JPH0639937A - Manufacture of cubic honeycomb structure and device thereof - Google Patents

Abstract

PURPOSE:To make it possible to manufacture lightweight cubic honeycomb structure foamed material with a few defect and to property control the expansion ratio of the foamed material. CONSTITUTION:The cubic honeycomb production equipment 1 concerned consists of a tank 3, in which liquid ultraviolet-curing resin 2 is stored, a determinate quantity of air delivery pipe group 4, through which a determinate quantity of gas is delivered in the liquid ultraviolet-curing resin 2, a base plate, which controls the uppermost part of bubbles developed in the liquid ultraviolet-curing resin 2, lifting bars, with which the base plate is vertically moved, the moving and positioning device of the lifting bars and the like so as to deliver the determinate quantity of gas from the determinate quantity of gas from the determinate quantity of air delivery pipe group 4 in the liquid ultraviolet-curing resin 2 in order to grow a plurality of plys of bubbles on the rearside of the base plate. After that, by irradiating ultraviolet rays on the bubble aggregate emerged on liquids level so as to solidify the aggregate in order to produce formed material having cubic honeycomb structure.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for manufacturing a three-dimensional honeycomb structure, and more particularly to a method and an apparatus for manufacturing a three-dimensional honeycomb structure suitable for reducing the weight and improving the strength of a material. Regarding

[0002]

2. Description of the Related Art Conventionally, so-called honeycomb (honeycomb) structure materials have been widely used as interior and exterior materials for machines and structures in various industrial fields. As a kind of the honeycomb-shaped structural material, by generating a large number of bubbles inside the material, a large number of hollow polyhedrons inside the material, a structure in which each surface of adjacent polyhedrons are in contact with each other A foam material has been developed and the structure is used to reduce the weight.

[0003]

However, the above-mentioned prior art has the following problems. In the process of foaming inside the material, the foam formation position inside the material is accidentally determined, so it is easy for adjacent foams to connect to each other in the area where the foam inside the material is dense, and the local foam inside the material This causes a problem that the void portion is formed. On the other hand, in a portion where the bubbles inside the material are rough, the number of voids formed may be too small. In addition, the conventional manufacturing technique has a limitation that the ratio of the material as the base material of the foam material to the foam (foaming rate) cannot be increased so much. In addition, there is a problem that the produced foam material may have a partial defect, and stable quality cannot be ensured.

[0004]

SUMMARY OF THE INVENTION The present invention is to solve the above-mentioned problems.
An object of the present invention is to provide a method and a device for manufacturing a three-dimensional honeycomb structure capable of manufacturing a lightweight foamed material having a three-dimensional honeycomb structure with few defects and appropriately adjusting the foaming rate of the foamed material.

[0005]

In order to achieve the above object, a method for manufacturing a three-dimensional honeycomb structure according to the present invention comprises:
In the method for producing a three-dimensional honeycomb-shaped structure for producing a foamed material having a three-dimensional honeycomb-shaped structure, which comprises an aggregate in which face-shaped cells are sequentially bonded in the plane direction in a state where the surfaces of adjacent cells match each other, UV curing A process of inserting a plate into a tank in which a liquid consisting of a polymeric material is stored and a fixed amount of gas is discharged into the liquid, and a fixed amount of gas is discharged from the pipes to the bottom side of the plate in the liquid. And forming a dodecahedron-shaped bubble assembly,
It comprises a step of pulling up a plate having a bubble assembly formed on the lower surface side, and a step of irradiating ultraviolet rays around the bubble assembly on the lower surface side of the pulled up plate to individualize it. The manufacturing apparatus for a three-dimensional honeycomb-shaped structure of the present invention provides a foam material having a three-dimensional honeycomb-shaped structure, which is composed of an aggregate in which dodecahedron-shaped cells are sequentially connected in the plane direction in a state where the surfaces of adjacent cells match each other. In a manufacturing apparatus for a three-dimensional honeycomb structure to be manufactured, a tank in which a liquid made of an ultraviolet curable polymer material is stored, a plate to be inserted into the tank, an elevating of the plate with respect to the inside of the tank, and an inside of the tank And a plate for discharging a fixed amount of gas into a liquid, the plate being arranged in the tank and comprising a plurality of pipes in which three mutually adjacent pipes are arranged in an equilateral triangle shape. A group of pipes for forming a dodecahedron-shaped bubble assembly on the lower surface side, and the bubble assembly on the lower surface side of the plate pulled up from the liquid by the moving means are irradiated with ultraviolet rays. Those provided with the irradiating means for individuation.

[0006]

According to the present invention, when a foam material having a three-dimensional honeycomb structure is manufactured by the three-dimensional honeycomb structure manufacturing apparatus, it is adjacent to each other in a tank which stores a liquid made of an ultraviolet curable polymer material. After arranging the pipes in a state where the pipes form an equilateral triangle, the plate is inserted into the tank from above the pipes, and a fixed amount of gas is discharged from the pipes to the lower surface side of the plate in the liquid. After forming the aggregate of bubbles, the plate having the aggregate of bubbles formed on the lower surface side is appropriately pulled up, and the periphery of the aggregate is irradiated with ultraviolet rays to be solidified. As a result, a foam material having a three-dimensional honeycomb structure is manufactured. That is, in the present invention, it consists of an aggregate of bubbles having a regular array structure,
It is possible to manufacture a foam material having a three-dimensional honeycomb structure having a high foaming rate, an extremely light weight, few defects, high isotropic property, and excellent strength. Further, since it is possible to appropriately change the discharge amount of gas in the pipe group, the intensity of ultraviolet rays, the pulling rate of the foam material from the liquid, and the like, it is possible to change the foaming rate of the foam material. In addition, it is possible to manufacture a foam material having a large shape by appropriately increasing the number of bubbles formed on the lower surface of the plate. Further, even after the foam material is cured, there is little difference between the atmospheric pressure and the outside air pressure in each of the bubbles forming the foam material, so that it is possible to manufacture the foam material with less internal stress.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments to which the method and apparatus for manufacturing a three-dimensional honeycomb structure of the present invention are applied will be described below with reference to the drawings.

FIG. 1 is a schematic configuration diagram of a three-dimensional honeycomb structure manufacturing apparatus (hereinafter, referred to as a three-dimensional honeycomb manufacturing apparatus) of the present embodiment. The three-dimensional honeycomb manufacturing apparatus 1 is, for example, an automobile, a motorcycle, a ship, an aircraft, Used to manufacture foam materials used for interior and exterior materials such as trains (floors, window frames, doors, frames, bumpers, etc.), and stores UV curable resin liquid (UV curable polymer material) 2 Tank 3 to
An air fixed amount discharge pipe group 4 for discharging a fixed amount of gas into the ultraviolet curable resin liquid, a base plate 5 (see FIG. 14) for controlling the uppermost part of the bubbles generated in the ultraviolet curable resin liquid,
A pull-up rod 6 (see FIG. 14) that is a moving unit for moving up and down the base plate 5, a positioning device that moves the pull-up rod 6, and an irradiation unit that irradiates ultraviolet rays from four directions around the bubbles (above illustration not shown). ) And is provided.

The ultraviolet curable resin liquid 2 stored in the tank 3 of the three-dimensional honeycomb manufacturing apparatus 1 is adjusted so that the liquid surface always maintains a constant height.
Further, in the air constant amount discharge pipe group 4, three air constant amount discharge pipes 4B adjacent to each other form a large number of equilateral triangular sections on the upper surface of the pipe base portion 4A arranged in the ultraviolet curable resin liquid. It is arranged in.

Then, by the solid honeycomb manufacturing apparatus 1 having the above-described structure, the air constant amount discharge pipe group 4 is arranged in the ultraviolet curable resin liquid of the tank 3, the base plate 5 is inserted, and then the gas is discharged from each air constant amount discharge pipe 4B. By ejecting a fixed amount and growing the bubbles generated in the ultraviolet curable resin liquid on the lower surface side of the base plate 5, moving and pulling up the base plate 5 appropriately and irradiating the ultraviolet rays from four directions around the bubble aggregate, The foamed material is manufactured from a three-dimensional cell aggregate (three-dimensional honeycomb structure) having a regular array structure.

In this case, by appropriately changing the gas discharge amount from the air constant amount discharge pipe group 4 of the three-dimensional honeycomb manufacturing apparatus 1, the intensity of irradiation ultraviolet rays, the speed of pulling up the foam material from the ultraviolet curable resin liquid, etc. It is possible to change the foaming rate of the above, and it is also possible to control the shape of the bubbles from outside the device.

Next, a method of manufacturing a foam material having a three-dimensional honeycomb structure using the three-dimensional honeycomb manufacturing apparatus of the present embodiment configured as described above will be described mainly with reference to FIGS.

(1) Manufacturing process 1 A fixed amount of air consisting of a large number of fixed-quantity air discharge pipes 4B supported by a pipe base 4A in the ultraviolet curable resin liquid 3 stored in a tank 3 of a three-dimensional honeycomb manufacturing apparatus 1. After arranging the discharge pipe group 4, the positioning device is driven and the base plate 5 is inserted into the ultraviolet curable resin liquid 2 by the pulling rod 6 (FIG. 2).

(2) Manufacturing process 2 A gas supply device (not shown) for feeding gas to the air constant amount discharge pipe group 4 is driven to discharge a constant amount of gas from each air constant amount discharge pipe 4B into the ultraviolet curable resin liquid, and many Bubble K
Are formed (FIG. 3).

(3) Manufacturing Step 3 A large number of bubbles K are grown on the lower surface side of the base plate 5 in the ultraviolet curable resin liquid (FIG. 4).

(4) Manufacturing Step 4 On the lower surface side of the base plate 5 in the ultraviolet curable resin liquid, one stage of the bubble K having a constant size shape (oblique dodecahedron shape) is completed. In this case, the center of the completed first-stage bubble K is located at each apex of a large number of equilateral triangles formed by the air quantitative discharge pipes 4B (FIG. 5).

(5) Manufacturing process 5 The positioning device is driven to pull up the base plate 5 slightly in the ultraviolet curable resin liquid by the pulling rod 6 (FIG. 6).

(6) Manufacturing process 6 In order to align the base plate 5 in order to form the second-stage bubbles forming the foam material having the honeycomb structure, the positioning device is driven and the base plate 5 is lifted by the pulling rod 6. It is moved a predetermined distance in the lateral direction in the ultraviolet curable resin liquid. In this case, since the center of the bubble K in the first stage is located at each apex of a large number of equilateral triangles formed by the air constant amount discharge pipes 4B, the base plate 5 is moved in the lateral direction to cause the second stage to move. Make the center of the bubble in the center of the equilateral triangle (Fig. 7).

(7) Manufacturing process 7 A gas supply device for feeding gas to the constant-quantity air discharge pipe group 4 is driven to discharge a constant amount of gas from each constant-quantity air discharge pipe 4B into the ultraviolet curable resin liquid, and a large number of air bubbles K '. Are formed (FIG. 8).

(8) Manufacturing Step 8 A large number of bubbles K ′ are grown below the first-stage bubbles K formed on the lower surface side of the base plate 5 in the ultraviolet curable resin liquid (FIG. 9).

(9) Manufacturing step 9 Below the first-stage bubble K on the lower surface side of the base plate 5 in the ultraviolet curable resin liquid, a further one-stage bubble K'having a constant size shape (oblique dodecahedron shape) is provided. Complete in minutes. In this case, the center of the completed second-stage bubble K ′ is located at the center of a large number of equilateral triangles formed by the air quantitative discharge pipes 4B (FIG. 10).

(10) Manufacturing Process 10 In order to form the third-stage bubbles forming the honeycomb-structured foam material, the positioning device is driven to align the base plate 5, and the base plate 5 is lifted by the pull-up rod 6. While being pulled up from the ultraviolet curable resin liquid, it is moved laterally by a predetermined distance. Further, ultraviolet rays are radiated by irradiation means (not shown) from four directions around the first-stage bubbles K that have come out on the liquid surface when the base plate 5 is pulled up, and solidified. In this case, since the center of the bubble K ′ in the second stage is located at the center of a large number of equilateral triangles formed by the air constant amount discharge pipes 4B, by moving the base plate 5 in the lateral direction, The center of the bubble is located at each vertex of the equilateral triangle (Fig. 11).

(11) Manufacturing process 11 A gas supply device for feeding gas to the air constant amount discharge pipe group 4 is driven to discharge a constant amount of gas from each air constant amount discharge pipe 4B into the ultraviolet curable resin liquid, and a large number of bubbles K '. '(FIG. 12).

(12) Manufacturing Step 12 A third-stage bubble K ″ is grown below the second-stage bubble K ′ already formed on the lower surface side of the base plate 5 in the ultraviolet curable resin liquid ( (Fig. 13).

Thereafter, in the same manufacturing process as described above, bubbles are grown under the base plate 5 in the ultraviolet curable resin liquid by a predetermined number of steps, and the aggregate of the grown bubbles is pulled out from the ultraviolet curable resin liquid. By irradiating ultraviolet rays from four directions around the cell aggregate to solidify it, a foam material (foam resin) 7 having a three-dimensional honeycomb structure can be manufactured, for example, as shown in FIG.

The rhombic dodecahedron-shaped cell aggregates constituting the foamed material 7 manufactured in the above manufacturing process have the same distance from the center of each cell to the center of each adjacent cell, and each cell has 12 faces. The structure is adjacent to 12 bubbles of the same shape and the same size. That is, since the rhombic dodecahedron-shaped bubbles are formed from 12 rhombic faces and the rhombic faces adjacent to each other are in contact with each other at an angle of 120 degrees, they are aggregates of many bubbles. The foam material 7 will form a three-dimensional honeycomb structure.

As described above, according to this embodiment, since the foam material is manufactured by the above-mentioned manufacturing process by the three-dimensional honeycomb manufacturing apparatus 1, the rhombic dodecahedron-shaped cell aggregate having a regular array structure is formed. It is possible to manufacture a foam material having a three-dimensional honeycomb structure having a high foaming ratio, a high foaming ratio, an extremely light weight, few defects, high isotropic property, and excellent strength. As a result, as in the conventional case, a dense portion and a rough portion are formed in the bubbles inside the material, adjacent bubbles are connected to each other in the dense portion of the bubble, and empty portions are reduced in the rough portion of the bubble. It is possible to solve such problems.

Further, according to the present embodiment, the discharge amount of gas in the air quantitative discharge pipe group 4 of the three-dimensional honeycomb manufacturing apparatus 1, the intensity of ultraviolet rays, the speed of pulling up the foam material from the ultraviolet curable resin liquid, etc. are appropriately changed. It is possible to change the foaming rate of the foam material, which is preferable.

Further, according to the present embodiment, it is possible to manufacture a large-sized foam material by appropriately increasing the number of stages of bubbles formed on the lower side of the base plate 5 of the three-dimensional honeycomb manufacturing apparatus 1. .

Further, according to this embodiment, even after the foamed material (foamed resin) is cured, the difference between the atmospheric pressure and the external atmospheric pressure in each of the bubbles forming the foamed material is small, so that a three-dimensional honeycomb with a small internal stress is produced. It is possible to form a foam material having a structure.

[0031]

As described above, according to the method and apparatus for manufacturing a three-dimensional honeycomb structure according to the present invention, a tank in which a pipe group for discharging a fixed amount of gas into a liquid made of an ultraviolet curable polymer material is arranged. A plate is inserted into the inside of the liquid, a fixed amount of gas is discharged from the pipe group to the lower surface side of the plate to form a dodecahedron-shaped bubble assembly, and the plate having the bubble assembly formed on the lower surface side is pulled up. Since the foamed material is manufactured by irradiating the periphery of the cell aggregate on the lower surface side with ultraviolet rays to solidify, the effects of the following items can be obtained. Manufacture of a foam material with a three-dimensional honeycomb structure, which is composed of a dodecahedron-shaped cell aggregate having a regular array structure, has a high foaming rate, is extremely lightweight, has few defects, isotropic, and has excellent strength. It becomes possible to do. As a result, as in the conventional case, a dense portion and a rough portion are formed in the bubbles inside the material, adjacent bubbles are connected to each other in the dense portion of the bubble, and empty portions are reduced in the rough portion of the bubble. It is possible to solve such problems. Further, since it is possible to appropriately change the discharge amount of gas in the pipe group of the three-dimensional honeycomb manufacturing apparatus, the intensity of ultraviolet rays, the speed of pulling up the foam material from the ultraviolet curable resin liquid, etc., it is possible to change the foaming rate of the foam material. This is preferable because it is possible. It is also possible to manufacture a foam material having a large shape by appropriately increasing the number of stages of bubbles formed below the plate of the three-dimensional honeycomb manufacturing apparatus. Further, even after the foam material is cured, there is little difference between the atmospheric pressure and the outside air pressure in each of the bubbles forming the foam material, so that the foam material having a three-dimensional honeycomb structure with less internal stress can be formed.

[Brief description of drawings]

FIG. 1 is a schematic perspective view showing a configuration of a three-dimensional honeycomb manufacturing apparatus according to an embodiment of the present invention.

FIG. 2 is a schematic view showing a foam material manufacturing process 1 of the present embodiment.

FIG. 3 is a schematic diagram showing a foam material manufacturing step 2 of the present embodiment.

FIG. 4 is a schematic view showing a foam material manufacturing process 3 of the present embodiment.

FIG. 5 is a schematic view showing a foam material manufacturing process 4 of the present embodiment.

FIG. 6 is a schematic diagram showing a foam material manufacturing process 5 of the present embodiment.

FIG. 7 is a schematic diagram showing a foam material manufacturing step 6 of the present embodiment.

FIG. 8 is a schematic diagram showing a foam material manufacturing process 7 of the present embodiment.

FIG. 9 is a schematic view showing a foam material manufacturing step 8 of the present embodiment.

FIG. 10 is a schematic view showing a foam material manufacturing step 9 of the present embodiment.

FIG. 11 is a schematic view showing a foam material manufacturing process 10 of the present embodiment.

FIG. 12 is a schematic view showing a foam material manufacturing process 11 of the present embodiment.

FIG. 13 is a schematic view showing a foam material manufacturing process 12 of the present embodiment.

FIG. 14 is a schematic perspective view showing a manufacturing state of a foam material by the three-dimensional honeycomb manufacturing apparatus of this embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Three-dimensional honeycomb manufacturing apparatus 2 UV curable resin liquid 3 Tank 4 Air fixed amount discharge pipe group 4A Pipe base part 4B Air fixed amount discharge pipe 5 Base plate 6 Pulling rod

Continuation of the front page (51) Int.Cl. ⁵ Identification number Office reference number FI technical display area B29L 31:58 4F

Claims (2)

[Claims] 1. A three-dimensional honeycomb-shaped structure for producing a foam material having a three-dimensional honeycomb-shaped structure, which comprises an aggregate in which dodecahedron-shaped cells are sequentially bonded in a plane direction in a state where the surfaces of adjacent cells are aligned with each other. In the manufacturing method, a step of inserting a plate into a tank in which a liquid composed of an ultraviolet-curing polymer material is stored and a pipe group for discharging a fixed amount of gas into the liquid is arranged, and a plate bottom surface in the liquid from the pipe group. Side to form a dodecahedron-shaped bubble aggregate by discharging a fixed amount of gas to the side, a step of pulling up a plate on which the bubble aggregate is formed on the lower surface side, and around the bubble aggregate on the lower surface of the pulled-up plate. And a step of solidifying by irradiating ultraviolet rays. 2. A three-dimensional honeycomb-shaped structure for producing a foam material having a three-dimensional honeycomb-shaped structure, which comprises an aggregate in which dodecahedron-shaped cells are sequentially bonded in a plane direction in a state in which surfaces of adjacent cells are aligned with each other. In the manufacturing apparatus, a tank in which a liquid made of a UV-curable polymer material is stored, a plate inserted into the tank, and a moving means for moving the plate up and down and moving in the tank. , Three adjacent pipes are composed of a large number of pipes arranged in an equilateral triangle, are arranged in the tank, and discharge a fixed amount of gas into the liquid to form dodecahedral bubbles on the lower surface side of the plate. A group of pipes for forming an aggregate, and an irradiation unit for irradiating ultraviolet rays to the bubble aggregate on the lower surface side of the plate pulled out of the liquid by the moving unit to solidify the bubbles. Apparatus for producing a three-dimensional honeycomb structure characterized by the.