WO2022080340A1 - 長尺発泡体シートの製造方法、複合材の製造方法、及び、長尺発泡体シート - Google Patents
長尺発泡体シートの製造方法、複合材の製造方法、及び、長尺発泡体シート Download PDFInfo
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- WO2022080340A1 WO2022080340A1 PCT/JP2021/037646 JP2021037646W WO2022080340A1 WO 2022080340 A1 WO2022080340 A1 WO 2022080340A1 JP 2021037646 W JP2021037646 W JP 2021037646W WO 2022080340 A1 WO2022080340 A1 WO 2022080340A1
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0221—Vinyl resin
- B32B2266/0235—Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0242—Acrylic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/025—Polyolefin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0264—Polyester
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0271—Epoxy resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0278—Polyurethane
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0285—Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/08—Closed cell foam
Definitions
- the present invention relates to a method for manufacturing a long foam sheet used for a material such as a composite material.
- Patent Document 1 describes a fiber-reinforced composite material laminate having a core portion containing a foamed resin and a surface layer portion having a thermosetting resin containing carbon fibers.
- Patent Document 2 describes that a rectangular foam is cut (sliced) using a cutting machine as a method for manufacturing a thermoplastic resin foam film laminated on an aluminum foil.
- Patent Document 3 describes a method for producing a foam sheet from a columnar foam block. In this method, a long and thin foam sheet is produced by continuously slicing a columnar foam block with a slicing blade in a manner of peeling the skin from the outer peripheral surface.
- foam sheets are manufactured in the form of thin sheets from the time of foam molding by an extrusion foaming method or the like, but many foam sheets are manufactured by cutting out from a foam block to a predetermined thickness. In this case, the foam sheet is inevitably in the form of a single leaf.
- the foamed film (foam sheet) produced by the method for producing a thermoplastic resin foamed film described in Patent Document 2 also has a sheet-like shape.
- the inventor of the present application has made an invention relating to a composite material having an island-like structure in which the core material layer is composed of a large number of plate-like pieces, and has filed a patent application (Japanese Patent Application No. 2020-24756).
- a method of obtaining a core material layer composed of a large number of plate-shaped pieces for example, there is a method of punching a foam sheet.
- the foam sheet is sheet-fed, it is difficult to continuously perform the punching process. Further, when the foam sheet is sheet-fed, continuous processing is difficult even when it is desired to continuously bond the foam sheet to a long roll material such as a metal film or a fiber reinforced resin.
- the inventor of the present application considered preparing a long foam sheet in order to realize continuous processing and improve productivity.
- the method for producing a long foam sheet described in Patent Document 3 it is necessary to mold the foam into a cylindrical shape.
- the material and thickness of the foam that can be processed and the accuracy thereof are extremely limited.
- the present invention has been made in view of such circumstances, and is capable of producing a long foam sheet with a highly accurate thickness without being limited to the material and thickness of the foam. It is an object of the present invention to provide a method for manufacturing a body sheet.
- a sheet pasting step of arranging and pasting a large number of foam sheets side by side on one side of a long base sheet is executed, and the base sheet is oriented in the length direction.
- This is a method for manufacturing a long foam sheet, which manufactures a long foam sheet in which a large number of foam sheets are connected.
- the slicing step of creating a foam sheet by slicing the foam block and the curling habit of the foam sheet created by the slicing step are described.
- the sheet stretching step of reducing is further executed, and in the sheet pasting step, the foam sheet whose winding habit is reduced by the sheet stretching step is pasted on the base sheet.
- a slicing step of creating a foam sheet by slicing a foam block and a foam sheet created by the slicing step are subject to inspection before the sheet pasting step. , At least one of the weight or thickness is inspected, and an inspection step of selecting a foam sheet that meets the sorting criteria is further executed. It will be pasted.
- the foam sheet is a hard foam sheet.
- a fifth invention comprises a cutting step of dividing a foam sheet constituting a long foam sheet manufactured by the production method of any one of the first to fourth inventions into a large number of plate-shaped pieces by a cutting process. It is a method for manufacturing a composite material, which comprises performing a laminating step of sandwiching a large number of plate-shaped pieces divided by a cutting step between a pair of sheets for a skin material to manufacture a composite material.
- the sheet connecting step of connecting the adjacent foam sheets on the base sheet by the connecting member is further executed after the sheet pasting step and before the cutting step.
- the seventh invention in the sixth invention, removes chips other than a large number of plate-shaped pieces from the foam sheet after cutting by winding.
- an intermediate sheet in which a large number of plate-shaped pieces are attached to the base sheet is prepared, and after the cutting step, the intermediate sheet is placed on the intermediate sheet.
- a transfer step of transferring a large number of plate-shaped pieces to one of a pair of skin material sheets is executed, and in the laminating step, a large number of plate-shaped pieces transferred from the other of the pair of skin material sheets by the transfer step. Stack on one piece.
- an intermediate sheet in which a large number of plate-shaped pieces are attached to the base sheet is produced, and in the laminating step, a pair of skin materials. Place the intermediate sheet between the sheets.
- a tenth invention is a long foaming process for producing a long foam sheet in which a large number of foam sheets are connected by executing a sheet connecting step of arranging a large number of foam sheets in a fixed direction and connecting them by a connecting member. This is a method for manufacturing a body sheet.
- the eleventh invention includes a long base sheet and a large number of foam sheets attached side by side in the length direction of the base sheet on one side of the base sheet, and is rolled into a roll. It is a long foam sheet.
- a long foam sheet is manufactured by arranging and pasting a large number of foam sheets on one side of a long base sheet.
- a long foam sheet with a high-precision thickness from a columnar foam block without being limited by the material and thickness of the foam, but a foam sheet having a short length is used. If there is, it is possible to prepare a large number of products manufactured with high precision thickness. Therefore, by arranging and pasting a large number of foam sheets side by side, it is possible to manufacture a long foam sheet with a highly accurate thickness without being limited by the material and thickness of the foam.
- 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 a slicing step of the first manufacturing step according to the embodiment.
- FIG. 6 is a schematic configuration diagram for explaining a sheet stretching step of the first manufacturing step according to the embodiment.
- FIG. 7 is a perspective view for explaining a sheet attaching step of the first manufacturing step 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 core material layer of the composite material according to the embodiment on the side where the
- FIG. 8 is a schematic configuration diagram of a production line used in the second production process according to the embodiment.
- FIG. 9 is a cross-sectional view for explaining a cutting step of the second manufacturing step according to the embodiment.
- FIG. 10 is a cross-sectional view for explaining the transfer step of the third manufacturing step according to the embodiment.
- FIG. 11 is a cross-sectional view for explaining a laminating step of the third manufacturing step according to the embodiment.
- FIG. 12 is a cross-sectional view of the composite material according to the embodiment when the gap is filled with the cured resin.
- FIG. 13 is a cross-sectional view of the laminated lumber in the process of manufacturing the composite lumber according to the first modification.
- FIG. 14 is a cross-sectional view for explaining a transfer process in the manufacturing process of the adhesive core material sheet according to the second modification.
- FIG. 15 is a cross-sectional view of the composite material manufacturing sheet according to the third modification.
- FIG. 16 is a cross-sectional view of the composite material according to the fourth modification.
- FIG. 17 is a perspective view of the composite material according to the fifth modification.
- FIG. 18 is a cross-sectional view of a cylindrical body using the composite material according to the fifth modification.
- FIG. 19 is a cross-sectional view for explaining how a notch is formed between adjacent plate-shaped pieces at the time of press cutting in the composite material according to another modification.
- FIG. 20 is a perspective view for explaining a sheet connecting step of the first manufacturing step with respect to a method of manufacturing a long foam sheet according to another modification.
- FIG. 21 is a diagram for explaining a slicing step of the first manufacturing step according to another modification.
- the present embodiment is a method for producing a composite material 30 to which the method for producing a long foam sheet (long foam film) 12 according to the present invention is applied.
- the structure of the composite material 30 and the structure of the transfer sheet 10 used for manufacturing the composite material 30 will be described, and then the method of manufacturing the composite material 30 will be described.
- 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 electric appliance, a medical device, or a panel material of 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 made of a material different from 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 is 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 each of the skin materials 31 and 32.
- 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 surface of each 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 core material layer 20 is at least 10 or more. In addition, this number may be 50 or more.
- a material having a lower density than the skin materials 31 and 32 can be used.
- a hard resin foam is used as the material of the plate-shaped piece 13.
- the density of the plate-shaped piece 13 is, for example, a value in the range of 30 kg / m 3 or more and 500 kg / m 3 or less.
- Examples of the hard resin foam used for the material of the plate-shaped piece 13 include polystyrene foam, polyvinyl chloride foam, cellulose acetate foam foam, polyurethane foam, phenol foam, epoxy foam, acrylic foam, and polymethacrylicimide.
- Examples thereof include foams, polypropylene foams, polyethylene terephthalate foams, polycarbonate foams, polyamideimide foams, and polyphenylene sulfide foams.
- a polymethacrylicimide (PMI) closed cell foam for example, "ROHACELL (registered trademark)" (EVONIC Industries AG)
- PMI polymethacrylicimide
- the planar shape (outer peripheral shape) of the plate-shaped piece 13 is a regular polygon (regular hexagon in this embodiment).
- a triangle, a quadrangle, a hexagon, or an isosceles pentagon can be selected.
- the planar shape of the plate-shaped piece 13 may be other than these shapes, and other polygons, circles, ellipses, or the like can be selected.
- the planar shape of the plate-shaped piece 13 may be chamfered at each corner when a polygon is used as the basic shape.
- 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 set to 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. 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.
- the adjacent plate-shaped pieces 13 face each other with a gap 16 on each side.
- the width W of the gap 16 varies depending on 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 each side 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.
- a large number of plate-shaped pieces 13 are regularly arranged. A large number of plate-shaped pieces 13 are evenly 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 13a and 13b parallel to the arrangement surface of each plate-shaped piece 13) 13a (lower surface in FIG. 2) is chamfered over the entire circumference.
- the portion 13c 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.
- plate-shaped pieces 13 for example, all plate-shaped pieces 13 of the core material layer 20
- the orientation of the cuts in the thickness direction is 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 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 an adhesive or adhesive surface).
- the transfer sheet 10 corresponds to an intermediate sheet.
- the "intermediate sheet (intermediate material)" refers to a sheet produced in an intermediate process in the manufacturing process of the composite material 30.
- the transfer sheet 10 includes a core material layer 20 and a base material sheet 11 on which the core material layer 20 is laminated.
- the base sheet 11 is created by cutting a long base sheet 11A, which will be described later.
- a cutting scratch (V-shaped groove) 43 when a large number of plate-shaped pieces 13 are cut remains (see FIG. 9).
- adjacent plate-shaped pieces 13 are separated by a gap 16.
- a chamfered portion 13c is formed on the outer periphery of the main surface 13a on the same side of each plate-shaped piece 13 in the thickness direction.
- 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.
- the main surface 13b on the side opposite to the main surface 13a on the chamfered portion 13c side is attached to the base sheet 11. 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 of 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 method for manufacturing the composite material 30 includes a first manufacturing step for manufacturing the foam roll 12, a second manufacturing step for manufacturing the transfer sheet 10 using the foam roll 12 obtained in the first manufacturing step, and a second manufacturing step.
- the third manufacturing step of manufacturing the composite material 30 using the transfer sheet 10 obtained in the manufacturing step is performed in this order.
- the foam roll 12 corresponds to a long foam sheet.
- the sheet pasting step of continuously arranging and pasting the (sheet-leaf foam sheet) 14 is executed in this order, and a large number of foam sheets 14 are arranged in a roll shape in the length direction of the base sheet 11A.
- the rolled foam roll 12 is manufactured.
- a sheet stretching step and an inspection step are performed between the slicing step and the sheet pasting step.
- "many" in “many foam sheets” means 5 or more.
- the number of foam sheets 14 in the foam roll 12 is at least 5 (when the foam block 35 having the dimensions described in the next paragraph is used, the length of the foam roll 12 is 5000 mm or more). In some cases, the number of sheets is 10 or more (the length of the foam roll 12 is 10000 mm or more).
- the foam block 35 and the base sheet 11A are prepared as materials, respectively.
- a substantially rectangular parallelepiped hard resin foam for example, a polymethacrylicimide (PMI) closed cell foam
- the dimensions of the foam block 35 are, for example, 2000 mm in length, 1000 mm in width, and 50 mm in thickness.
- the base sheet 11A is a long sheet wound in a roll shape.
- the base sheet 11A has a uniform thickness in the length direction, and the thickness is, for example, in the range of 0.01 mm or more and 0.5 mm or less.
- the width of the base sheet 11A needs to be equal to or larger than the width of the foam sheet 14, and is equal to the width of the foam sheet 14 in the present embodiment.
- the base material sheet 11A for example, a resin sheet or film (thermoplastic resin sheet or the like) is used.
- resin used for the base sheet 11 various resins such as polyethylene, polypropylene, urethane, polyester, polyethylene terephthalate (PET), and polycarbonate can be used.
- PET polyethylene terephthalate
- an acrylic, urethane, or silicone-based adhesive is applied to one surface of the base sheet 11A over the entire surface. That is, the long base sheet 11A is an adhesive tape (or a slightly adhesive tape).
- a separate sheet (not shown) is laminated on the back surface.
- a rubber or paper sheet (or film) may be used in addition to the resin sheet.
- the slicing step slicing is performed to cut the foam block 35 with a uniform thickness (value 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)).
- the foam block 35 is cut by the slicing blade 36 while moving at least one of the foam block 35 and the slicing blade 36 in a certain direction.
- cutting is performed while moving the foam block 35 out of the slicing blade 36 and the foam block 35.
- slicing is repeatedly performed on each of the plurality of foam blocks 35 to produce a large number of foam sheets 14 having the same thickness.
- the description of the member for fixing the slicing blade 36 is omitted.
- each foam sheet 14 obtained by slicing remains curled and curled in the sliced direction. Therefore, in the present embodiment, a sheet stretching step for reducing the winding habit of the foam sheet 14 is performed before the sheet pasting step. Further, usually, the density of the foam block 35 is not uniform, and there is a possibility that the weight may vary among a large number of foam sheets 14 produced in the slicing step. Further, since the foam block 35 also varies in hardness as the density varies, there is a possibility that the thickness also varies among a large number of foam sheets 14 produced in the slicing step. Therefore, in the present embodiment, an inspection step of selecting the foam sheet 14 by inspecting at least one of the weight and the thickness is performed before the sheet pasting step.
- Both the sheet stretching step and the inspection step may be omitted, or only one of them may be performed. Further, regarding the inspection process, only one of the weight and the thickness may be inspected. Further, in the order of the sheet stretching step and the inspection step, the sheet stretching step may be performed first, or the inspection step may be performed first. Further, a sheet stretching step may be performed between the weight inspection step and the thickness inspection step.
- the foam sheet 14 having a curl is put into the stretching device 55 shown in FIG. 6 one by one, and the foam sheet 14 is stretched.
- the stretching device 55 drives the belt 56 and conveys the foam sheet 14 inserted between the adjacent rollers 72 and 74 by the belt 56, while the belt 56 and the rollers 74 and the adjacent rollers 73, It is a device that stretches the foam sheet 14 by passing the foam sheet 14 between 74.
- some of the rollers 73 and 74 are thermal rollers, and the foam sheet 14 is heated by the rollers 73 and 74 so that the curl of the foam sheet 14 is effectively removed. There is.
- the stretching device 55 includes a plurality of rollers 71 to 74, a belt 56 composed of an endless belt, and a drive motor (not shown) that rotates at least one roller 71 to rotationally drive the belt 56. It is equipped with.
- the belt 56 is wound around a first roller 71 and a second roller 72 and a third roller 73 arranged apart from the first roller 71.
- the belt 56 has a traveling track recessed inward by a fourth roller 74 arranged between the second roller 72 and the third roller 73.
- the second roller 72, the third roller 73, and the fourth roller 74 are arranged next to each other with a gap in the vertical direction.
- the foam sheet 14 inserted between the second roller 72 and the fourth roller 74 is conveyed around the fourth roller 74 in a state of being sandwiched between the fourth roller 74 and the belt 56. It is further stretched, passed through the gap between the third roller 73 and the fourth roller 74, and is conveyed and stretched around the third roller 73. Then, the foam sheet 14 stretched substantially straight is conveyed to the first roller 71 side and picked up by the operator.
- the foam sheet 14 is inspected for weight and thickness, and the foam sheet 14 is selected.
- sorting criteria set for each of weight and thickness are used.
- the weight selection criterion is that the weight measurement value of the foam sheet 14 is included in the error range (for example, within ⁇ 10%) with respect to the design value of the weight.
- the thickness selection criterion is that the thickness measurement value of the foam sheet 14 is included in the error range (for example, ⁇ 10% range) with respect to the design value of the thickness.
- weight measurement and thickness measurement are performed on each foam sheet 14, foam sheet 14 that does not meet the selection criteria in either the weight measurement value or the thickness measurement value is excluded, and foam that meets both selection criteria. Only the body sheet 14 is sorted.
- the roll-shaped base material sheet 11A installed on the first reel 81 is unwound and wound around the second reel 82.
- the base sheet 11A moves between the two reels 81 and 82.
- the foam sheet 14 is stuck to the base sheet 11A between the two reels 81 and 82 while the base sheet 11A is stopped while repeatedly moving and stopping the base sheet 11A. I do.
- the sheet attaching step a plurality of foam sheets 14 are arranged and attached so as not to overlap each other without a gap (or with a slight gap) along the length direction of the base sheet 11A. Then, the base sheet 11A to which a large number of foam sheets 14 are attached is wound around the second reel 82, and the foam roll 12 is completed.
- a sheet connecting step of connecting the adjacent foam sheets 14 on the long base sheet 11A with the tape 85 may be further executed as in FIG. 20.
- the tape 85 corresponds to a connecting member and is attached along the seam of the adjacent foam sheets 14, and the adjacent foam sheets 14 are connected to each other.
- a cutting step of dividing each foam sheet 14 constituting the foam roll 12 into a large number of plate-shaped pieces 13 by a cutting process is executed.
- the transfer sheet 10 shown in FIG. 4 is manufactured by performing a punching process (press cut) on the foam sheet 14 in a state of being attached to the base sheet 11A.
- the foam roll 12 is installed on the reel 51 of the production line 50 shown in FIG. Then, the foam sheet 14 is unwound from the foam roll 12 together with the base sheet 11A in the longitudinal direction and passed through the press device 15 shown in FIG. 9A. Then, the foam sheet 14 on the lower die 22 of the press device 15 is press-cut by being vertically cut by the blade 24 of the upper die 23. At that time, as shown in FIG. 9B, the base sheet 11A is not cut, but is so-called half-cut (that is, cut to the extent that it does not penetrate). Chips 39 are formed between the blades 24 (see FIG. 9 (c)).
- a large number of plate-shaped pieces 13 are formed on the base sheet 11A to manufacture the transfer sheet 10.
- the 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.
- burrs may be formed on the outer periphery of the main surface 13a of each plate-shaped piece 13 instead of the chamfered portion 13c.
- the chips 39 other than the large number of plate-shaped pieces 13 are the net-like sheet 38.
- the mesh sheet 38 composed of the chips 39 is taken up by the take-up reel 25 and removed (see FIG. 8). Further, 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. Further, in the present embodiment, the long transfer sheet 10 is cut to a predetermined length by the cutter 28 and divided into a plurality of transfer sheets 10. It should be noted that winding by the take-up reel 25, coating by the protective film 27, and cutting by the cutter 28 may be omitted.
- 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).
- a transfer step of transferring a large number of plate-shaped pieces 13 on the transfer sheet 10 to the first skin material sheet 31A and a transfer step of transferring a large number of plate-shaped pieces 13 transferred by the transfer step to the second skin material The laminating step of laminating the sheets 32A to form 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 is executed in this order, and the composite material 30 is formed.
- 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 transfer step first, the first skin material sheet 31A is placed on the molding die (for example, the die) 33.
- the transfer sheet 10 obtained in the second manufacturing step is arranged with respect to the first skin material sheet 31A on the molding die 33 with the plate-shaped piece 13 facing. Will be done.
- FIG. 10B 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 second skin material sheet 32A is separated so as to face the plate-shaped piece 13 side of the laminated 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.
- the laminated material 30B obtained in the laminating step is sealed by using the bagging film.
- the laminated material 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 hardened into a predetermined shape in the case of FIG. 11B, a flat plate shape
- the 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 resin that has flowed in is cured in the gap 16. Therefore, the local decrease in strength of the composite material 30 is suppressed.
- 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 cured resin for example, a thermosetting type, a two-component reaction type, a moisture-reactive type adhesive, etc.
- a cured resin for example, a thermosetting type, a two-component reaction type, a moisture-reactive type adhesive, etc.
- the injected 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, when the laminated material 30B is heated, the film-like adhesive is melted, and the melted adhesive (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 is suppressed, and the rigidity is also improved.
- the filling of the cured resin can be performed even when the prepreg is not used as the material of the skin materials 31 and 32.
- the matrix of the prepreg 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 (for example, room temperature), and the composite material 30 is completed.
- the long foam sheet 12 is manufactured by arranging and pasting a large number of foam sheets 14 created by the slicing step on one side of the long base sheet 11A. As described above, it is possible to prepare a large number of foam sheets 14 having a substantially uniform thickness as long as the foam sheet 14 has a short length. Therefore, by attaching a large number of foam sheets 14 side by side, it is possible to manufacture a long foam sheet 12 having a substantially uniform thickness in the length direction.
- the foam sheet 14 since the curling habit of the foam sheet 14 is reduced by the sheet stretching step, the foam sheet 14 can be stuck at an accurate position in the sheet sticking step.
- the foam sheet 14 that satisfies the selection criteria for each of the weight and the weight is attached to the base sheet 11A by the inspection step, so that the foam sheet 14 layer of the long foam sheet 12 is formed.
- the weight and thickness in the length direction can be further made uniform.
- the chips 39 become the mesh sheet 38 and can be easily removed, the intermediate sheet 10 and the composite material 30 can be efficiently manufactured.
- a large number of plate-shaped pieces 13 in the core material layer 20 are arranged by using the transfer sheet 10. Therefore, it is not necessary to arrange a large number of plate-shaped pieces 13 individually, and the core material layer 20 can be easily formed.
- the laminated material 30B shown in FIG. 13 is manufactured by sandwiching the intermediate sheet 10 as it is between a pair of skin material sheets 31A and 32A in the laminating step without executing the transfer step.
- the intermediate sheet 10 is used as an adhesive core sheet in which the base sheet 11 is melted.
- an adhesive is used so that each plate-shaped piece 13 can be peeled off from the base sheet 11, but when used as an adhesive core sheet, the base sheet 11 is used.
- an adhesive is used to attach the foam sheet 14 to the foam sheet 14.
- the intermediate sheet 10 and the second skin material sheet 32A are laminated in this order on the first skin material sheet 31A on the molding die 33.
- the plate-shaped piece 13 side may be attached to the first skin material sheet 31A.
- the base sheet 11 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 in the above-described embodiment, the description thereof will be omitted.
- a resin sheet for example, a sheet-like adhesive, a prepreg, etc.
- a plurality of intermediate sheets 10 may be used as the adhesive core sheet for manufacturing one composite material 30.
- the sheet-like adhesive 111 is attached to the plate-like piece 13 side of the transfer sheet 10 (first intermediate sheet).
- a separate sheet 141 is laminated on the back surface thereof.
- the base sheet 11 is peeled off from the large number of plate-shaped pieces 13 to transfer the large number of plate-shaped pieces 13 to the sheet-shaped adhesive 111 as the second intermediate sheet.
- the adhesive core sheet 60 is manufactured.
- the laminated material 30B is manufactured by sandwiching the adhesive core material sheet 60 between the pair of skin material sheets 31A and 32A, similarly to the adhesive core material sheet 10 of the first modification. ..
- ⁇ Third modification example> In this modification, in the transfer step, a large number of plate-shaped pieces 13 on the transfer sheet (first intermediate sheet) 10 are transferred to the prepreg 31A, and the composite material manufacturing sheet (second intermediate sheet) 70 shown in FIG. 15 is transferred. Is manufactured. That is, in the second intermediate sheet, the semi-cured prepreg 31A is used instead of the sheet-like adhesive 111 of the second modification. As the prepreg 31A, a prepreg 31A having a separate sheet 141 laminated on the back surface can be used. The prepreg 31A corresponds to a sheet for a skin material. Then, in the laminating step, the composite material manufacturing sheet 70 is installed on the mold with the prepreg 31A on the lower side, and the prepreg 31B corresponding to the skin material sheet is laminated from the upper side.
- 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. Further, an intermediate adhesive layer 17 arranged between the layer 20 and the second core material layer 21 is provided.
- the intermediate adhesive layer 17 is configured by using a sheet-like adhesive (also referred to as a film-like adhesive or an adhesive sheet) that is melted by heating and thermally cured as it is, and the first core material layer 20 and the second core material layer 21 are formed. Glue.
- the first core material layer 20 and the intermediate adhesive layer 17 are integrated with the first skin material sheet 31A on the mold. It can be manufactured by a procedure in which a large number of plate-shaped pieces 13 are transferred from the transfer sheet 10 to the intermediate adhesive layer 17 after laminating the adhesive core material sheets, and further laminating the second skin material sheet 32A. Further, the composite material manufacturing sheet 70 of the third modification is installed on the mold with the prepreg 31A facing down, and the adhesive core sheet 10 and the prepreg 32A of the first modification are laminated in order from above. It can also be manufactured by the procedure of.
- the core material layers 20 and 21 are made into two layers in this modification, the core material layers 20 and 21 may be made into three or more layers. Also in this case, the intermediate adhesive layer 17 is provided between the core material layers 20 and 21 adjacent to each other in the thickness direction. Further, a prepreg or a thermosetting resin sheet (epoxy resin or the like) may be used for the intermediate adhesive layer 17 without using a sheet-like adhesive.
- a prepreg or a thermosetting resin sheet epoxy resin or the like
- the plate-shaped piece 13 has a two-layer structure in the core material layer 20.
- 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 having a single-layer structure. Therefore, the tensile strain generated on one side of each plate-shaped piece 13 becomes small, and even when a low toughness hard resin foam is used for the plate-shaped piece 13, damage is unlikely to occur. According to this modification, it is possible to provide a composite material 30 having excellent formability into a three-dimensional shape.
- 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 the adjacent plate-shaped pieces 13. Although the plate-shaped piece 13 is not divided in the length direction in FIG. 17, the plate-shaped piece 13 may be divided in the length direction.
- the foam sheet 14 in a state of being attached to the base sheet 11A is punched (press cut), so that the strip-shaped plate-shaped pieces 13 are formed on the base sheet 11A.
- a transfer sheet (not shown) in which is arranged in a certain direction is manufactured. Then, in the transfer step, a large number of plate-shaped pieces 13 on the transfer sheet are transferred to the skin material sheet 31A such as a prepreg.
- the cylindrical body 100 can be manufactured by winding the composite material 131 in a cylindrical shape.
- the cylindrical body 100 shown in FIG. 18 is obtained.
- the core material layer 20 is 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 (one sticking point to the outer skin material 31).
- the other end 31a 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 31a is used as a sticking allowance on the outer peripheral surface (a place to be stuck to the inner skin material 31). Become. On the innermost side, the end portion 31a of the skin material 31 is laminated so as to cover the plurality of plate-shaped pieces 13.
- the foam sheet 14 may be cut into a large number of plate-shaped pieces 13 by laser cutting instead of press cutting. Further, the foam sheet 14 may be cut 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.
- 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 blade 24 having a regular hexagonal arrangement pattern is used.
- FIG. 19 (c) when the blade 24 is pulled out, the plate-shaped piece 13 elastically deformed in the state of FIG. 19 (b) is restored, and between the adjacent plate-shaped pieces 13. A notch 40 remains in.
- the long base sheet 11 is used for manufacturing the long foam sheet, but the base sheet 11 may be omitted. That is, in the method for manufacturing a long foam sheet, a sheet connecting step of arranging a large number of foam sheets 14 in a certain direction and connecting them with a connecting member (tape) 85 is executed, and a large number of foam sheets 14 are connected. A long foam sheet may be manufactured (see FIG. 20).
- the inner portion of the blade 24 used for punching is used as the core material to form the core material layer 20 having an island-like structure.
- the inner portion of the 24 may be used as chips, and the outer portion of the blade 24 may be used as the core material.
- a full cut is performed in which both the foam sheet 14 and the base sheet 11 are cut in the thickness direction by the blade 24.
- the core material layer 20 has a structure in which a large number of chambers (chambers having a planar shape of the blade 24) are formed, and when the planar shape of the blade 24 is a regular hexagon, it has a honeycomb structure.
- the slicing process may be applied as the slicing process in the slicing process.
- the foam block 35 is passed through the straight portion of the rotating endless thin band knife 80 in the width direction of the band knife 80 to block the foam block. 35 is sliced to make a foam sheet 14.
- the foam block 35 may be fed to the band knife 80 by the roller 81, or as shown in FIG. 21 (c), the table 82 on which the foam block 14 is placed is placed. May be moved to feed the foam block 35 to the band knife 80.
- the foam sheet 14 has almost no curl, so that the sheet stretching step may be omitted.
- 21 (a) is a perspective view
- FIGS. 21 (b) and 21 (c) are cross-sectional views. Further, in FIG. 21A, the description of the pulley or the like for rotating the band knife 80 is omitted.
- a metal-based material may be used as the material of the skin materials 31 and 32.
- each plate-shaped piece 13 is joined to the skin materials 31 and 32 by an adhesive.
- the hard resin foam is used as the material of the plate-shaped piece 13, but when the slicing step is performed, any foam that can form the foam block 35 into a substantially rectangular shape by foam molding is suitable.
- a type of foam other than the hard resin foam may be used. Further, even when the slicing process is not performed, a foam of a type other than the hard resin foam may be used.
- 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 at the portion of the composite material 30 may be determined according to the curvature of the portion.
- 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 having a canaoutheastern structure does not form a central layer unlike the sandwich structure, but forms a central layer between the first skin material 31 and the structural material to be reinforced after being attached to the reinforcement target. ..
- the present invention is applicable to a method for manufacturing a long foam sheet used for a material such as a composite material.
- Transfer sheet (intermediate sheet) 11 Base material sheet 11A Long base material sheet 12 Foam roll (long foam sheet) 13 Plate-shaped piece 14 Foam sheet 20 Core material layer 30 Composite material 31, 32 Outer skin material 31A, 32A Outer skin material sheet 35 Foam block 36 Slicing blade
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Abstract
Description
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。
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。転写シート10は、中間シートに相当する。なお、本明細書で、「中間シート(中間材)」は、複合材30の製造過程における中間工程で作成されるシートのことをいう。
複合材30の製造方法は、発泡体ロール12を製造する第1製造工程と、第1製造工程で得られた発泡体ロール12を用いて転写シート10を製造する第2製造工程と、第2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3製造工程とを、この順番で行う。なお、発泡体ロール12は長尺発泡体シートに相当する。
本実施形態では、スライス工程により作成された多数の発泡体シート14を長尺の基材シート11Aの片面上に並べて貼り付けることにより、長尺発泡体シート12が製造される。上述したように、長さが短い発泡体シート14であれば、厚さが略均一のものを多数準備することは可能である。そのため、多数の発泡体シート14を並べて貼り付けることにより、厚さが長さ方向において略均一の長尺発泡体シート12を製造することができる。
本変形例では、転写工程を実行せずに、積層工程において一対の表皮材用シート31A,32Aの間に中間シート10をそのままを挟むことで、図13に示す積層材30Bを製造する。この場合、中間シート10は、基材シート11が溶解される接着用芯材シートとして用いられる。なお、中間シート10を転写シートとして用いる場合は、基材シート11から各板状片13が剥離可能となるように粘着剤を用いるが、接着用芯材シートとして用いる場合は、基材シート11に対する発泡体シート14の貼り付けに、粘着剤だけでなく接着剤を用いることもできる。
本変形例では、転写工程において、転写シート10上の多数の板状片13を第1表皮材用シート31Aに転写するのではなく、シート状接着剤111に転写する。
本変形例では、転写工程において、転写シート(第1中間シート)10上の多数の板状片13がプリプレグ31Aに転写されて、図15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。つまり、第2中間シートにおいて、第2変形例のシート状接着剤111の代わりに、半硬化状態のプリプレグ31Aが用いられる。プリプレグ31Aには、裏面にセパレートシート141が積層されたもの用いることができる。プリプレグ31Aは、表皮材用シートに相当する。そして、積層工程では、プリプレグ31Aを下側にして複合材製造用シート70が、金型上に設置されて、上側から、表皮材用シートに相当するプリプレグ31Bが積層される。
本変形例では、図16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、加熱により溶解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)を用いて構成され、第1芯材層20と第2芯材層21を接着する。
本変形例では、図17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17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。
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発泡体シート14を切断して多数の板状片13に分割してもよい。また、切断する形状に沿って刃を動かす切断装置(カッティングプロッター)を用いて、発泡体シート14を切断して多数の板状片13に分割してもよい。
11 基材シート
11A 長尺の基材シート
12 発泡体ロール(長尺発泡体シート)
13 板状片
14 発泡体シート
20 芯材層
30 複合材
31,32 表皮材
31A,32A 表皮材用シート
35 発泡体ブロック
36 スライス用刃物
Claims (11)
- 長尺の基材シートの片面上に、多数の発泡体シートを並べて貼り付けるシート貼付工程を実行して、
前記基材シートの長さ方向に前記多数の発泡体シートが連なった長尺発泡体シートを製造する、長尺発泡体シートの製造方法。 - 前記シート貼付工程前に、発泡体ブロックをスライス加工することにより発泡体シートを作成するスライス工程と、前記スライス工程により作成された発泡体シートの巻き癖を低減するシート延伸工程とをさらに実行し、
前記シート貼付工程では、前記シート延伸工程により巻き癖が低減された発泡体シートが、前記基材シートに貼り付けられる、請求項1に記載の長尺発泡体シートの製造方法。 - 前記シート貼付工程前に、発泡体ブロックをスライス加工することにより発泡体シートを作成するスライス工程と、前記スライス工程により作成された発泡体シートを検査対象として、重量又は厚みの少なくとも一方の検査を行い、選別基準を満たす発泡体シートを選別する検査工程とをさらに実行し
前記シート貼付工程では、前記検査工程において前記選別基準を満たす発泡体シートが、前記基材シートに貼り付けられる、請求項1に記載の長尺発泡体シートの製造方法。 - 前記発泡体シートは、硬質発泡体のシートである、請求項1乃至3の何れか1つに記載の長尺発泡体シートの製造方法。
- 請求項1乃至4の何れか1つに記載の製造方法により製造された長尺発泡体シートを構成する発泡体シートを、切断加工により多数の板状片に分割する切断工程と、
前記切断工程により分割された前記多数の板状片を、一対の表皮材用シートの間に挟む積層工程とを実行して、
複合材を製造する、複合材の製造方法。 - 前記シート貼付工程後で前記切断工程前に、前記基材シート上において隣り合う発泡体シートを連結部材により連結するシート連結工程をさらに実行する、請求項5に記載の複合材の製造方法。
- 前記切断加工後の前記発泡体シートのうち、前記多数の板状片以外の切り屑を、巻き取りにより除去する、請求項6に記載の複合材の製造方法。
- 前記切断工程では、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が作成され、
前記切断工程後に、前記中間シート上の多数の板状片を、前記一対の表皮材用シートのうち一方に転写する転写工程を実行し、
前記積層工程では、前記一対の表皮材用シートのうち他方を、前記転写工程により転写された前記多数の板状片に積層する、請求項5乃至7の何れか1つに記載の複合材の製造方法。 - 前記切断工程では、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が作成され、
前記積層工程では、前記一対の表皮材用シートの間に前記中間シートを挟む、請求項5乃至7の何れか1つに記載の複合材の製造方法。 - 一定方向に多数の発泡体シートを並べながら連結部材により連結するシート連結工程を実行して、
前記多数の発泡体シートが連なった長尺発泡体シートを製造する、長尺発泡体シートの製造方法。 - 長尺の基材シートと、
前記基材シートの片面上に、前記基材シートの長さ方向に並べて貼り付けられた多数の発泡体シートとを備え、
ロール状に巻かれた長尺発泡体シート。
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP21880079.5A EP4230391A1 (en) | 2020-10-15 | 2021-10-12 | Method for manufacturing long foam sheet, method for manufacturing composite material, and long foam sheet |
CN202180044472.5A CN115996834A (zh) | 2020-10-15 | 2021-10-12 | 长条发泡体片材的制造方法、复合材料的制造方法及长条发泡体片材 |
KR1020227045215A KR20230015442A (ko) | 2020-10-15 | 2021-10-12 | 긴 발포체시트의 제조방법, 복합재의 제조방법 및 긴 발포체시트 |
JP2022556982A JPWO2022080340A1 (ja) | 2020-10-15 | 2021-10-12 | |
US18/087,847 US20230127339A1 (en) | 2020-10-15 | 2022-12-23 | Method of manufacturing elongated foam sheet, method of manufacturing composite material and elongated foam sheet |
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US18/087,847 Continuation US20230127339A1 (en) | 2020-10-15 | 2022-12-23 | Method of manufacturing elongated foam sheet, method of manufacturing composite material and elongated foam sheet |
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JPS564449A (en) * | 1979-06-25 | 1981-01-17 | Ikuta Kogei:Kk | Preparation of sheet containing elastic body |
JPS6319235A (ja) | 1986-07-14 | 1988-01-27 | Sanpuku Kogyo Kk | 発泡体シ−トの製造方法 |
JPH0298008A (ja) * | 1988-10-03 | 1990-04-10 | Kyodo Giken Kagaku Kk | 導電性テープ状シール材の製造方法 |
JPH07150122A (ja) * | 1993-11-30 | 1995-06-13 | Sekisui Chem Co Ltd | 中継ぎ用テープ及び発泡体の積層構造 |
JP2001171006A (ja) * | 1999-12-16 | 2001-06-26 | Bridgestone Corp | シートの接合方法 |
JP2005084606A (ja) * | 2003-09-11 | 2005-03-31 | Mitsui & Co Ltd | 吸音シート |
WO2010047274A1 (ja) | 2008-10-23 | 2010-04-29 | 株式会社カネカ | 熱可塑性樹脂発泡フィルムの製造方法及び熱可塑性樹脂発泡フィルム |
WO2014017528A1 (ja) * | 2012-07-26 | 2014-01-30 | 株式会社カネカ | 熱可塑性樹脂発泡フィルム及びその製造方法 |
US20180194917A1 (en) * | 2015-12-23 | 2018-07-12 | Sabic Global Technologies, B.V. | Reinforced foam structure, and associated method of forming, and article |
JP2019006037A (ja) | 2017-06-27 | 2019-01-17 | 日産自動車株式会社 | 繊維強化複合材料積層体 |
JP2020024756A (ja) | 2019-11-14 | 2020-02-13 | 株式会社ワコム | 方法、プログラム、及びコンピュータ |
-
2021
- 2021-10-12 KR KR1020227045215A patent/KR20230015442A/ko unknown
- 2021-10-12 WO PCT/JP2021/037646 patent/WO2022080340A1/ja unknown
- 2021-10-12 CN CN202180044472.5A patent/CN115996834A/zh active Pending
- 2021-10-12 JP JP2022556982A patent/JPWO2022080340A1/ja active Pending
- 2021-10-12 EP EP21880079.5A patent/EP4230391A1/en active Pending
-
2022
- 2022-12-23 US US18/087,847 patent/US20230127339A1/en active Pending
Patent Citations (11)
Publication number | Priority date | Publication date | Assignee | Title |
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JPS564449A (en) * | 1979-06-25 | 1981-01-17 | Ikuta Kogei:Kk | Preparation of sheet containing elastic body |
JPS6319235A (ja) | 1986-07-14 | 1988-01-27 | Sanpuku Kogyo Kk | 発泡体シ−トの製造方法 |
JPH0298008A (ja) * | 1988-10-03 | 1990-04-10 | Kyodo Giken Kagaku Kk | 導電性テープ状シール材の製造方法 |
JPH07150122A (ja) * | 1993-11-30 | 1995-06-13 | Sekisui Chem Co Ltd | 中継ぎ用テープ及び発泡体の積層構造 |
JP2001171006A (ja) * | 1999-12-16 | 2001-06-26 | Bridgestone Corp | シートの接合方法 |
JP2005084606A (ja) * | 2003-09-11 | 2005-03-31 | Mitsui & Co Ltd | 吸音シート |
WO2010047274A1 (ja) | 2008-10-23 | 2010-04-29 | 株式会社カネカ | 熱可塑性樹脂発泡フィルムの製造方法及び熱可塑性樹脂発泡フィルム |
WO2014017528A1 (ja) * | 2012-07-26 | 2014-01-30 | 株式会社カネカ | 熱可塑性樹脂発泡フィルム及びその製造方法 |
US20180194917A1 (en) * | 2015-12-23 | 2018-07-12 | Sabic Global Technologies, B.V. | Reinforced foam structure, and associated method of forming, and article |
JP2019006037A (ja) | 2017-06-27 | 2019-01-17 | 日産自動車株式会社 | 繊維強化複合材料積層体 |
JP2020024756A (ja) | 2019-11-14 | 2020-02-13 | 株式会社ワコム | 方法、プログラム、及びコンピュータ |
Also Published As
Publication number | Publication date |
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US20230127339A1 (en) | 2023-04-27 |
JPWO2022080340A1 (ja) | 2022-04-21 |
KR20230015442A (ko) | 2023-01-31 |
CN115996834A (zh) | 2023-04-21 |
EP4230391A1 (en) | 2023-08-23 |
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