JPH1067061A - Honeycomb core-containing plastic panel and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce the wt. of a honeycomb core-containing plastic panel and to increase the strength thereof by inserting a honeycomb core made of aluminum into the gap between felts impregnated with a resin and putting the whole in a film to heat and cure the resin. SOLUTION: The whole of felt 1 is sufficiently and uniformly impregnated with a resin to a degree preventing the resin from flowing out to the outside. Two felts thus impregnated with the resin are prepared and a honeycomb core made of aluminum is inserted into the gap between the felts. The honeycomb core and the felts are lightly bonded by the sticking force of the resin infiltrated into the felts. The felts having the honeycomb core inserted into the gap therebetween is put in a film 6 formed into a bag shape and air is extracted from the film to hermetically seal the film. The deaerated felts 1 inserted into the film and the honeycomb core 6 are sunk into the water in a water tank 10 filled with a predetermined amt. of water and the water in the water tank 10 is heated by a boiler 12 through a pipe 14. By this method, a lightweight honeycomb core-containing plastic panel having high strength can be produced.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plastic plate containing a honeycomb core and a method for producing a plastic plate containing a honeycomb core. More specifically, an aluminum honeycomb core is inserted between felts impregnated with a resin. The present invention also relates to a plastic plate containing a honeycomb core obtained by placing the same in a film and heating the film, and a method for producing the same.

[0002]

2. Description of the Related Art FIG. 9 is a view showing a conventional plastic plate with a honeycomb core sandwiching a honeycomb core between plastics. In FIG. 9, 6 is a honeycomb core, 22 is a plastic plate, and 24 is an adhesive. In FIG. 9, conventionally, an adhesive 24 is applied to one surface of each of two plastic plates 22, the honeycomb core 6 is sandwiched therebetween, and the honeycomb core 6 and the plastic plate 22 are bonded with the adhesive 24. Was. Alternatively, an adhesive is applied to both surfaces of the honeycomb core 6 and the plastic plate 22 is pressed on both surfaces to bond the honeycomb core 6 and the plastic plate 22 together.

[0003]

However, in the conventional plastic sheet containing a honeycomb core, the adhesive 2
When the amount of the adhesive 4 is large, the adhesiveness is improved, but the adhesive 24 enters the eyes of the honeycomb core 6 and the weight becomes heavy. When the amount of the adhesive 24 used is small, the adhesiveness is poor.
And the plastic plate 22 was easily peeled off. Further, the plastic plate 22 has a disadvantage that the weight is heavy and even if a light honeycomb core 6 is used, only a very heavy plastic plate containing a honeycomb core can be obtained.

The present invention relates to a plastic sheet containing a honeycomb core, which has better adhesiveness, higher adhesive strength, a specific gravity of about 1 and a very light weight as compared with iron or the like as compared with a conventional bonding method, and a homogeneous honeycomb core-containing plastic plate. It is intended to provide a manufacturing method.

[0005]

According to the present invention, there is provided a plastic plate containing a honeycomb core, wherein a resin is sufficiently and uniformly impregnated in the felt entirely, and an aluminum honeycomb is interposed between the two resin-impregnated felts. The core is inserted, and the felt with the honeycomb core inserted is put into a bag-shaped film to bleed air and sealed. Is heated for a certain period of time.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiment 1 FIG. FIG. 1 to FIG. 5 are views of each step in a method for manufacturing a plastic sheet with a honeycomb core according to an embodiment of the present invention, as viewed obliquely. The steps of manufacturing a honeycomb core-containing plastic plate will be described below in order.

Step 1 FIG. 1 is a view showing a state in which a resin is soaked in felt. In FIG. 1, 1 is a felt (non-woven fabric), 2 is a container for containing a resin, and 4 is a thermosetting resin. Step 1
Then, the resin 1 is sufficiently and uniformly impregnated into the felt 1 so as not to flow out to the outside. For example, an epoxy resin is used as the resin. In order to sufficiently impregnate the felt with the epoxy resin, for example, a roller or the like is used to spread the epoxy resin evenly and uniformly on the felt surface. The type and thickness of the felt, the type of the resin, and the like are appropriately selected according to the type of the plastic plate containing the honeycomb core to be manufactured.

Step 2 FIG. 2 is a view showing a state in which the honeycomb core is sandwiched between two felts. In step 2, two felts impregnated with the resin in step 1 are prepared, and an aluminum honeycomb core is inserted between them. The honeycomb core and the felt lightly adhere to each other due to the adhesive force of the resin impregnated in the felt.

Step 3 FIG. 3 is a view showing a state in which a honeycomb core sandwiched between two felts is put in a film. In step 3, the felt into which the honeycomb core has been inserted in step 2 is put into a bag-shaped film 6, and air is released and sealed. By removing the air in the film in this manner, the air between the felt and the honeycomb core is eliminated, and the epoxy resin is injected between the felt 1 and the honeycomb core 6 without any gap. For this reason, the adhesive force between the felt 1 and the honeycomb core 6 after the epoxy resin is cured increases.

Step 4 FIG. 4 is a view showing a state in which the felt and the honeycomb core, which have been inserted into the film and the air has been evacuated, are submerged in the water tank 10. In step 4, the felt 1 and the honeycomb core 6, which have been inserted into the film and have been evacuated, are immersed in a water tank 10 filled with a predetermined amount of water, and the water in the water tank 10 is heated by a boiler 12 via a pipe 14. The water in the aquarium 10
Without using the boiler 12, a known technique, for example,
Heating may be performed using high frequency or the like. In addition, it is a matter of course that hot water heated outside may be poured into the water tank 10. By using such a water tank 10, a constant water pressure is applied to the entire surface of the film.
And the honeycomb core 6 is heated in a state where pressure is applied. After a certain period of time, the felt 1 and the honeycomb core 6 are bonded by the thermosetting property of the epoxy resin,
A desired honeycomb core-containing plastic plate is obtained. The heating temperature and the curing time vary depending on the type of the resin. For example, in the case of an epoxy resin, the water temperature is about 80 degrees, and the curing time is about 3 hours. Oil can be used instead of water.

Step 5 FIG. 5 is a view showing the completed plastic sheet containing the honeycomb core. By cutting the felt and the honeycomb core around the honeycomb core inserted and evacuated in the film manufactured in Step 4, a plastic plate with a honeycomb core as shown in FIG. 5 can be obtained. Since the surface of the plastic plate containing the honeycomb core is film-coated with the film 8, a plastic plate containing the honeycomb core having a smooth surface is obtained.

The feature of the plastic plate containing the honeycomb core is that since the felt 1, the honeycomb core 6 and the film 8 are all light, a plastic plate containing the honeycomb core which is light and strong as a whole can be produced. Also,
By changing the size and the thickness of the eyes of the aluminum honeycomb core, the strength of the plastic plate containing the honeycomb core can be changed. Furthermore, by increasing the thickness of the felt and increasing the amount of impregnating resin, the strength of the honeycomb core-containing plastic plate can be increased. Therefore, by changing the thickness of the felt depending on the use of the honeycomb core-containing plastic plate, it is possible to manufacture honeycomb core-containing plastic plates having various strengths and thicknesses.

FIG. 6 is a view showing a jig for manufacturing a plastic plate containing a honeycomb core having good flatness. In FIG. 6, the felt 1 and the honeycomb core 6 which have been inserted into the film 8 and have been evacuated are sandwiched between flat support plates (a jig made of a flat plate or an iron plate) 16 to provide a plastic plate containing a honeycomb core having good flatness. Can be manufactured.

FIG. 7 is a view showing a jig for manufacturing a plastic plate containing a honeycomb core having a curved surface. In FIG. 7, the felt 1 and the honeycomb core, which have been inserted into the film 8 and from which air has been removed, are sandwiched between curved surface supporting plates (a jig made of a plate having a curved surface or an iron plate), and both curved surface supporting plates are fixed with a crank or the like. Then, the felt 1 and the honeycomb core 6 which have been inserted into the film 8 including the jig and from which the air has been evacuated are sunk into the water tank 10, whereby a curved plastic sheet with a honeycomb core can be manufactured.

Further, in order to strengthen the bonding between the felt 1 and the honeycomb core 6, thermosetting fibers can be inserted in advance into the eyes of the honeycomb core. As described above, by inserting the thermosetting fibers into the eyes of the honeycomb core in advance, the weight per unit of the plastic plate containing the honeycomb core is increased, but the plastic plate containing the strong honeycomb core can be obtained. .

Embodiment 2 In the second embodiment of the present invention, only the step 4 is different from the first embodiment, and steps 1 to 3 are the same as the first embodiment. Therefore, in the second embodiment, only step 4 will be described below.

Step 4 FIG. 8 is a view showing a state in which the felt and the honeycomb core, which have been inserted into the film and the air has been removed, are submerged in the water tank 10. In step 4, the felt 1 and the honeycomb core 6, which have been inserted into the film 8 and from which air has been removed, are inserted into the heating and pressurizing support plate 26, pressurized, and simultaneously heated for a predetermined time. By using such a heating / pressing support plate 26, a certain pressure is applied to the entire film surface, so that the felt 1 and the honeycomb core 6 are heated in a state where the pressure is applied. After a certain period of time, the felt 1 and the honeycomb core 6 are adhered by the thermosetting property of the epoxy resin, and a desired honeycomb core-containing plastic plate is obtained. The heating temperature and the curing time vary depending on the type of the resin, but are the same as in the first embodiment. In addition, the honeycomb core-containing plastic plate having a curved surface can be manufactured by curving the surface of the heating / pressing support plate 26.

[0018]

As described above, according to the present invention, the following effects can be obtained.

A plastic plate containing a honeycomb core having a higher adhesion strength than a conventional bonding method can be obtained by thermosetting the resin impregnated in the felt and the honeycomb core.

Since the specific gravity of each of the felt, the honeycomb core, and the film is small, a very lightweight honeycomb core-containing plastic plate having a specific gravity of about 1 as compared with the conventional honeycomb core-containing plastic plate can be obtained.

[0021] Since the felt and the honeycomb core are covered with the film, a plastic plate containing a honeycomb core having strong resistance to acid and alkali is obtained.

Since the surface of the honeycomb core-containing plastic plate is film-coated, a honeycomb core-containing plastic plate having small surface grains can be obtained.

A plastic plate containing a honeycomb core having a curved surface can be easily manufactured using a jig having a curved surface shape.

By using the same resin as the resin impregnated in the felt, the surface of the plastic sheet containing the honeycomb core can be immediately repaired.

Since the plastic sheet with the honeycomb core is formed under a uniform pressure, a uniform plastic sheet with the honeycomb core can be obtained.

[Brief description of the drawings]

FIG. 1 is a diagram showing a state in which a resin is impregnated into a felt.

FIG. 2 is a diagram showing a state in which a honeycomb core is sandwiched between two felts.

FIG. 3 is a diagram showing a state in which a honeycomb core sandwiched between two felts is put in a film.

FIG. 4 is a view showing a state in which the felt and the honeycomb core, which have been inserted into the film and from which air has been removed, are submerged in the water tank 10.

FIG. 5 is a view showing a completed plastic plate containing a honeycomb core.

FIG. 6 is a view showing a jig for manufacturing a plastic plate containing a honeycomb core having good flatness.

FIG. 7 is a view showing a jig for manufacturing a plastic plate containing a honeycomb core having a curved surface.

FIG. 8 is a diagram showing a pressurized and heated support plate for manufacturing a plastic plate with a honeycomb core according to a second embodiment of the present invention.

FIG. 9 is a diagram showing a honeycomb core-containing plastic plate with a honeycomb core sandwiched between conventional plastics.

[Explanation of symbols]

1 felt (non-woven fabric), 2 container for resin, 4
Resin, 6 honeycomb core, 8 film, 10 water tank,
12 boiler, 14 pipe, 16 plane support plate, 18
Clamp, 20 Curved support plate, 22 Plastic plate, 24 Adhesive, 26 Heat and pressure support plate

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code Agency reference number FI Technical display location B32B 27/04 B29C 67/14 L // B29K 63:00 B29L 9:00

Claims (6)

[Claims] 1. A method of impregnating a resin sufficiently and uniformly throughout.
A plastic plate with a honeycomb core, wherein an aluminum honeycomb core is inserted between two felts, the outer surfaces of both felts are covered with a film, and the resin is cured. 2. The plastic plate with a honeycomb core according to claim 1, wherein a thermosetting fiber is filled in an aluminum honeycomb core. 3. A method for manufacturing a plastic plate containing a honeycomb core, wherein the resin is sufficiently and uniformly impregnated into the felt entirely, and an aluminum honeycomb core is inserted between the two resin-impregnated felts. The felt into which the honeycomb core is inserted is placed in a bag-shaped film to release air and sealed. A method for producing a honeycomb core-containing plastic plate, comprising producing a honeycomb core-containing plastic plate by heating. 4. The method for manufacturing a plastic sheet with a honeycomb core according to claim 3, wherein an epoxy resin is used as the resin, and a roller is used to sufficiently impregnate the felt with the epoxy resin. A method for producing a plastic plate containing a honeycomb core, wherein an epoxy resin is uniformly impregnated into a felt. 5. The method for producing a plastic sheet with a honeycomb core according to claim 3, wherein the water tank is filled with water so that a constant water pressure is applied to the entire surface of the film, and the entire film including the felt and the honeycomb core. A method for producing a plastic plate containing a honeycomb core, comprising: 6. A method for producing a plastic plate containing a honeycomb core, wherein a resin is sufficiently and uniformly impregnated into felt entirely, and an aluminum honeycomb core is inserted between the two resin-impregnated felts. Then, the felt into which the honeycomb core is inserted is put into a bag-shaped film to release air and sealed. A method for producing a plastic plate containing a honeycomb core, comprising producing a plastic plate containing a honeycomb core by applying pressure and heating for a predetermined time.