JP2019084677A - 構造体の製造方法、スキン材の準備方法及びスキン材の加熱条件設定方法 - Google Patents
構造体の製造方法、スキン材の準備方法及びスキン材の加熱条件設定方法 Download PDFInfo
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Abstract
Description
図1は、本発明の第1の実施形態に係る構造体の製造方法で製造される構造体10の概略構成図である。構造体10は、図1に示すように、コア材12と、スキン材14と、接着剤層16と、を含む。スキン材14は、コア材12の両方側の表面12aに、フィルム状の接着剤層16を介して積層され、接着されている。なお、図1では、構造体10の説明のために、コア材12と、スキン材14と、接着剤層16と、を分離して描いている。
図5は、本発明の第2の実施形態に係る真空加熱ステップS2のフローチャートである。本発明の第2の実施形態に係る構造体の製造方法は、図5に示すように、真空加熱ステップS2を、第1真空加熱ステップS12と、第2真空加熱ステップS14とを有するステップに変更したものである。本発明の第2の実施形態に係る構造体の製造方法は、本発明の第1の実施形態に係る構造体の製造方法とは異なり、用いられるコア材12が、厚さ方向に貫通して形成された穴が平面方向に配列されたハニカム構造材に限定されず、穴が形成されていなくても構わない。なお、第2の実施形態に係る構造体の製造方法は、他の構成については、第1の実施形態に係る構造体の製造方法と同様である。第2の実施形態に係る構造体の製造方法について、以下に説明する。第2の実施形態に係る構造体の製造方法は、その他の第1の実施形態と同様の構成に第1の実施形態と同一の符号群を用い、その詳細な説明を省略する。
12 コア材
12a 表面
14,114 スキン材
14a 板材
16 接着剤層
20 真空加熱設備
22 バッグ
30 密封加圧加熱設備
41,43,44,46,51,52,53 曲線
42 粘度極小領域
47 第1領域
48 第2領域
55 温度プロファイル
56 第1真空加熱領域
57 第2真空加熱領域
Claims (8)
- 厚さ方向に貫通して形成された穴が平面方向に配列されたハニカム構造材であるコア材と、前記コア材の表面に積層されたスキン材と、を含む構造体の製造方法であって、
前記スキン材は、熱硬化性樹脂を含み、
前記スキン材をバッグ内に置き、前記バッグ内を真空にして、前記バッグ外を大気圧下として加熱することで、前記熱硬化性樹脂を半硬化させる真空加熱ステップと、
前記コア材の前記表面の側に、前記熱硬化性樹脂が半硬化した前記スキン材を積層する積層ステップと、
前記積層した前記コア材と前記スキン材とを密封加圧加熱設備を用いて加圧しながら加熱することで、前記コア材と前記スキン材とを接着して一体化する密封加圧加熱ステップと、
を有することを特徴とする構造体の製造方法。 - 前記熱硬化性樹脂は、硬化する硬化温度よりも低温度の領域で発生する第1揮発成分を含有し、
前記真空加熱ステップは、
前記スキン材を前記低温度の領域で所定の時間加熱することで、前記スキン材から前記第1揮発成分を発生させて除去する第1真空加熱ステップと、
前記第1真空加熱ステップの後で、前記スキン材をさらに加熱することで、前記第1揮発成分が除去された前記熱硬化性樹脂を半硬化させる第2真空加熱ステップと、
を有することを特徴とする請求項1に記載の構造体の製造方法。 - コア材と、前記コア材の表面に積層されたスキン材と、を含む構造体の製造方法であって、
前記スキン材は、硬化する硬化温度よりも低温度の領域で発生する第1揮発成分を含有する熱硬化性樹脂を含み、
前記スキン材をバッグ内に置き、前記バッグ内を真空にして前記バッグ外を大気圧下として、かつ、前記低温度の領域で所定の時間加熱することで、前記スキン材から前記第1揮発成分を発生させて除去する第1真空加熱ステップと、
前記第1真空加熱ステップの後で、前記スキン材をバッグ内に置き、前記バッグ内を真空にして前記バッグ外を大気圧下として加熱することで、前記第1揮発成分が除去された前記熱硬化性樹脂を半硬化させる第2真空加熱ステップと、
前記コア材の前記表面の側に、前記熱硬化性樹脂が半硬化した前記スキン材を積層する積層ステップと、
前記積層した前記コア材と前記スキン材とを密封加圧加熱設備を用いて加圧しながら加熱することで、前記コア材と前記スキン材とを接着して一体化する密封加圧加熱ステップと、
を有することを特徴とする構造体の製造方法。 - 前記熱硬化性樹脂は、前記硬化温度を含む高温度の領域で発生する第2揮発成分をさらに含有し、
前記第2真空加熱ステップでは、前記スキン材を前記硬化温度以下の温度で加熱することで、前記第1揮発成分が除去された前記熱硬化性樹脂を半硬化させることを特徴とする請求項2または請求項3に記載の構造体の製造方法。 - 前記第1真空加熱ステップ及び前記第2真空加熱ステップの加熱条件は、前記熱硬化性樹脂を熱重量分析することで、前記熱硬化性樹脂が硬化する硬化温度よりも低温度の領域で発生する第1揮発成分を含有するか否かを判定した判定結果と、前記硬化温度を含む高温度の領域で発生する第2揮発成分を含有するか否かを判定した判定結果とに基づいて、設定されることを特徴とする請求項2から請求項4のいずれか1項に記載の構造体の製造方法。
- 前記積層ステップでは、前記コア材の前記表面の側に、フィルム状の接着剤層を介して、前記熱硬化性樹脂が半硬化した前記スキン材を積層し、
前記密封加圧加熱ステップでは、前記接着剤層により、前記コア材と前記スキン材とを接着して一体化することを特徴とする請求項1から請求項5のいずれか1項に記載の構造体の製造方法。 - コア材と、前記コア材の表面に積層されたスキン材と、を含む構造体の製造にあたり、前記スキン材を準備するスキン材の準備方法であって、
前記スキン材は、硬化する硬化温度よりも低温度の領域で発生する第1揮発成分を含有する熱硬化性樹脂を含み、
前記スキン材をバッグ内に置き、前記バッグ内を真空にして前記バッグ外を大気圧下として、かつ、前記熱硬化性樹脂が硬化する硬化温度よりも低温度の領域で所定の時間加熱することで、前記スキン材から前記第1揮発成分を発生させて除去する第1真空加熱ステップと、
前記第1真空加熱ステップの後で、前記スキン材をバッグ内に置き、前記バッグ内を真空にして前記バッグ外を大気圧下として加熱することで、前記第1揮発成分が除去された前記熱硬化性樹脂を半硬化させる第2真空加熱ステップと、
を有することを特徴とするスキン材の準備方法。 - コア材と、前記コア材の表面に積層されたスキン材と、を含む構造体の製造にあたり、前記スキン材を準備するスキン材の準備方法における加熱条件を設定するスキン材の加熱条件設定方法であって、
前記スキン材に含まれる熱硬化性樹脂を熱重量分析する熱重量分析ステップと、
前記熱重量分析の結果に基づいて、前記熱硬化性樹脂が硬化する硬化温度よりも低温度の領域で発生する第1揮発成分を含有するか否かを判定する第1判定ステップと、
前記熱重量分析の結果に基づいて、前記熱硬化性樹脂が前記硬化温度を含む高温度の領域で発生する第2揮発成分を含有するか否かを判定する第2判定ステップと、
前記第1判定ステップで、前記熱硬化性樹脂が硬化する硬化温度よりも低温度の領域で発生する第1揮発成分を含有すると判定した場合、前記スキン材をバッグ内に置き、前記バッグ内を真空にして前記バッグ外を大気圧下として、かつ、前記低温度の領域で所定の時間加熱することで、前記スキン材から前記第1揮発成分を発生させて除去する第1真空加熱ステップを設定する第1真空加熱ステップ設定ステップと、
前記第2判定ステップで、前記熱硬化性樹脂が前記硬化温度を含む高温度の領域で発生する第2揮発成分を含有すると判定した場合、前記スキン材をバッグ内に置き、前記バッグ内を真空にして前記バッグ外を大気圧下として、かつ、前記硬化温度以下の温度で加熱することで、前記第1揮発成分が除去された前記熱硬化性樹脂を半硬化させる第2真空加熱ステップを設定し、前記硬化温度を含む高温度の領域で発生する第2揮発成分を含有しないと判定した場合、前記スキン材をバッグ内に置き、前記バッグ内を真空にして前記バッグ外を大気圧下として加熱することで、前記第1揮発成分が除去された前記熱硬化性樹脂を半硬化させる第2真空加熱ステップを設定する第2真空加熱ステップ設定ステップと、
を有することを特徴とするスキン材の加熱条件設定方法。
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