JPH08156186A - Composite panel and production thereof - Google Patents

Abstract

PURPOSE: To maximize strength or rigidity without increasing a skin layer. CONSTITUTION: At least two grooves 4 are arranged on at least the single surface of a flat plate-shaped core material 1 in a row and a fiber reinforced resin skin layer 2 composed of long fibers (f) is laminated on the surface thereof so that the long fibers (f) cross the grooves 4 to be embedded in the grooves 4 along with embedding rods 3. A composite panel is produced by laminating the skin layer composed of the long fibers impregnated with an uncured resin to the core material so that the long fibers cross the grooves and pushing the same in the grooves along with the embedding rods to tension the skin layer and subsequently curing the uncured resin.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite plate comprising a flat plate-shaped core material and a fiber reinforced resin layer, and a method for producing the same.
The present invention relates to a composite board used for a floor board, a wall board, and the like, as well as a flat top board for wire equipment, and a manufacturing method thereof.

[0002]

2. Description of the Related Art A flat top plate for X-ray equipment is constructed as a composite plate in which skin layers of a carbon fiber reinforced resin are laminated in a sandwich shape on both sides of a flat plate-shaped core material made of foam. In the production of such a composite plate, as a method for laminating the material of the skin layer on the core material, for example, a carbon fiber cloth original fabric coated with an uncured resin is adhered, or a carbon fiber cloth prepreg is adhered. There are two ways. However, in either case, it is inevitable that the skin layer is loosened during lamination.

If the skin layers are laminated in such a loosened state, the reinforcing effect of the skin layers is diminished, and sufficient strength and rigidity cannot be obtained when the composite plate is formed. Therefore, in order to obtain required strength and rigidity, it is necessary to increase the number of laminated skin layers or increase the capacity of the reinforcing fibers, resulting in an increase in cost.

[0004]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a composite plate and a method for producing the composite plate that can maximize strength and rigidity without increasing the skin layer. Another object of the present invention is to provide a composite plate which can be produced at low cost and a method for producing the same by maximizing the reinforcing effect of the skin layer.

[0005]

In the composite plate of the present invention for achieving the above object, at least two concave grooves are arranged in a line on at least one surface of a flat plate-shaped core material, and long grooves are formed on the surface of the core material. A skin layer of a fiber reinforced resin made of fibers is laminated so that the long fibers intersect the groove, and a skin layer portion corresponding to the groove is embedded in the groove together with an embedding rod. It is what

Further, the method for manufacturing a composite plate according to the present invention is
At least two recessed grooves are formed on at least one surface of a flat plate-shaped core material so as to be arranged in rows, and a skin layer made of long fibers impregnated with an uncured resin is formed on the surface of the core material. Tensioning the long fibers in the skin layer by arranging them to intersect the groove and pushing the portion of the skin layer corresponding to the groove into the groove with an embedding rod, and then uncuring the skin layer. It is characterized in that the resin is cured.

As described above, at least two concave grooves are provided in a row on at least one surface of the core material, and a part of the skin layer is pushed into the concave grooves together with the embedding rod, whereby the reinforcing long fibers of the skin layer are tensioned. Can be in a state. Therefore, the strength and elastic modulus of the long fibers can be maximized, and the maximum reinforcing effect can be exhibited with the minimum amount of the reinforcing long fibers. As a result, it is possible to produce a high-performance composite board at low cost.

In the present invention, a resin, a wood material such as a plywood board, or the like is preferably used as the core material constituting the composite board. In particular, it is preferable to use a foam as the resin, and as the material of the resin foam, urethane, acrylic,
Polyethylene, styrene, phenol and the like can be used. A fiber reinforced resin made of long fibers is used for the skin layer forming the composite board. As the reinforcing long fiber, carbon fiber, aramid fiber, glass fiber, polyethylene fiber or the like can be used. The reinforcing long fibers may be used as a cloth woven from a warp and a weft, and may be used in a unidirectionally aligned sheet (so-called UD).
It may be used as.

As the matrix of the skin layer, a thermosetting resin such as epoxy, unsaturated polyester or vinyl ester is preferably used. As the material for the skin layer before laminating the composite plate, a cloth prepreg or a UD prepreg impregnated with an uncured matrix resin may be used, or an uncured matrix resin may be applied to the cloth or the UD. You may use it.

The material of the embedded rod is not particularly limited as long as it is rod-shaped. For example, a fiber reinforced resin in which long fibers are aligned in one direction to form a reinforcing material, or a metal such as steel or aluminum can be used. From the viewpoint of weight reduction, it is preferable to use a fiber reinforced resin, and carbon fiber reinforced resin, aramid fiber reinforced resin and glass fiber reinforced resin are particularly preferable because they have high specific rigidity.

In the present invention, a skin layer may be laminated on only one side of the core material, but it is preferable to laminate on both sides. The thickness of the skin layer is from 0.2mm
3mm is suitable. There are at least two recessed grooves provided on the surface of the core material, and the number may be appropriately set according to the surface area of the core material. The shape of the groove is preferably linear, and it is desirable that a plurality of grooves be provided in parallel with each other. The shape of the embedded rod is also linear according to the linear groove.

When the skin layer is laminated on the surface of the core material, the skin layer is arranged so that the direction of the long fibers thereof intersects the direction of the concave groove. Preferably, the direction of the long fibers of the skin layer and the direction of the groove are orthogonal to each other. As described above, the groove and the embedded rod are linear and parallel to each other,
Further, by arranging the long fibers of the skin layer so as to be orthogonal to the direction of the groove, when the skin layer is embedded in the groove of the core together with the embedding rod in this state, the skin layer does not loosen the long fibers. As a result, the entire surface of the core becomes evenly and evenly tensioned. As a result, the maximum reinforcing effect can be exhibited with the minimum amount of skin layers.

The present invention will be described below with reference to the embodiments shown in the drawings. FIG. 1 is a perspective view showing an example of a composite plate according to the present invention with a main part cut away. The composite plate C is composed of a resin foam core material 1, a fiber reinforced resin skin layer 2 and an embedded rod 3. Further, if necessary, a plurality of wood bosses 5 are provided as bolt mounting points at various places in the plane of the composite plate C.

On both sides of the core material 1, two linear concave grooves 4 are provided in parallel with each other on the left and right, and a skin layer 2 is arranged in the concave grooves 4 on the upper surface side. It is pushed in by the embedded rod 3. The skin layer 2 is made of a fiber-reinforced resin having the long fibers f as reinforcing fibers, and the long fibers f have the groove 4 and the embedded rod 3.
Are arranged so as to be orthogonal to the direction. With such an arrangement, the skin layer 2 is in a tension state in which the long fibers f are not loosened as a whole.

FIG. 2 illustrates a part of the manufacturing process of the above composite plate. In manufacturing the composite plate, first, two linear concave grooves 4 are formed on each of the two surfaces of the core material 1. The groove 4 may be integrally formed when the core material 1 is molded, or may be formed by post-processing by grinding. In this way, the surface of the core material 1 provided with the concave grooves 4 is covered with the skin layer 2 impregnated or coated with the uncured resin so that the direction of the long fibers f is in a positional relationship orthogonal to the concave grooves 4.

Then, as shown in FIG.
The embedding rod 3 is pressed against the portion of the skin layer 2 corresponding to, and is also pressed into the groove 4 as indicated by arrow A. By this pushing operation, a part of the skin layer 2 is pushed into the groove 4 together with the embedding rod 3, and at that time, a portion corresponding to the length of the skin layer 2 pushed into the groove 4 is indicated by an arrow B. It is pulled toward the groove 4. As a result, the long fibers f forming the skin layer 2 change into a tension state in which there is no looseness.

Next, the composite body in which the skin layer is attached to the core material as described above is heated to cure the uncured resin of the skin layer 2 to form the composite plate C. In this composite plate C, the long fibers of the skin layer are not loosened, and the whole surface of the core material is evenly and uniformly tensioned. Therefore, the maximum reinforcing effect can be achieved with the minimum amount of the skin layer. If necessary, a melamine plate or a decorative plate may be attached to the surface of the composite plate thus formed. The above-mentioned composite board can be effectively used as a flat top board for X-ray equipment, floor material,
It can also be used as a wallboard.

[0018]

[Example] A plate material of acrylic foam (10 times foam) is used as a core material, and a basis weight of 320 gr / m as a skin layer.
^2. By using a carbon fiber cloth prepreg with a thickness of 0.5 mm and using a rod material (3 mm × 6 mm × 2100 mm) made of carbon fiber reinforced resin as an embedding rod, both sides of the core material as shown in FIG. A skin layer was laminated on to prepare a flat top plate for X-ray equipment (composite plate of the present invention) having a size of 12.5 mm × 630 mm × 2100 mm.

As a comparison, an X-ray device having the same size as that of the above-mentioned present invention of the conventional structure in which the core material and the skin layer are made of the same materials as used in the present invention, and no groove or buried rod is provided. A flat top plate (conventional composite plate) was manufactured. With respect to these two types of flat top plates, both ends were fixed with bolts, and the bending that occurred when a load of 70 kg was applied to the central part was measured.

As a result, the flat top plate of the conventional structure generated a deflection of 2.5 mm, whereas the flat top plate of the present invention produced a deflection of 1.9 mm.
It was confirmed that the bending strength was only generated and the bending strength was improved by about 25%.

[0021]

As described above, according to the present invention, the performance of the reinforcing fiber of the skin layer can be maximized, and the strength and rigidity can be maximized with the minimum amount without increasing the skin layer. It will be possible to withdraw. Moreover, since the reinforcing effect of the skin layer can be maximized, a high-performance composite plate can be produced at low cost.

[Brief description of drawings]

FIG. 1 is a perspective view showing a main part of a composite plate according to an embodiment of the present invention in a cutaway manner.

FIG. 2 is an explanatory view illustrating a part of the manufacturing process of the composite plate of the present invention.

[Explanation of symbols]

 1 core material 2 skin layer 3 embedded rod 4 concave groove f (constituting skin layer) long fiber

Claims (2)

[Claims] 1. A flat plate-shaped core material is provided with at least two recessed grooves arranged in rows on at least one surface thereof, and a skin layer of a fiber-reinforced resin made of long fibers is provided on the surface of the core material, and the long fibers are the recessed grooves. And a skin layer portion corresponding to the groove is embedded in the groove together with an embedding rod. 2. A skin layer made of long fibers impregnated with an uncured resin is formed on at least one groove of at least one surface of a flat plate-shaped core material so as to be arranged in rows. The long fibers in the skin layer are tensioned by arranging the long fibers so as to intersect with the groove, and pressing a portion of the skin layer corresponding to the groove into the groove together with an embedding rod, and then tensioning the long fibers in the skin layer. A method for producing a composite plate, comprising curing an uncured resin for a skin layer.