WO2021166951A1 - 積層材、中間シートの製造方法、及び、複合材の製造方法 - Google Patents
積層材、中間シートの製造方法、及び、複合材の製造方法 Download PDFInfo
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- WO2021166951A1 WO2021166951A1 PCT/JP2021/005898 JP2021005898W WO2021166951A1 WO 2021166951 A1 WO2021166951 A1 WO 2021166951A1 JP 2021005898 W JP2021005898 W JP 2021005898W WO 2021166951 A1 WO2021166951 A1 WO 2021166951A1
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Definitions
- the present invention relates to a composite material or the like having a core material layer.
- a general feature of structural materials forming a so-called sandwich structure is light weight and high rigidity.
- the essence of this feature is the high rigidity per density.
- an I-type beam As a lightweight structural material with a single material, a mold material called an I-type beam is provided.
- This type I beam is used, for example, as a beam of a building structure.
- the I-type beam is composed of wide flanges (plates) that are vertically opposed to each other and a narrow web (plates) that connects them, and is widely used as a structure that can achieve light weight and high rigidity with a single material. Has been done.
- the rigidity can be exponentially increased by increasing the wall thickness of the plate material.
- the sandwich structure composite material is typically used as a wall material for prefabricated houses.
- an aluminum plate is used as the skin material and expanded polystyrene is used as the core material.
- the sandwich structure composite material is also used for aircraft and railroad vehicles.
- a fiber reinforced plastic material (FRP) is used as the skin material, and a honeycomb structural material made of aramid paper impregnated with aluminum or resin is used as the core material.
- the sandwich-structured composite is also used as a packaging box.
- the skin material is made of paper
- the core material is also made of the same paper.
- a corrugated truss structure is used for the core material.
- the core material of the sandwich structure has a lower density than the skin material. Therefore, the wall thickness of the core material is increased by the weight reduction of the core material, and as a result, the specific rigidity (rigidity per specific gravity (density)) can be increased as a sandwich structure, and light weight and high rigidity are achieved. Will be done. It is known that the flexural rigidity of a structural material increases exponentially as the thickness of the cross section in the bending direction increases, and in the case of a quadrangular cross section, the flexural rigidity increases in proportion to the cube of the thickness. In the sandwich structure, if the core material has a lower density than the skin material, the specific rigidity increases even if the resin foam is not adopted as the core material.
- FIG. 9 of Patent Document 1 discloses a core material, a sandwich structure composed of fiber reinforced materials arranged on both sides of the core material, and an island-like structure of the core material.
- This core material is obtained by punching a film obtained by press-molding a polypropylene resin to prepare a disk-shaped plate, and then arranging the disk-shaped plates at predetermined intervals.
- Patent Document 2 discloses a reinforcing structure made of a sheet-shaped base material. This reinforcing structure has a material damping portion that divides the base material into a large number of material islands. Material islands are separated by material damping, but interconnected.
- the present invention has been made in view of such circumstances, and an object of the present invention is to provide a composite material which is excellent in moldability into a three-dimensional shape and is easy to manufacture.
- the inventor of the present application cuts the material sheet in a state where the material sheet that is the basis of a large number of plate-shaped pieces is attached to the base material sheet, and a large number of plate-shaped pieces are used as a base.
- the first invention is a laminated material including a core material layer and a skin material laminated on the core material layer, and the core material layer is a laminated material.
- intermediate sheet means a sheet produced in the intermediate process in the manufacturing process of a composite material.
- core material layer is a member that forms the central layer of the sandwich structure. However, in the laminated material before molding of the composite material, the member corresponding to the central layer of the composite material after molding is referred to as "core material layer” even if it has a canacher structure.
- the ratio of the total area of the plate-shaped pieces to the total area is 50% or more in a plan view.
- the third invention is the core of the main surface of the plate-shaped piece, which is laminated on the main surface located on the cutting progress side as the cutting direction in the thickness direction in the first or second invention. There are no cutting scratches formed on the surface on the material layer side if a large number of plate-shaped pieces are formed by cutting on the skin material.
- each of the large number of plate-shaped pieces is composed of a hard foam.
- each of a large number of plate-shaped pieces is made of wood.
- the skin material is used as the first skin material and is arranged on the side opposite to the first skin material in the core material layer, and the core is arranged together with the first skin material. It further includes a second skin material that sandwiches the material layer.
- the seventh invention comprises a second core material layer having a large number of plate-like pieces arranged along the surface of the second skin material, with the core material layer as the first core material layer. It is arranged between the 1-core material layer and the 2nd core material layer, and further includes an intermediate adhesive layer for adhering the 1st core material layer and the 2nd core material layer, and is further provided with a first skin material, a 1st core material layer, and an intermediate.
- the adhesive layer, the second core material layer, and the second skin material are laminated in this order.
- the intermediate adhesive layer is formed of a sheet-like adhesive.
- the intermediate adhesive layer is formed of a sheet-like adhesive.
- the cured resin is embedded in the gap between the adjacent plate-shaped pieces.
- the skin material is a sheet-like adhesive.
- the skin material is a prepreg in a semi-cured state.
- a thirteenth invention is the first, second, fourth or fifth invention in which a large number of plate-shaped pieces are detachably attached to a skin material, and a large number of plates are attached from the skin material to another structural material. It is used as a transfer sheet on which the state pieces can be transferred.
- a large number of plate-shaped pieces are attached to the skin material by a temperature-sensitive adhesive.
- an adhesive layer or an adhesive layer for holding the position of the plate-shaped piece is provided between the skin material and the plate-shaped piece. There is.
- a compartmentalized space formed by through holes is formed in the plate-shaped piece.
- the seventeenth invention is a method for manufacturing an intermediate sheet to which a large number of plate-shaped pieces used for a core material of a composite material are attached, and a cutting process is performed on a material sheet in a state of being attached to a base sheet.
- the material sheet is divided into a large number of plate-shaped pieces, and a cutting step is performed to obtain an intermediate sheet in which a large number of plate-shaped pieces are attached to the base sheet, and the intermediate sheet is made of another structural material from the base sheet.
- the base sheet is dissolved in a state where a large number of plate-shaped pieces can be transferred to a transfer sheet or a skin material sheet that is a composite skin material for using the base sheet as an adhesive. Used as a core material sheet.
- a sticking step of sticking a sheet adhesive or a prepreg as a skin material of an intermediate sheet on a plate-shaped piece side of a transfer sheet and after the sticking step, from a large number of plate-shaped pieces.
- a transfer step of transferring a large number of plate-shaped pieces to the skin material of the intermediate sheet is performed.
- the nineteenth invention includes a sticking step of sticking a skin material sheet to be a skin material of a composite material on one plate-like side of the transfer sheet obtained by the manufacturing method of the seventeenth invention, and a large number of boards after the sticking step.
- This is a method for producing a composite material, in which a transfer step of transferring a large number of plate-shaped pieces to a skin material sheet is performed by peeling the base material sheet from the shaped pieces.
- a stretchable sheet is used as the skin material, and in the transfer step, a plate-shaped piece to be transferred from the back surface of the base sheet 10 while pulling the base sheet.
- the plate-shaped piece is transferred by pressing.
- the twentieth invention there is a laminating step in which a large number of plate-shaped pieces are sandwiched between a skin material sheet and a second skin material sheet, and a gap between a core material layer composed of a large number of plate-shaped pieces.
- a honeycomb forming step of forming a honeycomb structure of the resin in the core material layer by curing the resin after flowing the resin into the core material layer is performed after the transfer step.
- the laminated material when the laminated material is an intermediate sheet, it is formed on the outer periphery of a large number of plate-shaped pieces as a trace of forming a large number of plate-shaped pieces by cutting on a skin material (for example, a base sheet).
- the cutting directions in the thickness direction determined from the cutting marks to be made are the same as each other.
- a large number of plate-shaped pieces are formed on the skin material of the intermediate sheet according to the cutting shape in a plan view in the cutting process.
- the cutting direction in the thickness direction determined from the cutting marks formed on the outer periphery of a large number of plate-shaped pieces is determined. They are the same as each other.
- a large number of plate-shaped pieces are arranged on the skin material of the composite material according to the arrangement of the plate-shaped pieces in the intermediate sheet. Therefore, it is not necessary to individually arrange a large number of plate-shaped pieces on the material of the skin material (for example, a sheet for skin material), and a core material layer in which a large number of plate-shaped pieces are arranged can be easily formed. ..
- FIG. 1 is a perspective view of the composite material according to the embodiment.
- FIG. 2 is a cross-sectional view of the composite material according to the embodiment.
- FIG. 3 is a plan view of the core material layer of the composite material according to the embodiment on the side where the chamfered portion is formed.
- FIG. 4 is a cross-sectional view of the transfer sheet according to the embodiment.
- FIG. 5 is a cross-sectional view for explaining the first manufacturing process (method of manufacturing a transfer sheet) according to the embodiment.
- FIG. 6 is a schematic configuration diagram of a production line used in the first production process according to the embodiment.
- FIG. 7 is a cross-sectional view for explaining how a chamfered portion is formed on the plate-shaped piece during press cutting in the first manufacturing process according to the embodiment.
- FIG. 1 is a perspective view of the composite material according to the embodiment.
- FIG. 2 is a cross-sectional view of the composite material according to the embodiment.
- FIG. 3 is a plan view of the
- FIG. 8 is a cross-sectional view for explaining the transfer step of the second manufacturing process according to the embodiment.
- FIG. 9 is a cross-sectional view for explaining the laminating step of the second manufacturing process according to the embodiment.
- FIG. 10 is a cross-sectional view when a molding die having a curved cavity surface is used in the second manufacturing process according to the embodiment.
- FIG. 11 is a cross-sectional view of the composite material according to the embodiment when the cured resin is filled in the gap.
- FIG. 12 is a cross-sectional view of the composite material according to the first modification.
- FIG. 13 is a cross-sectional view of the laminated lumber in the process of manufacturing the composite lumber according to the second modification.
- FIG. 14 is a cross-sectional view of the adhesive core material sheet according to the third modification.
- FIG. 15 is a cross-sectional view for explaining a transfer step in the manufacturing process of the adhesive core material sheet according to the third modification.
- FIG. 16 is a cross-sectional view of the adhesive core material sheet according to the fourth modification.
- FIG. 17 is a cross-sectional view showing a state in which a base sheet (prepreg) to which a large number of plate-shaped pieces are attached is installed on a molding die in the fifth modification.
- FIG. 18 is a cross-sectional view of the laminated lumber in the process of manufacturing the composite lumber according to the sixth modification.
- FIG. 19 is a perspective view of the composite material according to the seventh modification.
- FIG. 20 is a cross-sectional view of a cylindrical body using the composite material according to the seventh modification.
- FIG. 21 (a) is a plan view of the core material layer of the composite material according to the eighth modification
- FIG. 21 (b) is a cross-sectional view of the composite material according to the eighth modification
- FIG. 22 is a plan view of the core material layer of the composite material according to the ninth modification
- 23 (a) is a cross-sectional view of the transfer sea according to the tenth modification
- FIG. 23 (b) is a cross-sectional view of the composite material according to the tenth modification
- FIG. 23 (c) is a cross-sectional view of the composite material.
- FIG. 10 is a plan view of a state in which the dot portion side of the transfer sheet for forming an adhesive layer is overlapped with the plate-shaped piece in the process of manufacturing the transfer sheet according to the 10th modification.
- FIG. 24 is a cross-sectional view of another composite material according to the tenth modification.
- FIG. 24 is a cross-sectional view showing a state in which a plate-shaped piece is transferred using the transfer sheet according to the eleventh modification.
- FIG. 26 (a) is a cross-sectional view of a transfer sheet according to another modified example
- FIG. 26 (b) is a cross-sectional view of a composite material according to another modified example.
- FIG. 27 is a cross-sectional view for explaining how a notch is formed between adjacent plate-shaped pieces during press cutting in the first manufacturing step in the composite material according to another modified example.
- the composite material (laminated material) 30 according to this embodiment will be described. As shown in FIGS. 1 and 2, the composite material 30 is a panel having a sandwich structure. The composite material 30 is on the side opposite to the core material layer (also referred to as “intermediate layer”) 20, the first skin material 31 laminated on the core material layer 20, and the first skin material 31 in the core material layer 20. A second skin material 32 that is laminated and sandwiches the core material layer 20 together with the first skin material 31 is provided.
- the composite material 30 can be used, for example, as a panel material in which light weight and rigidity are more important than strength.
- the composite material 30 is a structural material such as a moving body such as an aircraft, an automobile or a bicycle (sports bicycle, etc.), an electric device, an electronic device, an office device, a home appliance, a medical device, or a panel material for a building material. It can be used for such purposes.
- the composite material 30 can be used as an aerodynamic component constituting the exterior.
- Each of the skin materials 31 and 32 is, for example, a skin material or a panel material composed of a material different from that of the core material layer 20.
- any of metal-based, plastic-based, and inorganic-based materials may be used.
- fiber reinforced plastic is used as the material of each of the skin materials 31 and 32.
- a fiber reinforced plastic reinforced with carbon fiber can be used.
- the fiber reinforced resin a prepreg in which carbon fibers are impregnated with a resin (matrix) (for example, "Pyrofil prepreg (registered trademark)" manufactured by Mitsubishi Chemical Corporation) can be used.
- a thermosetting epoxy resin can be used for the matrix of this prepreg.
- any of inorganic fiber, organic fiber, and metal fiber may be used, and for example, glass fiber, carbon fiber, aramid fiber, polyethylene fiber, polyester fiber, and tungsten fiber may be used. , Steel fiber, boron fiber and the like can be used.
- a thermosetting resin or a thermoplastic resin may be used, and for example, polyester resin, epoxy resin, phenol resin, vinyl ester resin, polyimide resin, polypropylene resin, nylon.
- a resin, a polyether ether ketone resin, a polybutylene terephthalate resin, a bismaleimide resin, or the like can be used.
- the core material layer 20 is laminated on the skin materials 31 and 32, respectively.
- a large number of plate-shaped pieces 13 having the same thickness are arranged on a two-dimensional plane as a core material.
- a large number of plate-shaped pieces 13 are arranged along the surfaces of the skin materials 31 and 32.
- Each plate-shaped piece 13 is a small piece of a thin flat plate.
- Each plate-shaped piece 13 has the same material, the same shape, and the same size.
- "many" in "many plate-shaped pieces” means 10 or more.
- the number of plate-shaped pieces 13 in the laminated lumber 30 is at least 10 or more.
- the number of sheets may be 50 or more.
- the plate-shaped piece 13 is made of, for example, a sheet material, a film material, or a resin foam.
- a material having a density lower than that of the skin materials 31 and 32 can be used.
- a material having a density in the range of 30 kg / m 3 or more and 2000 kg / m 3 or less can be used.
- the density of the plate-shaped piece 13 may be appropriately designed according to the physical properties of the composite material 30 or the purpose of use, and may be a value outside the above range.
- the material of the plate-shaped piece 13 a resin (resin foam or the like), a wood material (plywood such as balsa or veneer), or a metal-based foam (aluminum alloy or the like) can be used.
- the plate-shaped piece 13 is made of a hard resin foam.
- the plate-shaped piece 13 is made of, for example, a polymethacrylicimide (PMI) closed cell foam (for example, "ROHACELL®" (EVONIC Industries AG)).
- the density of the plate-shaped piece 13 is set to a value in the range of 30 kg / m 3 or more and 500 kg / m 3 or less (for example, 110 kg / m 3 ) from the viewpoint of weight reduction of the composite material 30.
- the hard resin foam used as the material of the plate-shaped piece 13 includes polystyrene foam, polyvinyl chloride foam, cellulose acetate foam foam, polyurethane foam, phenol foam, epoxy foam, acrylic foam, and poly.
- a methacrylimide foam, a polypropylene foam, a polyethylene terephthalate foam, a polycarbonate foam, a polyamideimide foam, a polyphenylene sulfide foam, or the like may be used.
- the planar shape (outer peripheral shape) of the plate-shaped piece 13 is a regular polygon (regular hexagon in the present embodiment).
- the planar shape of the plate-shaped piece 13 can be selected from a triangle, a quadrangle, a hexagon, or an equilateral pentagon when a large number of plate-shaped pieces 13 are uniformly spread. Further, the planar shape of the plate-shaped piece 13 may be other than these shapes, and other polygonal, circular, or elliptical shapes can be selected.
- each corner may be chamfered or rounded in a plan view.
- the thickness of the plate-shaped piece 13 can be, for example, in the range of 0.05 mm or more and 10 mm or less (for example, 0.05 mm or more and 2 mm or less). Further, regarding the plane dimension of the plate-shaped piece 13, the average value of the distance from the center of gravity to the outer circumference (the average value of 360 degrees; the radius in the case of a circle) shall be a value in the range of 3 mm or more and 50 mm or less (for example, 5 mm). When the plate-shaped piece 13 is a regular hexagon, the length of one side can be a value in the range of 3 mm or more and 10 mm or less (for example, 5 mm). However, the dimensions of the plate-shaped piece 13 may be a value outside the range described in this paragraph.
- each plate-shaped piece 13 In the core material layer 20, all the plate-shaped pieces 13 are separated from each other and are separate bodies. The entire circumference of each plate-shaped piece 13 is separated from all adjacent plate-shaped pieces 13 with a gap 16. Each plate-shaped piece 13 has an island-like structure independent of each other. Unlike the reinforcing structure of Patent Document 2 described above, the adjacent plate-shaped pieces 13 are not connected to each other by a connecting portion made of the same material as the plate-shaped piece 13.
- the composite material 30 is a multi-web panel in which each of the skin materials 31 and 32 functions as a flange in an I-shaped beam structure, and each plate-shaped piece 13 functions as a web, and each plate-shaped piece 13 functions as a core material. Is.
- Adjacent plate-shaped pieces 13 face each other with a gap 16 on each side.
- the width W of the gap 16 changes according to the size of the gap between the adjacent blades 24 in the upper mold 23 described later.
- the width W of the gap 16 is constant along the sides facing each other. Further, in each plate-shaped piece 13, the width W of the gap 16 facing all the sides is equal to each other.
- the dimension of the width W of the gap 16 is appropriately designed according to the size of the composite material 30, and can be, for example, in the range of 0 mm or more and 10 mm or less.
- the ratio R1 of the total area of the plate-shaped pieces 13 to the total area of the laminated material 30 in a plan view can be adjusted by the size of the gap 16 between the adjacent plate-shaped pieces 13.
- S1 represents the total area of the core material layer 20 (the total area of the plate-shaped pieces 13 and the gap 16), and S2 represents the total area of all the plate-shaped pieces 13 (the area when viewed in the thickness direction).
- the value obtained by subtracting R1 from 100 (%) is substantially equal to the porosity R2 (%) of the core material layer 20.
- the ratio R1 is less than 100% and can be 50% or more (70% or more in some cases).
- the planar shape of each plate-shaped piece 13 is a triangle, a quadrangle, a hexagon, or an equilateral pentagon, the space of the core material layer 20 can be efficiently filled.
- the ratio R1 is 80%. Further, when the regular hexagonal plate-shaped pieces 13 having a side of 5 mm are uniformly spread with a gap of 3 mm, the ratio R1 is 55%.
- a large number of plate-shaped pieces 13 are regularly arranged.
- a large number of plate-shaped pieces 13 are uniformly spread.
- the arrangement of the plate-shaped pieces 13 a staggered arrangement in which the positions of the plate-shaped pieces 13 are shifted by half a pitch between adjacent plate-shaped pieces 13L is adopted.
- the planar shape of each plate-shaped piece 13 is a regular hexagon, and the arrangement of the plate-shaped pieces 13 can be said to be a honeycomb arrangement in which a gap is formed between the adjacent plate-shaped pieces 13.
- each plate-shaped piece 13 (one surface of both sides parallel to the arrangement surface of each plate-shaped piece 13 and the lower surface in FIG. 2) 13a is chamfered portion 13c over the entire circumference. Is formed.
- the chamfered portion 13c is a trace (cutting mark) indicating that the plate-shaped piece 13 is formed by punching, and is an arc-shaped curved surface (for example, an R surface of about 0.05 mm) or an outer side like an arc. It is a curved surface that bulges out.
- the shape of the chamfered portion 13c changes depending on the shape of the sword of the blade 24 used in the punching process and the like.
- the dimensions of the chamfered portion 13c are substantially uniform over the entire circumference.
- the "main surface" of the plate-shaped piece 13 is the front side or the back side surface.
- a large number of plate-shaped pieces 13 (for example, all plate-shaped pieces 13 of the core material layer 20), it is determined from the cut marks formed on the outer periphery as traces manufactured by using the transfer sheet 10 described later.
- the cutting directions in the thickness direction are the same as each other.
- chamfered portions 13c are formed on the outer periphery of the main surface 13a on the same side in the thickness direction.
- the skin material laminated on the main surface 13b located on the cutting progress side as the cutting direction in the thickness direction.
- the transfer sheet 10 is a sheet capable of transferring a large number of plate-shaped pieces 13 from the base sheet 11 to another structural material (a structure having adhesiveness or adhesiveness on the surface).
- the transfer sheet 10 includes a core material layer 20 and a base material sheet 11 laminated on the core material layer 20. On the surface of the base material sheet 11 on the core material layer 20 side, cutting scratches (dents) 43 when a large number of plate-shaped pieces 13 are cut remain. In the core material layer 20, adjacent plate-shaped pieces 13 are separated by a gap 16. Further, in a large number of plate-shaped pieces 13, chamfered portions 13c are formed on the outer periphery of the main surface 13a on the same side of each plate-shaped piece 13 in the thickness direction.
- the transfer sheet 10 corresponds to a "laminated material"
- the base material sheet 11 corresponds to a "skin material”.
- a resin sheet or film thermoplastic resin sheet, etc.
- various resins such as polyethylene, polypropylene, urethane, polyester, polyethylene terephthalate (PET), and polycarbonate can be used.
- PET polyethylene terephthalate
- polycarbonate polyethylene terephthalate
- the thickness of the base sheet 11 can be a value in the range of 0.01 mm to 0.5 mm (for example, 0.075 mm).
- a rubber or paper sheet (or film) may be used in addition to the resin sheet.
- a pressure-sensitive adhesive layer 18 is formed on one side (upper surface in FIG. 4) of the base material sheet 11 by applying a pressure-sensitive adhesive (a pressure-sensitive adhesive that does not cure at room temperature).
- a pressure-sensitive adhesive a pressure-sensitive adhesive that does not cure at room temperature.
- various types such as acrylic type, urethane type, and silicone type can be used.
- a pressure-sensitive adhesive layer 18 is formed in advance on one side by applying an acrylic pressure-sensitive adhesive.
- the pressure-sensitive adhesive layer 18 is formed by a pressure-sensitive adhesive such as spray glue.
- a spray glue such as an acrylic adhesive (for example, "Spray glue series” manufactured by 3M Japan Ltd.) can be used.
- the base sheet 11 may be a resin film to which a double-sided adhesive film is attached.
- a large number of plate-shaped pieces 13 are detachably attached to the surface of the base sheet 11.
- Each plate-shaped piece 13 is held by the pressure-sensitive adhesive layer 18 on the base sheet 11 with a constant adhesive force.
- Each plate-shaped piece 13 is attached to the base sheet 11 on the side opposite to the side on which the chamfered portion 13c is formed on the outer periphery. If the surface of the base sheet 11 is sticky, the pressure-sensitive adhesive layer 18 may be omitted.
- the arrangement of the plate-shaped pieces 13 on the base material sheet 11 is the basis for the arrangement of the plate-shaped pieces 13 in the core material layer 20 of the composite material 30.
- the plan view of the core material layer 20 of the transfer sheet 10 is the same as that of FIG.
- the planar shape (outer peripheral shape) of the plate-shaped piece 13 is a regular polygon (regular hexagon in the present embodiment).
- all the plate-shaped pieces 13 are separated from each other and are separate bodies.
- Each plate-shaped piece 13 has an island-like structure independent of each other.
- Adjacent plate-shaped pieces 13 face each other with a gap 16 on each side.
- the width W of the gap 16 is constant along the sides facing each other. Further, in each plate-shaped piece 13, the width W of the gap 16 facing all the sides is equal to each other. Further, in the core material layer 20, the ratio R1 of the total area of the plate-shaped pieces 13 to the total area of the laminated material 30 in a plan view is less than 100% and 50% or more (70% or more in some cases).
- the width W of the gap 16 does not have to be constant along the sides facing each other, and the width W of the gap 16 facing all the sides of each plate-shaped piece 13 does not have to be equal to each other.
- a chamfered portion 13c is formed on the outer circumference of one main surface 13a (upper surface in FIG. 4) of each plate-shaped piece 13 over the entire circumference.
- the dimensions of the chamfered portion 13c are substantially uniform over the entire circumference.
- the first manufacturing step for manufacturing the transfer sheet 10 and the second manufacturing step for manufacturing the composite material 30 using the transfer sheet 10 obtained in the first manufacturing step are performed in this order. Do it with.
- the transfer sheet 10 corresponds to an intermediate sheet.
- the material sheet is attached by attaching the material sheet 14 to the base sheet 11 and punching (press cutting) the material sheet 14 in the state of being attached to the base sheet 11.
- the cutting step of dividing 14 into a large number of plate-shaped pieces 13 is performed in this order.
- the material sheet 14 is a sheet used as a material for the plate-shaped piece 13, and for example, a polymethacrylicimide (PMI) closed-cell foam sheet sliced to a predetermined thickness of 0.05 mm or more and 10 mm or less may be used. can.
- PMI polymethacrylicimide
- a laminated sheet 19 in which a long material sheet 14 is bonded to a long base sheet 11 by an adhesive layer 18 is created.
- the laminated sheet 19 is wound in a roll shape and installed on a reel 51 (see FIG. 6) of the production line 50.
- the laminated sheet 19 is unwound in the longitudinal direction and passed through the press device 15.
- the base sheet 11 and the material sheet 14 may be attached by a press, a roller, an ultrasonic horn, or the like capable of pressurizing or heating and pressurizing.
- the material sheet 14 is press-cut by vertically cutting the laminated sheet 19 on the lower die 22 of the press device 15 by the blade 24 of the upper die 23.
- the base sheet 11 is not cut, but is so-called half-cut (that is, cut to the extent that it does not penetrate).
- a large number of plate-shaped pieces 13 are formed on the base sheet 11, and a transfer sheet 10 (see FIG. 5C) is manufactured.
- a planar shape of the blade 24 a shape corresponding to the outer peripheral shape of the plate-shaped piece 13 is used.
- a regular hexagonal blade 24 is used in a plan view.
- a large number of blades 24 are arranged on a two-dimensional plane with a gap.
- a portion 29 of the surface of the material sheet 14 where the tip of the blade 24 first contacts is pushed in. Then, the periphery of the portion 29 is plastically deformed. Therefore, after the material sheet 14 is cut by the blade 24, a chamfered portion 13c is formed on the outer periphery of the plate-shaped piece 13 as a trace of plastic deformation as shown in FIG. 7B. As described above, the chamfered portion 13c is an arc-shaped curved surface or a curved surface that bulges outward like an arc. In addition, chips 39 are formed between the blades 24. In the punching process, depending on the cutting conditions, burrs 13d (see FIG.
- 25B may be formed on the outer periphery of the main surface 13a of each plate-shaped piece 13 instead of the chamfered portion 13c.
- a cutting mark that can determine the cutting direction in the thickness direction remains on the outer periphery of the main surface 13a of the plate-shaped piece 13.
- the upper die 23 moves up and down with respect to the lower die 22 at the time of press cutting, but the press cutting may be performed by pressurizing the rotation by the rolling die (die cut roll).
- the chips 39 of the material sheet 14 cut by the press device 15 are reticulated sheets 38 connected to each other.
- the net-like sheet 38 composed of the chips 39 is taken up by the take-up reel 25 and removed (see FIG. 6).
- a protective film 27 unwound from a roll provided on another reel 26 is laminated on the plate-shaped piece 13 side of the transfer sheet 10.
- a large number of plate-shaped pieces 13 are covered with a protective film 27.
- the long transfer sheet 10 is cut to a predetermined length by the cutter 28 and divided into a plurality of transfer sheets 10. Note that winding by the take-up reel 25, coating by the protective film 27, and cutting by the cutter 28 may be omitted.
- the steps are performed in this order.
- the skin material sheets 31A and 32A are the materials of the skin materials 31 and 32 (see FIG. 2) described above, and for example, a semi-cured prepreg (prepreg sheet) can be used.
- the first skin material sheet 31A is arranged on the molding die (for example, the die) 33.
- the transfer sheet 10 obtained in the first manufacturing step is arranged with the plate-shaped piece 13 side facing the first skin material sheet 31A on the molding die 33. Will be done.
- FIG. 8B a large number of plate-shaped pieces 13 of the transfer sheet 10 are pressed against the first skin material sheet 31A.
- the surface of the first skin material sheet 31A has adhesiveness. Therefore, a large number of plate-shaped pieces 13 are attached to the first skin material sheet 31A.
- the base sheet 11 is peeled off from a large number of plate-shaped pieces 13.
- the adhesive force of the first skin material sheet 31A to a large number of plate-shaped pieces 13 is larger than the adhesive force of the pressure-sensitive adhesive layer 18 to a large number of plate-shaped pieces 13, the base sheet 11 to the first skin material A large number of plate-shaped pieces 13 are transferred to the sheet 31A.
- a temperature-sensitive adhesive may be used as the adhesive for the adhesive layer 18.
- a warm-off type adhesive whose adhesive strength decreases above a predetermined switching temperature (for example, "temperature-sensitive adhesive sheet Intellimar tape warm-off type” manufactured by Nitta Co., Ltd., for example, a switching temperature of 50 degrees) is applied to the adhesive layer 18
- the base sheet 11 is heated from the back side (upper side in FIG. 8) in the state shown in FIG. 8 (b), and the base sheet 11 is peeled off when the pressure-sensitive adhesive layer 18 is equal to or higher than the switching temperature.
- a cool-off type adhesive whose adhesive strength decreases below a predetermined switching temperature (for example, "temperature sensitive adhesive sheet Intellimar tape cool-off type” manufactured by Nitta Co., Ltd., for example, switching temperature 25 degrees) is applied to the adhesive layer 18
- the base sheet 11 is cooled from the back side in the state shown in FIG. 8 (b), and the base sheet 11 is peeled off when the pressure-sensitive adhesive layer 18 is below the switching temperature.
- the base sheet 11 can be easily peeled off from the plate-shaped piece 13. Further, when the base material sheet 11 is peeled off, the influence on the adhesive state between each plate-shaped piece 13 and the first skin material sheet 31A is small.
- the second skin material sheet 32A is separated from each other so as to face the plate-shaped piece 13 side of the laminating material 30A obtained in the transfer step. Be placed.
- the second skin material sheet 32A is laminated on the plate-shaped piece 13 side of the laminated material 30A.
- the surface of the second skin material sheet 32A has adhesiveness. Therefore, a large number of plate-shaped pieces 13 are attached to the second skin material sheet 32A.
- the laminated material 30B in which a large number of plate-shaped pieces 13 are sandwiched between the pair of skin material sheets 31A and 32A can be obtained.
- the molding step is performed.
- a bagging film is used to seal the laminated lumber 30B obtained in the laminating step.
- the laminated lumber 30B sealed by the bagging film is heated in the autoclave at a predetermined temperature and pressure (for example, 0.2 MPa, 130 ° C.) for a predetermined time (for example, 2 hours).
- a predetermined temperature and pressure for example, 0.2 MPa, 130 ° C.
- a predetermined time for example, 2 hours.
- the semi-cured skin material sheets 31A and 32A become the fully cured skin materials 31 and 32.
- the composite material 30 formed and cured into a predetermined shape in the case of FIG. 9B, a flat plate shape
- the matrix of the prepregs used for the skin material sheets 31A and 32A is a thermoplastic resin (for example, polyamide resin, polypropylene resin, polyether ether ketone resin)
- the matrix is formed after a molding step such as pressure heating press molding.
- the curing step is performed by cooling the laminated material 30B in an atmosphere having a temperature lower than the curing temperature of the above (for example, room temperature), and the composite material 30 is completed.
- chamfered portions 13c are formed on the same side in the thickness direction in a large number of plate-shaped pieces 13 as traces manufactured by using the transfer sheet 10.
- a large number of plate-shaped pieces 13 are arranged according to the arrangement of the plate-shaped pieces 13 on the transfer sheet 10. Therefore, it is not necessary to individually arrange a large number of plate-shaped pieces 13 on the skin material sheet 31A, and the core material layer 20 in which a large number of plate-shaped pieces 13 are arranged can be easily formed.
- FIG. 9 of Patent Document 1 it is difficult to precisely arrange the disc-shaped plates, but according to the present embodiment, a large number of plate-shaped pieces 13 are densely arranged on the skin material sheet 31A. It is also easy to place.
- the adjacent plate-shaped pieces 13 are separated by a gap 16 to form separate bodies.
- the conventional composite material having a sandwich structure includes a foam, a honeycomb structure, or a core material layer composed of a large number of material islands connected to each other. It is lightweight and has high rigidity.
- the core material layer has a continuous structure, bending of a hard foam having poor toughness tends to cause breakage, and it is difficult to form a complicated three-dimensional shape. When the shape of the composite material is curved, the range of bending is restricted.
- the adjacent plate-shaped pieces 13 are separated by the gap 16 and the adjacent plate-shaped pieces 13 are further separated. Interference between each other is suppressed by the gap 16. Therefore, as compared with the conventional composite material, the core material layer 20 is less likely to be damaged even if it is bent, and the restriction of the bending range when forming the three-dimensional shape is small. According to this embodiment, it is possible to provide a composite material 30 which is excellent in moldability into a three-dimensional shape and is easy to manufacture. Then, a composite material 30 having a complicated three-dimensional shape and a composite material 30 having a large bend can be realized.
- the composite material 30 having a three-dimensional shape curved along the cavity surface of the molding die 33 can be obtained.
- the cavity surface of the molding die 33 is not only convex but also concave, so that interference between adjacent plate-shaped pieces 13 is suppressed.
- the followability to the molding die 33 changes according to the width W of the gap 16. Therefore, the width W of the gap 16 can be appropriately designed according to the curvature of the molding die 33.
- prepreg is used as the material of each of the skin materials 31 and 32. Therefore, when the heat treatment is performed, the curable resin (matrix) of the prepreg flows into the gap 16 between the plate-shaped pieces 13 to fill the gap 16 of the core material layer 20. The curable resin that has flowed in is cured in the gap 16. The resin cured in the gap 16 includes short fibers that have flowed from the prepreg together with the resin. Therefore, it is possible to suppress a local decrease in strength of the composite material 30.
- the gap 16 of the core material layer 20 may be filled with the resin of the prepreg, but fillets may be formed at the corners between the side surface of the plate-shaped piece 13 and the inner surfaces of the skin materials 31 and 32, or air bubbles may be generated.
- the gap 16 may be filled in the included state. Further, as the prepreg used as the material of the skin materials 31 and 32, when the gap 16 is large, a prepreg having a large amount of resin per unit area can be used.
- a curable resin for example, a thermosetting type, a two-component reaction type, a moisture-reacting type adhesive, etc.
- a curable resin for example, a thermosetting type, a two-component reaction type, a moisture-reacting type adhesive, etc.
- the injected curable resin is cured in the gap 16.
- a film-like adhesive may be added between the two skin materials 31 and 32. In this case, the film-like adhesive is melted during the heat treatment, and the melted adhesive (curable resin) flows into the gap 16 and is finally cured. In these cases, as shown in FIG.
- the gap 16 between the adjacent plate-shaped pieces 13 is filled with the cured resin 6, the local strength decrease of the composite material 30 can be suppressed, and the rigidity is also increased. Can be improved.
- the curable resin is poured into the gap 16 of the core material layer 20 composed of a large number of plate-shaped pieces 13, and then the resin is cured to form the resin 6 in the core material layer 20. It corresponds to the honeycomb forming step of forming the honeycomb structure. Further, the filling of the curable resin can be performed even when the prepreg is not used as the material of the skin materials 31 and 32.
- the density of the plate-shaped pieces 13 is low, it is possible to realize the composite material 30 which is lightweight and has excellent specific rigidity.
- the density of the core material layer 20 can be adjusted by adjusting the thickness of the plate-shaped piece 13 and the gap 16 in addition to the density of the plate-shaped piece 13.
- the composite material 130 has a second core material layer 21 having a large number of plate-shaped pieces 13 arranged along the surface of the second skin material 32, and a first core material.
- An intermediate adhesive layer 17 arranged between the layer 20 and the second core material layer 21 is further provided.
- the intermediate adhesive layer 17 is formed of a sheet-like adhesive (also referred to as a film-like adhesive or an adhesive sheet) that is melted by heating and heat-cured as it is, and adheres the first core material layer 20 and the second core material layer 21. ..
- the first skin material 31, the first core material layer 20, the intermediate adhesive layer 17, the second core material layer 21, and the second skin material 32 are laminated in this order.
- the intermediate adhesive layer 17 may be composed of an adhesive layer in which a sheet-like adhesive is dissolved. Further, the cured resin 6 may be filled in the gaps 16 of the core material layers 20 and 21.
- the positions of the plate-shaped pieces 13 of the first core material layer 20 and the positions of the plate-shaped pieces 13 of the second core material layer 21 are matched in the plan view, but the first core The position of each plate-shaped piece 13 of the material layer 20 and the position of each plate-shaped piece 13 of the second core material layer 21 may be shifted from each other.
- the core material layers 20 and 21 are formed into two layers, but the core material layers 20 and 21 may be formed into three or more layers.
- an intermediate adhesive layer 17 may be provided between the core material layers 20 and 21 adjacent to each other in the thickness direction.
- a prepreg or a thermosetting resin sheet may be used for the intermediate adhesive layer 17 without using a sheet-like adhesive.
- the composite material 130 is manufactured by laminating a plurality of canaoutheastern-structured laminated lumbers 10 having a base sheet (prepreg) 11 and a large number of plate-shaped pieces 13 attached to the base sheet 11. You may.
- the resin flows during the heating step and flows into the gap 16 of each plate-shaped piece 13, it is possible to suppress a local decrease in strength of the composite material 30. Since the surface of the base sheet 11 has adhesiveness, the adhesive for holding the plate-shaped piece 13 can be omitted.
- the plate-shaped piece 13 has a two-layer structure in the core material layer 20.
- the thicker the plate-shaped piece 13 the larger the tensile strain on one side of the plate-shaped piece 13, and depending on the thickness of the plate-shaped piece 13 and the magnitude of bending, One side of the plate-shaped piece 13 may be damaged due to tensile strain.
- each plate-shaped piece 13 when compared with the composite material having the same thickness, each plate-shaped piece 13 is thinner than the composite material 30 in which the plate-shaped piece 13 has a single-layer structure.
- the intermediate sheet produced by the above-mentioned first manufacturing step is not the transfer sheet 10, but the base sheet in a state of being laminated on the skin material sheet 31A in order to use the base sheet 111 as an adhesive. It is used as an adhesive core sheet 60 (see FIG. 13) in which 111 is dissolved.
- the adhesive core sheet 60 a sheet having the same structure as the transfer sheet 10 described above can be used.
- an adhesive that allows each plate-shaped piece 13 to be peeled off from the base sheet 11 is used for the pressure-sensitive adhesive layer 18, but in the case of the adhesive core sheet 60, each plate-shaped piece 13 is used. It is not necessary to make the material sheet removable, and the material sheet 14 can be attached to the base material sheet 111 with an adhesive or an adhesive.
- the adhesive core material sheet 60 and the second skin material are opposed to the first skin material sheet 31A on the molding die 33.
- the sheets 32A are laminated in this order.
- the plate-shaped piece 13 side may be attached to the first skin material sheet 31A.
- the base sheet 111 side may be attached to the first skin material sheet 31A (not shown).
- the laminated material 30B is obtained. Since the method for producing the composite material 30 from the laminated material 30B is the same as that of the above-described embodiment, the description thereof will be omitted.
- a resin sheet (a sheet having the same properties as the intermediate adhesive layer 17, for example, a sheet-like adhesive, a prepreg, etc.) is laminated on one side or both sides of the core material layer 20. May be good.
- a plurality of adhesive core sheet 60s may be used for manufacturing one composite material 30.
- a plurality of adhesive core material sheets 60 may be laminated so that the plate-shaped pieces 13 face the same side in the thickness direction.
- the base material sheets 111 may be bonded to each other, or the core material layers 20 may be bonded to each other.
- the adhesive core sheet (second intermediate sheet) 60 shown in FIG. 14 is manufactured by using the transfer sheet (first intermediate sheet) 10 described above.
- the skin material 111 is a sheet-like adhesive.
- the pasting step and the transfer step are performed in this order after the first manufacturing step described above.
- the sticking step as shown in FIGS. 15A and 15B, the skin material 111 is pasted on the plate-shaped piece 13 side of the transfer sheet 10.
- a separate sheet 141 laminated on the back surface can be used as the sheet-like adhesive for the skin material 111.
- the transfer step as shown in FIG. 15C, a large number of plate-shaped pieces 13 are transferred to the skin material 111 by peeling the base sheet 11 from the large number of plate-shaped pieces 13. As a result, the adhesive core material sheet 60 is obtained.
- the step of laminating the protective film 27 on the plate-shaped piece 13 side of the adhesive core sheet 60 may be performed.
- the composite material manufacturing sheet (second intermediate sheet) 70 shown in FIG. 16 is manufactured by using the transfer sheet (first intermediate sheet) 10 described above.
- the composite material manufacturing sheet 70 is the same as the adhesive core material sheet 60 shown in FIG. 14, except that the skin material 61 is in a prepreg (semi-cured state).
- a separate sheet 41 laminated on the back surface can be used. Since the manufacturing method of the composite material manufacturing sheet 160 is the same as that of the third modification except that the skin material is different, the description thereof will be omitted.
- the intermediate sheet manufactured by the above-mentioned first manufacturing step is a composite material manufacturing sheet 70 using a prepreg as a base sheet 61.
- a base sheet 61 to which a large number of plate-shaped pieces 13 are attached is installed on the molding die 33.
- the laminated material 30B is produced by laminating the second skin material sheet 32A on the large number of plate-shaped pieces 13 of the base sheet 61 (not shown).
- the laminated lumber 30B is heated in the autoclave at a predetermined temperature and pressure for a predetermined time in the same manner as in the above-described embodiment. As a result, the laminated lumber 30B is fired to complete the composite lumber 30 having a predetermined shape in which the base material sheet 61 and the second skin material sheet 32A are completely cured and molded.
- the composite material 30 can be manufactured with a smaller number of steps as compared with the above-described embodiment.
- a sheet material or film material such as polyprepylene, polyolefin, polyester, polyethylene, polyethylene terephthalate, urethane, tetrafluoroethylene, polytetrafluoroethylene, polyphenylene sulfide, polyimide, polyetheretherketone, or paper is used. be able to.
- the separate sheet 41 is provided on the base sheet 11 so as to be peelable due to the adhesiveness of the prepreg. Further, when a thermoplastic resin sheet is used for the base sheet 11, the separate sheet 41 is similarly provided on the base sheet 11 so as to be peelable.
- the transfer sheet 10 can be easily handled during the transfer step. Therefore, the positioning of the base sheet 11 and the plate-shaped piece 13 becomes easy, and the molding work of the composite material 30 can be facilitated.
- the composite material 131 has a canaoutheastern structure. Further, in the core material layer 20 on the skin material 31, strip-shaped plate-shaped pieces 13 are arranged in a certain direction. A gap 16 is formed between adjacent plate-shaped pieces 13. Although the plate-shaped piece 13 is not divided in the length direction in FIG. 19, the plate-shaped piece 13 may be divided in the length direction. Further, the chamfered portion 13c is formed on the outer periphery of the main surface 13a on the skin material 31 side of each plate-shaped piece 13, but the description is omitted in FIGS. 19 and 20.
- the composite material 131 can be wound into a cylindrical shape to manufacture a cylindrical body 100.
- the cylindrical body 100 shown in FIG. 20 is obtained.
- the core material layers 20 are not laminated on both end portions 31a of the skin material 31, and one end portion 31a serves as a sticking allowance on the inner peripheral surface (a sticking point on the outer skin material 31).
- the other end 13a is laminated so as to cover the outermost plate-shaped piece 13. Further, even when the composite material 131 is wound with the skin material 31 side as the outside, the cylindrical body 100 can be obtained.
- one end 31a is laminated so as to cover the innermost plate-shaped piece 13, and the other end 13a is used as a sticking allowance on the outer peripheral surface (a place to be stuck to the inner skin material 31).
- the end portion 31a of the skin material 31 is laminated so as to cover the plurality of plate-shaped pieces 13.
- a partition space 53 formed by through holes is formed in each plate-shaped piece 13 of the core material layer 20.
- the partition space 53 is a space in which the periphery is partitioned in a plan view.
- the number of partition spaces 53 in one plate-shaped piece 13 may be one or a plurality. Further, the partition space 53 may be formed in all the plate-shaped pieces 13 of the composite material 30, or the partition space 53 may be formed in only a part of the plate-shaped pieces 13.
- the outer peripheral shape of the plate-shaped piece 13 is a regular polygon (regular hexagon in FIG. 21A) as in the above-described embodiment.
- the planar shape of the plate-shaped piece 13 may be a shape other than a regular polygon (for example, a polygon other than the regular polygon, a circle, an ellipse, etc.).
- the planar shape of the partition space 53 is the same as the outer peripheral shape of the plate-shaped piece 13.
- the planar shape of the partition space 53 may be different from the outer peripheral shape of the plate-shaped piece 13.
- the partition space 53 can be formed at the time of press cutting in which the material sheet 14 is divided into a large number of plate-shaped pieces 13 in the cutting step of the first manufacturing process.
- a blade (not shown) corresponding to the planar shape of the partition space 53 is provided inside the blade 24 corresponding to the planar shape of the plate-shaped piece 13.
- a trace (cutting mark) indicating that a partition space 53 was formed by punching on the same side as the chamfered portion 13c (or burr 13d) in the thickness direction.
- the inner chamfer portion 13e (or inner burr) is formed.
- FIG. 21B a trace (cutting mark) indicating that a partition space 53 was formed by punching on the same side as the chamfered portion 13c (or burr 13d) in the thickness direction.
- the description of the chamfered portion 13c and the inner side chamfered portion 13e is omitted.
- the material sheet 14 is attached to the base sheet 11, and the material sheet 14 is formed into a large number of plate-shaped pieces 13 by press-cutting in accordance with the position of the partition space 53. It may be divided.
- the gap 16 of the core material layer 20 is filled with the cured resin 6.
- the resin 6 is cured by injecting a curable resin (for example, a thermosetting type, a two-component reaction type, a moisture-reacting type adhesive, etc.) into the gap 16 by utilizing the pressure difference.
- the curable resin can be injected using, for example, an RTM (Resin Transfer Molding) molding method.
- the skin material sheets 31A and 32A sandwiching the core material layer 20 include a resin-free fiber woven fabric (carbon fiber or glass fiber woven fabric, carbon fiber or glass fiber non-woven fabric, etc.), a resin plate, or a resin plate.
- a metal plate or the like can be used, and a resin sheet 54 made of a material that does not allow the curable resin to pass through can be laminated between the skin material sheets 31A and 32A and the core material layer 20.
- a perforated sheet 54A in which a plurality of through holes 54a are formed or a non-perforated sheet 54B having no through holes 54a can be used.
- the perforated sheet 54A is used, by making at least a part of the through holes 54a of the resin sheet 54 overlap the gap 16, it becomes easy to fill the gap 16 with a low-fluidity curable resin. Further, at least a part of the through holes 54a of the resin sheet 54 may overlap the partition space 53.
- the curable resin is injected into the partition space 53 overlapping the through holes 54a, and the other compartments. No curable resin is injected into the space 53. Further, when none of the through holes 54a of the resin sheet 54 overlaps with the partition space 53, or when both of them use the non-perforated sheet 54B, the curable resin is not injected into any of the partition spaces 53. In any case, it is possible to control whether or not the curable resin flows into the partition space 53. Therefore, the porosity of the core material layer 20 can be adjusted according to the size of the partition member 53. It is not necessary to inject the above-mentioned curable resin into the gap 16. Even in this case, since the partition space 53 is provided in each plate-shaped piece 13, each plate-shaped piece 13 can easily follow the three-dimensional shape.
- This modification is the same as the eighth modification in that the partition space 53 is formed in the plate-shaped piece 13, but as shown in FIG. 22, the partition space 53 in the plate-shaped piece 13 has a honeycomb structure. Is formed.
- the number of partition spaces 53 in one plate-shaped piece 13 may be one or may be plural.
- the broken line represents the cutting portion (the position of the press cut described later).
- the planar shape of the cut portion with respect to one plate-shaped piece 13 is a polygon (hexagon). However, the planar shape of the cut portion may be other than a polygon.
- the material sheet 14 having a honeycomb structure is attached to the base material sheet 11
- the material sheet 14 in a state of being attached to the base material sheet 11 is punched out.
- the material sheet 14 is divided into a large number of plate-shaped pieces 13.
- the core material layer 20 is obtained by removing chips as needed.
- a film in which films are integrated on both sides of the honeycomb structure layer so as to close each through hole of the honeycomb structure can be used, or a material sheet composed of only the honeycomb structure layer can be used. It can also be used.
- the core material layer 20 of the eighth modification and the ninth modification is the composite material 30 of FIG. 2, the transfer sheet 10 of FIG. 4, the adhesive core sheet 60 of FIG. 13, and the composite of FIG. It can be used in place of the core material layer 20 without the partition space 53 in the laminated materials of all the above-described embodiments and modifications such as the material manufacturing sheet 70.
- the laminated material is an intermediate sheet such as a transfer sheet 10
- the laminated material 10 is laminated on the core material layer 20 and the core material layer 20.
- the core material layer 20 has a large number of plate-shaped pieces 13 arranged along the surface of the skin material 11, and in the core material layer 20, adjacent plate-shaped pieces 13 have gaps.
- a partition space 53 is formed in the plate-shaped piece 13 so as to be separated from each other or by a notch.
- the laminated material is a composite material 30 such as a panel having a sandwich structure
- the laminated material 30 is arranged on the side opposite to the first skin material 11 in the core material layer 20 with the skin material 11 as the first skin material.
- a second skin material 12 that sandwiches the core material layer 20 is further provided together with the first skin material 11.
- a resin sheet 54 that does not allow the curable resin to pass through is laminated.
- the holding portion 80 for holding the plane position of the plate-shaped piece 13 is laminated on the main surfaces 13a and 13b of the plate-shaped piece 13 of the core material layer 20.
- the holding portion 80 is an adhesive layer or an adhesive layer in which a gap is partially formed.
- the adhesive layer 80 is composed of a large number of dot portions 80a, each of which is composed of a thin film of an adhesive. In the adhesive layer 80, for example, a large number of dot portions 80a are regularly arranged.
- the adhesive layer 80 is laminated on at least one of the main surface 13a and the main surface 13b of the plate-shaped piece 13.
- the adhesive layer 80 is laminated on both the main surface 13a and the main surface 13b of the plate-shaped piece 13.
- the adhesive layer 80 may be laminated only on the main surface 13a of the plate-shaped piece 13, or may be laminated only on the main surface 13b of the plate-shaped piece 13.
- the misalignment of the plate-shaped piece 13 can be suppressed, and the finished product of the composite material 30 also has a plate-like shape.
- the misalignment of the piece 13 can be suppressed.
- a large number of dot portions 80a are formed on one or both sides of the material sheet 14 which is the material of the core material layer 20. It is conceivable to print. In this case, in the first manufacturing step, the material sheet 14 on which a large number of dot portions 80a are printed is attached to the base sheet 11, and then the material sheet 14 is divided into a large number of plate-shaped pieces 13 by punching. ..
- a transfer sheet 85 for forming an adhesive layer on which a large number of dot portions 80a are printed can be used (see FIG. 23 (c)).
- the transfer sheet 85 as the base sheet 86 on which a large number of dot portions 80a are printed, for example, an easily peelable sheet such as a resin sheet in which a PET film is treated with silicone can be used.
- the adhesive force of the dot portion 80a to the plate-shaped piece 13 is larger than the adhesive force of the dot portion 80a to the base material sheet 86.
- the dot portion 80a side of the transfer sheet 85 is overlapped with the main surface 13a of the plate-shaped piece 13 (the state shown in FIG.
- a large number of dot portions 80a can be transferred to the main surface 13a of the plate-shaped piece 13.
- a transfer sheet 85 is used to transfer a large number of dot portions 80a to the main surfaces 13a and 13b of the plate-shaped piece 13. You may.
- the dot portion 80a may be formed of a thin film of adhesive instead of an adhesive.
- the dot portion 80a fixed to each plate-shaped piece 13 serves as an anchor, so that the misalignment of the plate-shaped piece 13 can be suppressed.
- an adhesive sheet (or adhesive sheet) 87 in which a large number of gaps are formed in the thickness direction with respect to the main surfaces 13a and 13b of the plate-shaped piece 13. May be laminated.
- a pressure-sensitive adhesive sheet 87 a mesh sheet using a pressure-sensitive adhesive as a material, a non-woven fabric in which fibers of the pressure-sensitive adhesive are entwined, or the like can be used.
- a mesh sheet using an adhesive as a material, a non-woven fabric in which adhesive fibers are entangled, or the like can be used. In these cases as well, the misalignment of the plate-shaped piece 13 can be suppressed.
- the holding portion 80 of this modified example includes a composite material 30 as shown in FIG. 2, a transfer sheet 10 as shown in FIG. 4, an adhesive core sheet 60 as shown in FIG. 13, a composite material manufacturing sheet 70 as shown in FIG. It can be applied to the laminated materials of all the above-described embodiments and modifications.
- the laminated material is laminated on the core material layer 20 and the core material layer 20.
- the core material layer 20 has a large number of plate-shaped pieces 13 arranged along the surface of the skin material 11, and in the core material layer 20, the adjacent plate-shaped pieces 13 are It is separated by a gap or by a notch, and a holding portion 80 for holding the plane position of the plate-shaped piece 13 is laminated between the skin material 11 and the plate-shaped piece 13.
- the laminated material is a composite material 30 such as a panel having a sandwich structure
- the laminated material 30 is arranged on the side opposite to the first skin material 11 in the core material layer 20 with the skin material 11 as the first skin material.
- a second skin material 12 that sandwiches the core material layer 20 together with the first skin material 11 is further provided, and a holding portion 80 is laminated between the skin materials 11 and 12 and the plate-shaped piece 13.
- a stretchable sheet material is used for the base sheet 11 of the transfer sheet 10.
- a resin sheet such as a CPP film (unstretched polypropylene) can be used.
- the tensile strength is 100 MPa (JIS K 7127) or less, and the tensile elongation is 200% (JIS K 7127) or more.
- the base sheet 11 is pulled by the operator or the machine in the direction of the arrow shown in FIG.
- the plate-shaped piece 13 is transferred to the skin material sheet 31A.
- the adhesive force between the plate-shaped piece 13 to be transferred and the base sheet 11 is reduced, so that the plate-shaped piece 13 can be easily transferred.
- the contact area of the plate-shaped piece 13 with respect to the skin material sheet 31A is reduced, so that the plate-shaped piece 13 can be easily transferred.
- the material sheet 14 may be cut into a large number of plate-shaped pieces 13 by laser cutting instead of press cutting.
- burrs 13d are formed on the outer periphery of the main surface 13a of each plate-shaped piece 13 as a cutting mark capable of determining the cutting direction in the thickness direction.
- FIG. 26B even in the composite material 30, burrs 13d remain on the outer periphery of the main surface 13a of each plate-shaped piece 13.
- a chamfered portion 13c may be formed on the outer periphery of the main surface 13a of each plate-shaped piece 13 as the above-mentioned cutting mark. Further, the state of the cut surface can be controlled by adjusting the focal point, output, feed speed, etc. of the laser at the time of laser cutting.
- the material sheet 14 is cut and divided into a large number of plate-shaped pieces 13 by using a cutting device (cutting plotter) that moves the blade along the shape to be cut instead of press cutting or laser cutting. May be good. Also in this case, a chamfered portion 13c or a burr 13d is formed on the outer periphery of the main surface 13a of each plate-shaped piece 13 as a cutting mark capable of determining the cutting direction in the thickness direction.
- a cutting device cutting plotter
- the adjacent plate-shaped pieces 13 in the core material layer 20 are separated by a gap 16, but the adjacent plate-shaped pieces 13 may be separated by the notch 40. good.
- adjacent plate-shaped pieces 13 are cut by the same blade 24.
- a regular hexagonal array pattern blade 24 is used.
- FIG. 27 (c) when the blade 24 is pulled out, the plate-shaped piece 13 that has been elastically deformed in the state of FIG. 27 (b) is restored, and between the adjacent plate-shaped pieces 13. A notch 40 remains in.
- metal-based materials may be used as the materials for the skin materials 31 and 32.
- each plate-shaped piece 13 is joined to the skin materials 31 and 32 by an adhesive.
- this adhesive include vinyl acetal / phenol resin adhesive, nitrile rubber / phenol resin adhesive, chloroprene rubber / phenol resin adhesive, epoxy adhesive, recycled rubber adhesive, and Polybenz Imita.
- a sol-based (PBI) adhesive, a polyimide-based (PI) adhesive, or the like can be used. From the viewpoint of improving the efficiency of the adhesive work (stability of the amount of the adhesive applied and workability), a sheet-like adhesive (film-like adhesive) may be used.
- the resin on which the sheet adhesive is based is, for example, epoxy, nylon / epoxy, nitrile / epoxy, acrylic / epoxy, vinyl / epoxy, modified epoxy, epoxy / phenolic, polyimide, nylon, modified polypropylene, or the like. ..
- the size of each plate-shaped piece 13 becomes large, and the width W of the gap 16 between the adjacent plate-shaped pieces 13 also increases. growing.
- the width W of the gap 16 may be 10 mm or more.
- the shapes of all the plate-shaped pieces 13 in the core material layer 20 do not have to be the same.
- the planar shape of the plate-shaped piece 13 of the portion may be determined according to the curvature of the portion of the composite material 30.
- the composite material 30 shown in FIG. 2 may have a canaoutheastern structure by omitting the second skin material 32.
- the plate-shaped piece 13 side of the composite material 30 is attached to the structural material to be reinforced.
- the core material layer 20 is sandwiched between the first skin material 31 and the structural material to be reinforced.
- the core material layer 20 is composed of a large number of plate-shaped pieces 13 arranged along the surfaces of the skin materials 11 and 12, but the transfer sheet 10, the adhesive core material sheet 60, and the adhesive core material sheet 60, and In the intermediate sheet such as the composite material manufacturing sheet 70, the core material layer 20 may be composed of a sheet material (for example, a sheet material having a honeycomb structure) in which a large number of through holes are formed.
- a sheet material for example, a sheet material having a honeycomb structure
- the trade name "ROHACELL (registered trademark)" (EVONIC Industries AG) was used as the polymethacrylicimide (PMI) closed cell foam.
- the density of the plate-shaped piece 13 was 110 kg / m 3 .
- the planar shape of the plate-shaped piece 13 was based on a regular hexagon, and each of the six corners was chamfered.
- the thickness was 1.0 mm
- the length of one side of the regular hexagon was 5 mm
- the chamfering radius of each of the above-mentioned corners was 0.5 mm.
- the width W of the gap 16 between the adjacent plate-shaped pieces 13 was 1 mm.
- the plurality of plate-shaped pieces 13 were uniformly arranged in the above-mentioned honeycomb arrangement. As a cut mark in the punching process, a chamfered portion 13c having a radius of about 0.05 mm was formed on the outer circumference of the main surface (one surface) 13a of the plate-shaped piece 13.
- the area ratio R1 of the plate-shaped piece 13 to the total area in a plan view was 80.3% (calculated value reflecting the area reduction due to chamfering of each corner).
- the trade name "Pyrofil prepreg (registered trademark) TR3110 381GMX” (manufactured by Mitsubishi Chemical Corporation) was used as the prepreg.
- the specifications of this prepreg were a plain weave cloth made of carbon fibers having a total grain size of 333 g / m 2 and a tensile elastic modulus of 240 GPa, and the matrix was a thermosetting epoxy resin.
- the laminated lumber 30B was heated at 0.2 MPa and 130 ° C. for 2 hours. As a result, a composite material 30 having a thickness of 1.49 mm and a density of 503 kg / m 3 was formed.
- the present invention can be applied to a composite material or the like having a core material layer.
- Transfer sheet (laminated material, intermediate sheet) 11 Base sheet (skin material) 13 Plate-shaped pieces 13a, 13b Main surface 13c Chamfered part 13d Burr 16 Gap 18 Adhesive layer 20 Core material layer 30 Composite material (laminated material) 31, 32 Skin material 40 Notch 60 Adhesive core material sheet (laminated material, intermediate sheet) 70 Composite material manufacturing sheet (laminated material, intermediate sheet)
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Abstract
Description
本実施形態に係る複合材(積層材)30について説明を行う。複合材30は、図1及び図2に示すように、サンドイッチ構造のパネルである。複合材30は、芯材層(「中間層」とも言う。)20と、芯材層20に積層された第1表皮材31と、芯材層20における第1表皮材31とは反対側に積層されて第1表皮材31と共に芯材層20を挟む第2表皮材32とを備えている。複合材30は、例えば、強度に比べて軽量かつ剛性が重視されるパネル材に用いることができる。具体的に、複合材30は、構造材料として、航空機、自動車又は自転車(スポーツ用自転車など)などの移動体、電気機器、電子機器、オフィス機器、家電機器、医療機器、又は、建材のパネル材などに用いることができる。移動体の場合、複合材30は、外装を構成する空力部品として用いることができる。
式1:R1=(S2/S1)×100
次に、複合材30の製造に用いる転写シート10について説明を行う。転写シート10は、基材シート11から他の構造材(表面に粘着性又は接着性がある構造体)へ多数の板状片13を転写可能なシートである。
複合材30の製造方法は、転写シート10を製造する第1製造工程と、第1製造工程で得られた転写シート10を用いて、複合材30を製造する第2製造工程とを、この順番で行う。なお、転写シート10は、中間シートに相当する。
本実施形態の転写シート10では、基材シート11上で打抜き加工を行うことにより多数の板状片13を成形した痕跡として、多数の板状片13において、外周に形成される切断痕から判別される厚さ方向の切断の向きが、互いに同じである。具体的には、多数の板状片13において、厚さ方向における同じ側に面取り部13c(又はバリ13d)が形成される。転写シート10の基材シート11上には、打抜き加工での平面視の切断形状(打抜き形状)に応じて、多数の板状片13が成形される。
本変形例では、図12に示すように、複合材130が、第2表皮材32の表面に沿って並べられた多数の板状片13を有する第2芯材層21と、第1芯材層20と第2芯材層21の間に配置された中間接着層17とをさらに備えている。中間接着層17は、加熱により溶融してそのまま熱硬化するシート状接着剤(フィルム状接着剤又は接着シートともいう)により形成され、第1芯材層20と第2芯材層21を接着する。複合材130では、第1表皮材31、第1芯材層20、中間接着層17、第2芯材層21、及び第2表皮材32が、この順番で積層されている。なお、中間接着層17は、シート状接着剤が溶解した接着剤層により構成されていてもよい。また、各芯材層20,21の隙間16に、硬化した樹脂6が埋められていてもよい。
本変形例では、上述の第1製造工程により製造される中間シートが、転写シート10ではなく、基材シート111を接着剤として用いるために表皮材用シート31Aに積層した状態で、基材シート111が溶解される接着用芯材シート60(図13参照)として用いられる。なお、接着用芯材シート60は、上述の転写シート10と同じ構成のものを用いることができる。但し、転写シート10の場合は、基材シート11から各板状片13が剥離可能となる粘着剤を粘着剤層18に用いるが、接着用芯材シート60の場合は、各板状片13を剥離可能とする必要がなく、粘着剤又は接着剤により基材シート111に材料シート14を貼り付けることができる。
本変形例では、上述の転写シート(第1中間シート)10を用いて、図14に示す接着用芯材シート(第2中間シート)60が製造される。接着用芯材シート60は、表皮材111が、シート状接着剤である。
本変形例では、上述の転写シート(第1中間シート)10を用いて、図16に示す複合材製造用シート(第2中間シート)70が製造される。複合材製造用シート70は、表皮材61がプリプレグ(半硬化状態)である点を除き、図14に示す接着用芯材シート60と同じである。表皮材61のプリプレグには、裏面にセパレートシート41が積層されたもの用いることができる。なお、複合材製造用シート160の製造方法は、表皮材が異なる以外は第3変形例と同じであるため、説明は省略する。
本変形例では、上述の第1製造工程により製造される中間シートが、基材シート61にプリプレグを用いた複合材製造用シート70である。この場合に、複合材30の製造方法において、図17に示すように、成形型33上に、多数の板状片13が貼り付けられた基材シート61が設置される。そして、基材シート61の多数の板状片13に対し、第2表皮材用シート32Aを積層することで、積層材30Bが作製される(図示省略)。
本変形例では、図18に示すように、転写シート10において、基材シート11の裏面にセパレートシート41が積層されている。セパレートシート41は、基材シート11の裏面を被覆している。
本変形例では、図19に示すように、複合材131が、カナッペ構造である。また、表皮材31上の芯材層20では、短冊状の板状片13が一定方向に並べられている。隣り合う板状片13の間には隙間16が形成されている。なお、図19では、板状片13がその長さ方向に分割されていないが、板状片13をその長さ方向に分割してもよい。また、面取り部13cは、各板状片13における表皮材31側の主面13aの外周に形成されるが、図19及び図20では記載を省略している。
本変形例では、芯材層20の各板状片13に、貫通孔により構成された区画空間53が形成されている。区画空間53は、平面視において周囲が区画された空間である。なお、1つの板状片13における区画空間53の数は、1つであってもよいし、複数であってもよい。また、複合材30における全ての板状片13に区画空間53を形成してもよいし、一部の板状片13だけに区画空間53を形成してもよい。
本変形例は、板状片13に区画空間53が形成されている点では第8変形例と同じであるが、板状片13には、図22に示すように、ハニカム構造による区画空間53が形成されている。1つの板状片13における区画空間53の数は、1つであってもよいし、複数であってもよい。なお、図22では、破線が切断箇所(後述するプレスカットの位置)を表す。1つの板状片13に対する切断箇所の平面形状は、多角形(六角形)である。但し、この切断箇所の平面形状は、多角形以外であってもよい。
本変形例では、芯材層20の板状片13の主面13a,13bに、板状片13の平面位置を保持するための保持部80が積層されている。保持部80は、部分的に隙間が形成された粘着層又は接着層である。
本変形例では、転写シート10の基材シート11に、伸縮性を有するシート材が用いられている。基材シート11には、例えばCPPフィルム(無延伸ポリプロピレン)などの樹脂シートを用いることができる。基材シート11の物性値の一例としては、例えば、引張強さが100MPa(JIS K 7127)以下で、引張伸びが200%(JIS K 7127)以上である。
上述の実施形態において、プレスカットではなく、レーザーカットによって材料シート14を切断して多数の板状片13に分割してもよい。この場合、図26(a)に示すように、中間シート10では、厚さ方向の切断の向きを判別可能な切断痕として、各板状片13の主面13aの外周にバリ13dが形成される。また、図26(b)に示すように、複合材30でも各板状片13の主面13aの外周にバリ13dが残る。なお、レーザーカットの場合においても、各板状片13の主面13aの外周に、上述の切断痕として、面取り部13cが形成される場合がある。また、レーザーカットの際にレーザーの焦点、出力、又は送りスピードなどを調整することにより、切断面の状態をコントロールすることができる。
11 基材シート(表皮材)
13 板状片
13a,13b 主面
13c 面取り部
13d バリ
16 隙間
18 粘着剤層
20 芯材層
30 複合材(積層材)
31,32 表皮材
40 切れ込み
60 接着用芯材シート(積層材、中間シート)
70 複合材製造用シート(積層材、中間シート)
Claims (21)
- 芯材層と、前記芯材層に積層された表皮材とを備えた積層材であって、
前記芯材層は、前記表皮材の表面に沿って並べられた多数の板状片を有し、
前記芯材層において、隣り合う板状片は、隙間を隔てて又は切れ込みにより別体となっており、
前記多数の板状片では、外周に形成される切断痕から判別される厚さ方向の切断の向きが、互いに同じである、積層材。 - 前記芯材層では、平面視において、全面積に対する前記板状片の合計面積の割合が、50%以上である、請求項1に記載の積層材。
- 前記板状片の主面のうち、前記厚さ方向の切断の向きとして切断の進行側に位置する主面に積層された前記表皮材では、前記芯材層側の面に、仮に前記表皮材上で切断加工により前記多数の板状片を成形していたならば形成される切断傷が存在しない、請求項1又は2に記載の積層材。
- 前記多数の板状片の各々は、硬質発泡体により構成されている、請求項1乃至3の何れか1つに記載の積層材。
- 前記多数の板状片の各々は、木材により構成されている、請求項1乃至3の何れか1つに記載の積層材。
- 前記表皮材を第1表皮材として、
前記芯材層における前記第1表皮材とは反対側に配置され、前記第1表皮材と共に前記芯材層を挟む第2表皮材をさらに備えている、請求項1乃至5の何れか1つに記載の積層材。 - 前記芯材層を第1芯材層として、
前記第2表皮材の表面に沿って並べられた多数の板状片を有する第2芯材層と、
前記第1芯材層と前記第2芯材層の間に配置され、前記第1芯材層と前記第2芯材層を接着する中間接着層とをさらに備え、
前記第1表皮材、前記第1芯材層、前記中間接着層、前記第2芯材層、前記第2表皮材が、この順番で積層されている、請求項6に記載の積層材。 - 前記中間接着層は、シート状接着剤により形成されている、請求項7に記載の積層材。
- 複合材として構造材料に用いられる、請求項1乃至8の何れか1つに記載の積層材。
- 前記隣り合う板状片の間の隙間に、硬化した樹脂が埋められている、請求項6乃至9の何れか1つに記載の積層材。
- 前記表皮材は、シート状接着剤である、請求項1乃至5の何れか1つに記載の積層材。
- 前記表皮材は、半硬化状態のプリプレグである、請求項1乃至5の何れか1つに記載の積層材。
- 前記多数の板状片は、前記表皮材に対し剥離可能に貼り付けられ、
前記表皮材から他の構造材へ前記多数の板状片を転写可能な転写シートとして用いられる、請求項1、2、4又は5に記載の積層材。 - 前記多数の板状片は、感温性粘着剤により前記表皮材に貼り付けられている、請求項13に記載の積層材。
- 前記表皮材と前記板状片との間には、前記板状片の位置を保持するための粘着層又は接着層が設けられている、請求項1乃至13の何れか1つに記載の積層材。
- 前記板状片には、貫通孔により構成された区画空間が形成されている、請求項1乃至15の何れか1つに記載の積層材。
- 複合材の芯材に用いる多数の板状片が貼り付けられた中間シートの製造方法であって、
基材シートに貼り付けられた状態の材料シートに対し切断加工を行うことにより、前記材料シートを多数の板状片に分割し、前記基材シートに前記多数の板状片が貼り付けられた中間シートを得る切断ステップを行い、
当該中間シートは、前記基材シートから他の構造材へ前記多数の板状片を転写可能な転写シート、又は、前記基材シートを接着剤として用いるために前記複合材の表皮材となる表皮材用シートに積層した状態で前記基材シートが溶解される接着用芯材シートとして用いられる、中間シートの製造方法。 - 前記転写シートにおける板状片側に、前記中間シートの表皮材として、シート状接着剤又はプリプレグを貼り付ける貼付けステップと、
前記貼付けステップ後に、前記多数の板状片から前記基材シートを剥がすことにより、前記中間シートの表皮材に前記多数の板状片を転写する転写ステップとを行う、請求項17に記載の中間シートの製造方法。 - 複合材の製造方法であって、
請求項17に記載の製造方法により得られた前記転写シートにおける板状片側に、複合材の表皮材となる表皮材用シートを貼り付ける貼付けステップと、
前記貼付けステップ後に、前記多数の板状片から前記基材シートを剥がすことにより、前記表皮材用シートに前記多数の板状片を転写する転写ステップとを行う、複合材の製造方法。 - 前記表皮材には、伸縮性を有するシートが用いられ、
前記転写ステップにおいて、前記基材シートを引っ張りながら、前記基材シート10の裏面から転写対象の板状片を押すことにより該板状片の転写を行う、請求項19に記載の複合材の製造方法。 - 前記表皮材用シートと第2表皮材用シートとにより前記多数の板状片を挟む積層ステップと、
前記多数の板状片により構成された芯材層の隙間に樹脂を流入させた後に、該樹脂を硬化させることにより、前記芯材層に樹脂のハニカム構造を形成するハニカム形成ステップとを、前記転写ステップ後に行う、請求項20に記載の複合材の製造方法。
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