JP2001287290A - Honeycomb structure, honeycomb cell, and method for manufacturing honeycomb structure - Google Patents

Abstract

(57) [Summary] [Problem] To be considerably longer than a conventional honeycomb structural material,
To provide a honeycomb cell structural material that can be formed at low cost and a method for manufacturing the same. SOLUTION: As shown in FIG. 1A, a honeycomb cell wall member 12 provided with an adhesive 14 at a predetermined interval is laminated with an adhesive 14 while being laminated. At this time, the air bag 20 is placed in a portion to be a cell. Next, as shown in (B), air is injected into the air bag 20 and the air bag 20 is moved by an arrow H.
Inflate as shown. When the air bag 20 is inflated, the honeycomb cells 16 are shaped. When the honeycomb structural member 50 is manufactured in this manner, it is not necessary to mechanically pull and shape the wall member 12, and therefore, it is possible to easily manufacture a honeycomb structural member having a considerably longer length than a conventional honeycomb structural member.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a honeycomb cell structural material, a honeycomb cell, and a method for manufacturing a honeycomb structural material, and more particularly to a honeycomb cell having a honeycomb cell holding member provided inside the honeycomb cell. Related to the use of prepreg.

[0002]

2. Description of the Related Art Conventionally, a structural material composed of honeycomb cells has been widely used in the field of construction and aircraft, as a lightweight and highly rigid structural material. Also,
The specific form of utilization is generally a so-called sandwich structure in which a plate-like honeycomb cell structural material is sandwiched between plate materials or the like.

[0003]

The honeycomb cell structural material is manufactured by the following method. FIG. 8 is an explanatory view schematically showing a method for manufacturing a honeycomb structure according to the related art. That is, first, FIG.
As shown in (A), thin plate-shaped wall members 12 bent at regular intervals so as to protrude zigzag are laminated and adhered to each other. At this time, a portion in contact with the adjacent wall material 12 is provided with an adhesive 14 in advance. The adhesive application width 92 is set to be substantially the same as the zigzag top width 90.

After the adhesive 14 is sufficiently cured and the bonding process is completed, the uppermost wall material 12 and the lowermost wall material 12 are mechanically pulled in the directions of arrows A and B, respectively. Then, as shown in FIGS. 11B and 11C, the laminated and integrally formed wall material 12 is deformed, and the honeycomb cells 16 are shaped. Through the above steps, the honeycomb cell structural member 50 is completed. FIG. 11C is a plan view of the honeycomb cell structural material shown in FIG. 11B.

Further, when a honeycomb cell structural member having an arbitrary shape is formed, a honeycomb cell structural member 51 having a predetermined shape is formed by cutting a flat honeycomb cell structural member 50 shown in FIG.

However, in the method of mechanically pulling and deforming the wall material 12 as described above, the length 94 of the honeycomb structure shown in FIG. 11C is increased, for example, to several meters. Doing so can be difficult from a physical point of view. This is because, in order to form such a long honeycomb structure, considerable traction force is required, and the length of the wall material itself is several meters, which makes the traction machine much larger than the conventional one. There is a need. In addition, even if the above-mentioned traction machine is used, since the end of the honeycomb cell is destroyed and it becomes impossible to manufacture the honeycomb cell, it is not practically applicable. Further, when a honeycomb structure having an arbitrary shape is formed by cutting, a large cost is required.

[0007] In order to solve the above-mentioned disadvantages of the prior art, the present invention provides a honeycomb structural material, a honeycomb cell, and a honeycomb which can be formed much longer than conventional honeycomb structural materials and can be formed at low cost. It is an object of the present invention to provide a method for manufacturing a structural material. It is another object of the present invention to provide a method for manufacturing a honeycomb structure capable of forming a honeycomb structure having an arbitrary shape at low cost.

[0008]

Means for Solving the Problems In order to achieve the above-mentioned object, the present invention provides a honeycomb structure having a structure provided inside a honeycomb cell and having a holder for holding the shape of the honeycomb cell. did. In addition, it is preferable that the holding member has a structure having a hollow portion from the viewpoint of reducing the weight of the honeycomb structure.

Further, in the above-mentioned honeycomb structure, the holding member is configured such that an end is sealed by filling a gas into a cylindrical body having a sealable end. Further, in the above-mentioned honeycomb structure, the holding member is configured to be hermetically sealed in a state where a hard foam material is filled in a cylindrical body.
Further, in the above honeycomb structure, the holder is
The structure was made of a hard foam material.

[0010] In the above-mentioned honeycomb structure, the cell wall of the honeycomb cell includes at least a paper material or a fiber material. Further, in the above honeycomb structure, the paper material or the fiber material is impregnated and cured with a thermosetting resin. Further, the cell walls of the honeycomb cells were configured by impregnating and hardening a fibrous material with a thermosetting resin.

On the other hand, in the honeycomb cell, the cell walls of the honeycomb cells are laminated, and an adhesive portion is provided in parallel with a predetermined interval between the adjacent cell wall materials, and the adjacent cell wall material and the adhesive portion are provided. And a cylindrical body capable of enclosing a fluid is arranged in the space defined by the above.

Further, the cell wall material is constituted by impregnating a fibrous material with a thermosetting resin. In addition, an intermediate material is provided between the adjacent cell wall materials in the bonding portion, and a fixture for fixing the adjacent cell wall material to the intermediate material is provided. Further, the tubular body has a configuration in which a side edge portion is folded inward.

[0013] In the method for manufacturing a honeycomb structure, a first step of forming a honeycomb body inside the honeycomb cell while forming the honeycomb cell, and a step of heating a gas heated to a predetermined temperature inside the cylindrical body. A second step of press-fitting, expanding the tubular body to shape the honeycomb cells, and curing the thermosetting resin impregnated with the honeycomb cells, and pressurizing the end of the tubular body with the gas. And a third step of sealing in a sealed state.

Further, in the method for manufacturing a honeycomb structure, a first step of forming a cylindrical body inside the honeycomb cell while forming the honeycomb cell, and pressurizing a gas into the cylindrical body, A second step of shaping the honeycomb cells by expanding a shaped body, and a third step of heating the honeycomb cells and curing the thermosetting resin impregnated in the honeycomb cells. And

Further, in the method for manufacturing a honeycomb structure, a first step of forming a honeycomb body inside the honeycomb cell while forming the honeycomb cell, and forming the honeycomb cell provided with the cylindrical body in a mold frame A second step of arranging the honeycomb cells, pressurizing gas into the interior of the tubular body, expanding the tubular body, and shaping the honeycomb cells along the formwork, A fourth step of heating and curing the thermosetting resin impregnated in the honeycomb cells;
At least.

[0016] In the method for manufacturing a honeycomb structure, when the honeycomb cells are heated to cure the thermosetting resin impregnated in the honeycomb cells, reinforcing means disposed outside the honeycomb cells may be provided. Heating at the same time,
The thermosetting resin impregnated in the reinforcing means is cured.

Further, in the above-described method for manufacturing a honeycomb structure, in the first step, the cylindrical bodies arranged in parallel with the cell wall material of the honeycomb cells at predetermined intervals are alternately stacked, and The cell walls adjacent to each other are interposed at predetermined intervals in parallel with the cylindrical body to form a honeycomb cell.

[0018]

According to the present invention, as described above, the honeycomb structure is provided inside the honeycomb cell and has a holder for holding the shape of the honeycomb cell. The object prevents deformation of the honeycomb cell. Therefore, it is possible to easily form a considerably long honeycomb structure.

Further, since the holding member is formed by filling a gas into the inside of a tubular body whose end is formed so as to be sealable, the holding member can be reduced in weight and the honeycomb cell can be reduced. Even if the holding material is provided inside the honeycomb structure, the total weight of the honeycomb structure does not increase so much. Further, if the honeycomb cells are shaped when filling the inside of the tubular body with the gas, a traction machine becomes unnecessary.

[0020] Further, the holding member is hermetically sealed in a state in which the inside of the cylindrical body is filled with a hard foam material.
It is possible to easily reduce the cost of the holding object without requiring the holding object to have strict sealing properties. In addition, since the holding member is made of a hard foam material, when the honeycomb structure does not have a sufficient strength, by adopting this configuration, the cost of the honeycomb structure can be easily reduced.

Further, since the cell wall of the honeycomb cell contains at least a paper material or a fiber material, it is easy to reduce the weight and cost of the honeycomb structure.
Further, since the paper material or the fiber material is impregnated and cured with a thermosetting resin, the cell wall material impregnated with the thermosetting resin is deformed into a predetermined shape, and then the thermosetting resin is cured. This facilitates the formation of the honeycomb structure. Further, by impregnating and curing the thermosetting resin in the cell wall material, the strength of the cell wall material can be dramatically increased.

On the other hand, in the honeycomb cell, cell wall materials are laminated, and an adhesive portion is provided in parallel with a predetermined interval between adjacent cell wall materials, and formed by the adjacent cell wall material and the adhesive portion. Since a cylindrical body capable of enclosing a fluid is disposed in the space to be formed, a considerably long honeycomb cell can be shaped at low cost by enclosing the fluid in the cylindrical body.

Further, since the cell wall material is formed by impregnating a carbon fiber material with a thermosetting resin, the shaped honeycomb cells are heated to cure the thermosetting resin.
High strength honeycomb cells can be shaped. Also,
Since the intermediate member is installed in the adhesive portion and a fixing device for fixing the cell wall material to the intermediate material is installed, the honeycomb portion does not peel off even when the fluid is sealed therein, and the honeycomb is not peeled off. Cells can be shaped. In addition, since the cylindrical body is formed by folding the side edges inward, when the fluid is sealed, the central portion of the cylindrical body expands greatly, and the honeycomb cell can be easily shaped.

Further, in the method for manufacturing a honeycomb structure, a first step of providing a cylindrical body inside the honeycomb cell while forming the honeycomb cell, and a step of supplying a gas heated to a predetermined temperature to the inside of the cylindrical body. A second step of press-fitting, expanding the tubular body to shape the honeycomb cells, and curing the thermosetting resin impregnated with the honeycomb cells, and pressurizing the end of the tubular body with the gas. And at least a third step of sealing in a sealed state, so that the honeycomb cells can be extremely easily shaped into a predetermined shape.

Further, in the method for manufacturing a honeycomb structure, a first step of forming a honeycomb body inside the honeycomb cell while forming the honeycomb cell, and pressurizing gas into the inside of the cylindrical body, A second step of shaping the honeycomb cells by expanding a shaped body, and a third step of heating the honeycomb cells to cure the thermosetting resin impregnated in the honeycomb cells. The honeycomb cells can be easily shaped by expanding the cylindrical body, and a high-strength honeycomb structure can be formed by curing the thermosetting resin.

Further, in the method for manufacturing a honeycomb structure, a first step of forming a honeycomb body inside the honeycomb cell while forming the honeycomb cell, and forming the honeycomb cell provided with the cylindrical body in a mold frame A second step of arranging the honeycomb cells, pressurizing gas into the interior of the tubular body, expanding the tubular body, and shaping the honeycomb cells along the formwork, A fourth step of heating and curing the thermosetting resin impregnated in the honeycomb cells;
Therefore, a honeycomb structure having an arbitrary shape can be formed at low cost by expanding the tubular body in the mold.

Further, in the method for manufacturing a honeycomb structure, when the honeycomb cells are heated to cure the thermosetting resin impregnated in the honeycomb cells, reinforcing means disposed outside the honeycomb cells may be provided. Heating at the same time,
Since the thermosetting resin impregnated in the reinforcing means is cured, it is not necessary to separately add a heat treatment step, and it is necessary to separately apply an adhesive to the thermosetting resin for bonding the honeycomb cell and the reinforcing means. Thus, a low-cost, high-strength honeycomb structure can be formed.

Further, in the first step, the cell wall members of the honeycomb cells are alternately stacked on the cell wall members of the honeycomb cell at predetermined intervals alternately, and the cell wall members adjacent to each other via the cylindrical member are interposed. Are bonded in parallel to the tubular body at predetermined intervals to form the honeycomb cells, so that the tubular body can be provided very easily inside the honeycomb cells.

[0029]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, specific embodiments of a honeycomb cell structural material and a method for manufacturing the same according to the present invention will be described in detail with reference to the drawings. The description of the parts having the same configuration as that of the above-described related art will be simplified.

FIG. 1 is an explanatory view schematically showing a method for manufacturing a honeycomb structure according to the first embodiment of the present invention.
FIG. 2 is a cross-sectional view showing a column structure using the honeycomb structure according to the first embodiment of the present invention. Also,
FIG. 3 is a cross-sectional view of the honeycomb structure according to the first embodiment of the present invention, taken along line CC of FIG. FIG. 4 is an explanatory view showing a method for shaping the honeycomb cells and a method for curing the thermosetting resin impregnated in the wall material of the honeycomb cells. FIG. 5 is a cross-sectional view showing a modification of the column structure using the honeycomb structure according to the first embodiment of the present invention. FIG. 6 is a sectional view showing a sealing structure of the air bag. FIG. 7 is a cross-sectional view showing a state where a joint material is connected to an end of the honeycomb cell.

In the honeycomb structure according to the first embodiment of the present invention, a holding member for preventing deformation of the honeycomb cell is provided in each honeycomb cell, and the holding member is expanded and deformed, thereby towing the honeycomb cell. This makes it possible to shape a honeycomb cell without using a machine.

Hereinafter, a method for manufacturing a honeycomb structure according to an embodiment of the present invention will be described. As shown in FIG. 1A, a honeycomb structure 5 according to an embodiment of the present invention
0, first, a tubular air bag 20 is provided in advance in each honeycomb cell internal space 10. As shown in FIG. 3, the air bag 20 is slightly longer than the wall material 12 so that both ends thereof come out of the internal space of the honeycomb cell in order to easily press air into the air bag 20. . The material of the wall material 12 is formed of paper such as cardboard when the honeycomb structure 50 is made of low cost, and carbon fiber material or glass fiber material is used when strength against stress is required. A so-called prepreg obtained by impregnating a thermosetting resin into a mainly configured fiber material is used. Furthermore, the air bag 20
In the state where the honeycomb cell is expanded to the maximum, the honeycomb cell has the same or slightly smaller volume as the inner space 10 of the honeycomb cell. Furthermore, when the air bladder 20 is inflated in the honeycomb cell internal space 10, the portion of the wall material 12 where the adhesive 14 is provided has a size not to be damaged. In addition, the air bladder 20 is formed from a synthetic fiber material that is impregnated with a resin and cured so as to have airtightness.

The air bag 20 may be alternately laminated with the wall material 12 in the process of sequentially laminating the wall material 12 and bonding them together, or the wall material 12 is shown in FIG. After assembling to the state, the honeycomb cell internal space 1
0 may be provided. Further, in the state shown in FIG. 1A, the air bag 20 is kept in a deflated state. Further, the shape of the wall material 12 and the adhesion between the wall materials 12 are the same as in the case of the related art. Further, as will be described later, when urethane foam is directly provided in the honeycomb cell internal space 10, it is preferable that the wall material 12 be formed of aluminum (Al) in order to increase airtightness to the external space. In addition, when the strength is insufficient even when the fiber material is impregnated with a thermosetting resin, a material having higher strength such as a steel plate may be used.

Next, air is press-fitted into the air bladder 20 to inflate the air bladder 20 as shown by an arrow 20. The method of press-fitting air into the air bag 20 and the method of sealing the end of the air bag 20 will be described later. When the air bag 20 is inflated, the wall material 12 is pressed by the air bag 20 and deformed.
As shown in (B) and (C), the honeycomb cells 16 are shaped. When the shaping of the honeycomb cell 16 is completed, the end of the air bag 20 is sealed so that a state in which air is filled therein is maintained. When a so-called prepreg in which a fibrous material is impregnated with a thermosetting resin is used as the wall material 12, air having a temperature at which the impregnated thermosetting resin is cured is press-fitted. It is preferable that the internal pressure of the sealed air bag 20 be about 50 to 100 MPa. Alternatively, the honeycomb cell may be shaped by injecting normal-temperature air and then heating in a heating furnace or the like to cure the thermosetting resin.

In order to increase the strength of the wall member 12, reinforcing means such as pasting a reinforcing fiber material such as carbon fiber or spraying a glass fiber material may be provided in advance. After the honeycomb structure 50 is formed, the reinforcing means may be provided only on the outer peripheral surface of the honeycomb structure 50. Further, when not much strength is required for the honeycomb structure 50, the material of the wall material 12 is paper,
Instead of providing the air bag 20 in the honeycomb cell interior space 10, a hard foam material such as urethane foam may be directly blown and solidified in the honeycomb cell interior space 10. This makes it possible to provide a very inexpensive honeycomb structure 50.

According to the above configuration, the honeycomb cells 16 can be shaped only by injecting air into the air bladder 20, so that a machine for pulling the wall material 12 is unnecessary. Further, the length 94 of the honeycomb structure shown in FIG.
There is no limitation as long as the air bladder 20 can be formed according to the length, so that it is possible to manufacture a long honeycomb structure 50 extending to several meters, which has not been realized conventionally. In addition, since the honeycomb cell internal space 10 is provided with the air bag 20 filled with air in a compressed state, the honeycomb cells 16 are prevented from being deformed by external stress. Consequently, the rigidity of the entire honeycomb structure 50 is increased, and the reliability as a structural material is improved.

Next, a method for pressurizing air into the air bag 20 will be described. As shown in FIG. 4, air circulation paths 40a and 40b are connected to both ends of the air bag 20, respectively. Air heating between the air circulation paths 40a and 40b
A circulation device 42 is provided. Air heating and circulation device 42
Circulates the air in the air circulation path 40a to the air circulation path 40b. Further, the internal pressures of the air circulation paths 40a and 40b and the air bag 20 can be set in a range of about 50 to 100 MPa. Further, the circulating air can be heated to cure the thermosetting resin (not shown) impregnated in the wall material 12. In the above configuration, by operating the air heating / circulating device 42, it is possible to circulate the air circulation paths 40a, 40b and the inside of the air bag 20 as shown by arrows D, E, F, G. Further, the circulating air can be heated as required. It is not always necessary to circulate the air as described above, and one end of the air bag 20 may be sealed with a sealing plug and air may be injected from the other end.

As described above, when air is injected into the air bag 20, both ends of the air bag 20 are sealed. First, the sealing structure of the air bag 20 will be described. As shown in FIG. 6, sealing plugs 24 each having a through hole at the center thereof are fitted into both ends of the air bag 20 at a depth of about 20 mm from an end of the air bag 20. 24 is fixed with an adhesive 38. A check valve 28 provided with an air inlet 26 is fitted into the through hole of the sealing plug 24. The check valve 28 circulates air only in the directions indicated by arrows E and F in FIG. The material of the air inlet 26 is a resin such as polyethylene.

Next, a method of sealing the air bag 20 will be described. When the internal pressure of the air bag 20 reaches a predetermined pressure, the air inlet 26 is sandwiched between heating elements, and the air inlet 26 is crushed. Further, following the sealing of the air bag 20, as shown in FIG. 7, the fitting portions 36 arranged in the joint material 34 for allowing the honeycomb structure 50 to be incorporated into another structural material and to be attached are provided. Push into each honeycomb cell. At this time, the process is performed while pushing the inside of the end of the air inlet 26. Further, since the adhesive is applied to the fitting portion 36, the fitting portion 36 is bonded to the sealing plug 24 and the wall material 12. Through the above steps, the air bag 20 can be sealed.
Further, since the fitting portions 36 of the joint material 34 are fitted into both ends of the honeycomb cell and are double-sealed, even if the air bag 20 or the check valve 28 is damaged, air leaks to the outside. I will not give it out.

As the material of the joint member 34, iron or aluminum can be preferably used, and when not much strength is required, an organic material such as engineering plastic can also be preferably used. Also,
The material of the fitting portion 36 may be the same material as the joint material 34 or may be different. For example, the fitting portion 36 may be attached to an iron joint material 34 as an aluminum casting. Further, a bolt hole or the like may be provided in the joint material 34 in order to facilitate attachment to another structural material.

Further, the honeycomb structure 50 shown in FIG.
FIG. 2 shows an example in which is applied to architectural columns. Architectural pillar 100
Is provided with the exterior material 30 around the honeycomb structure 50. In addition, in order to increase the strength of the building column 100, mortar 32 is filled in a cell where the air bag 20 is not provided. In addition, although not shown in FIG.
The joint materials described above are provided at both ends of the, so that it can be incorporated into and attached to other structural materials.

According to the above configuration, unlike the honeycomb structure according to the prior art, the long honeycomb structure 50 of several mails is used, so that it can be used for a building column which has not been conventionally used. . Further, it is possible to provide an extremely lightweight architectural column having the same strength as a conventional column made of reinforced concrete or the like.

The structure shown in FIG. 2 may be used as a structural material other than architectural columns, for example, a beam, a girder, or an outer wall material. Further, it may be used for large structures such as bridges and tunnel segments, and marine structures such as mega floats. In particular, in the case of a marine structure, it is necessary to provide a structure that gives buoyancy to the structure.
The honeycomb structure 50 filled with air can be used very preferably. Further, the present invention may be used for machines such as large machine tools, and transport devices such as ships and aircraft.

Note that, as shown in FIG.
Is pressed by the inflation force of the air bag of the honeycomb cell 52 near the center, so that the exterior material 3 is pressed.
In order to prevent it from being deformed by being pressed against zero, the urethane foam 2
2 may be filled. By filling the urethane foam 22, the strength of the honeycomb cells 54 in the peripheral portion can be increased. The air bladder 20 of the honeycomb cell 54 in the peripheral portion may be filled with a hard foam material other than urethane foam.

In the honeycomb structure according to the second embodiment of the present invention, a honeycomb cell base material is formed by using a so-called prepreg obtained by impregnating a fibrous material with a thermosetting resin as a cell wall material,
The honeycomb cell is formed by expanding and deforming a tubular body disposed therein, and by heating the same to cure a thermosetting resin to form a honeycomb structure. FIG. 8 is an explanatory view of a bonding portion in a laminate of cell wall materials, and FIG. 9 is an explanatory view of a cylindrical body. FIG. 10 is an explanatory diagram of a method of shaping a honeycomb cell in a mold. The description of the parts having the same configuration as the above-described related art or the first embodiment will be omitted.

First, the structure of the honeycomb cell base material will be described. The honeycomb cell base material of the second embodiment is formed by laminating cell wall materials 12, providing adhesive portions 13 at regular intervals between adjacent cell wall materials 12, and forming the adjacent cell wall materials and adhesive portions. The air bag 20b as a cylindrical body is disposed in the space to be formed.

For the wall material 12 of the honeycomb cell, a so-called prepreg obtained by impregnating a fibrous material with a thermosetting resin is used.
As the fiber material, a carbon fiber material, a glass fiber material, or the like is used, and a woven fabric woven in an orthogonal direction is formed. By forming the honeycomb structure using such a woven fabric, the tensile strength and the bending rigidity in each direction of the honeycomb structure can be ensured. In addition, unsaturated polyester or epoxy is used as the thermosetting resin to impregnate the woven fabric of the fiber material.

At the time of stacking the above-mentioned cell wall materials, an adhesive portion is provided between the adjacent cell wall materials in parallel at a predetermined interval. FIG. 8 is an explanatory view of a bonding portion in the laminate of cell wall materials. FIG. 1A is a component diagram, and FIG.
Is an assembly drawing. When the cell wall materials are bonded to each other, an intermediate material (filler) 17 made of a material such as vinyl chloride is sandwiched between the adjacent cell wall materials 12a and 12b, and the cell wall material and the intermediate material are interposed. Apply adhesive and glue. However, since the thermosetting resin before curing is present on the surface of the prepreg, when the air bag is inflated as described later, there is a possibility that the adhesive portion 13 may peel. Therefore, in order to fix the cell wall members 12a and 12b to the intermediate member 17, a plurality of U-shaped needles 18 are inserted into the end of the adhesive portion 13 as a fixing tool, and the ends of the needles are bent at the opposite side to bond. Reinforce the part. This, in addition to chemical bonding by the adhesive,
The mechanical bonding by the U-shaped needle 18 is performed, and the bonding portion 13 is formed.
Can be prevented from peeling.

An air bag as a cylindrical body is arranged in a space formed by the adjacent cell wall material and the bonding portion. FIG. 9 shows an explanatory view of the air bag. FIG. 1A is a perspective view, FIG. 2B is a cross-sectional view taken along the line DD, and FIG. 3C is a cross-sectional view in a state where an air bag is arranged in a honeycomb cell.
As shown in FIGS. 9A and 9B, the air bag 20b is formed in a state where the side edge portion 21 is folded inward over the entire length. Thereby, when air is press-fitted, the central portion of the air bag expands greatly, and the honeycomb cells can be easily shaped. On the other hand, the air bag 20b before air filling is used.
Becomes narrower. Therefore, the cell wall material 12 and the air bag 20
b), the air bag is mistakenly attached to the bonding portion 13.
The adhesive portion is not peeled off when the air bag is inflated. Further, even when the bonding portion 13 is reinforced by the above-described U-shaped needle 18, the air bag 20b is not damaged by the U-shaped needle 18 and air leakage does not occur. After forming as shown in FIG. 9 (2),
The open ends on both sides are sealed, and one of the air
Is installed. Then, as shown in FIG.
Is placed inside the honeycomb cell. In order to prevent the cell wall material 12 and the air bladder 20b from adhering to each other by heating, it is preferable to arrange the air bladder in the honeycomb cell with a release agent interposed therebetween.

From the honeycomb cell configured as described above,
The honeycomb structure is formed as follows. First, air is injected into each air bag, and each air bag is inflated to shape a honeycomb cell. Although high-temperature air may be press-in as in the first embodiment, a separate heating step is provided in the second embodiment, so it is sufficient to press-in normal-temperature air.
Next, the honeycomb cell is placed in a heating furnace or the like while maintaining the air pressure in the air bag 20b, and the honeycomb cells are heated to cure the thermosetting resin impregnated in the honeycomb cells. Further, the cured honeycomb cell base material is taken out of the mold 60, and each air bag 2
If the air of 0b is evacuated and taken out from each honeycomb cell, a honeycomb structure using prepreg as a cell wall material can be formed.

By shaping the honeycomb cell configured as described above in a mold, a honeycomb structure having an arbitrary shape can be formed. FIG. 10 is an explanatory diagram of a method of shaping a honeycomb cell in a mold. First, a mold 60 corresponding to a product shape to be formed by the honeycomb structure is created. Next, as shown in FIG. 10A, the honeycomb cell base material 15 in which the air bags are arranged inside each honeycomb cell is placed in a mold frame 60.
Place within. In order to prevent the prepreg and the mold frame 60 from being bonded to each other by the thermosetting resin, the honeycomb cell base material is disposed inside the mold frame with a film adhered to the outer surface thereof.
Next, as shown in FIG. 10 (2), air is press-fitted into each air bag 20b, and each air bag is inflated to shape the honeycomb cells along the mold 60. Next, while maintaining the air pressure in the air bag 20b, the mold frame 60 is put into a heating furnace (not shown) or the like, and the honeycomb cells are heated to cure the thermosetting resin impregnated in the honeycomb cells. Further, as shown in FIG. 10 (3), if the cured honeycomb cell base material is taken out from the mold frame 60, the air in each air bag 20b is evacuated and taken out from each honeycomb cell, a honeycomb structure having an arbitrary shape can be formed. it can.

When a high-strength honeycomb structure is formed by arranging reinforcing means using a prepreg on the outside, the following procedure is performed. First, as shown in FIG. 10A, the reinforcing means 62 is attached to the inner surface of the mold. In order to prevent the reinforcing means 62 and the mold frame 60 from being bonded by the thermosetting resin, the reinforcing means is attached to the inner surface of the mold with the film attached to the surface of the reinforcing means on the mold side. Next, the honeycomb cell base material 15 is disposed in the mold 60. The film on the outer surface of the honeycomb cell base material 15 was removed from the mold 60
Place within. Next, as shown in FIG. 10B, the airbag is inflated to shape the honeycomb cells along the mold 60. Next, the mold 60 is put into a heating furnace (not shown) or the like, and the honeycomb cells and the reinforcing means 62 are simultaneously heated to cure the impregnated thermosetting resin. Further, by taking it out of the mold frame 60 as shown in FIG. 10C, a high-strength honeycomb structure 64 with reinforcing means 62 can be formed.

Note that the reinforcing means 62 is previously
May be placed on the outer surface of the honeycomb cell base material 15 and placed in the mold at the same time as the honeycomb cell base material. Also, even without shaping in the mold, the reinforcing means is placed on the outer surface of the honeycomb cell base material to inflate the air bag, and the honeycomb cells and the reinforcing means are simultaneously heated to cure the thermosetting resin. You may. Thereby, a high-strength honeycomb flat plate or honeycomb column can be formed.

The internal space of each honeycomb cell after each air bag is taken out may be filled with a hard foam material. In that case, after forming the honeycomb structure as described above, both ends of each honeycomb cell are sealed. Unlike the case where high-pressure air is sealed, strict sealing is not required for the hard foam material, so that the sealing is performed using the joint material 3 in the first embodiment.
4 can be performed. The joint material 34 is previously formed with a filling hole and an air vent hole of a hard foam material. Next, a hard foam material such as styrene foam is filled from the filling hole. The hard foam material foams in the honeycomb cell internal space, and overflows from the air vent hole when foaming more than necessary. Thereby, foaming can be performed with uniform pressure in each honeycomb cell. By filling the internal space of the honeycomb cell with the hard foam material as described above, it is possible to obtain a honeycomb structural material that is resistant to concentrated loads and has high buckling strength.

As described above, in the second embodiment, since the prepreg is used for the cell wall material 12, the honeycomb cell can be easily shaped by its flexibility before the thermosetting resin is cured. After curing, a honeycomb structure having high strength can be provided. In this regard, conventionally, since the honeycomb structure was made of an aluminum foil material or the like, even though the honeycomb cells could be easily formed, the formed honeycomb structure alone had low strength. Therefore, it is necessary to provide a reinforcing means using a prepreg or the like outside the honeycomb structure, and a heat treatment step for curing the thermosetting resin is required. Therefore, there is a problem that the cost is high and that it can be used only for high-performance materials such as aircraft parts.

However, in the second embodiment, the prepreg is used for the cell wall material 12, so that the honeycomb cell can be easily shaped by the flexibility before the thermosetting resin is cured, like the aluminum foil material. it can. In particular, if the air bag arranged in the honeycomb cell is inflated and deformed, even a long honeycomb cell can be uniformly shaped without requiring a conventional traction machine. On the other hand, if the shaped honeycomb cell is subjected to a heat treatment to cure the thermosetting resin, the cured resin and the fiber material are combined, so that the strength can be markedly increased as compared with the related art. Therefore, it can be used alone without adding reinforcing means unlike the prior art, and the cost can be reduced. Further, as in the first embodiment, it is not necessary to fill the air bag with compressed air to secure the strength of the honeycomb structure. Therefore, it is not necessary to secure the strength of the air bag itself, and the cost of the air bag is reduced. be able to. In addition, by using a prepreg for the cell wall material 12, it is possible to provide a honeycomb structure that is light in weight and does not corrode.

The honeycomb structure of the second embodiment is used for marine structures such as mega-floats floating on the sea for a long period of time because of their high strength, light weight and corrosion resistance. be able to. In addition, the honeycomb structure of the second embodiment can be used as a structural material such as a bridge girder or a pillar, and a wall material of a building.

In the second embodiment, since the honeycomb cells using the prepreg as the cell wall material are shaped in the mold,
A honeycomb structure having an arbitrary shape can be formed at low cost. In this regard, in the related art, a honeycomb structure having a predetermined shape is formed by cutting a honeycomb structure formed in a flat shape. Therefore, there is a problem that a great cost is required. However, in the second embodiment, since an air bag is arranged in the honeycomb cell and is inflated and deformed in the mold, the honeycomb cell is shaped along the mold to provide a honeycomb structure having an arbitrary shape. it can. In addition, since the prepreg is used for the cell wall material, the shaped honeycomb cell is heated and the thermosetting resin is cured, so that even after removing the air from the air bag and removing it from the mold, the shaped honeycomb cell Can be maintained. Accordingly, a honeycomb structure having an arbitrary shape can be formed at low cost without requiring cutting work as in the related art.

Since the honeycomb structure having an arbitrary shape can be formed as described above, the honeycomb structure according to the second embodiment is used as a structural material of a product requiring various shapes, such as a propeller of a windmill or a wing of an aircraft. Can be.

In addition, in the second embodiment, even when reinforcing means using a prepreg is added, it is not necessary to increase the number of heat treatment steps, and strength can be increased at low cost. In this respect, conventionally, there has been a problem that a heat treatment step for curing the thermosetting resin of the reinforcing means is required, and thus a great cost is required. However, in the second embodiment, after arranging the reinforcing means outside the honeycomb cell base material and shaping the honeycomb cells, the honeycomb cells and the reinforcing means are simultaneously heated to cure the thermosetting resin impregnated in each of them. Let it. Therefore, it is not necessary to separately add a heat treatment step, and since the honeycomb cells and the reinforcing means are fixed by the thermosetting resin, it is not necessary to separately apply an adhesive. Therefore, a honeycomb structure having high strength at low cost can be formed.

[0061]

As described above, according to the present invention, since a structure is provided inside the honeycomb cell and has a holding member for holding the shape of the honeycomb cell, a considerable length is obtained. It is possible to easily form a honeycomb cell structure having the same. Therefore, it is possible to adopt a honeycomb structure in a field where it was conventionally difficult to use the honeycomb structure, such as a building column, and it is possible to significantly reduce the weight and cost of a structural material for a building.

[Brief description of the drawings]

FIG. 1 is an explanatory view schematically showing a method for manufacturing a honeycomb structure according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view showing a column structure using the honeycomb structure according to the embodiment of the present invention.

FIG. 3 is a diagram illustrating a honeycomb structure according to an embodiment of the present invention;
It is -B sectional drawing.

FIG. 4 is an explanatory view showing a method for shaping a honeycomb cell and a method for curing a thermosetting resin impregnated in a wall material of the honeycomb cell.

FIG. 5 is a cross-sectional view showing a modification of the column structure using the honeycomb structure according to the embodiment of the present invention.

FIG. 6 is a sectional view showing a sealing structure of the air bag.

FIG. 7 is a cross-sectional view showing a state where a joint material is connected to an end of a honeycomb cell.

FIG. 8 is an explanatory view of a bonding portion in a laminate of cell wall materials, wherein (1) is a component diagram and (2) is an assembly diagram.

FIG. 9 is an explanatory view of an air bag, (1) is a perspective view, (2) is a cross-sectional view taken along line DD, and (3) is a cross section in a state where the air bag is arranged in a honeycomb cell. FIG.

FIG. 10 is an explanatory diagram of a method of shaping a honeycomb cell in a mold.

FIG. 11 is an explanatory view schematically showing a method for manufacturing a honeycomb structure according to a conventional technique.

FIG. 12 is an explanatory diagram relating to a method for manufacturing a honeycomb structure having an arbitrary shape according to the related art.

[Explanation of symbols]

10: honeycomb cell internal space, 12: cell wall material, 13: adhesive part, 14: adhesive, 15 ...
Honeycomb cell base material, 16 ... Honeycomb cell, 17 ...
... Intermediate material, 18 U-shaped needle, 20, 20b ...
Air bag, 21 ... side edge, 22 ... urethane foam,
24 sealing plug 26 air inlet 28
Check valve, 30 ... exterior material, 32 ... mortar, 34
... joint material, 36 ... fitting part, 38 ... adhesive, 40a ... air circulation path, 40b ... air circulation path, 42 ... air heating / circulation device, 50 ... Honeycomb structure, 51: Honeycomb structure, 52: Honeycomb cell near the center, 54: Honeycomb cell at the periphery, 60: Form frame, 62: Reinforcing means, 64:
Honeycomb structure, 90 ... Zigzag top width, 92 ...
... Adhesive application width, 94 ... Length of honeycomb structure, 1
00 …… Architectural pillar

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 2E162 CA33 CA39 CC07 CE10 DA00 DA09 4F100 AD11 AE01 AG00 AK01A BA01 CB00 DC02A DC07A DG03A DG10A DH00A DH01 DJ01A EJ08A EJ082 EJ422 EJ82A EJ902 GB08 GB31 JB13A

Claims (16)

[Claims] 1. A honeycomb structure having a holder provided inside a honeycomb cell and holding a shape of the honeycomb cell. 2. The honeycomb structure according to claim 1, wherein the holding member is formed by filling a gas into a cylindrical body whose end is formed so as to be sealable and hermetically sealed. 3. The honeycomb structure according to claim 1, wherein the holding member is hermetically sealed with a hard foam material filled in a cylindrical body. 4. The honeycomb structure according to claim 1, wherein the holding member is made of a hard foam material. 5. The honeycomb structure according to claim 1, wherein a cell wall of the honeycomb cell includes at least a paper material or a fiber material. 6. The honeycomb structure according to claim 5, wherein the paper material or the fiber material is impregnated and cured with a thermosetting resin. 7. A honeycomb structure, wherein a cell wall of a honeycomb cell is formed by impregnating and curing a thermosetting resin in a fibrous material. 8. A cell wall material of a honeycomb cell is laminated, an adhesive portion is provided in parallel with a predetermined interval between adjacent cell wall materials, and formed by the adjacent cell wall material and the adhesive portion. A honeycomb cell comprising a cylindrical body capable of enclosing a fluid in a space defined therein. 9. The honeycomb cell according to claim 8, wherein the cell wall material is obtained by impregnating a fibrous material with a thermosetting resin. 10. An intermediary member is provided between adjacent cell wall members at the bonding portion, and a fixture for fixing the adjacent cell wall member to the intermediate member is provided. The honeycomb cell according to claim 9. 11. The honeycomb cell according to claim 9, wherein the cylindrical body has a side edge portion folded inward. 12. A method for manufacturing a honeycomb structure, comprising: a first step of forming a honeycomb body inside a honeycomb cell while forming a honeycomb cell; and forming a gas heated to a predetermined temperature inside the cylindrical body. Press fit
A second step of expanding the tubular body to shape the honeycomb cells and curing the thermosetting resin impregnated in the honeycomb cells, and the gas is press-fitted into the end of the tubular body. And a third step of sealing in a state. 13. A method for manufacturing a honeycomb structure, comprising: a first step of forming a cylindrical body inside the honeycomb cell while forming a honeycomb cell; and press-fitting a gas into the cylindrical body, A second step of shaping the honeycomb cells by expanding a shaped body, and a third step of heating the honeycomb cells and curing the thermosetting resin impregnated in the honeycomb cells. A method for manufacturing a honeycomb structure, comprising: 14. A method for manufacturing a honeycomb structure, comprising: a first step of forming a cylindrical body inside the honeycomb cell while forming the honeycomb cell; and forming the honeycomb cell provided with the cylindrical body in a mold frame. And a third step of injecting gas into the tubular body to expand the tubular body and shape the honeycomb cells along the mold.
And a fourth step of heating the honeycomb cells to cure the thermosetting resin impregnated in the honeycomb cells, the method comprising the steps of: 15. The method for manufacturing a honeycomb structure according to claim 1, wherein, when the honeycomb cells are heated to cure the thermosetting resin impregnated in the honeycomb cells, reinforcing means disposed outside the honeycomb cells is provided. The method for manufacturing a honeycomb structure according to claim 13, wherein the thermosetting resin impregnated in the reinforcing means is cured by heating at the same time. 16. In the first step, the cell wall materials of the honeycomb cells are alternately laminated with the cell wall materials of the honeycomb cells arranged at predetermined intervals in parallel, and the cell wall materials adjacent to each other via the cylindrical body are stacked. The method for manufacturing a honeycomb structure according to any one of claims 12 to 14, wherein a honeycomb cell is formed by adhering a plurality of pieces at predetermined intervals in parallel with the cylindrical body.