JP3233971B2 - Method for manufacturing curved honeycomb panel - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a curved honeycomb panel. That is, it has a quadratic surface, a cubic surface, a curved surface in which these surfaces are integrally continuous, and other multi-dimensional surfaces.
The present invention relates to a method for manufacturing a curved honeycomb panel used for a structural material.

[0002]

2. Description of the Related Art Such a honeycomb panel having a curved surface is formed by bonding an inner plate and an outer plate made of fiber reinforced plastics, that is, FRP, to both surfaces of a honeycomb core as a core material and having a predetermined curvature. And such a curved honeycomb panel was conventionally manufactured as follows. FIGS. 6A and 6B are used to explain a conventional example of this type. FIG. 6A is a front sectional view of the inner plate and the outer plate at the time of press forming, and FIG. 6B is a front sectional view of the final press forming process. FIG. 3 (3) is an enlarged view of a main part in a state where wrinkles are generated, and FIG. That is, in the manufacturing method of FIG. 6, first, as shown in FIG. 1A, the inner plate 1 and the outer plate 2 in a prepreg state are pressure-formed using a mold C having a predetermined curvature, and then (2) )
As shown in the drawing, a pressure forming process is performed in which a honeycomb core 3 having a predetermined thickness H is sandwiched between the inner surface plate 1 and the outer surface plate 2 thus formed and bonded using a mold C. An inner plate 1 made of FRP is adhered to one surface of the honeycomb core 3 as a material, and an outer plate 2 is adhered to the other surface. The honeycomb core 3 has a secondary curved surface, a tertiary curved surface, a continuous curved surface thereof and the like, and a predetermined radius R is formed. Curved honeycomb panels with curvature were being manufactured. In the figure, reference numeral 4 denotes a vacuum sheet.

[0003]

The following problems have been pointed out in such a conventional example. First, a problem has been pointed out with respect to the smoothness of the surface of the manufactured curved honeycomb panel. That is, the inner plate 1 and the outer plate 2
6 (see FIG. 6 (1)), the surface (tool surface) in contact with the mold C fits the mold C and is formed into a flat state like the mold C surface, and the smoothness is improved. On the other hand, the outer surface (vacuum side surface) of the vacuum sheet 4 on the opposite side is the wrinkle P ₁ of the vacuum sheet 4 (see FIG. 6 (3)) and the step P ₂ ( (See FIG. 6 (4))), causing a problem in smoothness. In other words, it wrinkles P ₁ is likely to occur because the vacuum sheet 4 is rich in flexibility, and, by their inter-connections tape 5 is adhered in the joint (in FIG. 6 (4) refer to FIG.) Thickness of the other step or the like P ₂ is liable to occur, has been, wrinkles P ₁ and step or the like P ₂ such vacuum sheet 4 during pressure molding is also the outer surface of the inner plate 1 and the outer surface plate 2 of the prepreg state, similar causing unevenness like Nashiwa P ₁ and step or the like P _2. Therefore, the manufactured curved honeycomb panel also has a problem in that the smoothness of the surface is impaired and the appearance is not flat, and the quality, performance, dimensional accuracy, and the like are pointed out. In particular, a curved surface in which a secondary curved surface and a tertiary curved surface are continuous is used. In the case of a honeycomb panel with curved surfaces, its manufacture becomes difficult,
Also, pressing during the processing in ((2) see FIG. 6), such wrinkles P ₁ and steps such as P ₂ buckling P ₃ on the core material serving honeycomb core 3 on the basis of the ((4 in FIG. 6) (See the figure) may occur.

Secondly, in order to ensure the smoothness of the surface of such a curved honeycomb panel, the surface, that is, the outer surface of the inner plate 1 or the outer plate 2 is polished, thereby forming wrinkles P ₁ and steps P _2. It is also possible to flatten by removing irregularities such as
Traditionally done. However, such a conventional example requires skilled technology, labor, and time for work, and costs,
There were problems with work efficiency, manufacturing time, construction period, etc.

Third, on the other hand, in order to ensure the smoothness of the surface of such a curved honeycomb panel, a solid plate is applied between the inner surface plate 1 and the outer surface plate 2 at the time of pressure molding. Setting as a plate has also conventionally been performed. However, such a conventional example also has problems in cost, work efficiency, manufacturing time, construction period, and the like as described below. First, when the manufactured curved honeycomb panel is large, the rigidity of the solid plate is insufficient or the weight becomes heavy, and the curved honeycomb panel has a continuous curved surface of the secondary curved surface and the tertiary curved surface. However, such a solid plate is not applicable. Further, as a countermeasure against breakage of the vacuum sheet 4 at the time of press molding, a breathable nonwoven fabric as an auxiliary material is often interposed on the vacuum sheet 4 side, but in order to prevent the influence of such an auxiliary material. However, it was necessary to make the thickness of the solid plate very thick.

The present invention has been made in view of such circumstances, and has been made in order to solve the above-mentioned problems of the prior art, and a vent material is thin on one surface of a honeycomb core communicating between cells. The use of a vacuum panel having a predetermined curvature with the plate material attached to the plate makes it possible, firstly, to have excellent surface smoothness and, secondly, to make it simple, easy and time-saving. Thirdly, it is another object of the present invention to propose a method for manufacturing a curved honeycomb panel in which the plate has excellent rigidity, light weight, and relatively small thickness.

[0007]

The technical means of the present invention for achieving this object is as follows. That is, this manufacturing method relates to a method for manufacturing a curved honeycomb panel having a predetermined curvature in which an inner plate and an outer plate made of FRP are bonded to both surfaces of a honeycomb core as a core material. And, in advance, with a mold for manufacturing the curved honeycomb panel having a predetermined curvature, a ventilation material is attached to one surface of a vacuum honeycomb core in which cells are communicated with each other, and a thin plate material is attached to the other surface, A vacuum panel having a predetermined curvature is formed by pressure. Then, first, using the vacuum panel as a contact plate, a prepreg is set between the mold having a predetermined curvature and the thin plate material of the vacuum panel, and the inner plate and the outer plate are pressure-formed. Then, by sandwiching the honeycomb core serving as the core material between the inner plate and the outer plate formed in this way, and performing pressure molding with the mold having a predetermined curvature, the curved honeycomb panel is formed. Is obtained.

[0008]

The present invention comprises the above-mentioned means, and operates as follows. In this manufacturing method, a curved honeycomb panel can be obtained by sandwiching a honeycomb core serving as a core material between an inner surface plate and an outer surface plate that have been formed in advance by pressure, setting the core in a mold, and performing pressure forming. At this time, a vacuum panel having a predetermined curvature with a ventilation material and a thin plate material attached to both surfaces of a vacuum honeycomb core in which the cells communicate with each other is used as a contact plate, and the inner plate and the outer plate are added in advance. It is designed to be pressed. Therefore, firstly, the vacuum panel pressed and formed by the mold prevents wrinkles, steps, and the like of the vacuum sheet from being transferred to the outer surfaces of the inner plate and the outer plate. Not only the surface in contact with the mold but also the outer surface on the opposite side of the vacuum sheet is excellent in smoothness, and the buckling of the honeycomb core as the core material during the press forming is prevented. Thus, a curved honeycomb panel having excellent surface smoothness can be obtained. Secondly, it is simple, easy and time-saving, with no need for particularly skilled techniques and with little effort and time. Third
In addition, since the vacuum panel is made by adhering a ventilation material and a thin plate material to the honeycomb core, it is possible to use those having excellent rigidity, light weight and relatively thin wall thickness by making use of these characteristics.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the embodiments shown in the drawings. 1, 2, 3, 4, 5
Is provided for explanation of an embodiment of the present invention, and FIG.
It is a front sectional view at the time of pressure molding of the vacuum panel K,
FIG. 2 is an enlarged view of a main part of the vacuum panel K.
FIG. 2 is a front sectional view of the inner plate 6 and the outer plate 7 at the time of pressure molding, and FIG. 3 is a perspective view of the inner plate 6, the outer plate 7 and the honeycomb core 8 formed by the pressure molding. FIG. 4 is a front cross-sectional view at the time of final pressure forming, and FIG.
It is a perspective view of the manufactured curved-surface honeycomb panel 9,
FIG. 2 is a front sectional view thereof.

In this manufacturing method, as shown in FIG.
First, a vacuum panel K is manufactured and prepared. That advance, the type C for the manufacture of the curved honeycomb panel 9 (see FIG. 5) having a predetermined curvature, breathable material K ₂ on one surface of the honeycomb core K ₁ for vacuum is that between the cells is communicated, other surface thin plate K ₃ together with the affixed respectively, vacuum panels K having a predetermined curvature is molded under pressure. First, the vacuum panel K as a molding jig will be described in detail. Honeycomb core K ₁ is made of a planar assembly of hollow columnar cells, it is used what is sliced to a predetermined thickness,
Slits drilled in the cell walls, the small hole K _4, etc., between the cells are communicated. Also, as this vent material K ₂ that is affixed to the vacuum-side of the honeycomb core K _1, a number of Paforeito shaped prepreg plate, i.e. FRP plate having a small hole, wire mesh plates, other Paforeito sheet is used. As the thin plate K ₃ which is affixed to the side opposite to this, a flat prepreg plate clogging FRP plate, a metal sheet, plate was Kai裝sheet metal inside the FRP plate, and other thin plate is used. The vent material K ₂ on one surface of the honeycomb core K ₁ is vacuum panels K formed by having a predetermined curvature with the thin plate K ₃ on the other surface is affixed is prepared in advance is pressure molding using a mold C . In addition,
In the figure, reference numeral 10 denotes a vacuum sheet.

[0011] Then First, as shown in FIG. 2, with the vacuum panels K as wear plate, set the prepreg between the thin plate K ₃ types C and the vacuum panel K having a predetermined curvature, the inner surface plate 6 And the outer panel 7 are pressure-formed. As the prepreg, a combination of a base material and plastics such as resin is used. That is, as the base material, a woven base material in which glass fibers, Kevlar fibers, carbon fibers, these hybrid fibers, and the like are woven with warp and weft yarns by plain weave, satin weave, twill weave, or the like, or
What is called a uni-direction, which is a unidirectional base material of only warp yarns, is used. Further, as the plastics, for example, an epoxy-modified resin, a phenolic resin or the like is used. Such a base material and a resin are generally used in a weight ratio of 6: 4, and are used in combination by impregnation, adhesion, polymerization and the like. Next, the mold C is made of a tool mandrel made of metal such as aluminum or iron, or made of FRP. For example, a secondary curved surface, a tertiary curved surface, and a curved surface in which these curved surfaces are continuously integrated and other multi-dimensional curved surfaces are formed. It has the shape provided. Then, on such a mold C, a prepreg, a vacuum panel K serving as a plate, a vacuum sheet 1
0, and pressure molding is performed to form the inner surface plate 6.
Then, the outer panel 7 is obtained.

[0012] Such pressure molding is performed by a vacuum back method or an autoclave method. That is, a prepreg in which plastics such as resin is combined with a base material is placed on a mold C, and a vacuum panel K serving as a plate and a non-breathable and highly flexible vacuum sheet 10 are placed thereon. After the periphery is attached to the mold C and sealed, the inside is suctioned, decompressed, and vacuumed, and then pressurized densely from the outside (in the case of the autoclave method, in addition to this, by applying air pressure from the outside, ), The inner surface plate 6 which is closely pressed against the mold C;
And the outer panel 7 are pressure-formed. Depending on the molding temperature and time, the inner plate 6 and the outer plate 7 are kept in a semi-cured prepreg state, or are finally cured from the prepreg state, or immediately before being cured. Is obtained. For example, if the final cured product is obtained at a temperature of 150 degrees Celsius in 60 minutes, the state immediately before curing is, for example, a temperature of 150 degrees Celsius for 30 minutes or a temperature of 130 degrees Celsius. For 60 minutes. In this way, for example, as shown in FIG. 3, the FRP inner surface plate 6 and the outer surface plate 7 having a predetermined curvature and having a secondary curved surface and a tertiary curved surface, which are integrally continuous, are formed by pressure. You.

Next, as shown in FIG. 4, a honeycomb core 8 as a core material made of plastics or the like is sandwiched between the predetermined inner surface plate 6 and the outer surface plate 7 made of FRP.
By performing the press molding using the mold C, the curved honeycomb panel 9 shown in FIG. 5 is obtained. That is, using the mold C described above, the outer plate 7 formed first thereon, then the honeycomb core 8 sliced to a constant thickness H, and the inner plate 6 formed thereon are sequentially stacked, The vacuum sheet 10 is put on the inner surface plate 6. Then, pressure forming is performed by a vacuum back method or an autoclave method or the like in accordance with the above description, so that the inner plate 6 and the outer plate 7 that are FRP surface plates are formed on both surfaces of the honeycomb core 8 serving as the core material. Are adhered and, for example, a secondary surface D and a tertiary surface E are provided integrally and continuously formed, and a curved honeycomb panel 9 having a predetermined curvature and a radius R is manufactured.

As a method for manufacturing the curved honeycomb panel 9 by such press forming, a so-called co-cure method and a curing method are known. What is the co-cure method?
The inner plate 6 and the outer plate 7 are bonded to both surfaces of the honeycomb core 8 by pressure molding only without using an adhesive in a prepreg state without being cured. After the face plate 7 is further cured from the state of the prepreg, it is bonded to both surfaces of the honeycomb core 8 by pressure molding using an adhesive. In the present invention, these methods are appropriately selected and used. Is done.

The method for manufacturing the curved honeycomb panel 9 according to the present invention is as described above. Then, it becomes as follows. In the method for manufacturing the curved honeycomb panel 9, the inner plate 6 and the outer plate
By pressing the honeycomb core 8 serving as a core material between them (see FIGS. 2 and 3), setting the die in the mold C and performing bonding or the like (see FIG. 4), a predetermined curved honeycomb panel is formed. 9 is obtained (see FIG. 5). And in that case this manufacturing method, breathable material K ₂ on one surface of the honeycomb core K ₁ for vacuum of between the cells is communicated, together with the thin plate K ₃ on the other surface is affixed respectively, with a predetermined curvature The vacuum panel K is used as the contact plate, and the inner plate 6 and the outer plate 7 are pressure-formed in advance. That inner plate 6 and the outer surface plate 7, since the honeycomb core K ₁ and breathable material K ₂ of the vacuum panel K is provided with a breathable type C and suction-pump-vacuum between thin plate K ₃ Vacuum panels K Then, pressure molding is performed as specified. Therefore, in the method of manufacturing the curved honeycomb panel 9, the following first, second, and third steps are performed.

First, the vacuum sheet 10 used for pressure molding is highly flexible, and the wrinkles P
₁ (see FIG. 6 (3)) is likely to occur, and a step or the like P ₂ (see FIG. 6 (4)) due to the thickness of the bonded connection tape 5 (see FIG. (4) in FIG.
A vacuum panel K is interposed between the vacuum sheet 10 and the inner surface plate 6 or the outer surface plate 7 in a prepreg state (see FIG. 2). . So, with this vacuum panel K,
The transfer of the wrinkles P ₁ and the steps P _{2 of the} vacuum sheet 10 to the outer surfaces of the inner plate 6 and the outer plate 7 is prevented. Further, since the vacuum panel K is formed in a flat state by the mold C, the inner and outer plates 6 and 7 formed by pressing are not limited to the surface in contact with the mold C (tool surface). the opposite side of the vacuum sheet 10 side of the outer surface (vacuum side surface) also fits into the mold C, as with form C surface excellent in smoothness is formed into a flat state, wrinkles P ₁ and steps such as P ₂ irregularities No longer occurs. Further, (see FIG. 4) at the time of pressure forming process, the core material serving honeycomb core 8, wrinkles P ₁ and steps such as P ₂ in basis buckling P ₃ ((4 in FIG. 6) FIG see) by the also Is prevented. As described above, according to the method for manufacturing the curved honeycomb panel 9, the curved honeycomb panel 9 having excellent surface smoothness can be obtained.

[0017] Second, moreover curved honeycomb panel 9 having excellent smoothness of the thus surface, as this kind of prior art, essential to remove by polishing unevenness of wrinkles P ₁ and step or the like P ₂ It is realized without. Therefore, a skilled technique for polishing is not required, and no labor or time is required. Therefore, according to this manufacturing method, a curved honeycomb panel 9 excellent in surface smoothness can be obtained easily, easily and without any time. Can be

[0018] Third, and vacuum panels K used as a wear plate during press molding is formed by impregnating the vent material K ₂ and the thin plate member K ₃ in the honeycomb core K for vacuum. Taking advantage of these characteristics, compared to a conventional plate using a solid plate of this type, a plate having excellent rigidity, light weight, and relatively small thickness can be used.

First, in the illustrated embodiment, as shown in FIG. 2, the inner plate 6 and the outer plate 7 are separately formed by pressure, but the present invention is not limited to this. A release paper or a release agent is interposed between the face plate 6 and the outer plate 7, and the mold C, the vacuum panel K, and the vacuum sheet 10
The inner plate 6 and the outer plate 7 may be simultaneously pressed. Second, in the present invention, when the vacuum panel K of FIG. 1 is pressed, the inner plate 6 of FIG. 2 is pressed, the outer plate 7 of FIG. 2 is pressed, and the curved honeycomb of FIG. At the time of press forming of the panel 9, etc., the common mold C
However, different types are not used. Third, in the illustrated embodiment, the vacuum panel K is used when the inner plate 6 and the outer plate 7 shown in FIG.
However, the present invention is not limited to this, and the vacuum panel K may be used even when the curved honeycomb panel 9 in FIG. In this case, there is an advantage that the curved honeycomb panel 9 having more excellent surface smoothness can be obtained.

[0020]

As described above, according to the method for manufacturing a curved honeycomb panel according to the present invention, a ventilation material is attached to one surface of the connected honeycomb core, and a thin plate material is attached to the other surface.
The use of a vacuum panel having a predetermined curvature as the plate provides the following effects. First, a curved honeycomb panel having excellent surface smoothness can be obtained. That is,
The pressure-molded inner and outer plates have excellent smoothness as well as the outer surface (vacuum side surface) on the opposite side of the vacuum sheet as well as the surface (tool surface) in contact with the mold. Irregularities no longer occur, and buckling of the honeycomb core, which is the core material, is also prevented. Therefore, the curved honeycomb panel manufactured by this manufacturing method also has excellent surface smoothness, flat appearance, and excellent quality, performance, dimensional accuracy, and the like. Of course, a curved honeycomb panel having a continuous curved surface of a secondary curved surface and a tertiary curved surface can be manufactured without any trouble.

Second, and this is achieved simply, easily and in a short time. That is, unlike the conventional example of this type, it is not necessary to polish the inner and outer plates, and it is possible to manufacture a curved honeycomb panel simply, easily and without time, and there is no need for a skilled polishing technique. It doesn't take much effort or time. Therefore, this method for manufacturing a curved honeycomb panel is excellent in cost, work efficiency, manufacturing time, construction period, and the like.

Third, the vacuum panel used as the plate has excellent rigidity and light weight. Therefore, when a curved honeycomb panel to be manufactured is large, rigidity is not insufficient or the weight is not increased, and a curved honeycomb panel having a continuous curved surface with a secondary curved surface and a tertiary curved surface is also applicable. , Will be applicable. Further, the vacuum panel as the contact plate does not need to be particularly thick, unlike the conventional contact plate of this type, because of the relationship with the air-permeable nonwoven fabric as the auxiliary material interposed on the vacuum sheet side. If glass cloth is used as a measure against breakage of the vacuum sheet, it is even possible to eliminate the need for a non-woven fabric as an auxiliary material. The method of manufacturing this curved honeycomb panel is as follows.
From these aspects, it is excellent in cost, work efficiency, manufacturing time, construction period, and the like. As described above, the effects exhibited by the present invention are remarkable and large, for example, the problems existing in this type of conventional example are eliminated.

[Brief description of the drawings]

FIG. 1 is a view for explaining an embodiment of a method for manufacturing a curved honeycomb panel according to the present invention, wherein FIG. 1A is a front sectional view of a vacuum panel at the time of pressure molding, and FIG. 1B is a view of a vacuum panel. FIG.

FIG. 2 is a front cross-sectional view of the inner plate and the outer plate at the time of pressure molding for the description of the embodiment.

FIG. 3 is a perspective view of an inner plate and an outer plate, a honeycomb core, and the like, which are provided for the description of the embodiment and are formed by pressure.

FIG. 4 is a front sectional view at the time of final pressure molding for the description of the embodiment.

FIGS. 5A and 5B are views for explaining the embodiment, and FIG. 5A is a perspective view of the manufactured curved honeycomb panel, and FIG. 5B is a front sectional view thereof.

6A to 6C are used to explain a method of manufacturing a curved honeycomb panel according to a conventional example, wherein FIG. 6A is a front sectional view of an inner plate and an outer plate at the time of press forming, and FIG. FIG. 3 is a front sectional view at the time of press forming, and FIG.
FIG. 4D is an explanatory view of a main part in a state where a step or the like occurs.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Inner board 2 Outer board 3 Honeycomb core 4 Vacuum sheet 5 Connection tape 6 Inner board 7 Outer board 8 Honeycomb core 9 Curved honeycomb panel 10 Vacuum sheet C type D Secondary curved surface E Tertiary curved surface H Wall thickness R K Vacuum panel K ₁ Honeycomb core K ₂ Ventilation material K ₃ Thin plate material K ₄ Small hole P ₁ Wrinkle P ₂ Step difference P ₃ Buckling

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI B32B 31/12 B32B 31/12 // B29K 105: 08 B29K 105: 08 B29L 31:60 B29L 31:60 (58) Fields surveyed (Int.Cl. ⁷ , DB name) B29C 69/00-69/02 B29C 43/00-43/20 B29C 70/00-70/56 B32B 3/12 B32B 31/20 WPI (DIALOG)

Claims (1)

(57) [Claims] 1. A method for manufacturing a curved honeycomb panel having a predetermined curvature in which an inner plate and an outer plate made of FRP are bonded to both surfaces of a honeycomb core as a core material, wherein the curved honeycomb panel has a predetermined curvature in advance. Depending on the type of panel manufacturing, a vent material is attached to one surface of a vacuum honeycomb core communicating between the cells, and a thin plate material is attached to the other surface, and a vacuum panel having a predetermined curvature is formed by pressure. First, a prepreg is set between the mold having a predetermined curvature and the thin plate material of the vacuum panel using the vacuum panel as a contact plate, and the inner plate and the outer plate are pressure-formed. By sandwiching the honeycomb core serving as the core material between the inner surface plate and the outer surface plate formed as described above, and performing pressure forming with the mold having a predetermined curvature, the curved honeycomb panel is formed. Obtaining a curved honeycomb panel.