JPS6391236A - Manufacture of laminated panel of stainless steel foil core - Google Patents

Abstract

(57) [Abstract] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to a method of manufacturing a laminated panel, and more particularly to a method of manufacturing a completely novel laminated panel core from stainless steel foil. The laminated panels produced by the method of the present invention can be used as structural materials for ships, vehicles, aircraft, and space rockets.

It also has very high utility value as an interior and exterior material for buildings.

<Prior Art> Conventionally, laminated panels such as honeycomb panels have been used, for example, as ceiling materials, wall materials, and floor materials for buildings, and as structural materials for ships and aircraft.

Conventional honeycomb panels use aluminum foil, resin-impregnated paper, cellulose ester sheets, and other plastic sheets as honeycomb core materials. In particular, the aluminum core honeycomb panel is Jl! , = 71 and is often used from the viewpoint of productivity.

<Problems to be Solved by the Invention> However, laminated panels using aluminum are susceptible to corrosion by contact with aqueous systems, particularly salt water, and there is a problem in that the strength of the panels is significantly reduced as the corrosion progresses.

On the other hand, 4-panel panels made of paper and plastic are very lightweight, but have the disadvantage of being easily deformed by heat and usually flammable.

Considering both corrosion resistance and heat resistance, stainless steel or the like is considered to be optimal as the core material. However, a laminated panel consisting of a stainless steel core has not yet been developed.

The present invention provides a method for manufacturing a laminated panel with a stainless steel foil core that can reliably produce a laminated panel with a stainless steel foil core that has excellent strength, lightness, abrasion resistance, and heat resistance. It is something to do.

Means for Solving the Problems> As a result of intensive research, the present inventor has developed a stainless steel foil that is formed by repeatedly folding a stainless steel foil upward and downward in one direction in advance. A required number of three-layer folded sheets are laminated using an adhesive, and then the laminated body is sliced to an appropriate thickness. After that, the thinly sliced laminated body is stretched and deformed in a direction perpendicular to the lamination direction. discovered that a honeycomb-shaped porous core of stainless steel could be obtained by stretching and deforming the same in the lamination direction, and also by stretching and deforming the thinly sliced laminate until it became almost planar, and then applying an appropriate surface pressure. Stainless steel foil cores with various cell shapes, such as rectangular, hexagonal, and decagonal, can be produced by adding or deforming the laminate in a direction opposite to the stretching direction. Find out what you can do.

The present invention was completed.

The method for producing a stainless steel foil core laminated panel of the present invention involves bonding a desired three-layer folded sheet formed by repeatedly folding stainless steel foil outward and inward in one direction in a fixed manner. This method is characterized in that the core of the laminated panel is manufactured by laminating the laminated body through a laminating agent, slicing the laminated body to an appropriate thickness, and then stretching and deforming the laminated body in a direction perpendicular to the laminating direction.

The manufacturing method of the present invention preferably involves stretching and deforming the thinly sliced laminate of three-layer folded sheets two-dimensionally in the lamination direction and in a direction perpendicular thereto, simultaneously or in one direction and then in the other direction. It's a method. A method in which the thinly sliced laminate is stretched to some extent in the lamination direction, and then further stretched in a direction perpendicular to the lamination direction is preferred.

In addition, in a preferred manufacturing method of the present invention, the thinly sliced laminate of the three-layer folded sheet is stretched in a direction perpendicular to the lamination direction until the three-layer folded sheet becomes almost flat, and the tensile force is released, so that the thinly sliced laminate is restored. This is a method of manufacturing a honeycomb-shaped porous core using force.

A more preferred method of the present invention is to change the strength of the restoring force by applying an appropriate surface pressure to the thinly sliced laminate in the stacking direction when the thinly sliced laminate is stretched until the three-layer folded sheet becomes substantially flat. It's a method.

Furthermore, in a preferred manufacturing method of the present invention, the thinly sliced laminate of the three-layer folded sheet is stretched and deformed in a direction perpendicular to the lamination direction until the three-layer folded sheet becomes substantially flat, and then pressure is applied in the stretching direction. In this method, in addition to the opposite direction, the thinly sliced laminate is forcibly deformed back so that the three-layer folded sheet bends again and is newly bent at the boundary between the adhesive application area and the non-adhesive application area.

The three-layer folded sheet used in the present invention is made by repeatedly folding a stainless steel foil in a certain folding pattern consisting of inward folds and outward folds in one direction, preferably keeping each fold parallel.

Here, "inward folding" refers to the folding method in which the stainless steel foil is bent upward at the fold line and folded so that the upper bent part overlaps the base of the same position, and "outward folding" refers to the folding method in which the stainless steel foil is folded upward at the fold line. A method of folding in which the steel foil is bent downward at the crease and then folded so that the lower bent portion overlaps the lower part of the fold.

A three-layer folded sheet is formed by repeating inward folding and outward folding of stainless steel foil in a certain manner, for example, by repeating outward folding and inward folding alternately in one direction.

In particular, when stainless steel foil is repeatedly folded using a series of folds such as outward folds, inward folds, inward folds, and outward folds as a repeating unit, a three-layer folded sheet with continuous so-called box folds is produced. be done.

It is preferable that the fold lines of the three-layer folded sheet are parallel to each other, and in this case, the interval between the fold lines is arbitrary, but the interval between the fold lines is, for example, 1:1.1:2 or 1:3. It is preferable to repeat it at equal intervals.

Further, the bending of the stereoless steel foil is preferably carried out automatically using a device to which the mechanism of an automatic new bending device for paper, thin metal plates, etc. is applied.

The three-layer folded sheet used in the present invention is a completely new sheet structure made of stainless steel foil, which the inventors have named FOP.

The stainless steel foil used in the present invention may be made of various types of stainless steel specified in the JIS standard, for example, and may have a thickness of 5 mm.
An ultra-thin plate having a thickness of 0 to 150 tttn, preferably 50 to 80 μm, is used. Instead of stainless steel foil,
Titanium (Ti) foil may also be used.

In the present invention, a predetermined number of three-layer folded sheets, for example, 520 sheets, are laminated with a thermosetting resin adhesive for bonding metals interposed therebetween, and then pressure is applied in the lamination direction under heating to harden the laminating agent. A laminate of folded sheets is made.

For a three-layer folded sheet with continuous box folds,
It is preferable to stack the sheets so that the outermost upper and lower surfaces (hereinafter referred to as outer fold surfaces) face each other.

The method of applying the adhesive interposed between the three-layer folded sheet is arbitrary. For example, in the case of the above-mentioned three-layer folded sheet, the adhesive may be applied to all or part of the outer surface of the box folds, and in particular, the adhesive may be applied in a single row only in the center of the outer surface of the box folds, or in two rows on both left and right sides of the outer surface. This is preferred because the application results in a stainless steel foil core with a complex cell shape.

The adhesive may be one that has a high adhesive strength that does not cause peeling between the three-layer folded sheets due to stretching deformation.1For example, thermoplastic adhesives such as Cell 4's adhesive, vinyl acetate adhesive, styrene adhesive, etc. Rubber-based adhesives such as butadiene-based, butadiene-based, and epoxy-based.

A thermosetting adhesive such as a phenolic adhesive can be used.

The adhesive is used after being prepared as a liquid with appropriate viscosity.

Furthermore, before applying the adhesive, it is preferable to perform appropriate surface pretreatment on the surface of the three-layer folded sheet to which the adhesive is to be applied, thereby increasing the activity of the surface and improving the adhesive effect. Examples of pretreatment include physical treatments such as buffing, sandblasting, and polishing, chemical treatments such as acid treatment and alkali treatment, and degreasing treatment using chlorinated solvents, acetone, and the like. It is convenient to use a stainless steel foil that has been previously subjected to degreasing treatment, etc., since it eliminates the need for a pretreatment step for the three-layer folded sheet.

In addition, when stacking and forming three-layer folded sheets, for example, when using an epoxy thermosetting adhesive, 520 three-layer folded receipts are subjected to a 4kg 1-0 surface pressure for 60 to 180 minutes under heating at 170°C. It is best to do this by adding it for a period of time.

After the adhesive has hardened, the three-layer folded sheet laminate is sliced using a slicing device to a thickness corresponding to the core width of the intended laminate panel, for example, 5 mm to 70 pieces.

Thereafter, the thinly sliced laminate is placed on a stretching device, and the loop around the periphery of the laminate is hooked onto the movable bin and fixed pin of the stretching device, and the laminate is stretched in its longitudinal direction, that is, in a direction perpendicular to the lamination direction. It is then expanded in the stacking direction to form honeycomb-like porous cores with various cell shapes. As described above, the thinly sliced laminate is stretched until it becomes almost planar, and then a surface pressure of, for example, 11 to 10 kg/-〇 is applied, or the laminate is then returned to its original position by applying pressure in the opposite direction to the stretching direction. It is preferable to deform it. Further, the dimensions of each core cell are determined by the distance between the folded portion of the three-layer folded sheet and the adjacent folded portion (distance between creases). By changing this spacing design, it is possible to produce cores with a cell diameter of, for example, 2 to 30 m, preferably 3 to 8 m.

Thus, a sandwich-type laminated panel can be manufactured by attaching a skin material to both sides or one side of the molded core. The skin material is conventionally used, such as aluminum, steel or stainless steel sheet metal.

Unidirectional prepregs, resin-impregnated fabrics and other fiber-reinforced plastics can be used, as well as slate,
A thin stone skin such as marble may also be applied. When using prepreg as a skin material, appropriate heating and pressure are required.Also, when attaching the skin material to the core with an adhesive film, it is not economical to perform heat and pressure treatment. advantageous in terms of

Stainless steel foil is a material with much higher rigidity than aluminum foil, etc.

- When you try to open it again after folding it, a large restoring force acts and it tries to fold again at the crease. Accordingly, according to the process of the method of the present invention, a number of tri-folded sheets of successively folded stainless steel foil are laminated and then the sliced laminate is folded open, preferably so that each tri-folded sheet is approximately When stretched and deformed until it becomes flat, and then the tensile force for stretching is released, the sliced laminate deforms by folding again at the creases, resulting in a honeycomb-like porous stainless steel core with various cell shapes. is formed. That is, in the method of the present invention, a stainless steel foil core is formed by utilizing the high rigidity and strong restoring force of stainless steel foil. In the method of the present invention, even if the thinly sliced laminate is forcibly returned to deformation by pressure in the direction opposite to the stretching direction after being stretched to the maximum extent, the stainless steel foil itself is hardly damaged.

On the other hand, aluminum foil, which has traditionally been widely used as panel core material, has lower rigidity than stainless steel foil, so when it is folded and then unfolded, large distortions often remain at the fold. Cracks may develop on their own or the bent parts may break off if the cracks develop further.

Therefore, even if a laminated panel core is manufactured by a method similar to the method of the present invention using aluminum foil, cracks in the foil, deformation of the three-layer folded sheet, etc. are likely to occur, and it is difficult to back-produce the core. Even if it could be produced, it would result in a panel core with very low strength.

<Example> Embodiments of the present invention will be described below with reference to the drawings.

Figures 1-3 illustrate each side of a laminated panel core made by the example method. These laminated panel cores are all honeycomb-shaped porous cores made of stainless steel foil, and the panel cores shown in FIGS. 2 and 3 are conventionally known rectangular cell and hexagonal cell cores.
The panel core shown is a new and unique 14 corner rectangular cell core. In Figure 1, decimal numbers 1 to 14
indicate each corner of the core cell.

These stainless steel foil cores 1 are manufactured according to the manufacturing procedure described below. Laminated panel cores having cell shapes other than these can also be manufactured according to similar procedures.

First, a three-layer fold sheet as shown in Figures 4 to 6)
Prepare gold for 2a, 2b, and 2c. The three-layer folded sheets 2a and 2b shown in FIGS. 4 and 5 are made by folding stainless steel foil with a thickness of 50μ in one direction in the order of outward folding, inward folding, inward folding, and outward folding, with each fold parallel to each other. A sheet (length 26 mm) is made by repeatedly folding the so-called box folds by
00 wn, width 1500 tpan). In these figures, the sFi outward folding site is shown, and 4 indicates the internal folding site. The three-layer fold seam) 2a in Figure 4 has approximately 1 fold.
:2 intervals, for example 5. On the other hand, in the third folded sheet 2b, the folds are repeated at an interval of approximately 1:5, for example, at an interval of j1m++ and 12 cod. It is.

Further, the three-layer folded sheet 2c shown in FIG. 6 is a sheet formed by alternately repeating outward folding and inward folding of stainless steel foil having a thickness of 50 μm in one direction. The folds of this paper 2c are also all parallel.

Next, the upper and lower surfaces of these three-layer folded sheets 2a, 2b, and 2C are pretreated, such as buffing or degreasing, to form the required number of three-layer folded sheets) 2a, 2b.
, 2c are laminated. Sheet 2a.

In the case of sheet 2b, as shown in FIGS. 7 and 8, the outer surfaces of the box folds, that is, the outer surfaces 5 of the folds, are stacked so that they face each other and are close to each other, and in the case of sheet 2C, the 9th As shown in the figure, stack the layers so that the fold pattern of the upper sheet matches that of the lower sheet.

In this case, before lamination, fold the adhesive 6 into three layers (see) 2a~
Apply it to the outermost surface of 2C, for example, the outer surface 5 of No-Kohida. The method of applying the adhesive 6 is arbitrary; for example, in the case of a three-layer fold sheet 2a, the adhesive 6 may be applied to the entire outer surface 5 of the box folds as shown in FIG. 10, or as shown in FIG. 1 only in the center of the outer surface 5 of the box folds as shown in
For example, it may be applied, or as shown in FIG. 12, it may be applied only to the left and right sides of the outer surface 5 of the box folds in two rows.

For example, using an epoxy thermosetting adhesive,
A surface pressure of 4 kt/crA was continuously applied to 20 three-layer folded sheets (2a) under heating at 170°C for 60 to 180 minutes in the stacking direction (direction of arrow Q in Figures 10 to 12). , a laminate 7a of three-layer folded sheets by curing the adhesive;
Make 7b and 7C.

Next, as shown in FIG. 13, the three-layer folded sheet laminate 7bi is sliced into pieces with a width of, for example, 5 to 5 otrtn, the thickness of the desired laminated panel core
A thinly sliced laminate 8 is obtained.

Thereafter, as shown in FIG. 14, the thinly sliced laminate 8 of the three-layer folded sheet is placed on a stretching device (not shown), and the loops 9 and ... on the pins 10 of the stretching device, and then, as shown in FIG. ,
Then, it is stretched and deformed to the maximum extent until Fig. 16 becomes almost flat, and then several ky /
A surface pressure of cr/l is applied to the laminate 8 in a direction perpendicular to its stretching direction (direction of arrow P in the figure).

Thereafter, when the tensile force for expansion is released, a honeycomb-shaped porous core as shown in FIGS. 2 and 3 is produced. Furthermore, when using the laminate 7b shown in FIG.
Following the release of the tension, an appropriate pressure is applied to the laminate 8.
In addition, the stretching direction (tensile direction) and the opposite direction (the 14th
In the figure, add in the direction of arrow R). Then, the laminate 8 is deformed so that the three-layer fold 9 sheet 2a is bent again at the boundary between the area where the adhesive 6 is applied and the area where the adhesive 6 is not applied, and as a result, a cell is formed as shown in FIG. A honeycomb-like porous core with a unique rectangular shape is fabricated. By changing the way the stainless steel foil is folded, the adhesive application method, and the conditions for stretching and deforming the thinly sliced laminate.

Various honeycomb-like porous cores having various cell shapes such as rectangular, hexagonal, hexagonal, or similar shapes are obtained.

Finally, a skin material such as a thin metal plate or prepreg is attached to both sides or one side of the molded stainless steel foil core 1, thereby completing a laminated panel of stainless steel cores.

<Effects of the Invention> As mentioned above, by the method of the present invention, it is possible to produce various types of porous stainless steel cores having various, often unique, cell shapes, which were previously unobtainable. Can be completed with stainless steel core laminated panels.

[Brief explanation of the drawing]

1 to 3 are cross-sectional views showing the stainless steel foil core of a laminated panel manufactured by the method of the embodiment of the present invention, and FIGS. Figures 7 to 9 show the three-layer folded sheet for a laminated panel core, and Figures 7 to 9 show the lamination style of the three-layer folded sheet shown in Figures 4 to 6, respectively. Figures 10 to 12 are diagrams showing three types of adhesive application methods for the three-layer folded sheet shown in Figure 4, respectively. Figure 13 is a diagram showing the process of slicing the laminate of the three-layer folded sheet in the method of the embodiment. , FIGS. 14 to 16 are diagrams showing the process of stretching and deforming a thinly sliced laminate of three-layer folded sheets in the method of the embodiment. In the figure. 1...Stainless steel foil core 2a, 2#OX 2c...Three-layer folded sheet 3...Outward folding part 4...Inward folding part 6...Adhesive 7a, 7b, 7c... Laminate of three-layer folded sheets 8...
・Thinly sliced laminate of three-layer folded sheet figure

Claims (4)

[Claims] (1) A desired number of three-layer folded sheets, which are formed by repeatedly folding outward and inward folding of stainless steel foil in one direction in a fixed manner, are laminated and molded using an adhesive, and the laminate is formed into an appropriate thickness. A method for manufacturing a laminated panel of a stainless steel foil core, characterized in that the core of the laminated panel is manufactured by thinly slicing the stainless steel foil core and then stretching and deforming it in a direction perpendicular to the lamination direction. (2) The manufacturing method according to claim 1, characterized in that the thinly sliced laminate of three-layer folded sheets is stretched and deformed not only in a direction perpendicular to the lamination direction but also in the lamination direction. (3) A thinly sliced laminate of three-layer folded sheets is stretched and deformed in a direction perpendicular to the lamination direction until the three-layer folded sheet becomes almost flat, and then surface pressure is applied to the laminate in the lamination direction. Features Claim 1 or 2
Manufacturing method described in section. (4) The thinly sliced laminate of the three-layer folded seal is stretched and deformed in a direction perpendicular to the lamination direction until the three-layer folded sheet becomes almost planar, and then the thinly sliced laminate is returned by applying pressure in the opposite direction to the stretching direction. The manufacturing method according to any one of claims 1 to 3, characterized in that the manufacturing method is deformed.