KR20210110837A - 샌드위치 형태의 복합 재료의 제조를 위한 방법 - Google Patents

샌드위치 형태의 복합 재료의 제조를 위한 방법 Download PDF

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Publication number
KR20210110837A
KR20210110837A KR1020217022700A KR20217022700A KR20210110837A KR 20210110837 A KR20210110837 A KR 20210110837A KR 1020217022700 A KR1020217022700 A KR 1020217022700A KR 20217022700 A KR20217022700 A KR 20217022700A KR 20210110837 A KR20210110837 A KR 20210110837A
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South Korea
Prior art keywords
core
sandwich
outer layer
insert
preform
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KR1020217022700A
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English (en)
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KR102508576B1 (ko
Inventor
가에탄 마오
니콜라스 두몬트
Original Assignee
생-고뱅 퍼포먼스 플라스틱스 프랑스
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Priority to KR1020237005647A priority Critical patent/KR102656324B1/ko
Publication of KR20210110837A publication Critical patent/KR20210110837A/ko
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14467—Joining articles or parts of a single article
    • B29C45/14508—Joining juxtaposed sheet-like articles, e.g. for making trim panels
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
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    • B29C35/16—Cooling
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/08—Dimensions, e.g. volume
    • B32B2309/10—Dimensions, e.g. volume linear, e.g. length, distance, width
    • B32B2309/105—Thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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Abstract

본 발명의 목적은 코어 및 외부 층을 포함하는 샌드위치 형태의 제품을 제조하는 방법일 수 있다. 외부 층은 섬유 강화 중합체 매트릭스를 포함하는 복합 재료로 구성될 수 있다. 이 방법은 실리콘과 같은 내열성 소재의 인서트를 이용한다. 본 발명의 목적은 외부 층의 재료의 선택으로부터 샌드위치의 코어의 재료의 선택을 분리하는 샌드위치의 제조 방법을 제공하는 것이다.

Description

샌드위치 형태의 복합 재료의 제조를 위한 방법
본 발명은 복합 재료 또는 복합 재료로 제조된 제품 분야에 관한 것이다. 복합 재료로 제조된 제품은 폴리머 재료, 특히 열가소성 또는 열경화성 재료로 구성된 수지 매트릭스를 포함할 수 있는 제품을 의미한다. 이 매트릭스는 중합체 재료의 용융점보다 더 높은 융점을 가질 수 있는 재료에 의해 강화될 수 있다. FRP는 일반적으로 "섬유 보강 플라스틱"을 지칭한다.
FRP 유형의 복합 재료는 재료의 중량에 대해 기계적 저항이 우수하다. 또한 이 재료는 부식에 대한 매우 우수한 저항성을 갖는다. 이는 별도로 취한 구성 요소보다 우수한 특성을 갖는다. 특히 자동차 또는 항공 분야에서 전통적으로 스틸로 제조된 부품의 경량화가 허용된다. 이는 또한 피로에 대한 저항력이 높다.
복합물의 보강은 매트릭스에 분산된 광물 섬유의 추가, 강철 또는 합성 재료로 제조된 지지 구조 사용, 강화 섬유 직물 사용, 부직포 또는 매트 또는 직물 방법으로 얻은 기타 제품의 사용에 의해 얻어질 수 있다.
직물 보강물은 편평한 구조를 가질 수 있으며, 수직으로 교차하고 얽힌 씨실 및 날실로 구성될 수 있다. 이의 제조는 날실로 별도의 스풀을 사용해야 할 수 있다.
최근에는 편직 보강재가 사용되었다. 편직 보강재는 일반적으로 얀이 연속적인 줄로 배열된 메시를 형성하는 연속 얀에서 얻은 제품을 의미할 수 있다. 전통적인 니트의 제조는 얀 메쉬를 위한 얀의 스풀만 필요로 한다.
얀은 모노 필라멘트 또는 멀티 필라멘트 유형일 수 있다. 멀티 필라멘트는 로빙(즉, 비틀림 없이 조립된 평행 연속 필라멘트 세트), 방적사(즉, 비틀림으로 조립된 짧은 스테이플 섬유 세트)일 수 있다. 얀은 또한 여러 얀 또는 다른 재료의 필라멘트의 집합체일 수 있다. 이 조립은 트위스트 및 랩핑에 의해 수행될 수 있다. 따라서 중합체 재료 및 보강 재료를 포함하는 얀을 제조할 수 있다. 예를 들어, 아라미드, 탄소, 유리 유형 및 열가소성 얀(즉, 폴리프로필렌, 폴리카보네이트, 폴리에테르이미드(PEI))의 강화 얀을 조립할 수 있다. 이러한 유형의 얀은 혼합 얀을 불릴 수 있다.
이러한 유형의 혼합 얀을 편직하면 보강재와 매트릭스를 모두 포함하는 프리폼을 얻을 수 있다. 이 프리폼은 일반적으로 "프리프레그(prepreg)"라고 부르는 끈적끈적한 수지 사전 함침 직물과는 달리 "건식"이다.
FRP 유형 복합 재료로 제조된 2개의 외부 층 또는 스킨과 폼 유형의 더 가벼운 재료 또는 셀룰러 허니콤 재료의 중심 몸체 또는 코어를 포함할 수 있는 샌드위치 형태로 제품을 제조할 수도 있다. 샌드위치 형태의 구조 덕분에 이러한 제품은 동일한 중량으로 훨씬 더 나은 성능을 얻을 수 있다.
스킨의 함침과 이들의 코어 결합은 샌드위치 복합물의 최종 특성에 영향을 미칠 수 있다. 스킨의 우수한 함침은 일반적으로 여러 단계의 압밀 방법이 필요로 하고, 이는 시간과 자원을 소모한다. 이는 특히 완제품이 복잡한 3D 형상을 갖는 경우이다.
샌드위치를 제조하는 전통적인 방법에는 일반적으로 다음 단계가 포함될 수 있다: 중합체 재료로 미리 함침된 스킨을 사용하여 외부 층의 제조;
예를 들어 허니콤 또는 폼과 같은 코어의 측면에 외부 층의 병치;
중합체 재료의 용융을 보장하는 동시에 모든 층이 코어에 연결되도록 하기 위한 외부 층의 압밀(consolidation).
스킨의 두께에 따라 복수의 폴드를 적층할 필요가 있다. 그 뒤에 각 스킨의 직물 폴드의 우수한 압밀을 보장하고 스킨과 코어 사이에 우수한 접착력을 보장하기 위해 여러 경화 사이클이 필요할 수 있다. 이러한 유형의 제조 방법을 사용하면 샌드위치의 코어를 특별히 선택하여 외부 층의 경화를 방지할 수 있다. 어떤 경우에는 온도와 압력을 가하면 이는 손상되는 것으로 밝혀졌다. 예를 들어, 이 처리 중에 폼 코어가 처지거나 수축될 수 있음이 관찰되었다.
또한 경화하는 동안 중합체 재료가 허니콤의 세포로 유동할 수 있는 것으로 나타났다.
문헌 EP 0 770 472 A1은 개방 셀 구조로 형성된 코어와 섬유 및 수지로 형성된 스킨을 사용하여 복합 재료 샌드위치 패널을 제조하는 방법을 개략적으로 설명한다. 코어의 개방 셀에서 수지가 용융하는 것을 방지하기 위해 이 문헌은 방수 멤브레인과 스킨과 코어 사이에 접착제 필름을 삽입하는 방법을 제공한다. 몰드를 밀폐한 후, 단일 열 사이클로 접착제를 중합한 다음 압력 하에서 수지를 섬유에 주입하고 마지막으로 수지를 중합할 수 있다.
그러나 이 방법은 여러 층, 특히 방수 멤브레인을 사용해야 한다는 단점이 있다. 이는 완제품의 비용을 증가시킨다.
문헌 EP 1 086 801 A1은 수지 주입 기술인 RTM에 의해 샌드위치 패널을 제조하는 방법을 설명한다. 허니콤 구조를 충전하는 것을 방지하기 위해 이 방법은 팽창성 재료의 필름 몰드와 코어의 각 면에 배리어 직물을 설치해야 한다.
본 발명에 따른 방법은 외부 층이 압밀될 때 코어에 의해 인서트의 교체 및 코어 대신에 외부 층을 형성하기 위하여 열 저항 재료의 인서트를 사용한다. 그 뒤에 외부 층을 코어에 결합하기 위해 열 처리가 수행된다.
제1 실시예에 따라서, 본 발명에 따른 방법은 다음의 단계를 포함한다:
예를 들어 중합체 재료 및 강화 재료를 포함할 수 있는 얀을 편직 또는 직조함으로써 외부 층 또는 사전 함침된 스킨의 실시예;
몰드, 외부 층, 내열성 재료의 인서트 및 제2 외부 층의 병치;
보강 재료의 용융점에 도달하지 않고 중합체 재료의 압밀 및 융합을 허용할 수 있는 온도 및 압력을 경화함으로써 스킨의 성형;
인서트의 제거 및 2개의 프리폼 스킨 사이에 샌드위치, 예를 들어 폼 또는 허니콤의 코어의 삽입;
샌드위치의 외부 층과 코어 사이의 접착을 허용하는 온도에서 조립체의 경화.
또 다른 실시예에 따라서, 스킨은 보강 재료의 직물로부터 제조될 수 있고 중합체 재료는 주입에 의해 제공될 수 있다.
방법은 그 뒤에 다음의 단계를 포함할 수 있다:
보강 직물의 몰드에, 열에 저항성 재료 인서트, 그 뒤, 다른 보강 직물의 병치;
수지 주입;
인서트의 제거 및 2개의 프리폼 스킨 사이에 샌드위치, 예를 들어 폼 또는 허니콤의 코어의 삽입;
샌드위치의 외부 층과 코어 사이의 접착을 허용하는 온도에서 전체를 경화.
인서트는 강성일 수도 있고 아닐 수도 있다. 이는 특히 실리콘일 수 있다.
일부 실시예에서, 이는 이 온도에서 팽창할 수 있다. 이를 통해 압밀 중에 압축을 증가시킬 수 있다.
인서트는 예를 들어 경사진 형상과 같이 특정 형상을 완성된 제품에 제공할 수 있다.
일부 실시예에서, 접착제 층은 외부 층과 샌드위치 몸체 사이에 삽입될 수 있다. 이 접착제는 액체 글루, 접착제 필름 또는 열가소성 섬유를 포함하는 직조된 프리폼일 수 있다. 외부 층은 동일하거나 또는 상이할 수 있다.
바람직하게, 우수한 샌드위치 효과를 얻기 위하여, 코어의 두께는 일반적으로 약 2 mm 이상 내지 약 50 mm 이하, 약 3 mm 이상 내지 약 40 mm 이하, 약 5 mm 이상 내지 약 25 mm 이하일 수 있고, 스킨의 두께는 약 0.2 mm 이상 내지 약 5 mm 이하, 바람직하게, 약 0.4 mm 이상 내지 약 2 mm 이하, 및 더 바람직하게 약 0.5 mm 이상 내지 약 1 mm 이하일 수 있다.
본 발명의 목적은 샌드위치를 제조하는 대안적인 방법을 제공하는 데 있으며, 특히 샌드위치 몸체의 재료 선택과 외부 층의 재료 선택을 분리하는 제조 방법을 제공하는 것이다.
중합체 재료는 예를 들어 폴리카보네이트(PC), 폴리에테르이미드(PEI), 폴리 프로필렌(PP), 폴리(에틸렌 테레프탈레이트)(PET), 폴리에테르 에테르 케톤(PEEK) 또는 예를 들어 열경화성 재료, 예컨대 에폭시, 시아네이트 에스테르, 페놀 수지, 폴리에스테르를 포함할 수 있다.
보강 재료는 파라-아라미드, 폴리프로필렌과 같은 합성 재료, 린넨과 같은 천연 재료, 유리, 석영, 탄소, 코발트, 금속과 같은 무기 재료를 포함할 수 있다.
본 발명에 따른 방법은 변형 방법의 선택으로부터 샌드위치의 코어 유형의 선택을 분리할 수 있기 때문에 특히 유리한 것으로 입증되었다.
본 발명에 따른 방법은 외부 스킨의 우수한 함침을 달성하는 것을 가능하게 할 수 있다.
많은 다른 양태 및 실시예가 가능하다.
이러한 양태 및 실시예 중 일부가 여기에 설명된다.
본 명세서를 읽은 후, 당업자는 이러한 양태 및 실시예가 단지 예시일 뿐이며 본 발명의 범위를 제한하지 않는다는 것을 이해할 것이다.
실시예는 아래 나열된 실시예 중 어느 하나 이상에 따를 수 있다.
실시예 1: 샌드위치형 복합 재료 제품을 제조하는 방법으로서, 샌드위치형 복합 재료 제품은 2개의 외부 층 및 코어를 포함하고, 외부 층은 섬유 보강 탄성중합체 재료의 매트릭스를 가지며, 탄성중합체 재료는 섬유를 구성하는 재료의 용융점 미만의 용융점을 가지며, 상기 방법은 외부 층이 압밀되는 중합체 재료의 용융점보다 높은 용융점을 갖는 재료로 구성된 인서트를 사용하고, 상기 인서트는 샌드위치의 코어에 의해 교체되고, 조립체는 그 뒤에 외부 층을 코어에 결합하기 위해 압밀 처리가 수행된다.
실시예 2. 실시예 1에 따라서, 상기 방법은 샌드위치의 외부 층으로 형성되는 섬유 보강 중합체 재료로 구성된 프리폼의 제조 단계, 제2 프리폼 및 인서트의 제1 프리폼을 몰드 내에 병치하는 단계, 인서트의 재료 또는 보강 재료의 융융점의 온도에 도달되기 전에 중합체 재료의 용융점의 온도에 도달되도록 가열 및 가압에 의해 외부 층을 형성하기 위하여 프리폼의 압밀 단계, 인서트를 제거하고 외부 층을 분리하고 샌드위치의 코어를 삽입하는 단계, 외부 층을 코어에 부착하기 위해 열 처리하는 단계, 이에 따라 생성된 제품의 냉각 단계를 포함한다.
실시예 3. 실시예 2에 따라서, 프리폼은 사전함침된 중합체 수지 직물을 사용하여 제조된다.
실시예 4. 실시예 2에 따라서, 프리폼은 중합체 재료와 보강 재료를 포함하는 얀을 편직함으로써 형성된다.
실시예 5. 실시예 2에 따라서, 필 코스트는 코어 없이 구역을 형성하는 위치에서 프리폼들 사이에 첨가된다.
실시예 6. 실시예 1에 따라서, 보강 재료로 제조된 제2 직물 또는 니트, 인서트 및 보강 재료로 제조된 직물 또는 니트를 몰드 내에 병치하는 단계, 압력 및 온도 하에서 중합체 재료의 수지를 주입하는 단계, 인서트를 제거하고 샌드위치의 코어를 삽입하는 단계, 외부 층을 샌드위치의 코어에 접합하기 위하여 압밀 경화하는 단계, 이에 따라 생성된 제품의 냉각 단계를 포함한다.
실시예 7. 실시예 1에 따라서, 인서트는 실리콘으로 제조된다.
실시예 8. 실시예 1에 따라서,보강 재료는 유리, 탄소 및 아라미드 섬유로부터 선택된다.
실시예 9. 실시예 1에 따라서, 중합체 재료는 특히 폴리카보네이트(PC), 폴리에테르이미드(PEI), 폴리프로필렌(PP), 폴리(에틸렌 테레프탈레이트)(PET), 폴리에테르 에테르 케톤(PEEK)로부터 선택된 열가소성 유형이다.
실시예 10. 실시예 1에 따라서, 중합체 재료는 특히 에폭시, 시아네이트 에테르, 페놀 수지 및 폴리에테르로부터 선택된 열경화성 유형이다.
실시예 11. 실시예 1에 따라서, 샌드위치의 코어는 셀룰러 허니콤 재료로 구성된다.
실시예 12. 실시예 1에 따라서, 코어의 두께는 약 2 mm 이상 내지 약 50 mm 이하이다.
실시예 13. 실시예 1에 따라서, 외부 층의 두께는 약 0.2 mm 이상 내지 약 5 mm 이하다.
다음의 실시예는 비 제한적인 방식으로 본 발명을 예시한다.
실시예 1
여러 "프리프레그" 시아네이트 에스테르 함침 탄소 섬유 직물을 스틸 몰드에 드레이핑하여 샌드위치의 제1 스킨을 형성한다.
강성 인서트(예를 들어, 수 밀리미터의 Teflon® 블록)가 직물에 증착된다.
샌드위치의 제2 스킨은 강성 인서트에 여러 "프리프레그" 직물을 드레이핑하여 제조된다.
테프론 코팅 필 플라이(PTFE 코팅 유리 섬유)는 두 스킨 사이의 접합부에 배치된다. 접합부는 스킨이 결합되어 코어 영역을 덮는 영역이다.
몰드는 가요성 카운터 몰드로 밀폐된다.
스킨은 진공 상태에서 약 180-220 °C에서 몇 시간 동안 열처리를 통해 압밀된다(consolidate).
조립체는 냉각되어 인서트가 제거된다.
내열성 접착제가 코어와 접촉하는 각각의 면에 도포된다.
인서트 대신에 폴리이미드 폼 유형 코어(대략 밀도 50kg/m3)가 도입된다.
그런 다음 전체 샌드위치가 진공 상태에서 약 90-120 °의 온도에서 최종 압밀되어 스킨과 코어의 우수한 접착력을 보장한다.
실시예 2
제1 스킨은 스틸 몰드에 적층된 탄소 섬유의 여러 비함침 압밀 직물의 스택으로 형성된다.
연성 인서트(몇 밀리미터 두께의 실리콘 판)가 직물에 적층된다.
제2 스킨은 인서트에 적층된 동일한 유형의 직물로 형성된다.
몰드는 스틸 카운터 몰드로 밀폐된다.
시아네이트 에스테르 수지는 10 ~ 15bar의 압력하에 80 ~ 120 ° C의 온도에서 알려진 RTM 유형 방법에 의해 주입된다.
열처리는 4 시간 연장된다.
몰드는 냉각되고 그 뒤 인서트가 제거되고 필 플라이를 제거하여 스킨이 분리된다.
시아네이트 에스테르 수지의 매우 얇은 층이 스킨(허니콤과 접촉하도록 의도 된 면)에 추가된다.
인서트 대신 허니콤 코어가 두 스킨 사이에 삽입되어 샌드위치를 형성한다.
샌드위치 전체를 진공 상태에서 4 시간 동안 열처리(180-200 °C)하여 스킨과 코어를 접착한다.
실시예 3
니트는 유리 섬유와 열가소성 섬유로 구성된 혼합 사를 사용하여 제조된다.
이 니트는 스틸 몰드에 증착되어 제1 스킨을 형성한다.
온도의 영향으로 팽창할 수 있는 재료의 인서트가 니트에 증착된다.
동일한 유형의 제2 니트가 인서트에 증착되어 제2 스킨을 형성한다.
테프론 코팅 필 플라이(PTFE 코팅 유리 섬유)는 두 스킨 사이의 접합부에 배치된다. 접합부는 코어 영역을 덮기 위해 두 스킨이 결합되는 영역이다.
테프론 코팅된 필 플라이는 두 스킨 사이의 접합부에 배치된다.
몰드는 스틸 카운터 몰드에 의해 밀폐된다.
스킨은 200-250 °C, 3-10 바의 압력 하에서 수십 분 동안 열처리에 의해 압밀된다.
몰드는 냉각되고 그 뒤에 제거되어 스킨이 필 플라이를 제거함으로써 분리된다.
열가소성 얀의 니트 프리폼은 샌드위치의 코어와 스킨 사이에 연결 층을 형성하기 위해 허니콤 코어의 양쪽에 증착된다.
허니콤 코어와 니트 프리폼은 인서트 대신 두 스킨 사이에 삽입되어 샌드위치를 형성한다.
샌드위치 전체가 진공 상태에서 몇 시간 동안 열처리(200-250 °C)하여 스킨과 코어를 결합한다.
실시예 4
니트는 유리 섬유와 열가소성 섬유를 포함한 혼합 얀을 사용하여 제조된다.
이 니트는 스틸 몰드에 증착되어 제1 스킨을 형성한다.
온도의 영향으로 팽창가능한 재료의 강성 인서트가 니트에 증착된다.
동일한 유형의 제2 직물이 인서트에 증착되어 제2 스킨을 형성한다.
테프론 코팅된 필 플라이는 두 스킨 사이의 접합부에 배치된다.
몰드는 스틸 카운터 몰드로 밀폐된다.
스킨은 200-250 ° C, 3-10 bar의 압력 하에서 수십 분 동안 열처리에 의해 압밀된다.
몰드는 냉각되고 그 뒤에 제거되어 스킨이 필 플라이를 제거함으로써 분리된다.
팽창된 에폭시 폼 코어가 인서트 대신 두 스킨 사이에 주입되어 샌드위치를 형성한다.
전체 샌드위치는 진공 상태에서 몇 시간 동안 열처리(65-120 °C)하여 스킨과 코어를 결합한다.
실시예 5
니트는 유리 섬유와 열가소성 섬유를 포함한 혼합 얀을 사용하여 제조된다.
제1 니트는 실리콘 블래더 위에 드레이핑되고 조립체는 외부 스킨의 압밀을 위해 제1 스틸 몰드에 증착된다. 몰드는 밀폐되고 진공이 형성된다. 몰드는 가압(3 ~ 10 바)되고 200 ~ 250 °C의 온도로 유도 가열하여 빠르게 가열된다. 온도는 몇 분 동안 유지된다. 냉각 후 블래더가 제거되고 제1 스킨이 생성된다.
제2 스킨(내부 스킨)은 제2 몰드의 제1 스킨과 동일한 방식으로 제조된다.
외부 스킨을 압밀하는데 사용되는 툴링에서, 다음이 연속적으로 증착된다: 미리 압밀된 외부 스킨, 에폭시 또는 액체 형태의 접착제 필름, 허니콤 구조, 최종 복합 제품의 미리 압밀된 내부 스킨.
내부 스킨을 압밀하는 데 사용되는 실리콘 블래더가 제자리에 배열되고 몰드가 폐쇄된다. 진공을 최대로 형성하고(draw) 조립체가 65-120 °C의 온도로 몇 시간 동안 가열되어(오븐 가열 방식) 스킨과 코어가 결합된다.

Claims (13)

  1. 샌드위치형 복합 재료 제품을 제조하는 방법으로서,
    샌드위치형 복합 재료 제품은 2개의 외부 층 및 코어를 포함하고, 외부 층은 섬유 보강 탄성중합체 재료의 매트릭스를 가지며, 탄성중합체 재료는 섬유를 구성하는 재료의 용융점 미만의 용융점을 가지며,
    상기 방법은 외부 층이 압밀되는 중합체 재료의 용융점보다 높은 용융점을 갖는 재료로 구성된 인서트를 사용하고,
    상기 인서트는 샌드위치의 코어에 의해 교체되고, 조립체는 그 뒤에 외부 층을 코어에 결합하기 위해 압밀 처리가 수행되는 방법.
  2. 제1항에 있어서, 상기 방법은
    샌드위치의 외부 층으로 형성되는 섬유 보강 중합체 재료로 구성된 프리폼의 제조 단계,
    제2 프리폼 및 인서트의 제1 프리폼을 몰드 내에 병치하는 단계,
    인서트의 재료 또는 보강 재료의 융융점의 온도에 도달되기 전에 중합체 재료의 용융점의 온도에 도달되도록 가열 및 가압에 의해 외부 층을 형성하기 위하여 프리폼의 압밀 단계,
    인서트를 제거하고 외부 층을 분리하고 샌드위치의 코어를 삽입하는 단계,
    외부 층을 코어에 부착하기 위해 열 처리하는 단계,
    이에 따라 생성된 제품의 냉각 단계를 포함하는 방법.
  3. 제2항에 있어서, 프리폼은 사전함침된 중합체 수지 직물을 사용하여 제조되는 방법.
  4. 제2항에 있어서, 프리폼은 중합체 재료와 보강 재료를 포함하는 얀을 편직함으로써 형성되는 방법.
  5. 제2항 내지 제4항 중 어느 한 항에 있어서, 필 코스트는 코어 없이 구역을 형성하는 위치에서 프리폼들 사이에 첨가되는 방법.
  6. 제1항 또는 제3항 내지 제5항 중 어느 한 항에 있어서, 보강 재료로 제조된 제2 직물 또는 니트, 인서트 및 보강 재료로 제조된 직물 또는 니트를 몰드 내에 병치하는 단계,
    압력 및 온도 하에서 중합체 재료의 수지를 주입하는 단계,
    인서트를 제거하고 샌드위치의 코어를 삽입하는 단계,
    외부 층을 샌드위치의 코어에 접합하기 위하여 압밀 경화하는 단계,
    이에 따라 생성된 제품의 냉각 단계를 포함하는 방법.
  7. 제1항 내지 제6항 중 어느 한 항에 있어서, 인서트는 실리콘으로 제조되는 방법.
  8. 제1항 내지 제7항 중 어느 한 항에 있어서, 보강 재료는 유리, 탄소 및 아라미드 섬유로부터 선택되는 방법.
  9. 제1항 내지 제8항 중 어느 한 항에 있어서, 중합체 재료는 특히 폴리카보네이트(PC), 폴리에테르이미드(PEI), 폴리프로필렌(PP), 폴리(에틸렌 테레프탈레이트)(PET), 폴리에테르 에테르 케톤(PEEK)로부터 선택된 열가소성 유형인 방법.
  10. 제1항 내지 제8항 중 어느 한 항에 있어서, 중합체 재료는 특히 에폭시, 시아네이트 에테르, 페놀 수지 및 폴리에테르로부터 선택된 열경화성 유형인 방법.
  11. 제1항 내지 제10항 중 어느 한 항에 있어서, 샌드위치의 코어는 셀룰러 허니콤 재료로 구성되는 방법.
  12. 제1항 내지 제11항 중 어느 한 항에 있어서, 코어의 두께는 약 2 mm 이상 내지 약 50 mm 이하인 방법.
  13. 제1항 내지 제12항 중 어느 한 항에 있어서, 외부 층의 두께는 약 0.2 mm 이상 내지 약 5 mm 이하인 방법.
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IL284055A (en) 2021-08-31
BR112021011626A2 (pt) 2021-08-31

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