WO2022054388A1 - サンドイッチパネルの製造方法およびサンドイッチパネル - Google Patents
サンドイッチパネルの製造方法およびサンドイッチパネル Download PDFInfo
- Publication number
- WO2022054388A1 WO2022054388A1 PCT/JP2021/025960 JP2021025960W WO2022054388A1 WO 2022054388 A1 WO2022054388 A1 WO 2022054388A1 JP 2021025960 W JP2021025960 W JP 2021025960W WO 2022054388 A1 WO2022054388 A1 WO 2022054388A1
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- WO
- WIPO (PCT)
- Prior art keywords
- sandwich panel
- manufacturing
- panel according
- core layer
- prepreg
- Prior art date
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Definitions
- the present invention relates to a method for manufacturing a sandwich panel and a sandwich panel.
- the sandwich panel is composed of a hollow honeycomb core composed of a wall having a hexagonal cross section and a skin material such as a pair of prepregs joined to both sides of the honeycomb core.
- Sandwich panels which are lightweight and highly rigid, are used, for example, in structural members for aircraft.
- the present inventor has performed a first heat-pressurizing treatment for laminating and integrating a plurality of prepregs in advance to obtain a composite surface material. It was found that the voids on the surface of the obtained sandwich panel can be reduced by performing the process through the above step and setting the pressure to be equal to or higher than the pressure of the second heat-pressurizing treatment for sandwiching. That is, the present inventor pays attention to the fact that the unevenness due to the texture of the fiber base material constituting the prepreg causes pinholes in the sandwich panel, and controls the heating and pressurizing conditions in the step of laminating and integrating the prepreg. Was found to be effective, and the present invention was completed.
- the surface of the prepreg can be heated and pressed more uniformly by using the release film, and the prepreg can be heated by increasing the pressure. It is presumed that the slight unevenness of the constituent fiber base material can be effectively reduced.
- the process of preparing multiple sheet-shaped prepregs A step of performing a first heat-pressurizing treatment on the upper and lower surfaces of a laminated body in which a plurality of prepregs are laminated via a release film, and integrating the laminated bodies to obtain a composite surface material.
- the first heat-pressurization treatment provides a method for producing a sandwich panel, which has a pressure equal to or higher than that of the second heat-pressurization treatment.
- a sandwich panel comprising a core layer having a honeycomb structure and a composite surface material provided on both sides of the core layer and in which a plurality of cured products of prepreg are laminated and integrated.
- a sandwich panel is provided in which the number density of pinholes when observing the outermost surface of the composite surface material is 0 to 50 pieces / cm 2 .
- a technique capable of reducing pinholes in a sandwich panel is provided.
- FIG. 1 is a schematic view showing an example of a sandwich panel according to the present embodiment.
- the sandwich panel 100 of the present embodiment includes a core layer 10 having a honeycomb structure and a cured product (composite surface material 40) of prepregs 20 (prepreg 21 on the upper surface and prepreg 22 on the lower surface) provided on both sides of the core layer 10. , Equipped with. Further, the sandwich panel 100 of the present embodiment is provided with a hot melt adhesive layer 15 between the core layer 10 and the composite surface material 40 (not shown).
- the number density of pinholes when observing the outermost surface of the composite surface material 40 is 0 to 50 per cm 2 .
- the number density of pinholes when observing at least one surface of the sandwich panel 100 is 0 to 50 per cm 2 . That is, since the sandwich panel 100 of the present embodiment is obtained by the manufacturing method described later, the generation of voids is suppressed as compared with the conventional case, and as a result, the number density of pinholes on the surface is reduced.
- the smaller the number density of the pinholes the more preferable it is, more preferably 45 pieces / cm 2 or less, more preferably 40 pieces / cm 2 or less, and further preferably 30 pieces / cm 2 or less.
- both sides of the sandwich panel 100 have the above-mentioned pinhole number density.
- the number density of pinholes is determined by counting the holes that can be seen when observing the surface of the sandwich panel 100 with a magnifying glass (4 to 50 times) and dividing by the observed area.
- the core layer 10 for example, a sheet-like member formed by impregnating a base material for a core layer having a honeycomb structure with a binder resin can be used.
- the core layer 10 can have high strength and light weight due to the honeycomb structure.
- the honeycomb structure is a known structure, and is intended to be a structure in which a plurality of substantially regular hexagonal through holes penetrating from the upper surface to the lower surface are formed.
- Examples of the base material having the honeycomb structure of the core layer 10 include those obtained by molding aramid fiber, paper, balsa wood, plastic, aluminum, titanium, glass, an alloy thereof and the like into a honeycomb shape by a known method. From the viewpoint of heat resistance, it is preferable that the base material having the honeycomb structure of the core layer 10 contains aramid fibers.
- the core layer 10 is preferably a woven fiber cloth as the shape of the base material. As a result, the processability to the honeycomb structure is improved, and the weight of the sandwich panel 100 can be reduced.
- the core layer 10 contains the fiber cloth on the woven fabric, the portion where the fiber crosses is less likely to be pressurized in the manufacturing process, and voids are likely to remain.
- the manufacturing described later Depending on the method, the generation of voids can be effectively suppressed.
- the layer thickness of the core layer 10 is not particularly limited, but may be, for example, 1 mm or more and 50 mm or less, 3 mm or more and 40 mm or less, or 5 mm or more and 30 mm or less.
- each core cell in the core layer 10 is not particularly limited, but can be, for example, 1 mm or more and 10 mm or less on one side.
- the area of the surface (upper surface, lower surface) of the core layer 10 is not limited, but for example, it may have a surface area for one sandwich panel or a total surface area for a plurality of sandwich panels. good. This makes it possible to separate one sandwich panel 100 into individual pieces and cut out a plurality of panels to obtain the sandwich panel 100, thereby improving productivity.
- the area of the surface (upper surface, lower surface) of the core layer 10 can be a large area, and may be, for example, 1 m 2 or more.
- the core layer 10 may have various surface treatments on the inside and / or the outside from the viewpoint of improving corrosion resistance and heat resistance.
- the prepreg 20 for example, a sheet member in a B stage state in which a binder resin is impregnated into a prepreg base material can be used.
- the prepreg 20 is a stack of the prepreg 211 and the prepreg 212 (see FIG. 2).
- the prepreg 20 may be a stack of three or more prepregs.
- the reaction rate calculated from the measurement result of DSC (Differential Scanning Calorimeter) for the binder resin impregnated in the prepreg substrate is more than 0% and 60% or less, preferably 0. It means that it is 5% or more and 55% or less, and more preferably 1% or more and 50% or less.
- the prepreg base material of the prepreg 20 examples include a fiber base material.
- aramid fiber, polyester fiber, polyphenylene sulfide fiber, carbon fiber, graphite fiber, glass fiber, silicon carbide fiber and the like can be used.
- the fiber base material preferably contains glass fiber.
- the heat resistance of the sandwich panel 100 can be further improved. Further, since the difference in linear expansion coefficient between the composite surface material 40 and the core layer 10 can be reduced, the warp of the sandwich panel 100 can be suppressed.
- the upper limit of the glass transition temperature (Tg) of the cured product (composite surface material 40) of the prepreg 20 is, for example, 250 ° C. or lower, preferably 220 ° C. or lower, and more preferably 200 ° C. or lower. This makes it possible to carry out the heat and pressurization treatment under low temperature conditions.
- the lower limit of the glass transition temperature (Tg) may be, for example, 110 ° C. or higher, or 120 ° C. or higher. This makes it possible to improve the thermal characteristics.
- the binder resins used in the core layer 10 and the prepreg 20 may be the same or different from each other, but they can effectively improve the adhesion and the combustion resistance. It is preferably the same binder resin.
- the binder resin will be described later.
- the composite surface material 40 of the present embodiment is obtained by laminating and integrating the prepreg 211 and the prepreg 212, and curing the binder resin by the first heat-pressurizing treatment described later.
- the composite surface material 40 is formed by laminating and integrating a cured product of the prepreg 211 and the prepreg 212.
- the hot melt adhesive layer 15 is interposed between the core layer 10 and the composite surface material 40 (see FIG. 3). As a result, it is possible to suppress the generation of voids while improving the adhesion.
- a known hot melt adhesive layer 15 can be used, but it is preferably made of a hot melt adhesive. As a result, it becomes easy to reduce the occurrence of internal stress and strain after curing, and the generation of voids can be effectively suppressed.
- the hot melt adhesive contains a non-curable resin as a main component, which becomes fluid at a high temperature and returns to a non-fluid state by cooling. That is, it melts at a specific temperature or higher and develops adhesiveness.
- the non-curable resin include polyurethane-based, acrylonitrile-based, diene-based, acrylic-based, butadiene-based, polyamide-based, polyvinyl butyral-based, olefin-based, isoprene-based, butadiene-based, chloroprene-based, acrylonitrile-based, polyester-based, and poly.
- the hot melt adhesive contains polyamide as a main component.
- the viscosity of the hot melt adhesive is preferably about 30,000 cmpoise (cP) or less at 163 ° C., preferably 20,000 cmpoise (cP) or less, and 10,000 cmpoise (cP) or less. It is more preferable to have.
- the hot melt adhesive is a polymer component showing a tensile stress of 0.5 to 3.5 MPa at 300% elongation when tested by ASTM D 421-06A, by weight of 20 to 65. % Means the adhesive contained.
- the shape of the hot melt adhesive layer 15 is not particularly limited, but is preferably a non-woven fabric or a film from the viewpoint of effectively suppressing the generation of voids.
- the sandwich panel 100 of this embodiment can be suitably used for an aircraft panel.
- the sandwich panel 100 can be used for the interior of an aircraft such as a toilet and a partition, and the equipment inside the aircraft such as a wagon housing.
- Step 1 Preparation of Core Layer 10 and Prepregs 211 and 212
- Base materials for core layer are prepared.
- the base material for the core layer has a honeycomb structure and is preferably formed of aramid fibers.
- a base material having a honeycomb structure is prepared, and the base material is impregnated with the binder solution. Then, the substrate is dried to obtain the core layer 10.
- a base material for prepreg examples include a fiber base material.
- the binder resin is impregnated into the prepreg base material.
- the substrate is dried to obtain the B-stage prepregs 211 and 212, respectively.
- a method of impregnating the binder resin for example, a method of dissolving the binder resin in a solvent and spraying the obtained solution onto the base material using an injection device such as a spray nozzle to apply the base material, or immersing the base material in the solution.
- a method of applying the solution to the base material with various coaters such as a knife coater and a comma coater, a method of transferring the solution to the base material with a transfer roll, and the like. Of these, a method of immersing the prepreg substrate in the solution is preferable.
- the conditions for heating and drying are not particularly limited, but usually 100 to 220 ° C., preferably 120 to 190 ° C. for 2 to 10 minutes.
- the binder solution As the binder solution, a binder resin or the like is dissolved in a known organic solvent, and a known one can be used.
- the binder resin is preferably a thermosetting resin, and examples thereof include a thermosetting resin such as a phenol resin, an unsaturated polyester resin, or an epoxy resin.
- the phenolic resin includes a compound having one or more phenolic hydroxyl groups in the molecule, for example, novolak resin such as novolak type phenol, novolak type cresol, novolak type naphthol; bisphenol resin such as bisphenol F, bisphenol A; paraxylylene.
- the binder resin preferably contains a phenol resin from the viewpoint of obtaining releasability from the pressing plate or the like in the laminating and integrating step.
- the binder solution may contain other additives.
- the additive is not particularly limited, and examples thereof include fillers such as inorganic fillers, rubber, and thermoplastic resins.
- Step 2 Integration of Prepreg
- sheet-shaped prepregs 211 and 212 are prepared.
- the prepregs 211 and 212 are in the B stage state.
- the prepregs 211 and 212 may be of the same material and thickness, or may be different from each other.
- the laminated body in which the prepregs 211 and 212 are laminated is subjected to the first heat and pressure treatment via the release film to cure the binder resin, and the prepreg 211 is cured.
- 212 are integrated to obtain a cured product of prepreg 20, that is, a composite surface material 40.
- a flat pressing plate is arranged from the upper and lower surfaces of the laminated sheet-shaped prepregs 211 and 212 via a release film, and uniformly heated and pressed from above and below.
- the first heat-pressurizing treatment is preferably 110 to 150 ° C. and 0.5 to 3.0 MPa, more preferably 120 to 140 ° C. and 1.5 to 2.5 MPa.
- the prepregs 211 and 212 can be firmly integrated with each other.
- the prepregs 211 and 212 can be appropriately integrated while being suppressed from being damaged.
- the pressure of the first heat-pressurizing treatment is equal to or higher than that of the second heat-pressurizing treatment described later.
- the pressure of the first heat-pressurization treatment is higher than that of the second heat-pressurization treatment described later. This makes it possible to more effectively reduce the generation of voids in the sandwich panel 100.
- the first step is performed while pressing the smooth surface of the pressing plate against the upper and lower surfaces of the laminated prepregs via the release film 25. Heat and pressurize. As a result, pressure can be applied more uniformly to the entire surfaces of the prepregs 211 and 212, and voids in the sandwich panel 100 can be effectively suppressed.
- the release film 25 of the present embodiment is, for example, a polyalkylene terephthalate resin such as polyethylene terephthalate resin (PET), polybutylene terephthalate resin (PBT), polytrimethylene terephthalate resin (PTT), polyhexamethylene terephthalate resin (PHT).
- a polyalkylene terephthalate resin such as polyethylene terephthalate resin (PET), polybutylene terephthalate resin (PBT), polytrimethylene terephthalate resin (PTT), polyhexamethylene terephthalate resin (PHT).
- Poly4-methyl1-pentene resin (TPX), syndiotactic polystyrene resin (SPS), and polypropylene resin (PP) are preferably selected from one or more. Of these, poly 4-methyl-1-pentene resin (TPX) and polypropylene resin (PP) are more preferable.
- the release film 25 preferably has a storage elastic modulus (frequency 100 Hz, 100 ° C.) measured after heat treatment at 180 ° C. for 120 seconds, preferably satisfying 0.05 GPa or more and 10 GPa or less, more preferably. , 0.1 GPa or more and 5 GPa or less.
- a storage elastic modulus frequency 100 Hz, 100 ° C. measured after heat treatment at 180 ° C. for 120 seconds, preferably satisfying 0.05 GPa or more and 10 GPa or less, more preferably. , 0.1 GPa or more and 5 GPa or less.
- the thickness of the release film 25 is preferably 50 ⁇ m or more and 150 ⁇ m or less, more preferably 75 ⁇ m or more and 140 ⁇ m or less, and most preferably 90 ⁇ m or more and 130 ⁇ m or less. By doing so, it becomes possible to apply the press pressure more uniformly to the release film 25 at the time of producing the molded product, and it is possible to further suppress the generation of voids.
- Step 3 Batch Laminating Next, the prepared composite surface material 40 is used to integrate with the core layer 10. As shown in FIG. 3A, the composite surface material 40 is arranged on the opening surfaces of the upper surface side and the lower surface side of the core layer 10, and is laminated together by the second heat and pressure treatment. Further, a metal plate 30 (the upper side is the metal plate 31 and the lower side is the metal plate 32) for applying the pressure heat treatment to the composite surface material 40 is arranged.
- the core layer 10 and the composite surface material 40 are collectively laminated by the second heat and pressure treatment while the metal plate 30 is in contact with the composite surface material 40.
- the core layer 10 and the composite surface material 40 can be integrated.
- the second heat and pressurization treatment is preferably, for example, 110 ° C. to 140 ° C., 30 minutes to 90 minutes, 0.35 MPa to 2.0 MPa, 120 ° C. to 130 ° C., 30 minutes to 90 minutes, 0.5 MPa to 1. 0.0 MPa can be adopted as a more preferable condition. Further, the second heat and pressurization treatment can be performed in the atmosphere. Therefore, productivity can be improved.
- the hot melt adhesive layer 15 is interposed between the composite surface material 40 and the core layer 10, and the layers are laminated. As a result, the voids existing in the core layer 10 and the composite surface material 40 are embedded by the hot melt adhesive layer 15, and the generation of voids on the surface of the sandwich panel 100 can be suppressed.
- the metal plate 30 a known one can be used, and examples thereof include a metal plate such as a SUS plate, a tin plate, an aluminum plate, and a magnesium plate.
- the film thickness of the metal plate 30 is not particularly limited, but may be, for example, 0.5 mm or more and 10 mm or less, 0.8 mm or more and 5 mm or less, or 1.0 mm or more and 2.0 mm or less. By setting it within such a range, it is possible to achieve a balance between rigidity and thermal conductivity.
- the sandwich panel 100 is obtained by separating the metal plate 30 from the composite surface material 40.
- Example 1 Manufacturing of composite surface material
- a phenol resin resole-type phenol resin, “34370” manufactured by Durez
- glass fiber # 7781, manufactured by HEXCEL
- a SUS plate (thickness: 1.5 mm, Rz: 1.0 ⁇ m) is pressed on both sides, and a mechanical press is used to heat and pressurize at 2.0 MPa, 130 ° C., 60 minutes ( The first heat-pressurization treatment) was performed to cure the phenol resin in the prepreg to form a composite surface material.
- a release film polymethylpentene: TPX® film, thickness 120 ⁇ m was placed between the SUS plate and the prepreg.
- a hot melt adhesive (main component polyamide) is placed on both sides of the honeycomb core (aramid fiber, thickness: 10 mm, HRH-10-1 / 8-3.0 (manufactured by HEXCEL), area: 1 m x 3 m). Further, the obtained composite surface material was placed on it to obtain a laminated body. Subsequently, a SUS plate (thickness: 1.5 mm, Rz: 1.0 ⁇ m) was pressed against both sides of the obtained laminate, and heated and pressed at 0.7 MPa, 127 ° C., 60 minutes using a mechanical press (No. 1). (2) Heat-pressurization treatment) was performed to cure the prepreg to form a resin plate. Then, the SUS plate was separated from the resin plate to obtain a sandwich panel composed of a resin plate, a honeycomb core, and a resin plate.
- Example 2 As the release film, "Polymethylpentene: TPX (registered trademark) film” was changed to “Polypropylene film: Trefan (registered trademark), thickness 100 ⁇ m” and used in the same manner as in Example 1. I got a sandwich panel.
- TPX registered trademark
- Trefan registered trademark
- Example 3 A sandwich panel was obtained in the same manner as in Example 1 except that the 2.0 MPa of the first heat treatment was changed to 0.7 MPa.
- Example 1 A sandwich panel was obtained in the same manner as in Example 1 except that the release film was not placed between the SUS plate and the prepreg.
- a phenol resin was blended and impregnated into glass fiber (# 7781, manufactured by HEXCEL) to obtain a sheet-shaped prepreg (250 ⁇ m).
- the prepreg was in the B stage state.
- the B-stage prepregs obtained on both sides of the honeycomb core were arranged to form a laminated body, and the laminated body was placed in a vacuum bag, which was collectively placed in an autoclave under the conditions of 0.7 MPa, 127 ° C., and 60 minutes.
- the sandwich panel was obtained by heating and curing.
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Abstract
Description
シート状の複数のプリプレグを準備する工程と、
前記複数のプリプレグを積層した積層体の上下面に対し、離型フィルムを介して第1の加熱加圧処理を行い、前記積層体を一体化して複合表面材を得る工程と、
ハニカム構造を有するシート状のコア層の上面側と下面側のそれぞれの面上に前記複合表面材を配置し、第2の加熱加圧処理により一体化する工程と、
を含み、
前記第1の加熱加圧処理は、前記第2の加熱加圧処理よりも圧力が同等以上である、サンドイッチパネルの製造方法が提供される。
ハニカム構造を有するコア層と、前記コア層の両面に設けられ、複数のプリプレグの硬化物が積層し一体化された複合表面材と、を備えるサンドイッチパネルであって、
前記複合表面材の最外面を観察したときのピンホールの数密度が0~50個/cm2である、サンドイッチパネルが提供される。
本明細書中、数値範囲の説明における「a~b」との表記は、特に断らない限り、a以上b以下のことを表す。例えば、「1~5質量%」とは「1質量%以上5質量%以下」を意味する。
図1は、本実施形態に係るサンドイッチパネルの一例を示す概略図である。
本実施形態のサンドイッチパネル100は、ハニカム構造を有するコア層10と、コア層10の両面に設けられたプリプレグ20(上面をプリプレグ21、下面をプリプレグ22)の硬化物(複合表面材40)と、を備える。
また、本実施形態のサンドイッチパネル100は、コア層10と複合表面材40との間にそれぞれホットメルト系接着層15を備えている(図示無し)。
すなわち、本実施形態のサンドイッチパネル100は、後述する製造方法によって得られたものであるため従来よりもボイドの発生が抑制され、その結果、表面のピンホールの数密度が低減されている。
ピンホールの数密度は、少なければ少ないほど好ましく、45個/cm2以下であることがより好ましく、40個/cm2以下であることがより好ましく、30個/cm2以下であることがさらに好ましく、20個/cm2以下であることがことさらに好ましい。また、サンドイッチパネル100の両面において、上記のピンホール数密度となっていることが好適である。
ピンホールの数密度は、サンドイッチパネル100の表面を拡大鏡(4~50倍)で観察したときに視認できる穴を数え、観察した面積で割ることによって求められる。
コア層10は、例えば、ハニカム構造を備えるコア層用基材に、バインダー樹脂を含浸してなるシート状の部材を用いることができる。コア層10は、ハニカム構造により、高強度と軽量性を有することができる。
なお、ハニカム構造とは、公知の構造であり、上面から下面に亘って貫通する略正六角性の貫通孔が複数形成された構造を意図する。
コア層10が織物上の繊維クロスを含む場合、繊維と繊維がクロスする箇所は製造工程において加圧されにくく、ボイドが残存しやすくなるが、本実施形態のサンドイッチパネル100においては、後述の製造方法により、ボイドの発生を効果的に抑制できる。
プリプレグ20としては、例えば、バインダー樹脂をプリプレグ用基材に含浸してなる、Bステージ状態のシート部材を用いることができる。
本実施形態において、プリプレグ20は、プリプレグ211とプリプレグ212とが積層したものである(図2参照)。
なお、プリプレグ20は、3枚以上のプリプレグが積層したものであってもよい。
上記繊維基材としては、アラミド繊維、ポリエステル繊維、ポリフェニレンスルフィド繊維、炭素繊維、黒鉛繊維、ガラス繊維、および炭化珪素繊維等を用いることができる。高い耐熱性の観点から、上記繊維基材は、ガラス繊維を含むことが好ましい。
本実施形態の複合表面材40は、プリプレグ211とプリプレグ212とを積層一体化し、後述する第1の加熱加圧処理により、バインダー樹脂を硬化することによって得られたものである。言い換えると、複合表面材40は、プリプレグ211とプリプレグ212の硬化物が積層し一体化されたものである。
本実施形態において、コア層10と複合表面材40との間に、ホットメルト系接着層15が介在している(図3参照)。これにより、密着性を高めつつ、ボイドの発生を抑制できる。
上記の非硬化性樹脂としては、ポリウレタン系、アクリロニトリル系、ジエン系、アクリル系、ブタジエン系、ポリアミド系、ポリビニルブチラール系、オレフィン系、イソプレン系、ブタジエン系、クロロプレン系、アクリロニトリル系、ポリエステル系、ポリ塩化ビニル系、スチレン系、エチレン-酢酸ビニル系、フッ素系、シリコーン系およびそれらの共重合体を含む熱可塑性樹脂等からなる群から選ばれる1種以上または2種以上が挙げられる。
なかでも、ホットメルト接着剤は、ポリアミドを主成分として含むことがより好ましい。
本実施形態のサンドイッチパネル100は、航空機用パネルに好適に用いることができる。例えば、サンドイッチパネル100は、トイレやパーテーション等の航空機の内装や、ワゴンの筐体等の航空機内の備品に用いることができる。
次に、本実施形態のサンドイッチパネル100の製造方法について説明する。
コア層用基材を準備する。コア層用基材は、ハニカム構造を有するものであり、アラミド繊維から形成されることが好ましい。
ハニカム構造を備える基材を準備し、バインダー溶液を当該基材に含浸させる。その後、基材を乾燥させ、コア層10が得られる。
また、加熱乾燥する条件としては特に限定されないが、通常100~220℃、好ましくは120~190℃で2~10分間行う。
バインダー溶液は、バインダー樹脂などを公知の有機溶剤に溶解したものであり、公知のものを用いることができる。バインダー樹脂は、熱硬化性樹脂が好ましく、例えば、フェノール樹脂、不飽和ポリエステル樹脂またはエポキシ樹脂等の熱硬化性樹脂が挙げられる。フェノール樹脂としては、分子内にフェノール性水酸基を1つ以上有する化合物が含まれ、例えば、ノボラック型フェノール、ノボラック型クレゾール、ノボラック型ナフトールなどのノボラック樹脂;ビスフェノールF、ビスフェノールAなどのビスフェノール樹脂;パラキシリレン変性フェノール樹脂などのフェノールアラルキル樹脂;ジメチレンエーテル型レゾール、メチロール型フェノール等のレゾール型フェノール樹脂;上記樹脂等をさらにメチロール化させた化合物などが挙げられる。
なかでも、積層一体化工程での押し当て板等に対する離型性を得る観点から、バインダー樹脂は、フェノール樹脂を含むことが好ましい。
また、バインダー溶液には、上記の熱硬化性樹脂以外に、他の添加剤を含むことができる。添加剤としては、特に限定されないが、例えば、無機充填材などの充填材、ゴム、熱可塑性樹脂などが挙げられる。
次に、図2(a)に示すように、シート状のプリプレグ211および212を準備する。プリプレグ211および212は、Bステージ状態である。プリプレグ211および212は、同一の材料および厚みのものであってもよく、互いに異なるものであってもよい。
続けて、図2(b)に示すように、プリプレグ211および212を積層した積層体に、離型フィルムを介して、第1の加熱加圧処理を施して、バインダー樹脂を硬化させ、プリプレグ211および212を一体化して、プリプレグ20の硬化物、すなわち複合表面材40を得る。このとき、積層されたシート状のプリプレグ211および212の上下面から、離型フィルムを介して、平坦な押し当て板を配置し、上下方向から均一に加熱加圧する。
第1の加熱加圧処理の温度、および圧力を上記下限値以上とするにより、プリプレグ211および212同士を強固に一体化できる。
一方、第1の加熱加圧処理の温度、および圧力を上記上限値以下とするにより、プリプレグ211および212の破損を抑制しつつ、適切に一体化できる。
本実施形態において、当該第1の加熱加圧処理は、後述する第2の加熱加圧処理よりも圧力が同等以上である。これにより、複合表面材40におけるボイドを低減しつつ、複合表面材40とコア層10との密着性を良好に保持し、サンドイッチパネル100内でのボイドの発生を効果的に低減できる。
また、第1の加熱加圧処理は、後述する第2の加熱加圧処理よりも圧力が高いことが好ましい。これにより、サンドイッチパネル100内でのボイドの発生を一層効果的に低減できる。
これにより、プリプレグ211および212の全面により一層均一に圧力をかけることができ、サンドイッチパネル100におけるボイドを効果的に抑制できる。
本実施形態の離型フィルム25は、例えば、ポリエチレンテレフタレート樹脂(PET)、ポリブチレンテレフタレート樹脂(PBT)、ポリトリメチレンテレフタレート樹脂(PTT)、ポリヘキサメチレンテレフタレート樹脂(PHT)等のポリアルキレンテレフタレート樹脂、ポリ4-メチル1-ペンテン樹脂(TPX)、シンジオタクチックポリスチレン樹脂(SPS)、およびポリプロピレン樹脂(PP)の中から選ばれる1種または2種以上を含むものであることが好ましい。なかでも、ポリ4-メチル1-ペンテン樹脂(TPX)、ポリプロピレン樹脂(PP)がより好ましい。
こうすることで、離型フィルムの使用後(加熱プレス後)における離型フィルムの凸凹からの剥離性を向上させることが可能である。すなわち、熱履歴を加えた後の貯蔵弾性率の値が上記数値範囲内となるように制御することで、離型フィルムの使用前後(加熱プレス前後)での離型フィルムの結晶化度の変動を大きくすることが可能となり、結果として、追従性を保持しつつ、離型性を向上させることが可能となる。また、プリプレグの一体化の際に適度な弾性が得られ、より一層均一に圧力をかけることができ、サンドイッチパネル100のボイドの発生を効果的に低減できる。
次に、準備した複合表面材40を用いて、コア層10と一体化する。
図3(a)に示すように、コア層10の上面側と下面側のそれぞれの開口面上に、複合表面材40を配置し、第2の加熱加圧処理により一括して積層化する。また、複合表面材40に加圧加熱処理を施すための、金属板30(上側を金属板31、下側を金属板32とする)を配置する。
また、第2の加熱加圧処理は、大気下で行うことができる。このため、生産性を向上させることができる。
また、金属板30の膜厚は、特に限定されないが、例えば、0.5mm以上10mm以下でもよく、0.8mm以上5mm以下でもよく、1.0mm以上2.0mm以下でもよい。このような範囲内とすることにより、剛性と熱伝導性のバランスを図ることができる。
[実施例1]
(複合表面材の製造)
フェノール樹脂(レゾール型フェノール樹脂、Durez社製「34370」)を配合し、ガラス繊維(#7781、HEXCEL社製)に含浸させて、シート状のプリプレグ(厚さ250μm)を得た。当該プリプレグはBステージ状態であった。
得られたプリプレグを2枚積層し、両面にSUS板(厚み:1.5mm、Rz:1.0μm)を押し当て、機械プレスを用い、2.0MPa、130℃、60分で加熱加圧(第1の加熱加圧処理)して、当該プリプレグ中のフェノール樹脂を硬化させて複合表面材を形成した。このとき、SUS板とプリプレグとの間に離型フィルム(ポリメチルペンテン:TPX(登録商標)フィルム、厚み120μm)を配置した。
ハニカムコア(アラミド繊維、厚み:10mm、HRH-10-1/8-3.0(HEXCEL社製)、面積:1m×3m)の両面に、ホットメルト系接着剤(主成分ポリアミド)を配置し、さらにその上に得られた複合表面材を配置して、積層体を得た。
続いて、得られた積層体の両面にSUS板(厚み:1.5mm、Rz:1.0μm)を押し当て、機械プレスを用い、0.7MPa、127℃、60分で加熱加圧(第2の加熱加圧処理)して、当該プリプレグを硬化させて樹脂板を形成した。その後、樹脂板から、SUS板を分離して、樹脂板、ハニカムコア、樹脂板からなるサンドイッチパネルを得た。
離型フィルムとして、「ポリメチルペンテン:TPX(登録商標)フィルム」を、「ポリプロピレンフィルム:トレファン(登録商標)、厚み100μm」に変更して使用した以外は、実施例1と同様にして、サンドイッチパネルを得た。
第1の加熱処理の2.0MPaを、0.7MPaに変更した以外は、実施例1と同様にして、サンドイッチパネルを得た。
SUS板とプリプレグとの間に離型フィルムは配置しなかった以外は、実施例1と同様にして、サンドイッチパネルを得た。
フェノール樹脂を配合し、ガラス繊維(#7781、HEXCEL社製)に含浸させて、シート状のプリプレグ(250μm)を得た。当該プリプレグはBステージ状態であった。
上記ハニカムコアの両面に得られたBステージ状態のプリプレグを配置して積層体とし、当該積層体を真空バッグに入れ、これをオートクレーブ内で、0.7MPa、127℃、60分の条件で一括に加熱硬化してサンドイッチパネルを得た。
上記のサンドイッチパネルについて、以下の評価を行った。評価結果を表1に示す。
得られたサンドイッチパネルの表面側となる面を拡大鏡(4倍)を用いて観察し、ピンホールの数を測定し、密度を算出した。
15 ホットメルト系接着層
20 プリプレグ
21 プリプレグ
22 プリプレグ
25 離型フィルム
30 金属板
31 金属板
32 金属板
40 複合表面材
100 サンドイッチパネル
211 プリプレグ
212 プリプレグ
Claims (15)
- シート状の複数のプリプレグを準備する工程と、
前記複数のプリプレグを積層した積層体の上下面に対し、離型フィルムを介して第1の加熱加圧処理を行い、前記積層体を一体化して複合表面材を得る工程と、
ハニカム構造を有するシート状のコア層の上面側と下面側のそれぞれの面上に前記複合表面材を配置し、第2の加熱加圧処理により一体化する工程と、
を含み、
前記第1の加熱加圧処理は、前記第2の加熱加圧処理よりも圧力が同等以上である、サンドイッチパネルの製造方法。 - 前記第1の加熱加圧処理は、110~140℃、0.5~3.0MPaである、請求項1に記載のサンドイッチパネルの製造方法。
- 前記コア層は、織物状の繊維クロスを含む、請求項1または2に記載のサンドイッチパネルの製造方法。
- 前記積層化する前記工程において、前記コア層と、前記複合表面材との間に、ホットメルト系接着剤を介在させる、請求項1乃至3いずれか一項に記載のサンドイッチパネルの製造方法。
- 前記ホットメルト系接着剤は、ポリアミドを主成分として含む、請求項4に記載のサンドイッチパネルの製造方法。
- 前記ホットメルト系接着剤は、不織布状、またはフィルム状である、請求項4または5に記載のサンドイッチパネルの製造方法。
- 前記離型フィルムは、180℃で120秒間の加熱処理を行った後に測定される貯蔵弾性率(周波数1Hz、100℃)が、0.05GPa以上10GPa以下である、請求項1乃至6いずれか一項に記載のサンドイッチパネルの製造方法。
- 前記離型フィルムは、ポリエチレンテレフタレート樹脂(PET)、ポリブチレンテレフタレート樹脂(PBT)、ポリトリメチレンテレフタレート樹脂(PTT)、ポリヘキサメチレンテレフタレート樹脂(PHT)等のポリアルキレンテレフタレート樹脂、ポリ4-メチル1-ペンテン樹脂(TPX)、シンジオタクチックポリスチレン樹脂(SPS)、およびポリプロピレン樹脂(PP)の中から選ばれる1種または2種以上を含む、請求項1乃至7いずれか一項に記載のサンドイッチパネルの製造方法。
- 前記プリプレグは、バインダー樹脂をプリプレグ用基材に含浸してなる、Bステージ状態のシート部材である、請求項1乃至8いずれか一項に記載のサンドイッチパネルの製造方法。
- 前記離型フィルムの厚みは、50μm以上150μm以下である、請求項1乃至9いずれか一項に記載のサンドイッチパネルの製造方法。
- ハニカム構造を有するコア層と、前記コア層の両面に設けられ、複数のプリプレグの硬化物が積層し一体化された複合表面材と、を備えるサンドイッチパネルであって、
前記複合表面材の最外面を観察したときのピンホールの数密度が0~50個/cm2である、サンドイッチパネル。 - 前記コア層は、織物状の繊維クロスを含む、請求項11に記載のサンドイッチパネル。
- 前記複合表面材と、前記コア層との間にそれぞれ接着層を備える、請求項11または12に記載のサンドイッチパネル。
- 前記プリプレグの硬化物のガラス転移温度が、110℃以上、250℃以下である、請求項11乃至13いずれか一項に記載のサンドイッチパネル。
- 航空機用パネルに用いられる、請求項11乃至14いずれか一項に記載のサンドイッチパネル。
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