JPH0467122B2 - - Google Patents

Description

Detailed Description of the Invention (Field of Industrial Application) The present invention relates to gauges for inspecting the accuracy of vehicle parts, exterior panels, or interior materials (trim parts), and devices and jigs arranged in the manufacturing process. This article relates to the structure of a structure used in a model that serves as an accuracy standard, etc., and its manufacturing method.

(Prior Art) Conventionally, as shown in FIGS. 1 and 2, structures C such as inspection gauges and models have a surface layer 1 made of gel coat resin and an epoxy resin impregnated layer laminated on the inner surface of the surface layer 1. The glass cloth layer 2 is made of glass cloth, and the glass cloth layer 2 is composed of an FRP pipe 3 which is bonded with resin. The glass cloth layer is composed of about 9 layers laminated to maintain rigidity and precision. was.

In addition, what is shown by 4 in the figure is a leg made of epoxy FRP pipe, 5 is a frame made of epoxy FRP pipe,
6 is a base made of epoxy resin containing aluminum powder, 7
is a joint made of epoxy FRP.

However, in the case of such a conventional structure C, firstly, a glass cloth layer 2 with a thickness of about 9 layers and an FRP pipe 3 are used as a back-up structure that backs up on the surface layer 1. Therefore, the amount of resin used is large and the overall weight is considerable, for example, for medium and large inspection gauges, the weight is about 50Kg to 100Kg, which poses the problem that it is impossible to transport by one person. Was.

Secondly, since the legs 4 and frame 5 are made of epoxy FRP pipes, if there is any discrepancy in dimensional accuracy or mounting position, the surface layer 1 will be distorted.
Furthermore, since the resin used for the joint part 7 is also covered, the curing heat often causes dents in the surface layer 1, and these causes have the problem of poor finishing accuracy of the surface layer 1. Ta.

In addition, since the structure C uses the legs 4 and the frame 5, etc., it has a high structure and is bulky when stored or disposed of.
Since a large amount of pipes and the like are used, this method has the problem of being expensive.

Next, to explain the conventional manufacturing method of structure C, first, a weir is created around the master model,
Apply gel coat resin. After that, glass cloth is laminated to form a glass cloth layer 2.

Next, fix the frame 5 at a position above the master model where the necessary dimensions are secured, via the pillar and support frame,
A structure was formed by adhering the legs 4 between the frame 5 and the glass cloth layer 2 with a resin containing glass tips, tape, etc.

However, in the conventional manufacturing method of the structure C, since it is made by laminating a large number of glass cloth layers 2, it not only takes a lot of man-hours, but also requires 4 to 5 layers due to the resin curing temperature. After stacking,
The problem was that the process had to be repeated for several hours to a day and then repeated the next day, requiring at least two days.

In addition, since the surface layer 1 and the glass cloth layer 2 are prone to distortion and surface waviness due to resin curing heat, etc., the work requires skill and it is difficult to ensure a certain level of precision. It had the problem that.

Therefore, in order to improve the above-mentioned problems, a structure such as an inspection gauge model using a hard resin foam block as a back-up structure and its manufacturing method (Japanese Patent Laid-Open No. 122301/1983) was proposed.
No., JP-A-57-194172, JP-A-57-196101)
Although we were able to improve the conventional problems in terms of weight, manufacturing workability, and cost, it was still not sufficient, and the finishing accuracy of the structure was also improved. Although this method is improved over the conventional method, it still has the problem that the resin curing heat may cause dissolution defects in the foamed structure and roughness and waviness of the surface layer.

(Object of the Invention) The present invention has been made to solve the above-mentioned problems, and the purpose of the present invention is to provide a lightweight, high-precision, shortened manufacturing time and cost reduction. The object of the present invention is to provide a structure such as an inspection gauge model, etc., which can also be used as a test gauge, and a method for manufacturing the same.

(Structure of the Invention) That is, in order to achieve this object, a structure such as an inspection gauge model of the present invention has a central core formed of a honeycomb core, and an outer surface of the honeycomb core made of resin-impregnated glass. Although the cloth was laminated, it was formed by a glass cloth layer, and at least the upper surface of the structure among the outer surfaces of the glass cloth layer was formed with a coating layer of gel coat resin, and the honeycomb core of the central portion was formed to match the master motel surface. A slit is provided for this purpose, and the slit is filled with foamed resin.

In addition, the method for manufacturing structures such as inspection gauges and models of the present invention includes making slits in a honeycomb core,
A honeycomb core is molded to match the surface of the master model, and then the slits are filled with foamed resin to form a center core of the honeycomb core.Then, the inner surface of the master model with the center core removed After applying a mold release agent, a gel coat resin is applied, and a glass cloth is laminated on the gel coat resin while being impregnated with the resin, and then a central core made of the honeycomb core is applied onto the glass cloth layer. Then, glass cloth is laminated while impregnating the back side of the core with resin, and after the resin hardens, it is removed from the master model and manufactured.

(Effects of the Invention) Therefore, in the structure of the present invention, since a honeycomb core is used in the central portion and the slit portion is filled with foamed resin, it cannot be used as a back-up structure. Sufficient rigidity can be obtained, and because of this high rigidity, the amount of resin used for the glass cloth layer can be significantly reduced, resulting in an extremely lightweight structure. Furthermore, during the manufacturing process, even if gel coat resin or resin-impregnated glass cloth is laminated between the honeycomb core of the master model, there will be no thermal deformation because the curing heat can be released from the space of the honeycomb core. Since slits are formed in the honeycomb core to match the master model surface, it is possible to achieve a highly accurate structure.

Further, the method for manufacturing a structure of the present invention not only has the effect of manufacturing a lightweight and highly accurate structure as described above, but also can significantly reduce the number of laminated glass cloth layers. In addition, the waiting time for the resin to harden is significantly shortened, and the honeycomb core can be easily formed, which has the effect of shortening the manufacturing time.In addition, the amount of resin used can be significantly reduced as well as shortening the manufacturing time. Therefore, it is possible to reduce manufacturing costs as well.

(Example) In describing an example of the present invention, an automobile fender inspection gauge will be used as an example.

First, to explain the structure, reference numeral 8 is a central core part, and as shown in FIG. 9, the central core part of the structure D is formed by this honeycomb core 8a. I am using it. The honeycomb core 8a has a master model 9.
A slit 8a' is provided to match the inner surface shape of the slit 8a', and a portion expanded by the slit 8a' is filled with foamed urethane resin 8b.

In this embodiment, a plurality of narrow honeycomb cores 8a are bonded and used, and the bonded portion 8c is bonded with hot melt to fill in the irregularities on the end surface of the honeycomb cores 8a and to bond them together. There is.

Reference numeral 10 denotes a glass cloth layer, in which a glass cloth 10a impregnated with epoxy resin is laminated on the outer surface of the honeycomb core 8a, and the upper surface side of the structure D is layered with a thick glass cloth and a thin glass cloth. 2 sheets of thick glass cloth and 1 sheet of thin glass cloth are stacked on the bottom side of structure D.
The sheets are stacked.

11 is a coating layer, and the glass cloth layer 1
0, the top and side surfaces of structure D are covered with gel coat resin.

Note that the legs shown by 12 in FIG. 9 are made of a commercially available honeycomb plate in which the upper and lower openings of the honeycomb core are laminated with FRP. Also, 13
14 is a base made of epoxy resin containing aluminum powder, and 14 is a joint made of epoxy FRP.

Next, we will explain how to manufacture the structure.
First, as shown in FIG. 3, a slit 8a' is made in the honeycomb core 8a with a cutter knife to match the inner surface shape of the master model 9, and the honeycomb core 8a is molded. How to insert this slit 8a' is as follows.
If the inner surface of the master model 9 is a curved convex surface as in the example, a notch is made from the top side to match it, and conversely, if it is a curved convex surface, it is cut out from the top side or a notch is made from the bottom side. A slit 8a' is made in the honeycomb core 8a by various methods such as making a cut in the side surface and curving it laterally.

Thereafter, foamed urethane resin 8b is injected and filled into the expanded portion of the slit 8a', and the honeycomb cores 8a are bonded to each other by hot melt bonding (hot melt bonded portion 8
c) As shown in FIG. 4, the honeycomb core 8
A central core portion 8 is formed by a. In addition, slit 8
Filling a' with the foamed urethane resin 8b may be done while it is in the master model 9, or it may be removed from the master model 9 because it will not deform unless an external force is applied. It may be done in the same state.

Next, after applying a mold release material 15 to the inner surface of the master model 9 from which the core portion 8 has been removed (in the case of the example, it is applied before forming the core portion), gel coat resin 11a is applied to the inner surface of the master model 9. The gel coat resin 11a is coated on the inner surface, and as shown in FIG. 5, a glass cloth 10a is laminated on the gel coat resin 11a while impregnating it with epoxy resin.

Note that the mold release material 15 is applied using the gel coat resin 11a.
Any time is fine as long as it is before applying. Further, the glass cloth 10a is made by first stretching a thin glass cloth 10a that can fit easily even in a narrow space, and then laminating one sheet of thick glass cloth 10a.

Next, as shown in FIG.
is applied to the glass cloth 10a before the epoxy resin impregnated with it dries and hardens for resin bonding, and the glass cloth 10a is laminated while impregnating the back surface of the core 8 with the epoxy resin.
Incidentally, since a reference plane is necessary for measuring the structure D of the example, etc., the legs 12 and base 13 made of honeycomb plates are bonded before laminating the glass cloth 10a. In addition, when laminating the glass cloth 10a on the back side of the center core part, two thick glass cloths 10a are laminated.
This is because there is a surface layer 11 made of gel coat resin 11a on the surface of the core 8, so the surface layer 11 is layered to balance the amount of resin. It has more layers on the back side.

Thereafter, after confirming that the resin is partially cured, the weir 9a is removed from the master model 9 and the mold is demolded, as shown in FIG. If necessary, the base 13 is machined to give a surface finish after the resin has hardened and before demolding.

As shown in FIG. 8, after demolding, resin burrs 11a' and the like are removed and the surface is finished to produce a structure D.

Therefore, in the structure D of this example,
A honeycomb core 8a is used for the central core part 8, and a foamed urethane resin 8b is used in the expanded part by the slit 8a'.
As a back-up structure, the rigidity and strength of the honeycomb core 8a are higher than that of the glass cloth layer 10 formed by laminating the glass cloth 10a.
In combination with this, high back-up rigidity can be obtained.

Moreover, since the honeycomb core 8a itself has high rigidity, the rigidity reinforcement by the glass cloth 10a is sufficient even with two or three layers as in the embodiment, so the resin used for the glass cloth layer is sufficient. The amount can be significantly reduced, and as a result, the structure D can be extremely lightweight.

As an example, the front fender inspection gauge with the conventional structure shown in Figs. In the case of inspection gauges and inspection models, the weight can be reduced by an average of about 1/5 or even 1/10 compared to conventional structures, and can be carried by one person (within 20 kg). This has improved work and safety during handling.

Also, during the manufacturing process, a gel coat resin 11a is added between the master model 9 and the honeycomb core 8a.
Glass cloth 10a impregnated with or epoxy resin
Even if the honeycomb core 8a is laminated, the curing heat can be released from a large number of spaces in the honeycomb core 8a, so there is no thermal deformation due to the curing heat.Moreover, the slit 8a' is formed in the honeycomb core 8a to form the master. Since the shape matches the inner surface of the model 9, the structure D can have high precision. Incidentally, in the case of a large structure as in the embodiment, by forming the hollow portion 16, it is possible to prevent the surface of the structure from waviness.

Further, even if the structure D has legs 12 as in the embodiment, it can be made thinner and less bulky than a conventional structure without a frame or leg assembly. Coupled with the light weight, it is easy to handle, and space can be used effectively when stored on a shelf or propped up.

Furthermore, since the amount of resin used is small, industrial waste can be reduced at the time of disposal.

In addition, the method for manufacturing the structure D of this embodiment not only makes it possible to manufacture the structure D having various advantages such as high rigidity, light weight, and high precision as described above, but also enables the production of the glass cloth 10a. Since the number of laminated sheets can be significantly reduced, the time required to wait for the resin to harden is significantly shortened, and the molding of the honeycomb core 8a is as easy as inserting a slit 8a' and filling the expanded portion with the foamed urethane resin 8b. This makes it possible to significantly shorten manufacturing time.

Moreover, along with the reduction in manufacturing time as mentioned above,
The amount of resin used can be significantly reduced, and if a narrow honeycomb core 8a is used as in the embodiment, waste materials can be used, so costs can be reduced.

Generally, honeycomb products with curved shapes are
It is made by laminating FRP onto a honeycomb core block that has been machined using NC (numerical control) or copying. In this case, processing equipment is required, processing is time-consuming, and material is wasted. It has the following drawbacks. However, the present invention takes this point into consideration and attempts to eliminate these drawbacks by employing a method of forming slits 8a' in the honeycomb core 8a and filling the honeycomb core with foamed resin.

Although the embodiments of the present invention have been described above in detail with reference to the drawings, the specific configuration and manufacturing method are not limited to the embodiments. Of course, it can also be applied to the structure of

In addition, the material of the honeycomb core is not limited to aluminum honeycomb, but also includes FRP honeycomb, paper honeycomb, etc.
A honeycomb core made of other materials may also be used.

In addition, in the example, a foamed urethane resin is used as the foamed resin, and the foamed urethane resin is one-component, spray-like, easy to handle, quick-drying, room-temperature processability, precision, and cost-effective. Although it is preferable because it is economically inexpensive, it is not limited to foamed urethane resin, and other foamed resins such as the same foamed epoxy resin as the glass cloth layer may also be used.

Furthermore, in the example, multiple honeycomb cores are bonded together using hot melt, but since small inspection gauges can be manufactured using a single honeycomb core, bonding using hot melt is not an essential requirement. do not have.

In addition, the number of laminated layers of glass cloth may be set appropriately considering the size and rigidity of the structure.
It is not limited to the number of laminated layers in the example.

Further, since the legs are attached only when the structure is necessary for measurements, etc., they may be omitted for the purpose of the structure.

[Brief explanation of drawings]

Fig. 1 is a perspective view showing a conventional structure, Fig. 2 is a sectional view taken along line A-A in Fig. 1, Figs.
5, 6, and 7 are explanatory perspective views illustrating a method of manufacturing a structure according to an embodiment of the present invention, FIG. 8 is a perspective view showing a structure according to an embodiment of the present invention, and FIG. FIG. 8 is a sectional view taken along line B-B in FIG. D... Structure, 8... Central core, 8a... Honeycomb core, 8a'... Slit, 8b... Foamed urethane resin (foamed resin), 10... Glass cloth layer,
10a...Glass cloth, 11...Coating layer, 11
a... Gel coat resin, 9... Master model, 1
5...Mold release agent.

Claims (1)

[Scope of Claims] 1. The center core of the structure is formed by a honeycomb core, the outer surface of the honeycomb core is formed by a glass cloth layer laminated with resin-impregnated glass cloth, and the outer surface of the glass cloth layer is At least the upper surface of the structure is formed with a coating layer of gale coat resin, and the honeycomb core in the central portion is provided with a slit to match the master model surface, and the slit is filled with foamed resin. Structures such as inspection gauges and models characterized by 2.Mold the honeycomb core by making a slit in the honeycomb core so that it matches the master model surface, and then
The slit is filled with foamed resin to form a honeycomb core core, and then a release agent is applied to the inner surface of the master model with the core removed.
A gel coat resin is applied, a glass cloth is laminated while impregnating the gel coat resin with the resin, and then a core made of the honeycomb core is applied onto the glass cloth layer and bonded with the resin, and the core is bonded with the resin. A method for manufacturing inspection gauges, models, etc., characterized by laminating glass cloth while impregnating the back side with resin, and removing the mold from the master model after the resin hardens.