JPH05237954A - Manufacture of curved honeycomb panel - Google Patents

Abstract

PURPOSE:To provide a method for manufacturing a curved honeycomb panel wherein a unidirectional base material with which plastics such as resin is combined can be used without cracks when an inner face plate and an outer face plate are molded with pressure by a common die, and a spacer panel to be used at that time is excellent in light weight, rigidity, hardness, heat resistance, smoothness, durability, and preciseness of plane. CONSTITUTION:By using a common die C having a predetermined curvature, a honeycomb core as a core material is inserted between an inner face plate 6 and an outer face plate 7 molded with pressure, treated with pressure molding, so that a curved honeycomb panel having a surface of second order, a surface of third order, and a surface formed by continuation of these can be obtained. At the pressure molding of the inner face plate 6, an FRP plate S2 is stuck on both faces of a honeycomb core S1 and a spacer panel S having predetermined curvature and thickness is provided between the die C and the plate.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a curved honeycomb panel. That is, a quadric surface, a cubic surface, a curved surface in which these curved surfaces are integrally continuous, and other multi-dimensional curved surfaces are provided.
The present invention relates to a method for manufacturing a curved honeycomb panel used as a structural material.

[0002]

2. Description of the Related Art Such a curved honeycomb panel is provided with a predetermined curvature by bonding an inner surface plate and an outer surface plate made of fiber reinforced plastics, that is, FRP, to both sides of a honeycomb core as a core material. And, in such a curved honeycomb panel, the inner surface plate and the outer surface plate are different from each other in radius by the thickness of the honeycomb core as a core material. Therefore, conventionally, the inner surface plate and the outer surface plate each have a dedicated mold in a prepreg state. After being pressure-molded using, the curved honeycomb panels were adhered to both surfaces of the honeycomb core and pressure-molded. However, in such a conventional manufacturing method, since the inner surface plate and the outer surface plate are pressure-molded by using respective dedicated molds, it is troublesome,
Problems were pointed out in terms of period, cost, quality, etc.
Therefore, recently, there has been developed a manufacturing method of a pressure molding process in which an inner surface plate and an outer surface plate are pressure-molded using a common mold and then adhered to both surfaces of a honeycomb core.

FIG. 6 is used to explain the recently developed method for manufacturing a curved honeycomb panel. FIG. 6 (1) is a front sectional view of an inner plate and an outer plate during pressure molding, and FIG. FIG. 3C is a front cross-sectional view during the final pressure molding process, and FIG. That is, in the manufacturing method of the conventional example of FIG. 6, first, as shown in (1), the inner surface plate 1 and the outer surface plate 2 are sequentially pressure-molded by using a common mold C having a predetermined curvature, and then, (2) As shown in the figure, pressure molding is performed by using the mold C and sandwiching and adhering the honeycomb core 3 having a predetermined wall thickness H between the inner surface plate 1 and the outer surface plate 2. A curved honeycomb panel having a predetermined curvature has been manufactured in which an inner face plate 1 and an outer face plate 2 made of FRP are adhered to both sides of a honeycomb core 3 which is a barrel. In the figure, 4 is a vacuum sheet. In the method for manufacturing the curved honeycomb panel of FIG. 6, since the common mold C is used, there are problems in terms of labor, period, cost, quality, etc. which have been pointed out in the above-mentioned conventional example. Had been resolved.

[0004]

By the way, the following problems have been pointed out in the conventional example of FIG.
In this recently developed method for manufacturing a curved honeycomb panel, the inner face plate 1 and the outer face plate 2 are made of FRP in which a plastic material such as resin is combined with a woven base material. In other words, glass fiber and other fibers are plain weave, satin weave, twill weave, etc., and a woven base material woven with warp and weft threads is used, which is impregnated with resin or the like and adhered to it. It has been considered difficult to use a unidirectional base material called warp yarns called "uni". In other words, a product made of FRP using a woven base material has flexibility and
It has controllability, and even if a common mold C is used, the radius R corresponding to each is easily formed at the time of pressure forming processing of FIG. 1
The outer plate 2 is obtained. On the other hand, if the FRP is made by impregnating and adhering resin on a unidirectional base material called Uni.
If a product made of a material is used, cracks 5 shown in FIG. 6 (3) will be formed in the inner surface plate 1, the outer surface plate 2, etc. during the pressure forming process of FIG. Was becoming.

This is because the one using a uni or unidirectional base material has high tensile strength and elastic modulus, but it is poor in flexibility and controllability like the one using a woven base material. If a common mold C is used even though the radius R of the outer surface plate 2 is different, stress is applied to the inner surface plate 1 and the outer surface plate 2 which are difficult to expand and contract during the pressure forming process, and thin crack-like cracks 5 are generated. It was in this way,
In the conventional method for manufacturing the curved honeycomb panel using the common mold C, there is a problem that a uni-directional one, that is, a unidirectional substrate cannot be used for the inner face plate 1 and the outer face plate 2.

In view of such circumstances, the present invention has been made to solve the problems of the above-mentioned conventional example, in which FRP plates are attached to both surfaces of the honeycomb core and have a predetermined curvature and a predetermined wall thickness. By using the spacer panel,
First, in the case of press-molding the inner surface plate and the outer surface plate with a common mold, it is possible to use a unit, that is, a unidirectional base material in which plastics such as resin is combined, and
Another object of the present invention is to propose a method for manufacturing a curved honeycomb panel in which this spacer panel is also excellent in lightness, rigidity, hardness, heat resistance, smoothness, durability, plane accuracy, and the like.

[0007]

The technical means of the present invention for achieving this object are as follows. That is, this manufacturing method relates to a method for manufacturing a curved honeycomb panel having a predetermined curvature in which an inner surface plate and an outer surface plate made of FRP are bonded to both surfaces of a honeycomb core as a core material. Then, in advance, by a mold for its production having a predetermined curvature, FRP plates are attached to both sides of the honeycomb core for spacers, and the wall thickness is thinner than the curved honeycomb panel to be manufactured by the amount of the inner surface plate, The spacer panel is pressure molded. Then, first, while press-molding the outer plate with the mold,
The spacer panel is overlaid on the mold, and the inner surface plate is pressure-molded on the outer surface side thereof. Then, by sandwiching the honeycomb core, which is the core material, between the inner surface plate and the outer surface plate thus molded with an adhesive, and performing pressure molding with the mold, the curved honeycomb panel is obtained. Be done.

[0008]

Since the present invention comprises such means, it operates as follows. In this manufacturing method, a common mold having a predetermined curvature is used. First, by sandwiching a honeycomb core, which is a core material, between an inner surface plate and an outer surface plate that have been pressure-molded in advance, and performing pressure molding, a curved honeycomb panel is obtained. can get. At that time, FRP plates are attached to both surfaces of the honeycomb core for spacers, and the inner surface plate is preliminarily pressure-molded through spacer panels having a predetermined curvature and a predetermined thickness. Therefore, firstly, the inner surface plate and the outer surface plate are easily and accurately pressure-molded into a predetermined shape, for example, different radiuses are formed by the thickness of the honeycomb core as the core material. Therefore, even when a uni-directional base material, that is, a unidirectional base material, is used, cracks do not occur during the pressure molding process. Second
In addition, this spacer panel has a honeycomb core F
Since it is attached with an RP plate, it excels in lightness, rigidity, hardness, heat resistance, smoothness, durability, and plane accuracy.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below based on the embodiments shown in the drawings. 1, FIG. 2, FIG. 3, FIG. 4, and FIG.
Is used to explain an embodiment of the present invention, and (1) of FIG.
FIG. 9 is a front cross-sectional view of the spacer panel S during pressure molding,
(2) The figure is an enlarged view of a main part of the spacer panel S.
FIG. 2 (1) is a front sectional view of the outer surface plate 7 during pressure molding,
2 (2) is a front sectional view of the inner surface plate 6 during pressure molding,
FIG. 2 (3) is a front sectional view of the inner surface plate 6 using the contact plate during pressure molding. FIG. 3 is a perspective view of the pressure-molded inner surface plate 6, outer surface plate 7, honeycomb core 8 and the like, and FIG. 4 is a front cross-sectional view at the time of final pressure molding processing, and FIG. FIG. 1) is a perspective view of the manufactured curved honeycomb panel 9, and FIG. 5 (2) is a front sectional view thereof.

In this manufacturing method, first, the spacer panel S is manufactured and prepared as shown in FIG. That is, the mold C for manufacturing the curved honeycomb panel 9 (see FIG. 5) is prepared in advance.
Allows FR on both sides of the honeycomb core S ₁ for spacers.
The P plates S ₂ are attached, and the spacer panels S having a thickness smaller than that of the curved honeycomb panel 9 to be manufactured by the inner surface plate 6 are pressure-molded. First, the spacer panel S, which is the molding jig, will be described in detail. The wall thickness of the spacer panel S is obtained by removing the wall thickness of the inner surface plate 6 from the wall thickness of the curved honeycomb panel 9 as a product, that is,
The thickness is set to be the thickness H of the honeycomb core 8 as the core material (see FIGS. 4 and 5) plus the thickness of the outer surface plate 7. As the FRP plates S _{2 on} both sides of the spacer panel S, glass fiber,
Kevlar fiber, carbon fiber, hybrid fiber of these are used, and plastics such as epoxy modified resin and phenolic resin are used for these woven base materials or uni or unidirectional base materials (detailed later). Impregnation, adhesion,
A combination obtained by polymerization or the like is used. The FRP plate S ₂ is made of the same material as the inner surface plate 6 and the outer surface plate 7 of the curved honeycomb panel 9 as a product.
It is desirable because of the expansion coefficient during pressure molding.

Further, the FRP plate S _{2 of the} spacer panel S
Is made by stacking materials made of such materials, and in order to further improve its durability and flatness accuracy, a metal foil of aluminum, titanium, iron, etc.
A metal thin plate may be used, or a hard resin thin plate or the like may be used. The FRP plate S ₂ of such a spacer panel S has a release paper, a release agent or the like interposed between the FRP plate S ₂ and the inner surface plate 6 to be pressure-molded at the time of subsequent use in consideration of the releasability. However, this release paper or the like may cause wrinkles or the like on the surface of the inner surface plate 6.
Therefore, when the FRP plate S ₂ is molded, silicone or the like is added to the outermost layer of the resin within 10% or coated to ensure the above-mentioned releasability without using a release paper. You may do it. In this case, the FRP in which the thin plates of hard resin are laminated as described above
When it is applied to the plate S ₂ , it is necessary to consider it so as not to adversely affect the interlayer strength.

The spacer panel S in which such FRP plates S ₂ are attached to both sides of the honeycomb core S ₁ is a mold C for manufacturing the curved honeycomb panel 9 as a product, that is, a metal such as aluminum or iron or FRP. A honeycomb core S ₁ is sandwiched between FRP plates S ₂ which are still in the state of prepreg on a tool mandrel made of steel and pressure-molded. The mold C has a shape including, for example, a quadric surface, a cubic surface, a curved surface in which these curved surfaces are integrally continuous, or other multi-dimensional curved surface. For example, the inner surface plate 6 used conventionally.
Alternatively, it is conceivable to use either one for the outer surface plate 7, but in any case, the predetermined FRP plate S ₂ is pressure-molded using the common mold C. Further, when the spacer panel S is pressure-molded, a predetermined vacuum panel K (see FIGS. 2 (1) and (3) to be described later) as a contact plate is interposed between the spacer panel S and the vacuum sheet 10. If so, the spacer panel S, that is, the FRP plate S ₂ thereof having excellent smoothness on the outer surface on the side opposite to the mold C is obtained.
By using such a spacer panel S, it becomes possible to obtain the inner surface plate 6 having excellent smoothness on the outer surface.

Next, as shown in FIG. 2A, the outer surface plate 7 is pressure-molded by using a common mold C. In this illustrated example, the above-described vacuum panel K is used as a contact plate, so that the outer surface plate 7 having excellent smoothness on the outer surface on the side opposite to the mold C can be obtained. In this vacuum jig K, which is a molding jig, a ventilation material is attached to the upper surface of a vacuum honeycomb core in which cells are communicated with each other, and a thin plate material such as an FRP plate or a metal plate is attached to the lower surface. It has a predetermined curvature. Along with this, as shown in FIGS. 2 (2) and 3 (3), the spacer panel S is overlaid on the mold C, and the inner surface plate 6 is pressure-molded on the outer surface side thereof. If the outer surface plate 7 is pressure-molded first,
After the fact, the spacer panel S is set on the mold C and the inner surface plate 6 is pressure-molded, and conversely, when the inner surface plate 6 is pressure-molded first, the spacer panel S is removed from the mold C after the fact. After that, the outer surface plate 7 is pressure-molded. Further, in the example of FIG. (3), the above-mentioned vacuum panel K is used as the contact plate, and the inner surface plate 6 excellent in smoothness of the outer surface on the side opposite to the mold C and the spacer panel S can be obtained. ing.

By the way, such pressure molding is carried out by a vacuum back method or an autoclave method. That is, on the mold C and the spacer panel S, a prepreg in which a plastic material such as resin is combined with a base material is placed, and a vacuum sheet 10 having a high air permeability and a high flexibility is placed on the base material, and the surrounding area is covered. Spacer panel by attaching to mold C and sealing, and then pressurizing, depressurizing and vacuuming the interior and pressurizing it tightly from the outside (in the case of the autoclave method, by additionally applying air pressure from the outside) The inner surface plate 6 and the outer surface plate 7 are pressure-molded by being pressed into close contact with S, the mold C and the like. Then, the inner surface plate 6 and the outer surface plate 7 are cured or immediately before curing depending on the molding temperature and time, that is, a semi-cured prepreg state is finally changed to a cured plate, or immediately before curing during that period. It is obtained as a state. For example, if the former finally cured product is obtained in 60 minutes at a temperature of 150 degrees Celsius, the latter immediately before curing is, for example, 1 degree Celsius.
Obtained in 30 minutes at a temperature of 50 degrees or in 60 minutes at a temperature of 130 degrees Celsius. In this manner, for example, as shown in FIG. 3, the inner surface plate 6 and the outer surface plate 7 made of FRP and having a predetermined curvature, which have a quadric surface and a cubic surface and are integrally continuous, are pressure-molded. It

Next, as shown in FIG. 4, a honeycomb core 8 as a core material made of plastics or the like is interposed between a predetermined FRP inner surface plate 6 and outer surface plate 7 thus molded with an adhesive. The curved honeycomb panel 9 shown in FIG. 5 is obtained by sandwiching and performing pressure molding using the mold C. That is, the above-mentioned mold C is used again, and the outer surface plate 7 which is first molded thereon, and then the honeycomb core 8 which is a planar aggregate of a large number of cells are sliced into a constant thickness H, and further above The inner surface plates 6 formed in step 1 are stacked in order, an adhesive agent is interposed between them, and the inner surface plate 6 is covered with a vacuum sheet 10. Then, by performing pressure molding according to the vacuum back method or the autoclave method according to the above-mentioned conditions, as shown in FIG. 5, both sides of the honeycomb core 8 as the core material are covered with FRP surface plates. A certain inner surface plate 6 and an outer surface plate 7 are adhered to each other, and a curved honeycomb panel 9 having a predetermined curvature, which includes, for example, a quadric surface D and a cubic surface E and is integrally continuous, is manufactured.

The materials of the inner surface plate 6 and the outer surface plate 7 will be described. As the FRP inner surface plate 6 and outer surface plate 7, a combination of a base material and plastics such as resin is used. As such plastics,
For example, epoxy-modified resin, phenolic resin, etc. are used, and these are combined with the base material by impregnation, adhesion, polymerization and the like. As the base material, a woven base material or a unidirectional base material is used. First, the woven base material is made of glass fiber, Kevlar fiber, carbon fiber, hybrid fiber thereof, etc. by plain weave, satin weave, twill weave, etc. , Woven with warp and weft. On the other hand, the uni or unidirectional substrate is made of only warp yarns, although glass fibers, Kevlar fibers, carbon fibers, hybrid fibers thereof, etc. are also used.

Such a uni or unidirectional base material is, firstly, also called a complete uni, in which there are no weft yarns and only warp yarns are aligned in one direction, and secondly, such warp yarns. Which are sewn with a thin weft thread in order to align them and have excellent workability in weaving and workability in laminating. Thirdly, it is also called a high modulus weave. It is known that they are crimped with a weft thread for overlocking, which are stacked in the same direction. The above-mentioned second and third uni, that is, the weft yarns used in the unidirectional base material are made of a material or the like that has almost no effect on the strength of the warp yarn, and are generally considered to be within the range of the uni or unidirectional base material. There is. And while this uni or unidirectional base material has higher tensile strength, elasticity, etc. than the woven base material, it is inferior in flexibility and controllability that easily fit the molding conditions, that is, followability and stretchability. ..

The method of manufacturing the curved honeycomb panel 9 according to the present invention is as described above. Then it becomes as follows. In the method for manufacturing the curved honeycomb panel 9, a common mold C having a predetermined curvature is used. First, pressure molding is performed in a prepreg state to cure the inner surface plate 6 and the outer surface plate 7 between the inner surface plate 6 and the outer surface plate 7 which are in a state of being cured or just before being cured. The honeycomb core 8 as a core material is sandwiched between
A predetermined curved honeycomb panel 9 can be obtained by performing a pressure forming process such as bonding. At that time, in this manufacturing method, the FRP plates S ₂ are attached to both surfaces of the honeycomb core S ₁ for spacers, and the spacer panel S having a predetermined curvature and a predetermined wall thickness, that is, inside the curved honeycomb panel 9 to be manufactured. The inner surface plate 6 is preliminarily pressure-molded through the spacer panel S having a thickness smaller than that of the surface plate 6. Therefore, in the method for manufacturing the curved honeycomb panel 9, the following first and second steps are performed.

First, since the inner surface plate 6 is pressure-molded on the common mold C through the spacer panel S, the inner surface plate 6 and the outer surface plate 7 are formed of the meat of the honeycomb core 8 as a core material. Thickness H
It is easily and accurately pressure-molded into a predetermined shape, for example, a radius R different by the amount is formed. Therefore, although the inner surface plate 6 and the outer surface plate 7 using a uni-directional base material has high tensile strength and elastic modulus, it has poor flexibility and controllability and is difficult to expand and contract. Since it is molded, cracks 5 (see (3) in FIG. 6) as in the conventional example of this kind are generated even if the pressure molding process of sandwiching and bonding the honeycomb core 8 as a core material is performed. There is no. Secondly, since the spacer panel S used in this way is formed by attaching the FRP plate S ₂ to the honeycomb core S ₁ , the characteristics of the spacer panel S are utilized to reduce the weight, rigidity, hardness, heat resistance, smoothness, Excellent in durability and flatness.

[0020]

As described above, in the method for manufacturing the curved honeycomb panel 9 according to the present invention, the FRP plates are attached to both surfaces of the honeycomb core and the spacer panel having the predetermined curvature and the predetermined thickness is used. It has the following effects. First, in the case where the inner surface plate and the outer surface plate are pressure-molded by a common mold, a unit, that is, a unidirectional base material combined with plastics such as resin can be used without cracks. Therefore, it is possible to obtain a curved honeycomb panel which is excellent in tensile strength, elasticity, etc., by making the best use of the characteristics of the unit, that is, the unidirectional substrate. Second, the spacer panel
Excellent in lightness, rigidity, hardness, heat resistance, smoothness, durability, flatness, etc., easy to handle, easy to use and durable, and easy to set and remove from the mold by hand. , There is no hindrance to the manufacture of outer panel and curved honeycomb panel. As described above, the effects of the present invention are remarkably large, such as the problems existing in this type of conventional example are eliminated.

[Brief description of drawings]

BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is used to explain an example of a method for manufacturing a curved honeycomb panel according to the present invention. FIG. 1 (1) is a front cross-sectional view of a spacer panel during pressure molding, and FIG. 2 (2) is a spacer panel. FIG.

2A and 2B are used to explain the same embodiment, FIG. 1A is a front sectional view of an outer surface plate during pressure molding, and FIG. 2B is a front sectional view of an inner surface plate during pressure molding. ) The figure is a front cross-sectional view of the inner surface plate using the contact plate during pressure molding.

[Fig. 3] Fig. 3 is a perspective view of an inner surface plate and an outer surface plate, which are pressure-molded, a honeycomb core, and the like, which are used in the description of the embodiment.

FIG. 4 is a front cross-sectional view during the final pressure molding process, which is used for the description of the embodiment.

5 is a perspective view of a curved honeycomb panel manufactured, and FIG. 2 (2) is a front sectional view thereof for explaining the same embodiment.

FIG. 6 is used for explaining a method for manufacturing a curved honeycomb panel according to a conventional example. (1) is a front sectional view of an inner plate and an outer plate during pressure molding, and (2) is a final sectional view. A front cross-sectional view at the time of press forming, (3) is a perspective explanatory view of a state in which cracks are formed.

[Explanation of symbols]

1 Inner Surface Plate 2 Outer Surface Plate 3 Honeycomb Core 4 Vacuum Sheet 5 Crack 6 Inner Surface Plate 7 Outer Surface Plate 8 Honeycomb Core 9 Curved Honeycomb Panel 10 Vacuum Sheet C Type D Quadric Surface E Cubic Surface H Wall Thickness R R S Spacer Panel S ₁ Honeycomb core S ₂ FRP plate K vacuum panel

Continuation of front page (51) Int.Cl. ⁵ Identification number Office reference number FI technical display location // B29K 105: 08 B29L 9:00 4F

Claims (1)

[Claims] 1. A method for manufacturing a curved honeycomb panel having a predetermined curvature, wherein an inner surface plate and an outer surface plate made of FRP are adhered to both surfaces of a honeycomb core as a core material, which is for manufacturing the curved surface honeycomb panel having a predetermined curvature in advance. FRP plates are attached to both sides of the honeycomb core for the spacer by the mold of, and the spacer panel is pressure-molded, which is thinner than the curved honeycomb panel to be manufactured by the inner plate. While pressing the outer plate with the mold,
The inner panel is pressure-molded on the outer surface side by stacking the spacer panel on the mold, and then the honeycomb core as the core material is bonded with an adhesive between the inner panel and the outer panel thus molded. A method for manufacturing a curved honeycomb panel, characterized in that the curved honeycomb panel is obtained by sandwiching it through and performing pressure molding with the mold.