JP4070290B2 - Panel manufacturing method filled with foamed resin and panel manufacturing apparatus - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a manufacturing method and a manufacturing apparatus for a high-strength honeycomb panel using a core material (core) filled with foamed resin.
[0002]
[Prior art]
A honeycomb panel in which a surface material is bonded to both sides of a honeycomb core (honeycomb-shaped hollow core material) made of aluminum alloy foil, aramid fiber, kraft paper, or the like is lightweight and rigid, and thus is used in various applications.
Although depending on the purpose of use, the physical properties generally required for honeycomb panels include the following items.
1. 1. Bending and compressive strength 2. Adhesive strength Fire resistance4. Durability 5. 5. Moisture and water resistance Impact resistance Since it is difficult to have all of these characteristics in one type of honeycomb panel, depending on the application, the choice of surface material, core material (core), adhesive material, or panel thickness The physical requirements according to the application are achieved by adjusting the dimensions and the like. For example, when a bending moment is applied to the honeycomb panel, a compressive stress and a tensile stress are generated on the front and back surface materials, respectively, and a shear stress is generated on the core material, so that the front and back forces cancel each other and balance each other.
In such a state, since the adhesion between the surface material and the core material has an important significance, a strong adhesive strength is required.
[0003]
On the other hand, when water or moisture enters and accumulates in the hollow portion of the core material, there arises a problem that the core material is corroded by moisture. Or the adhesive which adhere | attached the core material and the surface material absorbed water, the adhesive strength fell, and it resulted in impairing the durability of a honeycomb panel.
Therefore, as a method of solving the problem of moisture (moisture) permeation into the hexagonal columnar or cylindrical hollow portion of the core material, the core material of water is filled with a foam resin having a low specific gravity in the hollow portion of the core material. And a method of preventing contact with the adhesive.
The honeycomb panel filled with the foamed resin has improved durability due to the filling of the foamed resin, and air convection inside the honeycomb core (core material) is eliminated, so that a heat insulating property is imparted to the panel.
Filling with foamed resin causes an increase in the weight of the panel, so use in aircraft is avoided.However, except for these special applications, the foamed resin-filled honeycomb panel ensures durability, so it can be used as a structural panel. in use. However, at present, the price is high, and there is a demand for lower prices.
On the other hand, there is a panel that uses foamed resin itself as a core material instead of a honeycomb core to solve economic problems, but it is not suitable for structural use due to the low shear rigidity of foamed resin, and used as a heat insulation panel It has been stopped.
[0004]
Here, a conventional method for manufacturing a honeycomb panel filled with foamed resin will be described.
Example of conventional manufacturing method
Method to make the filling resin also have the adhesive function of the surface material (see Fig. 10)
A resin layer 6 coated with unfoamed foamed resin powder is laminated as a surface material. Alternatively, a glass fiber nonwoven fabric 5 impregnated with resin is used. (Refer to a)
A nonwoven fabric 5 having a resin layer 6 is laminated on the front and back surfaces of the core material 3 and heated / pressurized by hot pressing. (Refer to b)
In this manufacturing method, the resin is foamed by heating, and at the same time, the nonwoven fabric 5 and the core material 3 are bonded by pressing to form a surface material.
Although this honeycomb panel is low in price, its use as a high-strength panel is limited because the adhesive strength between the core material 3 and the foamed resin 6 'is low.
In order to increase the adhesive strength, the expansion ratio of the foamed resin is also suppressed, but in this case, the weight of the panel is increased and the purpose of reducing the weight is not achieved.
[0005]
Conventional manufacturing method example 2
A method of peeling the attached surface material and applying a new surface material (see Fig. 11)
In this manufacturing method, the surface material 5 is mechanically peeled off (see c) after the step (see a and b) of bonding the surface materials 5 and 6 to the core material 3 by the manufacturing method shown in the manufacturing method example 1. At this time, the foamed resin 6 ′ filled in the end portion of the core material 3 is also removed together. Next, a new surface material 7 is bonded by a high strength adhesive 8.
Since this honeycomb panel can select the adhesive 8 irrespective of the foamed resin 6 ', a high-strength panel suitable for the structure can be manufactured. However, it is difficult to completely remove the foamed resin 6 ′ adhering to the end portion of the core material 3, and a fillet (adhesive is used as the core material) that secures adhesive strength when the new surface material 7 and the core material 3 are bonded. The problem is that the formation of the portion that swells along the line is uncertain, the desired adhesive strength cannot be obtained, and the bonding process is twice, which is not economical.
[0006]
2. Conventional manufacturing method example 3
Method of bonding surface materials one side at a time (see Fig. 12)
First, the surface material 5 is bonded to one side of the core material 3 (see a). A powdered foamed resin 6 ′ that foams in the bonding step is placed in the hollow portion of the core material 3 (see b). Thereafter, the other surface material 5 is bonded (see c).
Honeycomb panels by this method can ensure strength and heat insulation, but the problem is that the surface panels have different adhesive strengths, and the finished panel tends to warp, and the bonding process is twice, which is not economical. Met.
As described above, there are various methods for manufacturing a honeycomb panel filled with a foamed resin, but there is no method that satisfies all of the strength, weight, and cost.
[0007]
[Problems to be solved by the invention]
The problem to be solved by the present invention is to economically provide a high-strength honeycomb panel filled with foamed resin.
[0008]
[Means for Solving the Problems]
In the method for manufacturing a honeycomb panel of the present invention, two layers of an adhesive for adhering a surface material and a core material and a foamed resin having different thermal reaction temperatures are laminated in the order of the foamed resin layer, the adhesive layer, and the surface material, and then added by a press. After pressurization, the heating temperature is raised stepwise to first start melting / curing the adhesive layer of the surface material and the core material, and then foam the foamed resin to fill the space.
Further, by forming the adhesive layer and the foamed resin layer in a film shape, having you laminate constituting the adhesive layer of the film body to face the surface material between the core material and surface material in the lamination process.
The surface material is formed by applying or impregnating an adhesive that reacts at a predetermined temperature, and has a structure in which a foamed resin having a foaming temperature higher than the thermal reaction temperature of the adhesive is laminated on the surface material. Yes.
The method Oite the adhesion of the surface material and core material, the formation of the fillet can be reliably.
[0009]
The honeycomb panel manufacturing apparatus of the present invention includes a stacking means for stacking a surface material having a foamed resin layer and an adhesive layer on the upper and lower surfaces of the core material with the foamed resin layer facing the core material, and the surface material. A heating / pressurizing unit that holds and heats and presses the core material, and a heating temperature control unit that controls the heating temperature of the heating / pressurizing unit. The heating temperature control unit includes at least a reaction temperature and foaming at which the adhesive layer reacts. The structure which controls the temperature which a resin layer foams is comprised .
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of a method for manufacturing a honeycomb panel according to the present invention will be described with reference to the drawings.
The honeycomb panel 10 is formed by adhering a surface material 50 to both surfaces of a core material 30 via a two-layer film 40.
The surface material 50 uses a sheet-like aluminum alloy.
The core material 30 is a hexagonal cylindrical (honeycomb) core material made of an aluminum alloy foil material.
As shown in FIG. 4 (a), the core 30 has a honeycomb core that continuously forms a hexagonal cross section, or a roll core that continuously forms a round cross section cylinder as shown in (b). is there.
The two-layer resin film 40 is formed into a sheet by laminating an epoxy resin adhesive layer 42 having a glass fiber carrier 41 and a foamed phenol layer 44. ...... See Figure 3 [0011]
A process for forming the high-strength honeycomb panel 10 using these materials will be described. ...... Refer to FIG. 1 First step. (A)
The epoxy resin adhesive layer 42 of the two-layer resin film 40 is superimposed on both surfaces of the core material 30 so as to face the surface material 50.
Second step. (B)
The laminated material obtained by laminating the core material 30, the two-layer resin film 40 and the surface material 50 is applied to a press device and is pressure-bonded by a press at a normal temperature. The foamed phenol layer 44 pressed against the core material 30 is destroyed, and the core material 30 bites into the epoxy adhesive layer 42 and is pressed. In this state, the temperature of the press is raised to 125 ° C. The epoxy resin adhesive layer 42 melts at a temperature of about 125 ° C. Then, curing is started after a predetermined time.
[0012]
Third step. (C)
The temperature of the press is further raised to 180 ° C. and heated.
At this temperature, the foamed resin of the foamed phenol layer 44 is foamed. The foamed resin fills the space of the core material 30 and forms the foam layer 440.
The temperature of 180 ° C. is maintained for 20 minutes.
During this time, curing of the epoxy resin adhesive layer 42 is completed.
The panel 10 is removed from the press device by cooling to 150 ° C., and is vertically stood to cool to room temperature to complete.
[0013]
In this example, an epoxy resin is used as an adhesive between the surface material and the core material, but a resin having high adhesive strength such as a phenol resin or a nylon resin may be used.
Although the example of the phenol resin was shown as foamed resin, you may use a urethane resin and a styrene resin.
As the surface material, in addition to the aluminum alloy sheet, a woven fabric of carbon fiber or glass fiber is used. As the core material, a material such as aramid fiber paper, non-combustible paper (inorganic paper), craft paper or the like formed into a hexagonal cylindrical shape or a cylindrical shape is used.
[0014]
A strength test of the honeycomb panel formed by the above manufacturing method was performed.
As a result of the test, a panel using a high-strength, thin-walled aluminum alloy honeycomb core as the core material showed particularly high strength. This is because the end of the core material (core) of the thin aluminum alloy is sharp, and the degree of biting into the adhesive layer is strong in the second step, and it adheres to the end of the core material 30 as shown in FIG. The fillet 420 in which the agent 42 swells is reliably formed. For this reason, it is considered that the adhesive strength increases, the formation of the foamed resin layer 440 at the end of the core is eliminated, and the surface material 50 and the core material 30 are directly bonded.
The adhesive strength between the core material and the adhesive layer is a means to increase the biting into the adhesive layer by increasing the roughness of the saw blade used for cutting (slicing) the core material and increasing the unevenness of the end surface of the core material Can also be used. Also in this case, the adhesive strength can be increased by eliminating the influence of the foamed resin at the bonding portion between the core material and the surface material.
In addition, as shown in FIG. 6, sharp irregularities or cuts 45 are provided in advance in the foamed resin material layer 44. A method of biting the end of the core material into the notch 45 is also effective.
[0015]
The press apparatus which implements the manufacturing method of this form is demonstrated.
<Example 1>
A device that manufactures panels one by one by controlling the heating temperature using a single press.
FIG. 2 shows the temperature control of the press device in this case.
In the first step, each member is laminated at room temperature. The temperature is raised to 125 ° C. at the start time t ₁ of the second step. After a predetermined time for the adhesive resin to melt, the temperature is raised to 180 ° C. from time t ₂ . In the third step, the temperature is maintained at 180 ° C. for about 20 minutes until time t ₃ when the foamed resin is foamed and filling into the core material is completed. And heating is complete | finished and it is set as natural cooling.
[0016]
<Example 2>
This press machine has three press machines: a normal temperature press machine 71 that sets the set temperature to room temperature, an intermediate temperature press machine 73 that sets the set temperature to 125 ° C, and a high temperature press machine 75 that sets the set temperature to 180 ° C. Set up. Then, a single panel is sequentially passed through the room temperature press machine 71, the medium temperature press machine 73, and the high temperature press machine 75 in order, and the material is pressed by the room temperature press machine 71, and then heated / pressurized by the medium temperature press machine 73. Adhesion between the core material and the core material is allowed to proceed, and further, heating / pressurization is performed by a high-temperature press machine 73 to foam and fill the core material with foamed resin.
This press machine produces honeycomb panels filled with foamed resin one by one.
[0017]
<Example 3>
The press device 80 includes a room temperature press table 81 having a set temperature of room temperature, a medium temperature press table 83 having a set temperature of 125 ° C., and a high temperature press table 85 having a set temperature of 180 ° C. arranged in series.
A surface material 50 in which a two-layer resin film 40 wound in a roll is laminated is placed on the upper and lower surfaces of the core material 30, and the surface material 50 in which the two-layer resin film 40 is laminated is wound according to the progress of the core material 30. It is polymerized to the core material 30 while solving. The core material 30 on which the surface material 50 is laminated is moved intermittently according to the distance between the press bases 81, 83, 85. First, the laminated body is pressed by the room temperature press stand 81 and the end portion of the core material 30 bites into the adhesive layer. In this state, the press is released, and the core material 30 on which the surface material 50 is laminated is moved by a predetermined distance. At the intermediate temperature press stand 83 position, the adhesive layer melts, and the core material 30 and the surface material 50 adhere. The intermediate temperature press stand 83 is released, and the core material 30 to which the surface material 50 is bonded is moved by a predetermined distance. At the position of the high-temperature press stand 85, the foamed resin layer foams and fills the hollow portion of the core material 30. The panel after releasing the high-temperature press stand 85 and completing foam filling is gradually cooled to room temperature while moving a predetermined distance.
[0018]
The press device 80 forms a panel by intermittently and continuously automating the process. The three press stands 81, 83, and 85 are completely synchronized, and pressurization and depressurization are repeated intermittently, and the panel is moved by an appropriate length during depressurization to continuously produce panels. To do. The press table pressurization / decompression time and the panel feed rate are determined from conditions such as the resin material or the temperature setting of the heating porter.
In addition, this example shows an example in which the surface material is an aluminum alloy, and a surface material obtained by polymerizing a two-layer resin film on one side in advance is wound into a roll shape, but the surface material is made of glass fiber or carbon fiber. When used, fiber fabric (surface material) is impregnated with a semi-cured adhesive resin in advance (the fabric in this state is commonly called a prepreg), and the surface of the prepreg is coated with a foam resin that fills with foam. And it is good also as a surface material.
[0019]
<Example 4>
This press device 90 is provided with two pairs of room temperature press rolls having a set temperature of room temperature, and press rolls 91A and 91B. Two medium temperature press rolls 93A and 93B having a set temperature of 125 ° C. are provided on the downstream side, and two high temperature press rolls 95A and 95B having a set temperature of 180 ° C. are provided on the downstream side.
The surface material 50 in which the two-layer resin film 40 wound in a roll shape is stacked on the upper and lower surfaces of the core material 30 is placed, and the surface material 50 in which the two-layer resin film 40 is stacked on the core material 30 is wound at a predetermined speed. Polymerize while solving. The core material 30 on which the surface material 50 is laminated is pressed by the room temperature press rolls 91A and 91B, and the end of the core material 30 bites into the adhesive layer. The core material 30 laminated on the surface material 50 proceeding in this state is melted by the intermediate temperature press rolls 93A and 93B, and the core material 30 and the surface material 50 are bonded. In the core material 30 to which the surface material 50 that has passed the intermediate temperature press rolls 93A and 93B is bonded, the foamed resin layer foams and fills the hollow portion of the core material 30 at the high temperature press rolls 95A and 95B positions. The panel which has completed foam filling is gradually cooled to room temperature while moving a predetermined distance.
[0020]
This press device 90 continuously and automatically manufactures a panel filled with foamed resin. That is, a continuous panel can be formed by providing three sets of two upper / lower heating / pressurizing rolls and continuously moving them at a predetermined speed. The feed rate of the core material 30 is determined from conditions such as the resin material and the temperature setting of the heating nozzle.
Also in this case, a surface material obtained by coating the surface of the prepreg with a foamed resin to be foam-filled can be used.
[0021]
【The invention's effect】
According to the present invention, it is possible to easily and economically provide a high strength honeycomb panel filled with foamed resin.
[Brief description of the drawings]
FIG. 1 is a process explanatory diagram of a production method according to the present invention.
FIG. 2 is a graph showing changes in heating temperature.
FIG. 3 is an enlarged view of an adhesive / foamed resin bilayer film.
Fig. 4 is a top view of a core material (commonly called a honeycomb core).
FIG. 5 is a diagram illustrating the formation of a fillet.
FIG. 6 is an enlarged view showing another example of a two-layer film.
FIG. 7 is an explanatory view showing a first embodiment of the press device.
FIG. 8 is an explanatory view showing a second embodiment of the press device.
FIG. 9 is an explanatory view showing a third embodiment of the press device.
FIG. 10 is a process explanatory diagram of a conventional pressing method.
FIG. 11 is a process explanatory diagram of a conventional pressing method.
FIG. 12 is a process explanatory diagram of a conventional pressing method.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Honeycomb panel 30 Core material 40 Two layer film 41 Glass fiber carrier 42 Epoxy resin adhesive layer 44 Foamed phenol layer 50 Surface material 71 Room temperature press machine 73 Medium temperature press machine 75 High temperature press machine 80, 90 Press apparatus 81 Room temperature press stand 83 Medium temperature press stand 85 High temperature press stand 91A, 91B Press roll 93A, 93B Medium temperature press roll 95A, 95B High temperature press roll 420 Fillet 440 Foam layer

Claims (4)

In the manufacturing method of the panel in which the surface material is laminated on the upper and lower surfaces of the core material filled with the foam resin,
A lamination step of laminating a foamed resin layer, an adhesive layer, and a surface material in this order on the upper and lower surfaces of the core material with the hollow column;
An adhesion process in which the adhesive layer is heated and pressurized at a temperature at which the thermal reaction occurs;
And a filling step of heating and pressurizing at a temperature at which the foamed resin layer foams,
A method for producing a panel filled with a foamed resin, wherein the thermal reaction temperature of the adhesive layer is set lower than the foaming temperature of the foamed resin, and each step is configured to perform adhesion and foaming by a stepwise set heating temperature. The foamed resin layer and adhesive layer disposed on the upper and lower surfaces of the core material are composed of a film body in which the adhesive layer and the foamed resin layer are laminated, and the film body adhesive layer is provided between the core material and the surface material in the lamination process . The manufacturing method of the panel filled with the foamed resin of Claim 1 comprised so that it might oppose and laminate | stack on a surface material . In the manufacturing method of the panel in which the surface material is laminated on the upper and lower surfaces of the core material filled with the foam resin,
The surface material is formed by applying or impregnating an adhesive that reacts at a predetermined temperature, and is formed by laminating a foamed resin having a foaming temperature higher than the thermal reaction temperature of the adhesive on the surface material ,
The upper and lower surfaces of the core material which houses a hollow pillar, and a laminating step of laminating the surface member,
An adhesion step of heating and pressing at a temperature at which the adhesive melts;
And a filling step of heating and pressurizing at a temperature at which the foamed resin layer foams,
The method for manufacturing a panel filled with a foamed resin, wherein the bonding step and the filling step are configured to perform bonding and foaming at different heating temperatures set in stages. Laminating means for laminating a surface material having a foamed resin layer and an adhesive layer on the upper and lower surfaces of the core material with the foamed resin layer facing the core material ;
Heating and pressurizing means for holding and heating the core material laminated with the surface material;
A heating temperature control means for controlling the heating temperature of the heating and pressurizing means,
The apparatus for manufacturing a panel, wherein the heating temperature control means is configured to control at least the reaction temperature at which the adhesive layer reacts and the temperature at which the foamed resin layer foams .

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