JPH07223282A - Honeycomb core and production thereof - Google Patents

Abstract

PURPOSE:To enhance the accuracy and quality while preventing the deformation or displacement of cell walls or cells by laminating and bonding prepregs each molded into a corrugated sheet having corrugations continuously formed thereto and preliminarily coated and impregnated with a polymerizable substance. CONSTITUTION:A corrugated sheet 2 is formed by pressing a prepreg sheet 1 being a matrix to be cooled and cured. Next, a polymerizable substance is applied to and infiltrated into the corrugated sheet 2. An adhesive is linearly applied to the ridge or trough parts of the corrugated sheet 2 coated and impregnated with the polymerizable substance 4 and a large number of the corrugated sheets thus produced are mutually laminated while the trough and ridge parts thereof are matched with each other up and down to be formed into a block shape having spaces as a whole. By this constitution, the deformation and displacement of cell walls or cells are prevented and the unevenness, disturbance in arrangement, shift, crashing or destruction of the cell walls or cells can be eliminated and the shift of cells is not generated.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a honeycomb core and a method for manufacturing the same. That is, the present invention relates to a honeycomb core using a fiber-reinforced plastic prepreg sheet as a base material, and a method for manufacturing the honeycomb core.

[0002]

2. Description of the Related Art Honeycomb cores of this kind have hitherto been manufactured by the following corrugation method or spreading method. First
In the corrugated method, the prepreg sheet made of fiber reinforced plastic as the base material is continuously bent into a corrugated sheet by heating and pressing with a gear or a rack, and then,
This corrugated sheet is cut into pieces with a certain size, and the adhesive is applied in the form of stripes, and the troughs and tops are laminated together, and then heated and pressed at the melting point temperature of the inserted adhesive to form a wave. A honeycomb core is manufactured by bonding the plates. Secondly, in the spreading method, the adhesive is applied linearly to the fiber-reinforced plastic prepreg sheet, which is the base material, and then stacked while shifting by half a pitch, and then heated and pressed at the melting point temperature of the adhesive. The honeycomb core was manufactured by adhering the same to each other and then expanding in the stacking direction. In addition, in such a corrugated method and spread method,
In both cases, as a post-treatment, the manufactured honeycomb core is often subjected to reinforcement and rigidity replenishment of rigidity and strength by adhering and impregnating a polymerizable substance such as phenol resin.

[0003]

By the way, the following problems have been pointed out in such a conventional example. First of all, the corrugated method described above is as follows. That is, in the corrugated method, the corrugated sheets laminated by bending the prepreg sheet of the fiber-reinforced plastic in the bonding step of heating and pressurizing at the melting point temperature of the adhesive sandwiched When it was sandwiched and pressed from the top and bottom for adhesion, it was easy to be deformed and displaced by the pressure. As a result, the cell walls and cells formed by the corrugated sheet are deformed and displaced, resulting in unevenness, irregular alignment, misalignment, crushing, breakage, etc. In particular, the adhesive position of the striations by the adhesive is incorrect. Therefore, there was a big problem in the accuracy and quality of the honeycomb core, such as so-called misalignment.

Secondly, the spreading method described above is as follows. That is, in the spreading method, in the spreading step of applying a tensile force in the stacking direction, if the thickness of the prepreg sheets of fiber-reinforced plastic stacked is thick or the rigidity is high, flexibility is insufficient and spreading is difficult. However, there is a problem that the honeycomb core cannot be manufactured. Further, in the case of this spreading method, as in the corrugated method described above, a complicated cell wall structure or cell in which corrugated plates and flat plates made of a fiber reinforced plastic prepreg sheet as a base material are alternately laminated and bonded. There is also a drawback that a honeycomb core having a structure cannot be manufactured.

In view of the above situation, the present invention has been made to solve the problems of the above-mentioned conventional example, and after forming a prepreg sheet of fiber reinforced plastic into a corrugated sheet, laminating and adhering it. By adopting the corrugated system and attaching and impregnating the polymerizable substance after the forming and processing of the corrugated sheet and before the lamination and the adhesion,
Second, a honeycomb core made of a fiber reinforced plastic, which prevents deformation and displacement of cell walls and cells, and secondly, which can be easily and smoothly realized and has a complicated structure, and its manufacture The purpose is to propose a method.

[0006]

The technical means of the present invention for achieving this object are as follows. First, the claim 1 is as follows. That is, this honeycomb core is
This is a planar aggregate of hollow columnar cells, and a fiber reinforced plastic prepreg sheet is used as a base material of cell walls forming the cells. The corrugated corrugated sheet is continuously bent and formed, and the prepreg sheets preliminarily adhered and impregnated with a polymerizable substance are laminated and adhered.

Claim 2 is as follows. That is, this honeycomb core is a planar aggregate of hollow columnar cells, and a fiber reinforced plastic prepreg sheet is used as a base material of cell walls forming the cells.
Then, the corrugated corrugations are continuously bent and formed, and at the same time, the prepreg sheet, which is the base material on which the polymerizable substance is adhered and impregnated in advance, and the flat plate are used as the polymerizable substance. And another prepreg sheet, which is another base material adhered and impregnated with, are alternately laminated and adhered.

Claim 3 is as follows. That is, in this method for manufacturing a honeycomb core, first, a prepreg sheet of a fiber-reinforced plastic as a base material is formed into a corrugated plate in which corrugated irregularities are continuously bent, and then,
After the polymerizable substance is adhered and impregnated on the corrugated plate, an adhesive is attached in a striation form on the top and the valleys of the corrugated plate. After that, a plurality of the corrugated plates are vertically laminated so that the valleys and the tops are aligned with each other, and then heated and pressed to bond them, whereby a honeycomb core that is a planar aggregate of hollow columnar cells is obtained. .

Claim 4 is as follows. That is, in this method for manufacturing a honeycomb core, first, a prepreg sheet of a fiber-reinforced plastic as a base material is formed into a corrugated plate in which corrugated irregularities are continuously bent, and then,
After the polymerizable substance is adhered and impregnated on the corrugated plate, an adhesive is attached in a striation form on the top and the valleys of the corrugated plate. Thereafter, a plurality of the corrugated plates and a plurality of flat plates of fiber-reinforced plastic prepreg sheets, which are different base materials and are flat and preliminarily adhered and impregnated with a polymerizable substance, are laminated so as to be alternately positioned. Then, the honeycomb core, which is a planar aggregate of hollow columnar cells, is obtained by heating and pressurizing and adhering.

[0010]

Since the present invention comprises such means, it operates as follows. According to the present invention, a fiber reinforced plastic prepreg sheet as a base material is formed into a corrugated plate and an adhesive is attached to the corrugated plate. Then, in claims 1 and 3, only such corrugated plates are laminated, and Then, a honeycomb core is manufactured by alternately stacking such corrugated plates and flat plates of the prepreg sheet that are still flat, and then applying heat and pressure to bond them. Then, the polymerizable substance is adhered and impregnated on the prepreg sheet after the forming and processing of the corrugated plate and before attaching, laminating and adhering the adhesive, and the flat plate of the prepreg sheet according to claims 2 and 4 is also laminated. ， Before bonding, the polymerizable substance is attached and impregnated.

Therefore, firstly, the prepreg sheet as a base material is reinforced by the adhered and impregnated polymerizable substance, and the rigidity and
After the strength is increased, they are laminated as corrugated plates or flat plates and bonded by heating and pressing. Therefore, even if it is sandwiched from above and below and heated and pressed, it is not deformed or displaced by the pressure, and the deformation or displacement of the cell walls or cells is prevented. Second
In addition, since the honeycomb core is manufactured by the corrugated method, the prepreg sheet can be manufactured easily and smoothly even when the thickness of the prepreg sheet is high and the rigidity is high. Further, as described in claims 2 and 4, Also, a complicated cell wall structure or cell structure in which corrugated plates and flat plates are alternately laminated can be easily manufactured.

[0012]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below based on the embodiments shown in the drawings. 1 is a perspective view of a prepreg sheet, and FIG. 1 (1) is a perspective view of a prepreg sheet.
(2) is a perspective view of a corrugated plate, (3) is a front explanatory view of a dipping process, and (4) is a front explanatory view of a drying and curing process.
FIG. 2A is a front explanatory view of the adhesive applying step,
(2) is a front explanatory view of the laminating step, and (3) is a front explanatory view of the bonding step. FIG. 3 is used to explain another embodiment,
(1) is a front explanatory view of the adhesive applying step, and (2) is a front explanatory view of the laminating step. FIG. 4 is a perspective view of the honeycomb core.

In this manufacturing method, first, as shown in FIG. 1 (2), the prepreg sheet 1 of the fiber-reinforced plastic as the base material shown in FIG. 1 (1) has continuous corrugated irregularities. The corrugated sheet 2 is formed into a bent shape. To explain these in detail, fiber reinforced plastics (FR
Typical examples of P) are glass fibers, Kevlar fibers, carbon fibers, and other base fibers combined with a phenol resin, an epoxy resin, a polyimide resin, and other resins by adhesion, impregnation, or the like. The fiber-reinforced plastic prepreg sheet 1 is prepared as a flat plate 3 which is in the form of an ultrathin, flat strip-shaped sheet while being softened by heating and having a viscosity to be in a semi-cured state. The fiber reinforced plastic prepreg sheet 1 which is the flat plate 3 prepared in this way is heated and pressed by a corrugating device equipped with a mold such as a gear, a rack, and a corrugated belt, so that the corrugated plate 2 is molded. To be done.
In other words, the corrugated plate 2 is formed by continuously bending the trapezoidal shape, triangular shape, and other shapes of a corrugated shape at a predetermined pitch and height. In this way, the prepreg sheet 1 is formed.
After that, the corrugated sheet 2 including the base material is cooled and hardened.

Next, in this manufacturing method, FIG.
(4) As shown in the figure, the corrugated sheet 2 formed in this way
On the other hand, the polymerizable substance 4 is attached and impregnated. That is,
The corrugated plate 2 is immersed in a bath 5 of a solution of a polymerizable substance 4 such as a phenol resin, and the polymerizable substance 4 is adhered and impregnated. The corrugated sheet 2 thus adhered and impregnated with the polymerizable substance 4 is taken out of the bath 5 and then dried and heated by the heat source 6 in the processing chamber. It cures in the state that the surface of is coated. In addition, such adhesion and impregnation of the polymerizable substance 4 is repeatedly performed until the required rigidity, strength, and weight are reached.

Then, in this manufacturing method, as shown in FIG. 2 (1), an adhesive agent is applied to the tops and valleys of the corrugated sheet 2 thus adhered and impregnated with the polymerizable substance 4. 7 is attached in a striation form by coating or the like. In the illustrated example, the adhesive 7
Is applied to each of the tops of the corrugated plate 2 by a coating roll 8 and dried, and the corrugated plate 2 is cut after every predetermined length.

Then, in this manufacturing method, (2) in FIG.
As shown in the figure, a plurality of such corrugated sheets 2 are stacked while vertically aligning each valley and top. That is,
The corrugated sheets 2 are laminated with the adhesive 7 interposed therebetween, so that the entire corrugated sheet 2 has a block shape having a space.

Thereafter, in this manufacturing method, (3) in FIG.
As shown in the figure, each block-shaped corrugated plate 2
Is heated and pressed at a melting point temperature of the adhesive 7 in a furnace or the like, and thus the adhesive 7 is melted and cured, so that the laminated corrugated sheets 2 are bonded to each other. If the pressure applied at the time of bonding is high and the laminated corrugated sheets 2 may be deformed, both ends are restrained.

By following these steps, as shown in FIG. 4, the corrugated plate 2 is used as a cell wall 9 and a planar assembly of hollow columnar cells 10 partitioned into independent spaces is formed. There is a honeycomb core 11 made of fiber reinforced plastic
Is manufactured. That is, the honeycomb core 11 is formed by processing the corrugated plate 2 in which corrugated concavities and convexities are continuously bent and formed, and the prepreg sheets 1 preliminarily adhered and impregnated with the polymerizable substance 4 are laminated and adhered. Become. The cell 10
In addition to the hexagonal shape shown in the drawing, the cell wall 9 may have a triangular shape, a quadrangular shape, a trapezoidal shape, or other various shapes. The honeycomb core 11 is generally excellent in weight ratio strength, is lightweight, and has high rigidity and strength,
It is also known that it has excellent rectification effect, flatness accuracy, heat retention, sound insulation, and has a large surface area per unit volume. Since the honeycomb core 11 made of fiber reinforced plastic is reinforced with fibers, it has a particularly excellent weight-specific strength.

Next, another embodiment of the present invention will be described with reference to FIG. In the manufacturing method of the embodiment of FIG. 3, first, similarly to the place described in the embodiment of FIG. 2 described above, the prepreg sheet 1 of the fiber-reinforced plastic as the base material is continuously bent to form corrugated irregularities. The corrugated plate 2 is molded and processed, and then the corrugated plate 2 is adhered with and impregnated with the polymerizable substance 4, and then the adhesive 7 is applied to the tops and valleys of the corrugated plate 2 in a linear shape. Attach. As shown in FIG. 3A, the adhesive 7 is applied to the outer surface of both the top and the valley of the corrugated plate 2 by the application roll 8 (see each drawing of FIG. 1). ). Next, in the embodiment of FIG. 3, instead of laminating only the corrugated plates 2 as in the embodiment of FIG. 2 described above, as shown in FIG. 2 and the flat plate 3 (see FIG. 1 (1) of FIG. 1) of the fiber reinforced plastic prepreg sheet 1 which is another base material to which the polymerizable substance 4 is attached and impregnated in a flat state so that they are alternately positioned. To be laminated. Then, by heating and pressurizing, the corrugated plate 2 and the flat plate 3 are bonded to each other by the melt-cured adhesive 7.

In the embodiment of FIG. 3, the honeycomb core 1 made of fiber reinforced plastic 1 is obtained by following these steps.
1 is manufactured. The honeycomb core 11 has a hollow columnar cell 10 similar to that of the embodiment of FIG. 2 described above.
Cell wall 9 forming a cell 10
A prepreg sheet 1 made of fiber reinforced plastic is used as a base material. The honeycomb core 11 of the embodiment of FIG. 3 is formed into the corrugated plate 2 and is preliminarily polymerized unlike the honeycomb core 11 of the above-described embodiment of FIG. 2 in which only the corrugated plate 2 is laminated (see FIG. 4). The base material prepreg sheet 1 on which the polymerizable substance 4 is adhered and impregnated, and another base material prepreg sheet 1 on which the polymerizable substance 4 is adhered and impregnated in advance as a flat plate 3 are alternately laminated. ((2) in Figure 3
See figure). The honeycomb core 11 of the embodiment of FIG.
Regarding the manufacturing method and the manufacturing method, other configurations are shown in FIG.
Since the above embodiment is based on the above description, the same reference numerals are given and the description thereof is omitted.

The present invention has been described above. Then it becomes as follows. That is, in the present invention, the fiber-reinforced plastic honeycomb core 11 includes the fiber-reinforced plastic prepreg sheet 1 as a base material,
After forming the corrugated sheet 2 and applying the adhesive agent 7, in the embodiment of FIG. 2, only a plurality of such corrugated sheets 2 are laminated, and in the embodiment of FIG. The corrugated plate 2 and the flat plate 3 of the prepreg sheet 1 which is still flat are alternately laminated, and thus heated and pressed to bond the cell wall 9 to each other.
It is manufactured as a planar aggregate of the hollow columnar cells 10 formed in. Now, the polymerizable substance 4 is adhered to and impregnated into the prepreg sheet 1 after forming the corrugated plate 2 and before attaching, laminating and adhering the adhesive 7. Note that the prepreg sheet 1 as it is in the flat plate 3 of the embodiment of FIG. 3 is also impregnated with and impregnated with the polymerizable substance 4 before lamination and adhesion. Therefore, the honeycomb core 11 and the manufacturing method thereof are as follows.

First, the base material prepreg sheet 1 is
It is reinforced by the adhered and impregnated polymerizable substance 4 to increase its rigidity and strength, and then laminated and bonded by heating and pressing. Therefore, even if the corrugated plate 2 or the flat plate 3 is sandwiched from above and below for adhesion and is heated and pressed, it is reinforced in this way and is not deformed or displaced by the pressure. Therefore, the deformation and displacement of the cell walls 9 and the cells 10 of the honeycomb core 11, which have been pointed out in the conventional example of the corrugated method described above, are reliably prevented.

Secondly, since the honeycomb core 11 is manufactured by the corrugated method as described above, the prepreg sheet 1 as the base material has a large wall thickness as pointed out in the conventional example of this kind of the expanding method. In the case and the case where the rigidity is high, the manufacturing is not difficult, and the manufacturing can be performed easily and smoothly. Further, as shown in the embodiment of FIG. 3, a corrugated plate 2 and a flat plate 3 using the prepreg sheet 1 as a base material.
A honeycomb core 11 having a complicated cell wall 9 structure or cell 10 structure in which and are alternately laminated and adhered can be easily manufactured.

[0024]

As described above, the honeycomb core and the method for manufacturing the same according to the present invention are manufactured by forming a prepreg sheet of fiber reinforced plastic into a corrugated sheet, and then laminating the corrugated sheet.
Adopting the corrugated method of adhering, attaching the polymerizable substance after laminating and adhering after corrugated sheet forming processing,
The following effects are exhibited by the impregnation.

First, the deformation and displacement of the cell walls and cells are prevented. That is, in the honeycomb core made of the fiber reinforced plastic, the unevenness of the cell walls and the cells, the disorder of the arrangement, the shift, the crushing, which have been pointed out in the above-mentioned conventional example of this kind,
Breakage is eliminated, the striation adhesion position is particularly accurate, and so-called misalignment does not occur. Thus, a honeycomb core excellent in accuracy and quality can be obtained.

Secondly, and yet this is easily and smoothly implemented, complex structures are easily obtained. That is, the above-mentioned honeycomb core excellent in accuracy and quality is manufactured by a simple and easy manufacturing method, and is excellent in manufacturing cost. Further, as compared with the conventional example of this kind described above, even when the prepreg sheet has a large wall thickness or a high rigidity, the prepreg sheet can be smoothly produced without any problem. Furthermore, as described in claims 2 and 4, a honeycomb core having a complicated cell wall or a cell structure in which corrugated plates and flat plates are alternately laminated and adhered can be easily manufactured. 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 THE DRAWINGS FIG. 1 is used to explain an embodiment of a honeycomb core and a method for manufacturing the same according to the present invention. (1) is a perspective view of a prepreg sheet, (2) is a perspective view of a corrugated sheet, and (3) is an immersion. Front explanatory drawing of a process, (4) figure is a front explanatory drawing of a drying and hardening process.

FIG. 2 is a front explanatory view for explaining the embodiment,
The figure (1) shows an adhesive applying step, the figure (2) shows a laminating step, and the figure (3) shows an adhering step.

3A and 3B are front explanatory views for explaining another embodiment of the present invention, wherein FIG. 1A shows an adhesive applying step, and FIG. 2B shows a laminating step.

FIG. 4 is a perspective view of a honeycomb core.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Prepreg sheet 2 Corrugated plate 3 Flat plate 4 Polymerizable substance 5 Bath 6 Heat source 7 Adhesive 8 Coating roll 9 Cell wall 10 Cell 11 Honeycomb core

Claims (4)

[Claims] 1. A planar aggregate of hollow columnar cells, wherein a prepreg sheet of fiber reinforced plastic is used as a base material of cell walls forming the cells, and corrugated irregularities are continuously bent and formed. A honeycomb core characterized by being formed into a corrugated sheet, and the prepreg sheets preliminarily adhered and impregnated with a polymerizable substance are laminated and adhered. 2. A planar aggregate of hollow columnar cells, wherein a prepreg sheet of fiber reinforced plastic is used as a base material of cell walls forming the cells, and corrugated irregularities are continuously bent and formed. While being formed into a corrugated sheet,
The prepreg sheet, which is the base material impregnated and impregnated with the polymerizable substance in advance, and the polymerizable substance is attached in advance as a flat plate.
A honeycomb core, wherein the prepreg sheet as another impregnated base material is alternately laminated and adhered. 3. First, a fiber reinforced plastic prepreg sheet as a base material is formed into a corrugated plate in which corrugated irregularities are continuously bent and formed, and then a polymerizable substance is attached to the corrugated plate, After impregnating, an adhesive is attached to the tops and valleys of the corrugated sheet in a linear shape, and then a plurality of the corrugated sheets are laminated vertically with the valleys and the tops aligned, and then heated and pressed. To obtain a honeycomb core, which is a planar aggregate of hollow columnar cells,
A method for manufacturing a honeycomb core, comprising: 4. First, a fiber reinforced plastic prepreg sheet as a base material is formed into a corrugated plate in which corrugated irregularities are continuously bent and formed, and then a polymerizable substance is attached to the corrugated plate, After impregnation, the adhesive is attached to the tops and valleys of the corrugated sheet in a linear shape, and then a plurality of the corrugated sheets and the polymerizable substance are attached in a flat state in advance.
A plurality of different impregnated base materials, which are fiber-reinforced plastic prepreg sheets, and flat plates are laminated so that they are located alternately, and then heated and pressed to bond them together, thereby forming a planar assembly of hollow columnar cells. A method for manufacturing a honeycomb core, comprising obtaining a honeycomb core as a body.