiber sheet, or composite laminate thereof 23 of the surface material 21 in the honeycomb laminate 10 is made into multiple layers, the impregnated surface material member 27A is formed by laminating multiple sheets of the impregnated carbon fiber fabric, unidirectional carbon fiber sheet, or composite laminate thereof 23B and then laminating the porous sheet 25A.
前記含浸工程は、炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３Ａと多孔質シート２５Ａのそれぞれに熱硬化性樹脂Ｆを含浸させた後に積層して、含浸済み表面材用部材２７Ａとしてもよい。また、予め炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３Ａに多孔質シート２５Ａを積層して含浸前の表面材用部材を作製し、その表面材用部材に熱硬化性樹脂を含浸させて含浸済み表面材用部材２７Ａとしてもよい。 The impregnation process may involve impregnating the carbon fiber fabric, unidirectional carbon fiber sheet, or composite laminate thereof 23A and the porous sheet 25A with the thermosetting resin F, and then laminating them to form the impregnated surface material member 27A. Alternatively, the porous sheet 25A may be laminated on the carbon fiber fabric, unidirectional carbon fiber sheet, or composite laminate thereof 23A in advance to prepare a surface material member before impregnation, and the surface material member may be impregnated with the thermosetting resin to form the impregnated surface material member 27A.
積層工程では、図４に示すように、ハニカムコア１１Ａの両面に含浸済み表面材用部材２７Ａを配置して圧縮加熱用積層体１０Ａを得る。その際、含浸済み表面材用部材２７Ａは、多孔質シート２５Ａを内側にして、多孔質シート２５Ａとハニカムコア１１Ａが対向して接するようにする。ハニカムコア１１Ａは、前記ハニカム積層体１０において説明したとおりである。なお、積層作業は、次に行う圧縮加熱工程（図５）で用いるプレス成形用下型３１の上面に、含浸済み表面材用部材２７Ａ、ハニカムコア１１Ａ、含浸済み表面材用部材２７Ａの順に重ねて行ってもよい。また、含浸済み表面材用部材２７Ａとハニカムコア１１Ａは、平面サイズが同サイズのものが好ましい。 In the lamination process, as shown in FIG. 4, the impregnated surface material member 27A is placed on both sides of the honeycomb core 11A to obtain the compression heating laminate 10A. At this time, the impregnated surface material member 27A is arranged so that the porous sheet 25A faces the honeycomb core 11A and contacts it. The honeycomb core 11A is as described in the honeycomb laminate 10. The lamination work may be performed by stacking the impregnated surface material member 27A, honeycomb core 11A, and impregnated surface material member 27A in this order on the upper surface of the press molding lower mold 31 used in the next compression heating process (FIG. 5). It is also preferable that the impregnated surface material member 27A and the honeycomb core 11A have the same planar size.
圧縮加熱工程では、図５に示すように、圧縮加熱用積層体１０Ａをプレス成形用下型３１と上型３３により圧縮すると共に加熱する。なお、予め前記プレス成形用下型３１と上型３３間の間隔を変化させてハニカム積層体を実際に製造し、得られたハニカム積層体における表面材の厚みを測定して目的の表面材の厚みとなるプレス成形用下型３１と上型３３間の間隔を見つける。圧縮加熱工程時、プレス成形用下型３１と上型３３間には適宜の位置にスペーサを設置して、プレス成形用下型３１と上型３３間が所定間隔となるようにする。また、圧縮加熱用積層体の加熱方法は特に限定されないが、プレス成形用下型３１と上型３３にヒーター等の加熱手段を設けて、プレス成形用下型３１と上型３３を介して加熱するのが簡単である。加熱温度は、熱硬化性樹脂の硬化反応温度以上とされる。 In the compression heating process, as shown in FIG. 5, the compression heating laminate 10A is compressed and heated by the press molding lower die 31 and upper die 33. The honeycomb laminate is actually manufactured in advance by changing the gap between the press molding lower die 31 and upper die 33, and the thickness of the surface material in the obtained honeycomb laminate is measured to find the gap between the press molding lower die 31 and upper die 33 that will result in the desired surface material thickness. During the compression heating process, a spacer is installed at an appropriate position between the press molding lower die 31 and upper die 33 so that the press molding lower die 31 and upper die 33 are spaced apart by a predetermined distance. The method of heating the compression heating laminate is not particularly limited, but it is easy to provide a heating means such as a heater to the press molding lower die 31 and upper die 33 and heat it through the press molding lower die 31 and upper die 33. The heating temperature is set to be equal to or higher than the hardening reaction temperature of the thermosetting resin.
圧縮加熱工程時に圧縮加熱用積層体１０Ａが圧縮されると、含浸済み炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３Ｂに含浸している熱硬化性樹脂が押し出されて、含浸済み炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの２３Ｂと接している多孔質シート２５Ａに含浸し、含浸済み表面材用部材２７Ａの全体に含浸する。なお、多孔質シート２５Ａには、前記含浸工程においてすでに熱硬化性樹脂が含浸しているが、この圧縮加熱工程によって、多孔質シート２５Ａにさらに熱硬化性樹脂が含浸する。また、圧縮加熱工程によって、多孔質シート２５Ａは、ハニカムコア１１Ａと当接している部位がハニカムコア１１Ａの壁の端部によって圧縮されて窪み、ハニカムコア１１Ａが食い込む。ハニカムコア１１Ａが食い込んだ部位では、多孔質シート２５Ａ内の熱硬化性樹脂が滲出し、その滲出した熱硬化性樹脂が、ハニカムコア１１Ａの壁に沿って盛り上がって壁の端部を挟んだ状態となる。 When the compression heating laminate 10A is compressed during the compression heating process, the thermosetting resin impregnated in the impregnated carbon fiber fabric, unidirectional carbon fiber sheet, or composite laminate of these 23B is pushed out and impregnates the porous sheet 25A in contact with the impregnated carbon fiber fabric, unidirectional carbon fiber sheet, or composite laminate of these 23B, and impregnates the entire impregnated surface material member 27A. The porous sheet 25A has already been impregnated with the thermosetting resin in the impregnation process, but the compression heating process further impregnates the porous sheet 25A with the thermosetting resin. Also, the compression heating process causes the porous sheet 25A to be compressed and recessed at the portion abutting the honeycomb core 11A by the end of the wall of the honeycomb core 11A, and the honeycomb core 11A bites into it. At the locations where the honeycomb core 11A is embedded, the thermosetting resin in the porous sheet 25A seeps out, and the exuded thermosetting resin rises up along the walls of the honeycomb core 11A, pinching the ends of the walls.
熱硬化性樹脂は加熱により硬化反応を開始し、含浸済み表面材用部材２７Ａから前記表面材２１が形成され、該表面材２１とハニカムコア１１Ａ（１１）が接着一体化した前記ハニカム積層体１０が形成される。さらに、多孔質シートとハニカムコアの当接位置では、滲出した熱硬化性樹脂が、前記ハニカムコア１１Ａの壁に沿って盛り上がり、ハニカムコア１１Ａの壁の端部を挟んだ状態で硬化することにより、前記フィレット１７が形成される。その後、加熱圧縮を解除して前記ハニカム積層体１０を得る。 The thermosetting resin starts a hardening reaction when heated, and the surface material 21 is formed from the impregnated surface material member 27A, and the surface material 21 and honeycomb core 11A (11) are bonded together to form the honeycomb laminate 10. Furthermore, at the contact position between the porous sheet and the honeycomb core, the exuded thermosetting resin rises along the wall of the honeycomb core 11A and hardens while sandwiching the end of the wall of the honeycomb core 11A, forming the fillet 17. The heated compression is then released to obtain the honeycomb laminate 10.
フェノール樹脂溶液（住友ベークライト株式会社製、品名：ＰＲ－５５７９１Ｂ、樹脂濃度６０ｗｔ％エタノール溶液）中に、綾織の炭素繊維織物（帝人株式会社製、品名；Ｗ－３１６１、繊維重さ２００ｇ／ｍ２）を漬け、取り出して含浸済み炭素繊維織物を作製した。炭素繊維織物は、２００×３５０ｍｍの平面サイズに裁断したもの（重量１４ｇ／枚）を用いた。 A twill carbon fiber fabric (Teijin Limited, product name: W-3161, fiber weight: 200 g/m 2 ) was immersed in a phenolic resin solution (Sumitomo Bakelite Co., Ltd., product name: PR-55791B, resin concentration 60 wt % ethanol solution) and then removed to prepare an impregnated carbon fiber fabric. The carbon fiber fabric was cut to a planar size of 200 × 350 mm (weight: 14 g/sheet).
同様にして各実施例及び比較例に必要な枚数の含浸済み炭素繊維織物を作製し、そのうちの各実施例に使用する各２枚の含浸済み炭素繊維織物の片面には、炭素繊維織物に含浸した熱硬化性樹脂のタック性を利用して多孔質シートを貼り付けた。 In the same manner, the required number of impregnated carbon fiber fabrics were prepared for each Example and Comparative Example, and a porous sheet was attached to one side of each of the two impregnated carbon fiber fabrics used in each Example, utilizing the tackiness of the thermosetting resin impregnated into the carbon fiber fabric.
多孔質シートは、実施例１～３及び実施例５～６については、シート状の軟質ウレタンフォーム（連通気泡構造、株式会社イノアックコーポレーション製、品名：ＭＦ－５０、厚み０．７ｍｍ、密度３０ｋｇ／ｍ３）を用い、実施例４についてはカーボン不織布（阿波製紙製、品名：ＣＡＲＭＩＸ ＣＦＲＰ、厚み１ｍｍ、目付１２０ｇ／ｍ２）を用いた。
なお、比較例用の含浸済み炭素繊維織物については、多孔質シートを貼り付けなかった。
As the porous sheet, a sheet-shaped soft urethane foam (with an open cell structure, manufactured by Inoac Corporation, product name: MF-50, thickness 0.7 mm, density 30 kg/ m3 ) was used in Examples 1 to 3 and Examples 5 to 6, and a carbon nonwoven fabric (manufactured by Awa Paper, product name: CARMIX CFRP, thickness 1 mm, basis weight 120 g/ m2 ) was used in Example 4.
It should be noted that no porous sheet was attached to the impregnated carbon fiber fabric for comparison.
その後、多孔質シートが貼り付けられた含浸済み炭素繊維織物と、多孔質シートが貼り付けられていない含浸済み炭素繊維織物を、２５℃の室温で２時間自然乾燥させ、さらに６０℃の雰囲気下で１時間乾燥させて、多孔質シート有りのプリプレグと、多孔質シート無しのプリプレグを作製した。 Then, the impregnated carbon fiber fabric with the porous sheet attached and the impregnated carbon fiber fabric without the porous sheet attached were naturally dried at room temperature of 25°C for 2 hours, and then further dried in an atmosphere of 60°C for 1 hour to produce prepregs with and without the porous sheet.
ハニカムコアとして、各実施例及び比較例用に、それぞれ２００×３５０ｍｍの平面サイズに裁断した、セルサイズ１／８インチのアルミハニカム（厚み３ｍｍ、重量３７ｇ／枚）と、セルサイズ１インチのアルミハニカム（厚み３ｍｍ、重量４０ｇ）と、セルサイズ１／８インチのアルミハニカム（厚み２ｍｍ、重量２５ｇ）を用いた。 For each example and comparative example, the honeycomb cores used were aluminum honeycomb with a cell size of 1/8 inch (thickness 3 mm, weight 37 g/sheet), aluminum honeycomb with a cell size of 1 inch (thickness 3 mm, weight 40 g), and aluminum honeycomb with a cell size of 1/8 inch (thickness 2 mm, weight 25 g), all cut to a planar size of 200 x 350 mm.
次に、予め離型剤を表面に塗布したＳＵＳ製のプレス成形用の下型の上に、各実施例については、多孔質シート無しのプリプレグの所要枚数、多孔質シート有りのプリプレグ、アルミハニカム、多孔質シート有りのプリプレグ、多孔質シート無しのプリプレグの所要枚数を、この順に重ねて配置し、その際に多孔質シートがアルミハニカムと当接するようにした。それにより、ハニカムコアとプリプレグの多孔質シートが当接するようにして、プリプレグをハニカムコアの両面に配置した構成の圧縮加熱用積層体を、プレス成形用下型上にセットした。多孔質シート無しのプリプレグと多孔質シート有りのプリプレグの積層体は、含浸済み表面材用部材に相当する。なお、比較例については、多孔質シート無しのプリプレグの所要枚数、アルミハニカム、多孔質シート無しのプリプレグの所要枚数を、この順に重ねて配置した構成の圧縮加熱用積層体を、プレス成形用下型上にセットした。 Next, for each example, the required number of prepregs without a porous sheet, the prepreg with a porous sheet, the aluminum honeycomb, the prepreg with a porous sheet, and the required number of prepregs without a porous sheet were stacked in this order on a lower mold for press molding made of SUS, the surface of which had been coated with a release agent in advance, so that the porous sheet was in contact with the aluminum honeycomb. As a result, a laminate for compression heating in which the prepregs were arranged on both sides of the honeycomb core so that the honeycomb core and the porous sheets of the prepregs were in contact with each other was set on the lower mold for press molding. The laminate of the prepregs without a porous sheet and the prepregs with a porous sheet corresponds to the impregnated surface material member. For the comparative example, a laminate for compression heating in which the required number of prepregs without a porous sheet, the aluminum honeycomb, and the required number of prepregs without a porous sheet were stacked in this order was set on the lower mold for press molding.
プレス成形用下型の四隅に各実施例及び比較例のハニカム積層体の厚みに応じた厚みのＳＵＳ製スペーサを配置し、プレス成形用下型上の圧縮加熱用積層体を、１５０℃で３０分間、プレス成形用上型（平板状）で押圧し、圧縮及び加熱を行い、フェノール樹脂を反応硬化させた。その際の圧縮加熱用積層体の加熱は、プレス成形用下型と上型に取り付けられた鋳込みヒーターにより行った。なお、実施例１～２、実施例４～６及び比較例については１０ＭＰａの面圧（プレス圧力）をかけ、一方、実施例３については１５ＭＰａの面圧（プレス圧力）をかけてプレス成形用上型（平板状）で押圧し、圧縮及び加熱を行った。 SUS spacers of a thickness corresponding to the thickness of the honeycomb laminate of each Example and Comparative Example were placed at the four corners of the press molding lower die, and the compression heating laminate on the press molding lower die was pressed with a press molding upper die (flat) at 150°C for 30 minutes, compressed and heated, and the phenolic resin was reacted and cured. The compression heating laminate was heated by a cast-in heater attached to the press molding lower die and upper die. Note that a surface pressure (press pressure) of 10 MPa was applied for Examples 1-2, Examples 4-6, and Comparative Example, while a surface pressure (press pressure) of 15 MPa was applied for Example 3, and the press molding upper die (flat) was pressed, compressed, and heated.
その後、プレス成形用下型と上型を室温で冷却させた後に、プレス成形用下型と上型を開き、ハニカム積層体を得た。得られた各実施例のハニカム積層体は、多孔質無しプリプレグと多孔質シート有りプリプレグとの積層体（含浸済み表面材用部材）が硬化してなる表面材が、アルミハニカムの両面に積層一体化したものであり、多孔質シートにアルミハニカムが食い込み、該食い込み位置でフィリップが形成されていた。一方、比較例のハニカム積層体は、多孔質無しプリプレグの複数枚が積層されて硬化した表面材が、アルミハニカムの両面に積層一体化したものであり、ハニカムコアの食い込みがなく、フィレットが形成されていなかった。 Then, the press molding lower and upper dies were cooled at room temperature, and the press molding lower and upper dies were opened to obtain a honeycomb laminate. The obtained honeycomb laminates of each example were formed by laminating and integrating a surface material formed by hardening a laminate of non-porous prepreg and prepreg with a porous sheet (impregnated surface material member) onto both sides of an aluminum honeycomb, with the aluminum honeycomb biting into the porous sheet and forming a fillet at the biting position. On the other hand, the honeycomb laminate of the comparative example was formed by laminating and integrating a surface material formed by hardening a plurality of non-porous prepregs onto both sides of an aluminum honeycomb, with no biting into the honeycomb core and no fillet being formed.
また、各実施例及び比較例のハニカム積層体について、表面材の曲げ弾性率の測定を行った。その結果、曲げ弾性率が２０ＧＰａ以上でかつハニカム積層体の剥離がない場合に評価を「◎」とし、それ以外の場合（曲げ弾性率が２０ＧＰａ未満、又は／および、ハニカム積層体の剥離がある場合）に評価を「×」とした。
曲げ弾性率の測定は、ＪＩＳ Ｋ ７０７４に基づいて行った。
In addition, the bending modulus of the surface material was measured for the honeycomb laminates of each of the Examples and Comparative Examples. As a result, when the bending modulus was 20 GPa or more and there was no peeling of the honeycomb laminate, the evaluation was given as "◎", and when otherwise (when the bending modulus was less than 20 GPa and/or there was peeling of the honeycomb laminate), the evaluation was given as "×".
The flexural modulus was measured in accordance with JIS K 7074.
各実施例及び比較例の構成と評価を図６に示す。実施例１～６のハニカム積層体は、何れも、曲げ弾性率２５～３１ＧＰａで表面材の剥離無く、評価「◎」であった。実施例１～６のハニカム積層体は、ハニカムコアが表面材の多孔質シートに食い込んでいることによる接着強度増大と、フィレットによる接着強度増大との両方によって、表面材の剥離強度が高く、剛性の高いものであった。 The structure and evaluation of each example and comparative example are shown in Figure 6. All of the honeycomb laminates of Examples 1 to 6 had a flexural modulus of elasticity of 25 to 31 GPa, no peeling of the surface material, and were rated as "◎". The honeycomb laminates of Examples 1 to 6 had high peel strength of the surface material and high rigidity due to both the increased adhesive strength caused by the honeycomb core biting into the porous sheet of the surface material and the increased adhesive strength caused by the fillet.
一方、比較例のハニカム積層体は、曲げ弾性率が６ＧＰａであり、評価「×」であった。比較例のハニカム積層体は、表面材（プリプレグ）がハニカムコアに単に当接して硬化しているだけであって、表面材へのハニカムコアの食い込みが無く、フィレットも形成されてないため、各実施例と比べて表面材の接着強度が低くなって表面材が剥離し易く、かつ剛性が大きく低下した。 On the other hand, the honeycomb laminate of the comparative example had a flexural modulus of 6 GPa and was rated "X." In the honeycomb laminate of the comparative example, the surface material (prepreg) simply abuts against the honeycomb core and hardens, and the honeycomb core does not bite into the surface material, and no fillets are formed. As a result, the adhesive strength of the surface material was lower than in the examples, the surface material was more likely to peel off, and the rigidity was significantly reduced.
このように、本発明によれば、ハニカムコアの両面に積層された表面材の多孔質シートにハニカムコアが食い込んでフィレットが形成されたハニカム積層体を得ることができるため、ハニカムコアの食い込みにより得られる接着強度増大効果と、フィレットにより得られる接着強度増大との両方の効果により、ハニカムコアと表面材の接着を強固（表面材の剥離強度が大）なものにできる。 In this way, according to the present invention, it is possible to obtain a honeycomb laminate in which the honeycomb core bites into the porous sheets of the surface material laminated on both sides of the honeycomb core to form a fillet. As a result, the adhesion between the honeycomb core and the surface material can be strengthened (the peel strength of the surface material is high) due to both the effects of the increased adhesive strength obtained by the honeycomb core biting into the porous sheets and the increased adhesive strength obtained by the fillet.
さらに、本発明のハニカム積層体１０の製造方法では、表面材をあらかじめ形成して、その表面材をハニカムコアと接着剤で接着させることを要しない。すなわち、本発明のハニカム積層体１０の製造方法では、プリプレグの熱硬化性樹脂を硬化させる際に、表面材（プリプレグ）の形成とハニカムコアの接着とを同時に行うことができ、製造工程を合理化できる。 Furthermore, in the manufacturing method of the honeycomb laminate 10 of the present invention, it is not necessary to form the surface material in advance and then adhere the surface material to the honeycomb core with an adhesive. In other words, in the manufacturing method of the honeycomb laminate 10 of the present invention, when the thermosetting resin of the prepreg is cured, the formation of the surface material (prepreg) and the adhesion of the honeycomb core can be performed simultaneously, streamlining the manufacturing process.
１０ ハニカム積層体
１０Ａ 圧縮加熱用積層体
１１、１１Ａ ハニカムコア
１３ 壁
１７ フィレット
２１ 表面材
２３、２３Ａ 炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの
２３Ｂ 含浸済み炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたもの
２５、２５Ａ 多孔質シート
２７ 表面材用部材
２７Ａ 含浸済み表面材用部材
３１ プレス成形用下型
３２ プレス成形用上型
REFERENCE SIGNS LIST 10 Honeycomb laminate 10A Compression heating laminate 11, 11A Honeycomb core 13 Wall 17 Fillet 21 Surface material 23, 23A Carbon fiber fabric, unidirectional carbon fiber sheet, or composite laminate thereof 23B Impregnated carbon fiber fabric, unidirectional carbon fiber sheet, or composite laminate thereof 25, 25A Porous sheet 27 Surface material member 27A Impregnated surface material member 31 Press molding lower die 32 Press molding upper die
Claims (3)
前記炭素繊維織物、前記一方向炭素繊維シート、又はそれらが複合して積層されたものに熱硬化性樹脂を含浸させる含浸工程と、
前記熱硬化性樹脂が含侵したものに前記多孔質シートを貼り付けてプリプレグを作成するプリプレグ作成工程と、
前記ハニカムコアの両面に、前記多孔質シートが前記ハニカムコアと当接するように、前記プリプレグを配置して圧縮加熱用積層体を得る積層工程と、
前記圧縮加熱用積層体を１０～１５ＭＰａの面圧で圧縮及び加熱することにより、前記多孔質シートに前記ハニカムコアを食い込ませ、該食い込んだ部分で前記多孔質シートから前記熱硬化性樹脂を滲出させ、該滲出した前記熱硬化性樹脂及び前記表面材用部材内の前記熱硬化性樹脂を硬化させて、前記表面材と前記ハニカムコアを一体化する圧縮加熱工程と、
を有することを特徴とするハニカム積層体の製造方法。 A method for manufacturing a honeycomb laminate in which a surface material impregnated with a thermosetting resin and cured is laminated on both sides of a honeycomb core, the surface material being a surface material member formed by laminating a porous sheet on a carbon fiber fabric, a unidirectional carbon fiber sheet, or a composite of these,
an impregnation step of impregnating the carbon fiber fabric, the unidirectional carbon fiber sheet, or a composite laminate thereof with a thermosetting resin;
a prepreg preparation step of attaching the porous sheet to the thermosetting resin-impregnated material to prepare a prepreg;
a lamination step of arranging the prepregs on both sides of the honeycomb core so that the porous sheets are in contact with the honeycomb core to obtain a laminate for compression heating;
a compression and heating process in which the compression and heating laminate is compressed and heated at a surface pressure of 10 to 15 MPa to cause the honeycomb core to bite into the porous sheet, the thermosetting resin is exuded from the porous sheet at the bitten portion, and the exuded thermosetting resin and the thermosetting resin in the surface material member are hardened to integrate the surface material and the honeycomb core;
A method for producing a honeycomb laminate, comprising the steps of:
前記表面材は、炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたものに多孔質シートが積層された表面材用部材に熱硬化性樹脂が含浸硬化したものからなり、
前記表面材と前記ハニカムコアは、前記多孔質シートと前記ハニカムコアが当接し、
前記多孔質シートと前記ハニカムコアとの当接位置では、前記多孔質シート内に前記ハニカムコアが食い込んで前記多孔質シートから滲出した熱硬化性樹脂が硬化しており、曲げ弾性率が２０ＧＰａ以上であることを特徴とするハニカム積層体。 In a honeycomb laminate in which surface materials are laminated on both sides of a honeycomb core,
The surface material is a surface material member in which a porous sheet is laminated on a carbon fiber fabric, a unidirectional carbon fiber sheet, or a composite laminate of these, and the surface material member is impregnated with a thermosetting resin and cured;
The surface material and the honeycomb core are in contact with each other, and the porous sheet and the honeycomb core are in contact with each other.
At the contact position between the porous sheet and the honeycomb core, the honeycomb core is embedded in the porous sheet and a thermosetting resin exuded from the porous sheet is hardened, and the honeycomb laminate has a flexural modulus of 20 GPa or more.
前記表面材は、炭素繊維織物、一方向炭素繊維シートもしくはそれらが複合して積層されたものに多孔質シートが積層された表面材用部材に熱硬化性樹脂が含浸硬化したものからなり、
前記表面材と前記コアは、前記多孔質シートと前記コアが当接し、
前記多孔質シートと前記コアとの当接位置では、前記多孔質シート内に前記コアが食い込んで前記多孔質シートから滲出した熱硬化性樹脂が硬化していることを特徴とする積層体。 A laminate in which a surface material is laminated on both sides of a core having a plurality of cells whose planar shape is a triangle, a rectangle, a pentagon, an octagon, or a circle,
The surface material is a surface material member in which a porous sheet is laminated on a carbon fiber fabric, a unidirectional carbon fiber sheet, or a composite laminate of these, and the surface material member is impregnated with a thermosetting resin and cured;
The surface material and the core are in contact with each other, and the porous sheet and the core are in contact with each other.
A laminate characterized in that at the contact position between the porous sheet and the core , the core is embedded in the porous sheet and a thermosetting resin that has seeped out from the porous sheet is hardened.
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| JP2000238154A (en) | 1999-02-19 | 2000-09-05 | Toray Ind Inc | Honeycomb sandwich panel |
| JP2006328292A (en) | 2005-05-30 | 2006-12-07 | Toray Ind Inc | Prepreg for honeycomb cocuring and its manufacturing method |
| US20080233344A1 (en) | 2006-02-07 | 2008-09-25 | Burkhart Grob | Airplane component as well as method for manufacturing an airplane component |
| WO2018174217A1 (en) | 2017-03-23 | 2018-09-27 | 東邦テナックス株式会社 | Self-adhesive prepreg and method for producing same |
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| US4353947A (en) * | 1981-10-05 | 1982-10-12 | International Harvester Co. | Laminated composite structure and method of manufacture |
| JPH0390340A (en) * | 1989-09-01 | 1991-04-16 | Yoshimoto Kasei Kk | Sandwich structure and manufacture therefor |
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| JP2000238154A (en) | 1999-02-19 | 2000-09-05 | Toray Ind Inc | Honeycomb sandwich panel |
| JP2006328292A (en) | 2005-05-30 | 2006-12-07 | Toray Ind Inc | Prepreg for honeycomb cocuring and its manufacturing method |
| US20080233344A1 (en) | 2006-02-07 | 2008-09-25 | Burkhart Grob | Airplane component as well as method for manufacturing an airplane component |
| WO2018174217A1 (en) | 2017-03-23 | 2018-09-27 | 東邦テナックス株式会社 | Self-adhesive prepreg and method for producing same |
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