JPH0459248A - Production of honeycomb panel - Google Patents

Abstract

PURPOSE:To easily form a honeycomb panel by bonding an inner prepreg sheet material to a honeycomb material under heating and pressure through a peel ply and release paper and bonding an outer surface member to an inner surface member to form a surface material. CONSTITUTION:A honeycomb material 1, an inner prepreg sheet material 9, a peel ply material 8 and release paper 7 are heated and pressed at predetermined temp. under predetermined pressure by a hot plate 6 and an inner surface member 10 is formed by a perfectly cured inner prepreg sheet material 9. Recessed parts 11 depressed in an almost spherical surface shape are formed in a hollow part 3. The rough surface and recessed parts 11 of the inner surface member 10 are gradually and perfectly filled with the resin flowing out of the outer prepreg sheet material 13 at the pressed region to be accumulated in the recessed parts 11 while filling the rough surface 12 and almost no recessed parts are generated in the outer surface member 14 formed by the perfectly cured outer prepreg sheet material 13.

Description

DETAILED DESCRIPTION OF THE INVENTION "Field of Industrial Application" The present invention is made by using a Nicum material as a core material, and a surface material made of a prepreg sheet material is bonded to both sides of the Nicum material. This invention relates to improvements in the method for producing nikumnoquenelle.

"Technical background" First, the technical background etc. will be described.

In the case of the No. 1 honeycomb panel whose surface material is made of a prepreg sheet material, since the prepreg sheet material is a flexible material with strength and flexibility, it is particularly easy to form a curved honeycomb panel with high precision. Because it can be bonded to No. 1 Nikum material using the resin contained in the prepreg sheet material, setting etc. during No. 1 Nikum channel molding is easy, and it is possible to easily form the surface material of the desired thickness. Yes, and furthermore,
When forming a honeycomb panel with the same strength using the same honeycomb material as the core material, it is possible to obtain a lightweight honeycomb panel compared to, for example, using an aluminum plate as the surface material. It is widely used as a variety of structural materials for cutting-edge equipment.

``Prior art'' Honeycomb panels are also formed by bonding prepreg sheet materials made of flexible material as surface materials to both sides of honeycomb materials. Similar to the case of general honeycomb panels that are formed by joining, for example, honeycomb panels are produced by setting prepreg sheet materials on both sides of the honeycomb material between the hot platens that function as mold members in hot press. The honeycomb panel was formed by assembling the honeycomb panels into a pre-assembled state, and then heating and pressurizing the thus-assembled honeycomb panel in the pre-assembled state using a hot press.

By the way, in the conventional manufacturing method, the prepreg sheet material is made of a flexible material formed by impregnating a resin into a woven fabric or non-woven fabric of fibrous carbon, Kevlar, glass, etc. Due to the synergistic effects of resin contraction due to heating and pressing due to pressure during panel molding, in most cases, the areas corresponding to the hollow parts of each cell of the honeycomb material in the surface material of the formed honeycomb panel are In addition to the formation of recesses, sometimes a large number of pinholes were also formed at the same time. Therefore, C'! However, the planar accuracy is low, and in that state, for example, it could not be used as a structural material for aircraft, space equipment, etc., which requires flannel with a high planar accuracy.

Therefore, when using such a honeycomb panel as a structural material for aircraft, space equipment, etc., the surface material made of prepreg sheet material is thin, and in particular, due to its material, etc., it is difficult to process, etc. In order to improve the plane accuracy by cutting the convex part (because it is not possible, conventionally,
After recesses and the like were corrected using a correction putty such as polyester 7-piece, the surface was finished by polishing or the like to improve flatness.

``Problems to be Solved by the Invention'' By the way, such honeycomb panels are usually manufactured by using, for example, release paper between the prepreg sheet material and the heating plate to prevent adhesion between the prepreg sheet material and the heating plate. A honeycomb panel is formed in between. Therefore, the surfaces of the recesses present in the surface material of the formed honeycomb panel are also substantially smooth. Therefore, in order to firmly adhere the putty, it is necessary to first roughen the surface of the surface material and then perform putty correction. However, in order to make the surface of the surface material almost flat by using this putty correction, it is not possible to apply a thick layer all at once, but it must be applied multiple times, making the work tedious and requiring a lot of man-hours. In addition, it has been pointed out that the honeycomb panel becomes expensive because finishing processing such as polishing is also required.

The present invention was made in view of the above-mentioned circumstances, and its purpose is to easily produce a honeycomb panel in which a surface material made of a prepreg sheet material with excellent flatness is joined to both sides of a 1-nicomb material. The purpose of this invention is to propose a method for manufacturing honeycomb panels that can be formed into

"Means for Solving the Problems" The present invention has been made to achieve the above object, and the technical solutions thereof are as follows.

The present invention is a method for manufacturing a honeycomb panel in which a honeycomb material is used as a core material and surface materials made of prepreg sheet materials are bonded to both sides of the honeycomb material, and the method includes the following steps. .

That is, there is an internal prepreg sheet material bonding preparation step in which the honeycomb material is centered on the mold member, and internal prepreg sheet material, peel ply material, and release paper are set on both sides of the honeycomb material in order from the inside. By heating and pressing the internal prepreg sheet material set above with a heating and pressing device via peel ply and release paper, the internal prepreg sheet material is joined to the honeycomb material, and an internal surface member that forms an internal surface member is formed. a forming step, a rough surface forming step of peeling off the peel ply material from the inner surface member joined to the honeycomb material and forming a rough surface on the surface of the inner surface member, and then applying external prepreg to the surface of the inner surface member, respectively. The sheet material is set, and the external prepreg sheet material set in this state is heated and pressed by the heating and pressing device to form an external surface member, and is joined to the internal surface member to form a surface material. and a final step.

``Function: Since the method for manufacturing a honeycomb panel according to the present invention includes the above-mentioned means, it functions as follows.

That is, in the method for manufacturing a honeycomb panel according to the present invention, in the internal prepreg sheet material bonding preparation step, the honeycomb material is mainly placed on the mold member, and on both sides thereof,
In the next internal surface member forming process, the internal prepreg sheet material, which has been set in this order from the inside: the internal prepreg sheet material, the peel ply material, and the release paper, is heated and pressed into a predetermined shape through the peel ply material and the release paper using a heating and pressurizing device. temperature,
By heating and pressurizing with a predetermined pressure for a predetermined time, the resin contained in the internal prepreg sheet material melts, and a portion of it flows out to the honeycomb material side and the peel ply material side, respectively. Then, the resin flowing out to the honeycomb material side adheres to the cell wall ends of the honeycomb material. Further, the resin flowing out into the peel ply material enters into the weave of the peel ply material, which is formed by coating and baking a silicone resin onto a nylon fabric. By the way, since the release paper is closely placed on the outer surface of the peel ply material, the resin that has entered the peel ply material will not leak out from the outer surface of the peel ply material.

Next, by curing the resin in this transformed state, the internal surface member is formed from the completely cured internal prepreg sheet material.

The lower surface of this inner surface member is joined to the honeycomb material by the resin attached to the end of the cell wall, and the resin that has entered the peel ply material remains in that state and hardens. .

The inner surface member formed in this way is formed from an inner prepreg sheet made of a flexible material, so due to the synergistic effects of shrinkage of the resin due to heating and pressing due to pressure during the formation process, the inner surface member is made of a flexible material. In most cases, a recess is formed in a portion corresponding to the hollow portion of each cell.

In the next rough surface forming step, by peeling the peel ply material from the inner surface member, the peel ply material penetrates into the weave of the peel ply material over the entire surface of the inner surface member.
In this state, a rough surface consisting of fine irregularities formed by the completely cured resin is formed.

In the next final step, after each external prepreg sheet material is set on the rough surface of the inner surface member, which has a rough surface formed on its surface, a predetermined heat and pressure is applied using a heat and pressure device. By heating and pressurizing for a predetermined period of time under the conditions, the resin contained in the outer prepreg sheet material melts, and the negative part flows out to the inner surface member side.

By the way, for example, even if there is a recess in the internal surface member, some of the resin that has flowed out will first be mixed with the internal surface material as heating and pressing by the heating and pressing device progresses. The resin flowing out from the external prepreg sheet material located in the area pressed by the device, that is, the area corresponding to the cell walls of the honeycomb material, fills the rough surface of the internal surface member located in that area, and the other resin The particles do not stop there, but move toward the concave portion of the inner surface member while filling the nearby rough surface, and eventually reach the concave portion and accumulate there. In this way, the rough surface and recesses of the inner surface member are gradually filled with the resin that flows out from the external prepreg sheet material at the pressed region and accumulates in the recesses while filling the rough surfaces. Therefore, for example, even if pinholes exist in the recess, these pinholes are also filled. Furthermore, the resin filling the rough surfaces and recesses of the inner surface member simultaneously adheres to the entire surface of the inner surface member.

In addition, in this process, the external prepreg sheet material that is heated and pressurized will have recesses in the internal surface member due to the synergistic effects of shrinkage of the resin due to heating and pressing due to pressure, similar to when forming the internal surface member. In other words, in the region corresponding to the hollow part of the cells of the honeycomb material, an action to form a recess occurs, but this action is caused by accumulation in the recess of the inner surface member so as to completely fill the recess. blocked by the resin. Then, at the final stage of this process,
Since the external prepreg sheet material is uniformly pressurized over the entire surface, the resin is cured after being heated and pressurized under specified conditions for a specified period of time, so that the external surface formed by the completely cured external prepreg sheet material is There are almost no dents or the like in the member, and the outer surface member has high planar accuracy.

As a result, a honeycomb panel including the outer surface member and the inner surface member and having a surface material with excellent planar accuracy can be obtained.

In addition, since the outer surface member and the inner surface member that form the surface material are integrally and firmly joined via the rough surface of the inner surface member, there is a possibility that the outer surface member may peel off from the inner surface member. It never happens.

Therefore, according to this honeycomb panel manufacturing method,
Since there is no need for repair work using putty, which is troublesome and requires a lot of man-hours, or for surface roughening to strengthen the adhesion of putty, it is possible to easily form honeycomb panels, and moreover, finishing processing such as polishing is not required. Honeycomb panels with excellent flatness accuracy can be formed without the need for

"Example" Hereinafter, the present invention will be explained based on embodiments shown in the drawings.

FIG. 1 is a perspective schematic diagram of a honeycomb material, and FIGS. 2 to 5 each show the manufacturing process of a honeycomb panel.
Fig. 2 is an explanatory diagram showing a state in which internal prep sheet material, peel ply material, and release paper are set in predetermined positional relationships between the hot plates of a hot press, centering on honeycomb material, and Fig. 3 is an explanatory diagram showing the honeycomb material An explanatory view of the main parts showing the process of peeling off the peel ply material and release paper from the inner surface member joined to the inner surface member. FIG. 4 shows the external prepreg sheet material and release paper set on the inner surface member. Explanatory diagram of main parts,
FIG. 5 is an explanatory view of essential parts showing the process of peeling off the release paper from the surface material.

First, the outline of honeycomb material will be explained.

In FIG. 1, 1 is a honeycomb material prepared in advance, and this honeycomb material 1 is made of, for example, foil-like aluminum material, aramid paper of an appropriate thickness, etc. as a base material, and is formed by a well-known stretch forming method. In the illustrated example, it is composed of a planar assembly of approximately regular hexagonal hollow columnar cells 2 having a predetermined cell size and height formed by cell walls 4,
It has excellent characteristics of being lightweight, has an excellent weight-to-strength ratio, and has excellent planar accuracy.

Note that 3 is the hollow part of the cell 2.

Further, regarding the honeycomb material prepared in advance, in the above embodiment, the honeycomb material 1 consisting of a planar aggregate of substantially regular hexagonal hollow columnar cells 2 was explained, but the honeycomb material is limited to the embodiment. For example, when forming a curved honeycomb panel, the above-described honeycomb material 1 is further expanded by a predetermined amount, that is,
A honeycomb material for forming a curved surface (so-called overexpanded core) is used, which is formed by expanding the cell walls forming the cells so that the bending angle is approximately 90° and the planar shape of the cells becomes approximately rectangular. As a result, it is possible to easily form a curved honeycomb panel with high precision.

This is what honeycomb material looks like.

Next, regarding the manufacturing method of a honeycomb panel, based on an example showing the manufacturing process of a flat honeycomb panel, we will explain in detail the internal prepreg sheet material bonding preparation process, internal surface member forming process, rough surface forming process, and final process. Describe.

First, regarding the preparation process for joining internal prepreg sheet materials,
This will be explained with reference to FIG.

In FIG. 2, reference numeral 6 denotes a pair of hot platens that function as mold members in the hot press 5. As shown in FIG. First, a release paper 7 is set on the lower heating plate 6, and a peel ply material 8 formed by coating a nylon fabric with silicone resin and baking it is placed on top of the release paper 7, and a fibrous material is formed on the upper surface of the peel ply material 8. After setting the internal prepreg sheet material 9 formed by impregnating a woven fabric or non-woven fabric of carbon, Kevlar, glass, etc. with a resin and curing this resin to a semi-cured state, the prepreg sheet material 9 is further placed on top of it. By setting 1 piece of honeycomb material, and setting the internal prepreg sheet material 9, peel ply material 8, and release paper 7 on top of this honeycomb material in order from the bottom, the honeycomb material 1 is placed between the heating plates 6. An internal prepreg sheet material 9, a peel ply material 8, and a release paper 7 are set on both sides of the honeycomb material 1 in this order from the inside.

The preparation process for joining the internal prepreg sheet material is as follows.

Next, the internal surface member forming process will be explained with reference to the left side of the drawing in FIG.

In the internal prepreg sheet material bonding preparation process, each member is set in a predetermined positional relationship between the hot plates 6 of the hot press 5, namely, the honeycomb material 1, the internal prepreg sheet material 9, the peel ply material 8, and the release paper. By heating and pressurizing 7 at a predetermined temperature and a predetermined pressing force for a predetermined time using a heating plate 6, the internal prepreg sheet material 9, which was set in contact with the honeycomb material 1, is peel-ply material 8 and released. Heat and pressure are applied via the paper 7. Due to this heating and pressurization, the resin contained in the internal prepreg sheet material 9 is melted, and a portion thereof flows out to the honeycomb material 1 side and the peel ply material 8 side, respectively. However, the resin (not shown) that has flowed out to the honeycomb material 1 side adheres to the cell wall end portions 4a of the honeycomb material 1.

In addition, the resin that flowed out to the peel ply material 8 side (not shown)
penetrates into the weave of the peel ply material 8. by the way,
Since the release paper 7 is placed closely on the outer surface of the peel ply material 8, the resin that has entered into the peel ply material 8 is
There is no leakage from the outer surface side of the peel ply material 8.

Next, by curing the resin in this state, the internal surface member 10 is formed from the completely cured internal prepreg sheet material 9. The lower surface of this internal surface member 10 is joined to the honeycomb material 1 by the resin that has flowed out and adhered to the cell wall end portion 4a, and the resin that has entered into the peel ply material 8 is
It remains in the invaded state and hardens.

Note that the inner surface member 10 formed in this way is
Since it is formed from the internal prepreg sheet material 9 made of a flexible material, due to the synergistic effects of resin contraction due to heating and pressing due to pressure during the forming process, most of the portions corresponding to the hollow portions 3 of each cell 2 are In this case, a substantially spherical concave portion 11 is formed within the hollow portion 3.

The internal surface member forming process is as described above.

Next, the rough surface forming process will be explained with reference to FIG.

In the internal surface member forming step described above, the peel ply material 8 penetrates into the weave of the formed internal surface member 10 and is positioned in a polymerized state via the hardened resin;
By peeling off the release paper 7 that is closely positioned on the peel ply material 8, the surface of the internal surface member 10 is penetrated into the weave of the peel ply material 8 over its entire surface, and the intrusion state is A rough surface 12 consisting of fine irregularities formed by the completely cured resin is formed.

Note that when the peel ply material 8 is peeled off from the inner surface member 10, the inner surface member 10 and the peel ply material 8 penetrate into the weave of the peel ply material 8 in the process of forming the inner surface member 10, and the hardened inner surface member Although the resin No. 10 has penetrated into the weave of the peel ply material 8 and is in a polymerized state, the two are not completely bonded, so the peel ply material 8 can be easily removed by peeling it off from the end.
can be peeled off.

The rough surface forming process is as follows.

Next, regarding the final process, see Figures 4 and 5 (see Figure 2).
(see also figure).

First, as shown in FIG. 4, between the hot plates 6 of the hot press 5,
Internal surface member 10 having a rough surface 12 formed on its surface
External prepreg sheet material 13 is placed on the rough surface 12 of each
After setting the release paper 7 on the surface of the sheet material 13, the material contained in the external prepreg sheet material 13 is heated and pressurized for a predetermined period of time under predetermined heating and pressurizing conditions using the heating plate 6. The resin melts and a part of it becomes the inner surface member 1.
It flows out to the 0 side.

By the way, as the heating and pressurization by the hot platen 6 progresses, among the resin that has flowed out, first, a portion of the resin that has been pressed by the internal surface member 10 and the hot platen 6 corresponds to the cell walls 4 of the honeycomb material 1. External prepreg sheet material 1 located at the site
The resin (not shown) flowing out from 3 fills the rough surface 12 of the internal surface member 10 located at that location, and the other resin, that is, the surplus resin, spreads over the rough surface in the vicinity without stopping there. It moves in the direction of the recess 11 of the inner surface member 10 while filling the surface 12, and eventually reaches the recess 11 and accumulates there.

In this way, the resin flows out from the external prepreg sheet material 13 at the pressed area and fills the rough surface 12 while accumulating in the recess 11, causing the rough surface 1 of the internal surface member 10 to
2 and the recess 11 are gradually filled. therefore,
For example, even if pinholes exist in the recess 11, these pinholes are also filled. Furthermore, the resin that has filled the rough surface 12 and the recesses 11 of the inner surface member 10 adheres to the entire surface of the inner surface member 10 at the same time.

In addition, in this process, the external prepreg sheet material 13 that is heated and pressurized has a synergistic effect such as shrinkage of the resin due to heating and pressing due to pressurization, as in the case of forming the internal surface member 10. The effect of forming a recess or the like occurs in a portion corresponding to the recess 11 of the inner surface member 10, that is, a portion corresponding to the hollow portion 3 of the cell 2 of the cam member 1. , this recess 11
This is blocked by the resin that has accumulated to fill the area.

In the final stage of this process, the external prepreg sheet material 13 is uniformly pressurized over the entire surface by the heating platen 6, so that after heating and pressurizing it under predetermined conditions for a predetermined time, the resin is cured. , an external surface member 14 formed from a fully cured external prepreg sheet material 13.
, there are almost no recesses, etc., and the outer surface member 1
4 has high planar accuracy.

As a result, a honeycomb panel 16 including a surface material 15 with excellent planar accuracy, which is composed of the outer surface member 14 and the inner surface member 10, is obtained.

Further, since the outer surface member 14 and the inner surface member 10 forming the surface material 15 are integrally and firmly joined via the rough surface 12 of the inner surface member 10, the outer surface member 14
A situation such as peeling off from the inner surface member 10 does not occur at all.

In addition, in the above-mentioned example, the method of forming the flat honeycomb panel 16 using the hot press 6 was explained, but the present invention is not limited to the example. When molding, a core material for forming a curved surface (for example, an overexpanded core) is used, and each member is set in a predetermined positional relationship on a mold member having a curved mold surface, By forming each member set in such a state using, for example, a heating and pressurizing furnace such as an autoclave, a curved honeycomb panel with a surface material made of prepreg sheet material with excellent surface precision can be easily produced. can be molded.

The final process looks like this.

The method for manufacturing a honeycomb panel according to the present invention is as described above.

Therefore, since the inner surface member 10 made of the inner prepreg sheet material 9 is formed through the peel ply material 8, the surface of the inner surface member 10 is coated with fine particles by simply peeling off the peel ply material 8 after forming. A rough surface 12 having roughness is formed.

Next, an external prepreg sheet material 13 is set on the rough surface 12 of the internal surface member 10, and when the external prepreg sheet material 13 is heated and pressed by the hot press 5 to form the external surface member 14, for example, a recess is formed in the internal surface member 10. 11, etc., the rough surface 12 and recesses 11, etc. of the inner surface member 10 are gradually filled with resin flowing out from the outer buri pregusi member 13 as heating and pressing by the hot press 5 progresses. Also, at the same time, these resins have a rough surface 1
2 completely adheres to the surface. However, at the final stage of this process, the external prepreg sheet material 13 is uniformly pressed over the entire surface by the hot platen 6, so the formed external surface member 14 has high planar accuracy. As a result, it is possible to form a honeycomb panel 16 having a surface material 15 with excellent planar accuracy, which is composed of the outer surface member 14 and the inner surface member 10.

In addition, since the outer surface member 14 and the inner surface member 10 forming the surface material 15 are joined via the rough surface 12 of the inner surface member 10, they are extremely firmly joined.

"Effects of the Invention" As detailed above, the method for manufacturing a honeycomb panel according to the present invention exhibits the following effects.

That is, according to the method for manufacturing a honeycomb panel of the present invention, the inner surface member made of the inner prepreg sheet material that is first formed and directly joined to the honeycomb material is formed through a peel ply material during formation. Therefore, by simply peeling off the peel ply material after formation, a rough surface consisting of fine irregularities is formed on its surface.

Next, when forming an external surface member made of an external prepreg sheet material on the rough surface of this internal surface member, during this process, the resin contained in the external prepreg sheet material that melted and flowed out caused The rough surfaces, recesses, etc. of the internal surface member are filled, and at the final stage of this process, the external prepreg sheet material is uniformly pressurized over the entire surface by a heating and pressurizing device, so the formed external surface member has a high It has flatness accuracy. As a result, it is possible to obtain a No. 1 nicomb panel having a surface material with excellent planar accuracy, consisting of an outer surface member and an inner surface member that are firmly joined to each other.

Therefore, this honeycomb panel manufacturing method eliminates the need for troublesome and man-hour-intensive correction work using putty, and surface roughening to strengthen putty adhesion, making it easy to form honeycomb panels. Moreover, since a honeycomb panel with excellent planar accuracy can be formed without performing finishing processing such as polishing, it is possible to significantly reduce the forming cost.

In this way, the problems that existed in this type of conventional example are completely eliminated, and the effects of the present invention are remarkable and great.

[Brief explanation of drawings]

The drawings show an example of the method for manufacturing a honeycomb panel according to the present invention, and FIG. 1 is a schematic perspective view of a honeycomb material;
Figures 2 to 5 each show the manufacturing process of the honeycomb panel, and Figure 2 shows the honeycomb material, the lower prepreg sheet material, the peel ply material, and the release paper being placed between the hot plates of a hot press. FIG. 3 is an explanatory diagram showing the state in which the peel ply material and release paper are peeled off from the inner surface member joined to the honeycomb material. FIG. FIG. 5 is an explanatory view of the main parts showing a state in which the external prepreg sheet material and the release paper are set on the inner surface member. FIG. 5 is an explanatory view of the main parts showing the process of peeling the release paper from the surface material. 1...Honeycomb material, 2...Cell, 3.
...Hollow part, 4...Cell wall, 4a...
... Cell wall end, 5 ... Hot press, 6.
...Heating plate, 7...Release paper, 8...
・Peel ply material, 9... Internal prepreg sheet material, 10... Internal surface member, 11...
・Concavity, 12... Rough surface, 13... External prepreg sheet material, 14... External surface member,
15... Surface material, 16... Honeycomb panel.

Claims (1)

[Claims] A method for manufacturing a honeycomb panel in which a honeycomb material is used as a core material and a surface material made of a prepreg sheet material is bonded to both sides of the honeycomb material, the honeycomb material being centered on a mold member, , an internal prepreg sheet material joining preparation step of setting an internal prepreg sheet material, a peel ply material, and a release paper in order from the inside, and an internal prepreg sheet material set on the mold member,
The internal prepreg sheet material is joined to the honeycomb material by heating and pressing with a heating and pressing device through the peel ply material and release paper, and the internal surface member forming process is performed to form an internal surface member. A rough surface forming step in which the peel ply material is peeled off from the inner surface member and a rough surface is formed on the surface of the inner surface member, and then an outer prepreg sheet material is set on the surface of the inner surface member and set in this state. The prepared external prepreg sheet material,
A method for manufacturing a honeycomb panel, comprising the steps of forming an external surface member by applying heat and pressure using the heating and pressurizing device, and a final step of joining the outer surface member to the inner surface member to form a surface material.