JPH09207252A - Manufacture of fiber-reinforced plastics-made honeycomb core - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacture of a fiber-reinforced plastic made honeycomb core wherein a work cost, a material loss, a blanking loss, a cutting removal loss, etc., are reduced, it is excellent in cost, and its continuation, mechanization, and making mass production are accelerated, and it is excellent in cost also from those points. SOLUTION: In this manufacturing method, firstly a band-like sheet of a fiber base material 9 is supplied to a forming die 10 wherein a die face forms a waveform, and a size of the die face is gradually varied, and squeezed so as to become familiar to the die face while it is pulled. It is pressurized by heating after sticking, impregnation, mixing, etc., of a resin. Then, forming is executed. An irregularity of the wave form is made of the waveform wherein it is continuously formed being bent thereby. A corrugated panel 13 is formed wherein the resin is combined with the fiber base material 9. A fiber-reinforced plastic made honeycomb core is manufactured by bonding a plurality of pieces of corrugated panels 13 by superimposing in a positional relation in which a bottom part is conformed to a crest part.

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 honeycomb core made of fiber reinforced plastic. That is,
The present invention relates to a method for manufacturing a honeycomb core made of fiber reinforced plastic (FRP) in which a fiber base material and a resin are combined by adhesion, impregnation, mixing, or the like.

[0002]

2. Description of the Related Art FIGS. 7A and 7B are front explanatory views for explaining a method for manufacturing a honeycomb core made of a fiber reinforced plastic of this type of conventional example. FIG. 7A is a preparatory step and FIG. (3) shows the formed corrugated sheet, and (4) shows the stacking and joining steps. As shown in the figure, the honeycomb core 1 made of fiber reinforced plastic has been conventionally manufactured by the following steps. That is, first, as shown in FIG. 7 (1), the prepreg sheet 2 of fiber-reinforced plastic as a base material prepared in advance is cut into predetermined lengths, and then shown in FIG. 7 (2). Up and down 1
By supplying to a corrugating apparatus composed of a pair of racks 3 and the like and applying heat and pressure, the corrugated sheet 4 is formed as shown in FIG. 7 (3), and the corrugated sheet 4 thus formed is Further, it was heated in a furnace or the like to be completely cured. Then, as shown in FIG. 7 (4), a plurality of corrugated sheets 4 completely cured and completed in molding and cut into required lengths are placed at the positions where the bottom and the top are aligned with each other. The honeycomb core 1 made of fiber reinforced plastic, which is a planar assembly of hollow columnar cells 7 that are stacked in relation to each other and adhered by an adhesive 5 to form a corrugated plate 4 as a cell wall 6, is formed. I was getting.

As described above, in the method for manufacturing the honeycomb core 1 made of the fiber reinforced plastic of the conventional example of this kind, the fiber reinforced plastic prepreg sheet in which the resin is previously attached to the fiber base material by adhesion, impregnation, mixing, etc. 2 was prepared. Then, the prepreg sheet 2 thus prepared was molded into the corrugated plate 4 to obtain the honeycomb core 1 made of fiber reinforced plastic.

[0004]

The following problems have been pointed out in such a conventional example. First, as described above, in the conventional method for manufacturing the honeycomb core 1 made of the fiber-reinforced plastic, the prepreg sheet 2 of the fiber-reinforced plastic in which the resin is previously attached to the fiber base material by impregnation, impregnation, mixing, or the like is used. First, it was prepared, but it took a lot of time and labor for processing and preparing such a prepreg sheet 2, and it required special equipment and strict condition control. Therefore, processing and preparation of the prepreg sheet 2 required a large cost. Further, the prepreg sheet 2 processed and prepared in this way
Was cut into predetermined lengths at the time of forming into the corrugated plate 4, but the material loss, plate removal loss, and cutting removal loss were large, and the prepreg sheet 2 wasted and removed as waste. Was great. Particularly in the case of small-quantity production, the waste of the prepreg sheet 2 was remarkable (for example, 50
When it was necessary to prepare a prepreg sheet 2 having a size of about m, a plate having a thickness of about 150 m was prepared.

As described above, the preparation of the prepreg sheet 2 requires a great processing cost, and the material loss, the plate cutting loss, and the cutting removal loss are large, and the manufactured honeycomb core 1 made of the fiber-reinforced plastic is relatively expensive. It was pointed out that the cost would be high.

Secondly, in the conventional method for manufacturing the honeycomb core 1 made of the fiber reinforced plastic, the step of preparing the prepreg sheet 2 made of the fiber reinforced plastic in advance in this way,
Various steps such as a step of forming the corrugated sheet 4 by a corrugating apparatus such as the rack 3 and a step of completely curing the corrugated sheet 4 in the furnace while keeping the corrugated sheet 4 in shape are required. In the curing process,
The corrugated sheet 4 needs to be inserted and attached to a dedicated die jig, carried in and out of the furnace, and peeled off from the dedicated die jig, and moreover, they have been carried out manually. And
Each such process is processed in a badge type, and the work is divided for each process, which makes continuous, mechanized, and mass production difficult. Therefore, from these viewpoints as well, it has been pointed out that the manufactured honeycomb core 1 made of the fiber-reinforced plastic has a high cost.

In view of the above situation, the present invention has been made to solve the above-mentioned problems of the prior art, in which the forming process is performed while the resin is attached, impregnated or mixed with the belt-shaped sheet of the fiber base material. By carrying out and forming the corrugated plate made of fiber reinforced plastic, firstly, the processing cost, material loss, plate cutting loss, cutting removal loss, etc. are reduced, and secondly, it is made continuous. , The purpose of the present invention is to propose a method for manufacturing a honeycomb core made of fiber reinforced plastic, which facilitates mechanization and mass production.

[0008]

The technical means of the present invention for solving such a problem is as follows. That is, in this method for manufacturing a honeycomb core made of fiber reinforced plastic, first, a belt-shaped sheet of a fiber base material is supplied to a forming die in which the mold surface has a corrugated shape and the size of the mold surface is gradually changed, and then stretched. While performing the forming process while narrowing down so that it fits the mold surface and applying heat by applying resin, impregnating, mixing, etc., it has a shape in which corrugated irregularities are continuously bent and formed. A corrugated sheet made of fiber reinforced plastic, which is a combination of wood and resin, is formed. Then, by stacking and joining a plurality of corrugated plates cut into predetermined lengths in a positional relationship where the bottom and top are aligned, a hollow columnar cell partitioned and formed with the corrugated plates as cell walls To obtain a honeycomb core made of fiber-reinforced plastic, which is composed of a planar aggregate of.

As described above, in the method for manufacturing the honeycomb core made of the fiber reinforced plastic, first, the band-shaped sheet of the fiber base material is supplied to the forming die, and the forming process is performed while the resin is attached, impregnated or mixed. By doing so, a corrugated plate made of fiber reinforced plastic is molded. Then, by stacking and joining such corrugated plates, a honeycomb core made of fiber reinforced plastic is manufactured.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail based on embodiments of the invention shown in the drawings. 1, 2, 3, and 4 provide an explanation of an embodiment of the present invention. 1 is an overall plan view, and FIG. 2 (1) is a sectional view taken along the line AA of FIG.
(2) The figure is a sectional view taken along the line BB of FIG.
(3) The figure is a cross-sectional view taken along the line CC of FIG.
(4) The figure is a cross-sectional view taken along the line DD of FIG. 3A and 3B show an example in which pulp-mixed paper is used as the fiber base material, FIG. 1A is a plan explanatory view, and FIG. 3B is a side explanatory view. FIG. 4A is a side explanatory view of the drawing process,
(2) is a side view of the sanding process, (3) is a perspective view of the adhesive applying process, and (4) is a perspective view of the stacking process. 5 and 6 are front explanatory views of the honeycomb core. FIG. 5 (1) is a first example thereof, FIG. 5 (2) is a second example, and FIG. 6 is a third example. Indicates.

In this method for manufacturing the honeycomb core 8 made of fiber reinforced plastic, first, as shown in FIGS. 1 and 2, a strip-shaped sheet of the fiber base material 9 is formed into a corrugated mold surface and the size of the mold surface. The pressure is gradually supplied to the forming mold 10 and is narrowed down so as to fit the mold surface while pulling, and the resin 11 is adhered, impregnated, mixed, etc. and heated and pressed.
Forming processing is performed.

These will be described in more detail. First, the fibrous base material 9 has a strip-like thin sheet shape, is unwound from the state of being wound on the reel 12, and is supplied to the forming die 10. As the fiber base material 9, various fibers such as glass fiber, Kevlar fiber, carbon fiber, ceramic fiber, metal fiber, resin fiber, cotton fiber, pulp mixed paper, synthetic paper, and other woven / non-woven composite fiber are used. Is used. As the resin 11, epoxy-based, phenol-based, polyimide-based, polyester-based, melamine-based, other thermosetting resins or thermoplastic resins are used.

The forming die 10 has a corrugated mold surface corresponding to the corrugated plate 13 (see FIG. 4 described later) to be molded, and the size of the mold surface is similar to that of the corrugated plate. To a small one (corresponding to the size of the corrugated sheet 13 to be formed). As such a forming die 10, a pair of upper and lower male and female dies are used in the illustrated example, and the fiber base material 9 is supplied between them, but regardless of this, for example, the lower die is used. In addition to using only the forming die 10 of the above, a method of pressing the supplied fiber base material 9 against the lower forming die 10 from the upper side, or such a lower forming die 10 is used. It is also possible to employ a method in which the fiber base material 9 is sucked so as to have air permeability.

The fiber base material 9 unwound from the reel 12 and supplied to the forming die 10 is passed through the forming die 10 and pressed while applying a tensile force in the front-back direction (left-right direction in the drawing). A forming process, that is, a stretch forming process is performed, and the shape is gradually narrowed down so as to fit the mold surface of the forming mold 10. Along with this, as shown in FIG. 2 (2), the resin 11 is wholly injected during the process, and is further pressurized and heated, so that the resin 11 adheres to the fiber base material 9 during the forming process. Impregnated and mixed. Therefore, the fiber base material 9
Resin 11 is combined with the fiber reinforced plastic (FR
P) and a semi-hardened prepreg having flexibility and viscosity by heating, so that narrowing along the mold surface of the forming mold 10 is promoted.

Then, in the final stage of such forming, cooling is performed through the forming die 10. That is, as described above, the fiber reinforced plastic in which the resin 11 is combined with the fiber base material 9 is subjected to the forming process by the forming die 10 in the prepreg state, is molded into the corrugated sheet 13 of a predetermined size, and is then cooled. . Therefore, the corrugated sheet 13 is completely cured from the semi-cured prepreg state by such cooling, and the shape is stabilized as it is.

In this method of manufacturing the honeycomb core 8 made of fiber reinforced plastic, the corrugated irregularities are thus continuously bent and formed, and the resin 11 is combined with the fiber base material 9. The corrugated sheet 13 made of fiber reinforced plastic is molded. That is, the formation of the fiber-reinforced plastic in which the resin 11 is combined with the fiber base material 9 and the formation of the corrugated sheet 13 while utilizing the prepreg state, the forming die 10
Forming process using is performed simultaneously in parallel. In addition to the trapezoidal shape shown in the drawing, the corrugated plate 13 may have a corrugated shape with a substantially triangular shape, a substantially square shape, or other shapes, and such corrugated shape is linear in the lateral direction. It is formed by bending at a predetermined pitch and height while continuously repeating in parallel and in the longitudinal direction.

Thereafter, in the method of manufacturing the honeycomb core 8 made of the fiber reinforced plastic, as shown in FIG.
As shown in FIG. 5 and FIG. 6, by stacking and joining a plurality of corrugated sheets 13 cut into predetermined lengths in such a positional relationship that their bottoms and tops are aligned, as shown in FIG. 5 and FIG. A honeycomb core 8 made of fiber reinforced plastic, which is a planar aggregate of hollow columnar cells 15 in which the corrugated plate 13 is partitioned and formed as the cell wall 14, is obtained.

These will be described in more detail. That is, the corrugated plate 13 made of the fiber-reinforced plastic formed by the forming process as described above is pulled out from the forming die 10. That is, as shown in FIG. 4A, the clamp member 16 that holds the downstream end of the corrugated plate 13 is
The corrugated sheet 13 is pulled out from the forming die 10 by moving it further downstream. And corrugated sheet 13
Is cut into a predetermined length by using a cutting blade or the like as shown in FIG. Then, as shown in FIG. 4 (2), the corrugated sheet 13 is held by the mold 17 and sanded by the roll-shaped sanding machine 18 so that the surface of the bottom or top portion of the corrugated sheet 13 to be an adhesive surface is , Roughly polished for easy adhesion. It should be noted that such a sanding process is first performed on one of the bottom portion and the top portion of the corrugated sheet 13, then the corrugated sheet 13 is inverted, and the other is performed. Thereafter, the corrugated sheet 13 thus sanded is subjected to an air blow process of blowing compressed air in order to remove dust generated by the sanding, and thereafter, as shown in FIG. 4 (3). In addition, on the surface of one of the bottom and the top (top in the illustrated example) to be the adhesive surface,
A node bond or adhesive 5 is applied.

Then, as shown in FIG. 4 (4), a plurality of the corrugated plates 13 made of fiber reinforced plastic which have been subjected to such respective treatments are stacked. That is, the plurality of corrugated plates 13 are sequentially shifted in the vertical direction by a half pitch of the wave, and are placed in a laminated block shape in which there is a space as a whole based on the positional relationship in which the bottom and the top are aligned with each other. Stacked. A flat plate 19 made of fiber-reinforced plastic similar to the corrugated plate 13 may be further interposed between the corrugated plates 13 (see FIG. 5 (2) and FIG. 6 described later). . After that, the corrugated plates 13 thus stacked are heated and pressed, whereby the applied adhesive agent 5 is melted and cured, and thus the mutual adhesion is achieved. When the flat plate 19 is further interposed as described above, the corrugated plates 13 and the flat plate 19 are also bonded to each other. Further, in the illustrated example, the bonding method using the adhesive 15 is adopted, but the bonding method using the brazing material or the bonding method using the melting and hardening of the resin 11 forming the corrugated sheet 13 is not used. , Etc. are also conceivable.

By following these steps, the process shown in FIG.
The honeycomb core 8 made of fiber reinforced plastic shown in (1), (2), and FIG. 6 is manufactured. In this honeycomb core 8, the corrugated plate 13 (further, flat plate 19 in the example shown in FIG. 5 (2) of FIG. 5 and FIG. 6) made of fiber-reinforced plastic that has been stacked and joined as described above is used as the cell wall 14. The cell wall 14 is composed of a planar assembly of a large number of hollow columnar cells 15 each formed in a separate space.

The cross-sectional shape of the cell wall 14 and the cell 15 is typically a regular hexagon shown in FIG. 5 (1), but a trapezoidal shape shown in FIG. 5 (2). (Also referred to as a bisect type), a substantially triangular shape having the radius shown in FIG. 6, and other various shapes are also possible. The honeycomb core 8 made of fiber reinforced plastic has an excellent weight ratio strength like a general one, is lightweight and has high rigidity and strength, and has a rectifying effect, plane accuracy, heat retention and sound insulation. It is also widely used as various structural materials because of its excellent properties such as large surface area per unit volume, and so on.

FIG. 3 shows an example in which pulp-mixed paper is used as the fiber base material 9. The example of FIG. 3 will be described. The pulp mixed paper, that is, the base paper, which is the fiber base material 9 supplied from the reel 12, is first wet-rolled via the guide roll 20 as shown in FIG. After passing through 21, it is sent to the forming die 10. That is, when a base paper such as a pulp mixed paper or a synthetic paper is used as the fiber base material 9 as described above, if it is supplied to the forming mold 10 as it is and subjected to the forming process, it may be broken. The forming process is performed after performing a preliminary treatment for imparting flexibility and mold resistance by making the wet roll 21 passing through the wet roll 21. (The forming die 10 is not shown in FIG. 3 (1).)

The subsequent steps are the same as those described above. That is, the strip-shaped sheet of the fiber base material 9 made of pulp-mixed paper or the like, which has been wetted and has been provided with molding resistance, is supplied to the forming mold 10 and the phenol-based resin 11 or the melamine-based resin 11 (in FIG. 3). (Not shown) is attached, impregnated, mixed, etc., and is formed into a corrugated plate 13 made of fiber reinforced plastic. Then, by stacking and joining such corrugated sheets 13, the honeycomb core 8 made of fiber reinforced plastic using the fiber base material 9 such as pulp mixed paper is manufactured. A conventional manufacturing method of this kind, that is, a conventional manufacturing method of a honeycomb core (not shown) made of fiber reinforced plastic using pulp mixed paper as the fiber base material 9 will be described. In the manufacturing method of the example, first, the honeycomb core is formed from the fiber base material 9 such as pulp-mixed paper, and then the post-treatment includes adhesion, impregnation, and mixing of the resin 11 by the badge method. Therefore, even in the manufacturing method of this type of conventional example, as in the case of the general conventional manufacturing method described above, the process processing is divided, and the percentage of manual work is high, so that continuous, mechanized, and mass-produced. The difficulty was pointed out.

The present invention is constructed as described above. Then it becomes as follows. In the method for manufacturing the honeycomb core 8 made of fiber reinforced plastic, first, referring to FIG.
As shown in FIGS. 2 and 3, a strip-shaped sheet of the fiber base material 9 is supplied to the forming mold 10, and the resin 11 is adhered, impregnated and mixed into the forming mold 10 while being heated and pressed, and pulled to conform to the mold surface. The corrugated sheet 13 made of the fiber-reinforced plastic is formed by performing the forming process that narrows down.
Then, as shown in FIG. 4, by stacking and joining a plurality of such corrugated sheets 13 (further by interposing a flat plate 19 as appropriate), the fiber reinforced shown in FIGS. The honeycomb core 8 made of plastic is manufactured. Then, according to the method for manufacturing the honeycomb core 8 made of the fiber reinforced plastic, the following first and second steps are performed.

First, in this manufacturing method, the corrugated sheet 13 made of the fiber-reinforced plastic is formed by performing the forming process while combining the resin 11 with the fiber base material 9 by adhering, impregnating, mixing, or the like. Is molded. That is, the fiber-reinforced plastic (FRP) in which the resin 11 is combined with the fiber base material 9 and the corrugated sheet 13 are formed simultaneously using the forming process, not separately. Therefore, according to this manufacturing method, the time and labor required for forming the corrugated sheet 13 and manufacturing the honeycomb core 8 can be reduced, and dedicated equipment and its condition management can be performed. At least, it eliminates material loss, plate cutting loss, and cutting removal loss.

Secondly, in the same manner, in this manufacturing method, the fiber reinforced plastic in which the resin 11 is combined with the fiber base material 9 and the corrugated sheet 13 in the fiber base material 9 are performed not in parallel but in parallel. Continuous, mechanized plate 13 forming process
Mass production is realized. As a result, the continuous manufacturing process, mechanization, and mass production of the honeycomb core 8 made of fiber-reinforced plastic are promoted.

[0027]

As described above, the method for manufacturing the honeycomb core made of the fiber-reinforced plastic according to the present invention performs the forming process while adhering, impregnating or mixing the resin with the belt-shaped sheet of the fiber base material. By forming the corrugated sheet made of fiber reinforced plastic, the following effects are exhibited.

First, the processing cost, material loss, plate cutting loss, cutting removal loss, etc. are reduced. That is, in this method of manufacturing a honeycomb core made of fiber reinforced plastic, as in the conventional example of this kind described above, a prepreg sheet of fiber reinforced plastic in which resin is previously attached, impregnated, and mixed with a fiber base material is processed, After the preparation, the corrugated sheet is not formed into a corrugated sheet, but is formed into a corrugated sheet while adhering, impregnating, or mixing a resin with the fiber base material. In addition to reducing the number, it also eliminates the need for specialized equipment and condition management for processing and preparing prepreg sheets. Further, material loss, plate removal loss, and cutting removal loss at the time of forming the prepreg sheet into a corrugated sheet are also eliminated, and waste that is cut and removed as an unnecessary portion is wiped out.
Therefore, a honeycomb core made of fiber reinforced plastic can be manufactured easily and easily with excellent cost.

Secondly, continuation, mechanization and mass production are promoted. That is, in this method for manufacturing a honeycomb core made of fiber reinforced plastic, as in the conventional example of this kind described above, a step of preparing a prepreg sheet in advance, a step of forming a corrugated sheet, a curing step in a furnace, etc. The work is not divided for each process of the formula, and in particular, manual insertion, sticking, carrying in, carrying out, peeling and the like in the curing process are unnecessary. Then, the resin is attached to the fiber substrate, impregnated,
By performing the forming process while mixing, the corrugated plate made of fiber reinforced plastic is molded,
Realization of continuous, mechanized, and mass-produced corrugated sheet forming processes. Therefore, continuous, mechanized, and mass-produced manufacturing processes of the honeycomb core made of fiber-reinforced plastic are promoted, and from this aspect, the honeycomb core made of fiber-reinforced plastic can be manufactured with excellent cost. As described above, the effects exhibited by the present invention are remarkable and large, for example, all the problems existing in this type of conventional example are solved.

[Brief description of drawings]

FIG. 1 is an overall plan view for explaining an embodiment of the invention, regarding a method for manufacturing a honeycomb core made of fiber-reinforced plastic according to the present invention.

2 is a view for explaining the embodiment of the present invention, (1) is a sectional view taken along the line AA of FIG. 1, and (2) is
1 is a sectional view taken along line BB of FIG. 1, and FIG.
1 is a sectional view taken along the line CC of FIG.
FIG. 6 is a cross-sectional view taken along the line D.

FIG. 3 is a view for explaining an embodiment of the present invention and shows an example in which pulp-mixed paper is used as a fiber base material. (1) is a plan view and (2) is a side view.

FIG. 4 is used to explain an embodiment of the present invention,
(1) is a side view of the drawing process, and (2) is
A side view of the sanding step, (3) is a perspective view of the adhesive applying step, and (4) is a perspective view of the stacking step.

5A and 5B are front explanatory views of a honeycomb core, in which FIG. 1A shows a first example, and FIG. 2B shows a second example.

FIG. 6 is a front view showing a third example of a honeycomb core.

7A and 7B are front explanatory views for explaining a conventional example of this kind, wherein FIG. 1A shows a preparatory step, FIG. 2B shows a corrugated sheet forming step, and FIG. 3C shows a formed corrugated sheet. , (4) shows stacking and joining processes.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Honeycomb core (conventional example) 2 Prepreg sheet 3 Rack 4 Corrugated plate (conventional example) 5 Adhesive 6 Cell wall (conventional example) 7 Cell (conventional example) 8 Honeycomb core (of the present invention) 9) Fiber substrate 10 Forming type 11 Resin 12 Reel 13 Corrugated sheet (of the present invention) 14 Cell wall (of the present invention) 15 Cell (of the present invention) 16 Clamping member 17 type 18 Sanding machine 19 Flat plate 20 Guide roll 21 Wet roll

Claims (1)

[Claims] 1. First, a band-shaped sheet of a fibrous base material is supplied to a forming mold in which the mold surface has a corrugated shape and the size of the mold surface is gradually changed, and while being pulled, the resin is narrowed down so as to fit the mold surface, Forming process is performed by applying heat, pressure by adhering, impregnating, mixing, etc., resulting in a shape in which corrugated irregularities are continuously bent and formed. After molding a plastic corrugated sheet, stacking and joining a plurality of corrugated sheets that have been cut for each predetermined length in a positional relationship where the bottom and top are aligned, so that the corrugated sheet is used as a cell wall. A method for producing a honeycomb core made of fiber reinforced plastic, comprising obtaining a honeycomb core made of fiber reinforced plastic, which is composed of a planar aggregate of hollow columnar cells that are partitioned and formed.