JPH09150472A - Honeycomb composite molded object for truck body and molding thereof - Google Patents
Honeycomb composite molded object for truck body and molding thereofInfo
- Publication number
- JPH09150472A JPH09150472A JP7350701A JP35070195A JPH09150472A JP H09150472 A JPH09150472 A JP H09150472A JP 7350701 A JP7350701 A JP 7350701A JP 35070195 A JP35070195 A JP 35070195A JP H09150472 A JPH09150472 A JP H09150472A
- Authority
- JP
- Japan
- Prior art keywords
- phenol resin
- honeycomb
- composite
- honeycomb core
- heat
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 47
- 238000000465 moulding Methods 0.000 title claims abstract description 5
- 239000005011 phenolic resin Substances 0.000 claims abstract description 51
- 239000006260 foam Substances 0.000 claims abstract description 35
- 239000002657 fibrous material Substances 0.000 claims abstract description 18
- 238000000034 method Methods 0.000 claims abstract description 9
- 239000011347 resin Substances 0.000 claims abstract 3
- 229920005989 resin Polymers 0.000 claims abstract 3
- 239000000463 material Substances 0.000 claims description 99
- 238000005187 foaming Methods 0.000 claims description 7
- 229910052751 metal Inorganic materials 0.000 claims description 5
- 239000007769 metal material Substances 0.000 claims description 5
- 239000002023 wood Substances 0.000 claims description 5
- 239000004033 plastic Substances 0.000 claims description 4
- 238000005507 spraying Methods 0.000 claims description 3
- 229910010272 inorganic material Inorganic materials 0.000 claims 1
- 239000011147 inorganic material Substances 0.000 claims 1
- 239000002184 metal Substances 0.000 claims 1
- 229920003986 novolac Polymers 0.000 claims 1
- 239000011368 organic material Substances 0.000 claims 1
- 229920003987 resole Polymers 0.000 claims 1
- 238000007789 sealing Methods 0.000 claims 1
- 239000007787 solid Substances 0.000 claims 1
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 abstract description 10
- 238000010097 foam moulding Methods 0.000 abstract description 10
- 229920001568 phenolic resin Polymers 0.000 abstract description 10
- 238000010438 heat treatment Methods 0.000 abstract description 4
- 239000011162 core material Substances 0.000 description 45
- 230000000052 comparative effect Effects 0.000 description 24
- 229910052782 aluminium Inorganic materials 0.000 description 14
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 14
- 239000000123 paper Substances 0.000 description 14
- 239000011120 plywood Substances 0.000 description 14
- 238000010586 diagram Methods 0.000 description 13
- 238000006073 displacement reaction Methods 0.000 description 10
- 239000003365 glass fiber Substances 0.000 description 10
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 8
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 7
- 239000000853 adhesive Substances 0.000 description 6
- 230000001070 adhesive effect Effects 0.000 description 6
- 239000000805 composite resin Substances 0.000 description 6
- 238000009413 insulation Methods 0.000 description 6
- 238000010030 laminating Methods 0.000 description 6
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 4
- 240000007182 Ochroma pyramidale Species 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 4
- 239000004760 aramid Substances 0.000 description 4
- 229920003235 aromatic polyamide Polymers 0.000 description 4
- 238000005452 bending Methods 0.000 description 4
- 238000009863 impact test Methods 0.000 description 4
- 229920000728 polyester Polymers 0.000 description 4
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 4
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- 239000012209 synthetic fiber Substances 0.000 description 4
- 229920002994 synthetic fiber Polymers 0.000 description 4
- 229920000742 Cotton Polymers 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 2
- 229920000297 Rayon Polymers 0.000 description 2
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 2
- 239000004202 carbamide Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 229920001971 elastomer Polymers 0.000 description 2
- 229920006332 epoxy adhesive Polymers 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 238000007731 hot pressing Methods 0.000 description 2
- 230000001771 impaired effect Effects 0.000 description 2
- 239000012784 inorganic fiber Substances 0.000 description 2
- 239000002655 kraft paper Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000004745 nonwoven fabric Substances 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 239000002964 rayon Substances 0.000 description 2
- 125000006850 spacer group Chemical group 0.000 description 2
- 238000010998 test method Methods 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
Abstract
Description
【産業上の利用分野】本発明はトラックの床、ドア、ア
オリ、ウィング、フロントパネルに使用される軽量且つ
断熱性、防火性に優れたハニカム複合成形体に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a honeycomb composite molded body which is used for truck floors, doors, tilts, wings and front panels and which is lightweight and has excellent heat insulation and fire protection.
【従来の技術】従来、トラックのボデー材料にはアピト
ン材等の木質材料、アルミニウム等の金属材料が使用さ
れている。しかし、これらの材料は強度的には充分であ
るが、重量が重く車体の総重量が重くなるという欠点が
あった。最近、トラックの過積載が厳しく問われてきて
おり、積載量を増加するにはボデーの軽量化が必要とな
ってきた。また、積載物を保護するために、これらの材
料に断熱性、防火性が必要である。2. Description of the Related Art Conventionally, wood materials such as Apiton materials and metal materials such as aluminum have been used as the body materials of trucks. However, although these materials have sufficient strength, they have a drawback that they are heavy and the total weight of the vehicle body is heavy. Recently, there has been a strict demand for overloading trucks, and it has become necessary to reduce the weight of the body in order to increase the loading capacity. Further, in order to protect the load, these materials need to have heat insulation and fire protection.
【発明が解決しようとしている課題】本発明は上記事情
に鑑みてなされたもので、ハニカムコアのセルの内にフ
ェノール樹脂発泡体を充填させたハニカム複合成形体を
トラックのボデー材料に使用し必要強度を維持し軽量化
をはかること、且つ断熱性、防火性の向上をはかること
及びその製造方法を提供することにある。The present invention has been made in view of the above circumstances, and it is necessary to use a honeycomb composite molded body in which cells of a honeycomb core are filled with a phenol resin foam as a body material for a truck. It is intended to maintain the strength and reduce the weight, to improve the heat insulating property and the fireproof property, and to provide a manufacturing method thereof.
【課題を解決するための手段】本発明者は上記目的を達
成するために鋭意検討を重ねた結果、マット状繊維物の
少なくとも片面に発泡性フェノール樹脂を散布し加熱融
着させた発泡性フェノール樹脂複合物とハニカムコアと
を発泡性フェノール樹脂がハニカムコアのセル内に充填
される様に積層し表面材を同時に積層し加熱発泡成形す
ることによりセル内がフェノール樹脂発泡体で充填さ
れ、且つ表面材が接着されたハニカム複合成形体となる
こと、又この複合成形体が軽量で熱伝導率が低く断熱性
に優れ、且つ防火性に優れたものであることを見出し、
本発明に至った。以下に本発明を詳細に説明する。本発
明ではマット状繊維物の少なくとも片面に発泡性フェノ
ール樹脂を散布し加熱融着させた発泡性フェノール樹脂
複合物、図１とハニカムを積層し加熱発泡成形すること
により、ハニカム構造体の一つ一つのセル内に発泡体を
より均一に充填することが出来、また表面材を積層する
ことで、表面材を加熱発泡成形時に同時に接着すること
が出来る。この方法は成形も容易で作業性も良好であ
る。本発明に用いられるマット状繊維物の材質は有機繊
維系では木綿等の天然繊維、レーヨン等の半合成繊維、
ポリエステル等の合成繊維、無機繊維系ではガラス繊維
等があげられる。本発明に用いられるハニカムコアは材
質がクラフト紙、フェノール樹脂含浸紙、不燃紙アルミ
ニウム、ＦＲＰ、アラミドペーパー等のもの、セルの形
状が蜂の巣状、円柱状、波板状のもの等があげられる。
本発明に用いられる表面材は木質系、金属系、プラスチ
ック系の単独、あるいはそれらの２種以上の複合系の材
料で例えば、合板、合板用単板、アルミニウム板、ＦＲ
Ｐ、アラミドペーパー等があげられる。発泡性フェノー
ル樹脂複合物とハニカムコア、表面材を、図２の様に積
層し、金型温度を１２０〜２００℃に保持したプレスに
より、熱圧時間２〜３０分にて発泡成形でき、厚みは例
えば型枠、又はスペーサーを用いることにより容易に調
整できる。フェノール樹脂発泡体がハニカムコアのセル
内に充填されているため、断熱性が向上する。表面材と
ハニカムコアとの接着強度を向上させるために、あらか
じめ、表面材なしで発泡性フェノール樹脂複合物とハニ
カムコアを積層し加熱発泡成形したフェノール樹脂発泡
体で充填されたハニカム複合成形体にゴム系、エポキシ
系、フェノール系、ユリア系、アクリル系等の接着剤に
て表面材を接着することもできる。更に接着強度を向上
させるために、マット状繊維物のみを剥がしてフェノー
ル樹脂発泡体で充填されたハニカムコアと表面材とを直
接接着することもできる。Means for Solving the Problems The present inventor has conducted extensive studies in order to achieve the above-mentioned object, and as a result, a foamable phenol prepared by spraying a foamable phenol resin on at least one surface of a mat-like fiber material and heat-fusing the same. The resin composite and the honeycomb core are laminated so that the foamable phenol resin is filled in the cells of the honeycomb core, and the surface material is laminated at the same time, and the cells are filled with the phenol resin foam by heat foam molding, and It is found that the surface material is a bonded honeycomb composite molded body, and that this composite molded body is lightweight, has a low thermal conductivity and is excellent in heat insulation, and is excellent in fireproofness,
The present invention has been reached. Hereinafter, the present invention will be described in detail. In the present invention, a foamable phenolic resin composite in which a foamable phenolic resin is sprayed on at least one side of a mat-like fiber material and heat-bonded, one of a honeycomb structure is formed by laminating a honeycomb with FIG. 1 and heat-foaming. The foam can be more uniformly filled in one cell, and by laminating the surface material, the surface material can be simultaneously adhered during the heat-foam molding. This method is easy to mold and has good workability. The material of the mat-like fiber material used in the present invention is an organic fiber material such as natural fiber such as cotton, semi-synthetic fiber such as rayon,
Examples of the synthetic fiber such as polyester, and glass fiber and the like in the inorganic fiber system. Examples of the honeycomb core used in the present invention include kraft paper, phenol resin-impregnated paper, non-combustible paper aluminum, FRP, aramid paper, and the like, and cells having a honeycomb shape, a cylindrical shape, a corrugated plate shape, and the like.
The surface material used in the present invention is a wood-based material, a metal-based material, a plastic-based material, or a composite material of two or more kinds thereof, such as plywood, a veneer for plywood, an aluminum plate, and FR.
P, aramid paper and the like. A foamable phenol resin composite, a honeycomb core, and a surface material are laminated as shown in FIG. 2, and can be foam-molded in a hot pressing time of 2 to 30 minutes by a press maintaining a mold temperature of 120 to 200 ° C., and a thickness. Can be easily adjusted by using, for example, a mold or a spacer. Since the phenol resin foam is filled in the cells of the honeycomb core, the heat insulating property is improved. In order to improve the adhesive strength between the surface material and the honeycomb core, in advance, a honeycomb composite molded body filled with a phenol resin foam obtained by laminating the foamable phenol resin composite and the honeycomb core without the surface material and heating and foaming them. The surface material can be adhered with a rubber-based, epoxy-based, phenol-based, urea-based, acrylic-based, or other adhesive. Further, in order to further improve the adhesive strength, it is possible to peel off only the mat-like fiber material and directly adhere the honeycomb core filled with the phenol resin foam and the surface material.
【作用】マット状繊維物にあらかじめ均一に散布し加熱
融着させた発泡性フェノール樹脂は１２０℃以上で発泡
硬化し、ハニカムコアのセル内に均一に充填される。発
泡体の比重が０．０１〜０．１０と小さいため、ハニカ
ムコアと発泡体の重量を合計してもハニカムコア単独の
ものと比較して重量の増加は少なく、軽量性は損なわれ
ない。セル内にフェノール樹脂発泡体が１００％充填さ
れれば最も好ましいが、部分充填で厚み方向中央に空間
ができても、発泡体により上下を閉ざされた状態である
ため、フェノール樹脂発泡体が充填されていないハニカ
ムコア単体のものより断熱性は向上する。The foamable phenol resin, which has been uniformly sprayed and heat-bonded to the mat-like fibrous material in advance, foams and hardens at 120 ° C. or higher and is uniformly filled in the cells of the honeycomb core. Since the specific gravity of the foam is as small as 0.01 to 0.10, the total weight of the honeycomb core and the foam is less than that of the honeycomb core alone, and the lightness is not impaired. It is most preferable that the cell is filled with 100% phenolic resin foam, but even if there is a space at the center in the thickness direction due to partial filling, the upper and lower parts are closed by the foamed material, so the phenolic resin foam is filled. The heat insulating property is improved as compared with the case where the honeycomb core alone is not made.
【実施例】以下に実施例を示す、本発明は下記の実施例
に限定されるものではない。 ［実施例１］マット状繊維物としてポリエステル不織布
（目付量８０ｇ／ｍ2）を使用し、片面に発泡性フェノ
ール樹脂３５０ｇ／ｍ2を均一に散布、加熱融着させた
発泡性フェノール樹脂複合物とペーパーハニカムコア
（セルサイズ１４ｍｍ、厚み１５ｍｍ）を図２の様に積
層し、加熱発泡成形後、表面材として単板（アピトン材
厚み３．５ｍｍ）をフェノール樹脂発泡体で充填された
ハニカムコアをはさむ配置で積層し、エポキシ系接着剤
（塗布量３００ｇ／ｍ2）にて接着し、ハニカム複合成
形体（厚み２２．０ｍｍ）図３を得た。 ［実施例２］実施例１と同様の発泡性フェノール樹脂複
合物とペーパーハニカムコア（セルサイズ１４ｍｍ、厚
み１８ｍｍ）を図２の様に積層し、加熱発泡成形後、表
面材としてアルミニウム板（厚み０．８ｍｍ）を実施例
１と同様に積層し、同条件にて接着し、ハニカム複合成
形体（厚み１９．６ｍｍ）図３を得た。 ［実施例３］実施例１と同様の発泡性フェノール樹脂複
合物とペーパーハニカムコア（セルサイズ１４ｍｍ、厚
み１８ｍｍ）を図２の様に積層し、加熱発泡成形後、片
面をアルミニウム板（厚み０．８ｍｍ）、もう一方の面
を合板用単板（アピトン材厚み３．５ｍｍ）を積層し、
実施例１と同条件にて接着し、ハニカム複合成形体（厚
み２２．３ｍｍ）図３を得た。 ［比較例１］アピトン材、図４。 ［比較例２］表面材にクレイン合板、芯材にバルサ材を
使用した材料。株式会社ニッタックス製、アルバライ
ト、図５。 ［比較例３］アルミニウム材、日本軽金属株式会社製、
システムフロアー、図６。 ［比較例４］表面材にガラス繊維強化プロピレン樹脂複
合物（ＺＲ−〓）、及び合板、芯材にスチレンフォーム
を使用した材料。株式会社ビック製、ＺＲ−〓パネル、
図７。 ［比較例５］ガラス繊維にて強化されたウレタンフォー
ム。積水化成株式会社製、ネオランバー、図８。実施例
及び比較例によるトラックボデー用材料の物性を表１に
示す。比較例は全て市販の材料であるが、実施例の衝撃
試験、局部荷重曲げ試験結果は市販の材料とほぼ同等で
あり、実用上の問題はない。EXAMPLES Examples will be shown below, but the present invention is not limited to the following examples. [Example 1] A foamable phenol resin composite in which a polyester non-woven fabric (weight per unit area: 80 g / m 2 ) was used as a mat-like fiber material, and 350 g / m 2 of a expandable phenol resin was uniformly dispersed on one side and heat-fused. 2 and a paper honeycomb core (cell size 14 mm, thickness 15 mm) are laminated as shown in FIG. 2, and after heat-foaming and molding, a single plate (Apiton material thickness 3.5 mm) as a surface material is filled with a phenol resin foam honeycomb core. 3 were stacked in such a manner that they were sandwiched between them and bonded with an epoxy adhesive (coating amount 300 g / m 2 ) to obtain a honeycomb composite molded body (thickness 22.0 mm) as shown in FIG. [Example 2] A foamable phenol resin composite and a paper honeycomb core (cell size 14 mm, thickness 18 mm) similar to those in Example 1 were laminated as shown in Fig. 2, and after heat foam molding, an aluminum plate (thickness was used as a surface material. 0.8 mm) was laminated in the same manner as in Example 1 and adhered under the same conditions to obtain a honeycomb composite molded body (thickness 19.6 mm) as shown in FIG. [Example 3] The same expandable phenol resin composite as in Example 1 and a paper honeycomb core (cell size 14 mm, thickness 18 mm) were laminated as shown in FIG. 2, and after heat-foam molding, one surface was covered with an aluminum plate (thickness 0). .8 mm), the other surface is laminated with a plywood single plate (Apiton material thickness 3.5 mm),
Bonding was performed under the same conditions as in Example 1 to obtain a honeycomb composite molded body (thickness: 22.3 mm) in FIG. [Comparative Example 1] Apiton material, FIG. [Comparative Example 2] A material using a grain plywood as the surface material and a balsa material as the core material. Naltax Co., Ltd., Albalite, Figure 5. [Comparative Example 3] Aluminum material manufactured by Nippon Light Metal Co., Ltd.
System floor, Figure 6. [Comparative Example 4] A material in which a glass fiber reinforced propylene resin composite (ZR-〓) is used for the surface material, and styrene foam is used for the plywood and the core material. BIC Co., Ltd., ZR-〓 panel,
FIG. [Comparative Example 5] A urethane foam reinforced with glass fibers. Sekisui Kasei Co., Ltd., Neo-Lumber, Fig. 8. Table 1 shows the physical properties of materials for truck bodies according to Examples and Comparative Examples. Although the comparative examples are all commercially available materials, the impact test and local load bending test results of the examples are almost the same as those of the commercially available materials, and there is no practical problem.
【表１】 芯材の熱伝導率 熱伝導率熱線型熱伝導率計（京都電子製ＴＣ３２型）を
使用し測定した。 芯材の酸素指数 フェノールフォーム普及協会資料より引用。[Table 1] The thermal conductivity of the core material The thermal conductivity was measured using a hot-wire type thermal conductivity meter (TC32 type manufactured by Kyoto Denshi). Oxygen index of core material Quoted from Phenolic Foam Dissemination Association data.
【発明の効果】 本発明によれば、実施例の結果から明
らかな様に、軽量、且つ断熱性、防火性に優れたトラッ
クボデー用材料を得ることが出来る。EFFECTS OF THE INVENTION According to the present invention, as is clear from the results of the examples, it is possible to obtain a material for a truck body that is lightweight and has excellent heat insulating properties and fire prevention properties.
【図１】発泡性フェノール樹脂複合物の構成図である。FIG. 1 is a constitutional view of a foamable phenol resin composite.
【図２】ハニカム複合成形体の構成図である。FIG. 2 is a configuration diagram of a honeycomb composite formed body.
【図４】［比較例１］アピトン材の構成図である。FIG. 4 is a configuration diagram of [Comparative Example 1] Apiton material.
【図５】［比較例２］表面材にクレイン合板、芯材にバ
ルサ材を使用した材料（株式会社ニッタックス製、アル
バライト）の構成図である。FIG. 5 is a structural diagram of a material (comparative example 2) in which a grained plywood is used as a surface material and a balsa material is used as a core material (manufactured by Nittax Co., Ltd., Alvarite).
【図６】［比較例３］アルミニウム材（日本軽金属株式
会社製、システムフロアー）の構成図である。FIG. 6 is a configuration diagram of [Comparative Example 3] an aluminum material (manufactured by Nippon Light Metal Co., Ltd., system floor).
【図７】［比較例４］表面材にガラス繊維強化プロピレ
ン樹脂複合物（ＺＲ−〓）、及び合板、芯材にスチレン
フォームを使用した材料（株式会社ビック製、ＺＲ−〓
パネル）の構成図である。FIG. 7 [Comparative Example 4] A material using a glass fiber reinforced propylene resin composite (ZR-〓) for the surface material, and plywood, and styrene foam for the core material (ZR-〓 manufactured by BIC Co., Ltd.)
It is a block diagram of (panel).
【図８】［比較例５］ガラス繊維にて強化されたウレタ
ンフォーム（積水化成株式会社製、ネオランバー）の構
成図である。[Comparative Example 5] Fig. 8 is a configuration diagram of urethane foam reinforced with glass fibers (Neo Lumber, manufactured by Sekisui Kasei Co., Ltd.).
【図９】［衝撃試験方法］各材料上に１ｋｇの鋼性のナ
ス形オモリを２００ｃｍの高さから落下させ衝撃部のへ
こみ深さを測定した。FIG. 9 [Impact test method] 1 kg of a steel eggplant-shaped weight was dropped onto each material from a height of 200 cm, and the dent depth of the impact part was measured.
【図１０】［局部荷重曲げ試験方法］各材料上に１００
×１００ｍｍのパレット用鋼製脚を置き１０００ｋｇの
荷重をかけたとき、、の変位量を測定し、次式に
より材料の変位量を算出した。 材料の変位量＝−（の変位量＋変位量）×１／２FIG. 10: [Local load bending test method] 100 on each material
When a steel leg for a pallet of × 100 mm was placed and a load of 1000 kg was applied, the displacement amount of was measured, and the displacement amount of the material was calculated by the following formula. Material displacement =-(displacement + displacement) x 1/2
─────────────────────────────────────────────────────
────────────────────────────────────────────────── ───
【手続補正書】[Procedure amendment]
【提出日】平成８年６月１７日[Submission date] June 17, 1996
【手続補正１】[Procedure amendment 1]
【補正対象書類名】明細書[Document name to be amended] Statement
【補正対象項目名】発明の詳細な説明[Correction target item name] Detailed description of the invention
【補正方法】変更[Correction method] Change
【補正内容】[Correction contents]
【発明の詳細な説明】Detailed Description of the Invention
【産業上の利用分野】本発明はトラックの床、ドア、ア
オリ、ウィング、フロントパネルに使用される軽量且つ
断熱性、防火性に優れたハニカム複合成形体に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a honeycomb composite molded body which is used for truck floors, doors, tilts, wings and front panels and which is lightweight and has excellent heat insulation and fire protection.
【従来の技術】従来、トラックのボデー材料にはアピト
ン材等の木質材料、アルミニウム等の金属材料が使用さ
れている。しかし、これらの材料は強度的には充分であ
るが、重量が重く車体の総重量が重くなるという欠点が
あった。最近、トラックの過積載が厳しく問われてきて
おり、積載量を増加するにはボデーの軽量化が必要とな
ってきた。また、積載物を保護するために、これらの材
料に断熱性、防火性が必要である。2. Description of the Related Art Conventionally, wood materials such as Apiton materials and metal materials such as aluminum have been used as the body materials of trucks. However, although these materials have sufficient strength, they have a drawback that they are heavy and the total weight of the vehicle body is heavy. Recently, there has been a strict demand for overloading trucks, and it has become necessary to reduce the weight of the body in order to increase the loading capacity. Further, in order to protect the load, these materials need to have heat insulation and fire protection.
【発明が解決しようとしている課題】本発明は上記事情
に鑑みてなされたもので、ハニカムコアのセルの内にフ
ェノール樹脂発泡体を充填させたハニカム複合成形体を
トラックのボデー材料に使用し必要強度を維持し軽量化
をはかること、且つ断熱性、防火性の向上をはかること
及びその製造方法を提供することにある。The present invention has been made in view of the above circumstances, and it is necessary to use a honeycomb composite molded body in which cells of a honeycomb core are filled with a phenol resin foam as a body material for a truck. It is intended to maintain the strength and reduce the weight, to improve the heat insulating property and the fireproof property, and to provide a manufacturing method thereof.
【課題を解決するための手段】本発明者は上記目的を達
成するために鋭意検討を重ねた結果、マット状繊維物の
少なくとも片面に発泡性フェノール樹脂を散布し加熱融
着させた発泡性フェノール樹脂複合物とハニカムコアと
を発泡性フェノール樹脂がハニカムコアのセル内に充填
される様に積層し表面材を同時に積層し加熱発泡成形す
ることによりセル内がフェノール樹脂発泡体で充填さ
れ、且つ表面材が接着されたハニカム複合成形体となる
こと、又この複合成形体が軽量で熱伝導率が低く断熱性
に優れ、且つ防火性に優れたものであることを見出し、
本発明に至った。以下に本発明を詳細に説明する。本発
明ではマット状繊維物の少なくとも片面に発泡性フェノ
ール樹脂を散布し加熱融着させた発泡性フェノール樹脂
複合物、図１とハニカムを積層し加熱発泡成形すること
により、ハニカム構造体の一つ一つのセル内に発泡体を
より均一に充填することが出来、また表面材を積層する
ことで、表面材を加熱発泡成形時に同時に接着すること
が出来る。この方法は成形も容易で作業性も良好であ
る。本発明に用いられるマット状繊維物の材質は有機繊
維系では木綿等の天然繊維、レーヨン等の半合成繊維、
ポリエステル等の合成繊維、無機繊維系ではガラス繊維
等があげられる。本発明に用いられるハニカムコアは材
質がクラフト紙、フェノール樹脂含浸紙、不燃紙アルミ
ニウム、ＦＲＰ、アラミドペーパー等のもの、セルの形
状が蜂の巣状、円柱状、波板状のもの等があげられる。
本発明に用いられる表面材は木質系、金属系、プラスチ
ック系の単独、あるいはそれらの２種以上の複合系の材
料で例えば、合板、合板用単板、アルミニウム板、ＦＲ
Ｐ、アラミドペーパー等があげられる。発泡性フェノー
ル樹脂複合物とハニカムコア、表面材を、図２の様に積
層し、金型温度を１２０〜２００℃に保持したプレスに
より、熱圧時間２〜３０分にて発泡成形でき、厚みは例
えば型枠、又はスペーサーを用いることにより容易に調
整できる。フェノール樹脂発泡体がハニカムコアのセル
内に充填されているため、断熱性が向上する。表面材と
ハニカムコアとの接着強度を向上させるために、あらか
じめ、表面材なしで発泡性フェノール樹脂複合物とハニ
カムコアを積層し加熱発泡成形したフェノール樹脂発泡
体で充填されたハニカム複合成形体にゴム系、エポキシ
系、フェノール系、ユリア系、アクリル系等の接着剤に
て表面材を接着することもできる。更に接着強度を向上
させるために、マット状繊維物のみを剥がしてフェノー
ル樹脂発泡体で充填されたハニカムコアと表面材とを直
接接着することもできる。Means for Solving the Problems The present inventor has conducted extensive studies in order to achieve the above-mentioned object, and as a result, a foamable phenol prepared by spraying a foamable phenol resin on at least one surface of a mat-like fiber material and heat-fusing the same. The resin composite and the honeycomb core are laminated so that the foamable phenol resin is filled in the cells of the honeycomb core, and the surface material is laminated at the same time, and the cells are filled with the phenol resin foam by heat foam molding, and It is found that the surface material is a bonded honeycomb composite molded body, and that this composite molded body is lightweight, has a low thermal conductivity and is excellent in heat insulation, and is excellent in fireproofness,
The present invention has been reached. Hereinafter, the present invention will be described in detail. In the present invention, a foamable phenolic resin composite in which a foamable phenolic resin is sprayed on at least one side of a mat-like fiber material and heat-bonded, one of a honeycomb structure is formed by laminating a honeycomb with FIG. 1 and heat-foaming. The foam can be more uniformly filled in one cell, and by laminating the surface material, the surface material can be simultaneously adhered during the heat-foam molding. This method is easy to mold and has good workability. The material of the mat-like fiber material used in the present invention is an organic fiber material such as natural fiber such as cotton, semi-synthetic fiber such as rayon,
Examples of the synthetic fiber such as polyester, and glass fiber and the like in the inorganic fiber system. Examples of the honeycomb core used in the present invention include kraft paper, phenol resin-impregnated paper, non-combustible paper aluminum, FRP, aramid paper, and the like, and cells having a honeycomb shape, a cylindrical shape, a corrugated plate shape, and the like.
The surface material used in the present invention is a wood-based material, a metal-based material, a plastic-based material, or a composite material of two or more kinds thereof, such as plywood, a veneer for plywood, an aluminum plate, and FR.
P, aramid paper and the like. A foamable phenol resin composite, a honeycomb core, and a surface material are laminated as shown in FIG. 2, and can be foam-molded in a hot pressing time of 2 to 30 minutes by a press maintaining a mold temperature of 120 to 200 ° C., and a thickness. Can be easily adjusted by using, for example, a mold or a spacer. Since the phenol resin foam is filled in the cells of the honeycomb core, the heat insulating property is improved. In order to improve the adhesive strength between the surface material and the honeycomb core, in advance, a honeycomb composite molded body filled with a phenol resin foam obtained by laminating the foamable phenol resin composite and the honeycomb core without the surface material and heating and foaming them. The surface material can be adhered with a rubber-based, epoxy-based, phenol-based, urea-based, acrylic-based, or other adhesive. Further, in order to further improve the adhesive strength, it is possible to peel off only the mat-like fiber material and directly adhere the honeycomb core filled with the phenol resin foam and the surface material.
【作用】マット状繊維物にあらかじめ均一に散布し加熱
融着させた発泡性フェノール樹脂は１２０℃以上で発泡
硬化し、ハニカムコアのセル内に均一に充填される。発
泡体の比重が０．０１〜０．１０と小さいため、ハニカ
ムコアと発泡体の重量を合計してもハニカムコア単独の
ものと比較して重量の増加は少なく、軽量性は損なわれ
ない。セル内にフェノール樹脂発泡体が１００％充填さ
れれば最も好ましいが、部分充填で厚み方向中央に空間
ができても、発泡体により上下を閉ざされた状態である
ため、フェノール樹脂発泡体が充填されていないハニカ
ムコア単体のものより断熱性は向上する。The foamable phenol resin, which has been uniformly sprayed and heat-bonded to the mat-like fibrous material in advance, foams and hardens at 120 ° C. or higher and is uniformly filled in the cells of the honeycomb core. Since the specific gravity of the foam is as small as 0.01 to 0.10, the total weight of the honeycomb core and the foam is less than that of the honeycomb core alone, and the lightness is not impaired. It is most preferable that the cell is filled with 100% phenolic resin foam, but even if there is a space at the center in the thickness direction due to partial filling, the upper and lower parts are closed by the foamed material, so the phenolic resin foam is filled. The heat insulating property is improved as compared with the case where the honeycomb core alone is not made.
【実施例】以下に実施例を示す、本発明は下記の実施例
に限定されるものではない。 ［実施例１］マット状繊維物としてポリエステル不織布
（目付量８０ｇ／ｍ2）を使用し、片面に発泡性フェノ
ール樹脂３５０ｇ／ｍ2を均一に散布、加熱融着させた
発泡性フェノール樹脂複合物とペーパーハニカムコア
（セルサイズ１４ｍｍ、厚み１５ｍｍ）を図２の様に積
層し、加熱発泡成形後、表面材として単板（アピトン材
厚み３．５ｍｍ）をフェノール樹脂発泡体で充填された
ハニカムコアをはさむ配置で積層し、エポキシ系接着剤
（塗布量３００ｇ／ｍ2）にて接着し、ハニカム複合成
形体（厚み２２．０ｍｍ）図３を得た。 ［実施例２］実施例１と同様の発泡性フェノール樹脂複
合物とペーパーハニカムコア（セルサイズ１４ｍｍ、厚
み１８ｍｍ）を図２の様に積層し、加熱発泡成形後、表
面材としてアルミニウム板（厚み０．８ｍｍ）を実施例
１と同様に積層し、同条件にて接着し、ハニカム複合成
形体（厚み１９．６ｍｍ）図３を得た。 ［実施例３］実施例１と同様の発泡性フェノール樹脂複
合物とペーパーハニカムコア（セルサイズ１４ｍｍ、厚
み１８ｍｍ）を図２の様に積層し、加熱発泡成形後、片
面をアルミニウム板（厚み０．８ｍｍ）、もう一方の面
を合板用単板（アピトン材厚み３．５ｍｍ）を積層し、
実施例１と同条件にて接着し、ハニカム複合成形体（厚
み２２．３ｍｍ）図３を得た。 ［比較例１］アピトン材、図４。 ［比較例２］表面材にクレイン合板、芯材にバルサ材を
使用した材料。株式会社ニッタックス製、アルバライ
ト、図５。 ［比較例３］アルミニウム材、日本軽金属株式会社製、
システムフロアー、図６。 ［比較例４］表面材にガラス繊維強化プロピレン樹脂複
合物（ＺＲ−２）、及び合板、芯材にスチレンフォーム
を使用した材料。株式会社ビック製、ＺＲ−２パネル、
図７。 ［比較例５］ガラス繊維にて強化されたウレタンフォー
ム。積水化成株式会社製、ネオランバー、図８。 実施例及び比較例によるトラックボデー用材料の物性を
表１に示す。比較例は全て市販の材料であるが、実施例
の衝撃試験、局部荷重曲げ試験結果は市販の材料とほぼ
同等であり、実用上の問題はない。EXAMPLES Examples will be shown below, but the present invention is not limited to the following examples. [Example 1] A foamable phenol resin composite in which a polyester non-woven fabric (weight per unit area: 80 g / m 2 ) was used as a mat-like fiber material, and 350 g / m 2 of a expandable phenol resin was uniformly dispersed on one side and heat-fused. 2 and a paper honeycomb core (cell size 14 mm, thickness 15 mm) are laminated as shown in FIG. 2, and after heat-foaming and molding, a single plate (Apiton material thickness 3.5 mm) as a surface material is filled with a phenol resin foam honeycomb core. 3 were stacked in such a manner that they were sandwiched between them and bonded with an epoxy adhesive (coating amount 300 g / m 2 ) to obtain a honeycomb composite molded body (thickness 22.0 mm) as shown in FIG. [Example 2] A foamable phenol resin composite and a paper honeycomb core (cell size 14 mm, thickness 18 mm) similar to those in Example 1 were laminated as shown in Fig. 2, and after heat foam molding, an aluminum plate (thickness was used as a surface material. 0.8 mm) was laminated in the same manner as in Example 1 and adhered under the same conditions to obtain a honeycomb composite molded body (thickness 19.6 mm) as shown in FIG. [Example 3] The same expandable phenol resin composite as in Example 1 and a paper honeycomb core (cell size 14 mm, thickness 18 mm) were laminated as shown in FIG. 2, and after heat-foam molding, one surface was covered with an aluminum plate (thickness 0). .8 mm), the other surface is laminated with a plywood single plate (Apiton material thickness 3.5 mm),
Bonding was performed under the same conditions as in Example 1 to obtain a honeycomb composite molded body (thickness: 22.3 mm) in FIG. [Comparative Example 1] Apiton material, FIG. [Comparative Example 2] A material using a grain plywood as the surface material and a balsa material as the core material. Naltax Co., Ltd., Albalite, Figure 5. [Comparative Example 3] Aluminum material manufactured by Nippon Light Metal Co., Ltd.
System floor, Figure 6. [Comparative Example 4] A material in which a glass fiber reinforced propylene resin composite (ZR-2) is used as a surface material, and styrene foam is used as a plywood and a core material. BIC Co., Ltd., ZR-2 panel,
FIG. [Comparative Example 5] A urethane foam reinforced with glass fibers. Sekisui Kasei Co., Ltd., Neo-Lumber, Fig. 8. Table 1 shows the physical properties of materials for truck bodies according to Examples and Comparative Examples. Although the comparative examples are all commercially available materials, the impact test and local load bending test results of the examples are almost the same as those of the commercially available materials, and there is no practical problem.
【手続補正２】[Procedure amendment 2]
【補正対象書類名】明細書[Document name to be amended] Statement
【補正対象項目名】図面の簡単な説明[Correction target item name] Brief description of drawings
【補正方法】変更[Correction method] Change
【補正内容】[Correction contents]
【図面の簡単な説明】[Brief description of the drawings]
【図１】発泡性フェノール樹脂複合物の構成図である。FIG. 1 is a constitutional view of a foamable phenol resin composite.
【図２】発泡性フェノール樹脂複合物とハニカムコアの
積層構成図である。[Fig. 2] Fig. 2 is a stacking diagram of a foamable phenol resin composite and a honeycomb core.
【図３】ハニカム複合成形体の構成図である。FIG. 3 is a configuration diagram of a honeycomb composite formed body.
【図４】［比較例１］アピトン材の構成図である。FIG. 4 is a configuration diagram of [Comparative Example 1] Apiton material.
【図５】［比較例２］表面材にクレイン合板、芯材にバ
ルサ材を使用した材料（株式会社ニッタックス製、アル
バライト）の構成図である。FIG. 5 is a structural diagram of a material (comparative example 2) in which a grained plywood is used as a surface material and a balsa material is used as a core material (manufactured by Nittax Co., Ltd., Alvarite).
【図６】［比較例３］アルミニウム材（日本軽金属株式
会社製、システムフロアー）の構成図である。FIG. 6 is a configuration diagram of [Comparative Example 3] an aluminum material (manufactured by Nippon Light Metal Co., Ltd., system floor).
【図７】［比較例４］表面材にガラス繊維強化プロピレ
ン樹脂複合物（ＺＲ−２）、及び合板、芯材にスチレン
フォームを使用した材料（株式会社ビック製、ＺＲ−２
パネル）の構成図である。[Comparative Example 4] Glass fiber reinforced propylene resin composite (ZR-2) as a surface material, and a material using plywood and styrene foam as a core material (manufactured by BIC Co., Ltd., ZR-2).
It is a block diagram of (panel).
【図８】［比較例５］ガラス繊維にて強化されたウレタ
ンフォーム（積水化成株式会社製、ネオランバー）の構
成図である。[Comparative Example 5] Fig. 8 is a configuration diagram of urethane foam reinforced with glass fibers (Neo Lumber, manufactured by Sekisui Kasei Co., Ltd.).
【図９】［衝撃試験方法］各材料上に１ｋｇの鋼性のナ
ス形オモリを２００ｃｍの高さから落下させ衝撃部のへ
こみ深さを測定した。FIG. 9 [Impact test method] 1 kg of a steel eggplant-shaped weight was dropped onto each material from a height of 200 cm, and the dent depth of the impact part was measured.
【図１０】［局部荷重曲げ試験方法］各材料上に１００
×１００ｍｍのパレット用鋼製脚を置き１０００ｋｇの
荷重をかけたとき、、の変位量を測定し、次式に
より材料の変位量を算出した。 材料の変位量＝−（の変位量＋変位量）×１／２FIG. 10: [Local load bending test method] 100 on each material
When a steel leg for a pallet of × 100 mm was placed and a load of 1000 kg was applied, the displacement amount of was measured, and the displacement amount of the material was calculated by the following formula. Material displacement =-(displacement + displacement) x 1/2
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.6 識別記号 庁内整理番号 ＦＩ 技術表示箇所 Ｂ６２Ｄ 33/023 Ｂ６２Ｄ 33/02 Ｂ (72)発明者 森田 清司 群馬県高崎市宿大類町700番地 群栄化学 工業株式会社内─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. 6 Identification code Internal reference number FI technical display location B62D 33/023 B62D 33/02 B (72) Inventor Kiyoji Morita 700, Jukudaiji-cho, Takasaki-shi, Gunma Group Within Sakae Chemical Co., Ltd.
Claims (5)
フェノール樹脂を散布し加熱融着させた発泡性フェノー
ル樹脂複合物を用いてハニカムコアのセル内がフェノー
ル樹脂発泡体で充填されたことを特徴とする、トラック
ボデー用ハニカム複合成形体。1. A cell of a honeycomb core is filled with a phenol resin foam by using a foamable phenol resin composite prepared by spraying a foamable phenol resin on at least one surface of a mat-like fiber material and heat-sealing the same. A characteristic honeycomb composite molded body for truck bodies.
ノール樹脂、または固形レゾール樹脂に発泡性を付与し
たものである請求項１記載のトラックボデー用ハニカム
複合成形体。2. The honeycomb composite molded body for a track body according to claim 1, wherein the foamable phenol resin is a novolac type phenol resin or a solid resol resin provided with foamability.
独、又はそれらの複合された紙、金属のフィルム又はシ
ート、或はプラスチックである、請求項１及び２記載の
トラックボデー用ハニカム複合成形体。3. The honeycomb composite for a track body according to claim 1 or 2, wherein the material of the honeycomb core is an organic or inorganic material alone or a composite thereof, a paper, a metal film or sheet, or a plastic. Molded body.
の単独、あるいはそれらの２種以上の複合系である請求
項１〜３記載のトックボデー用ハニカム複合成形体。4. The honeycomb composite molded body for a toque body according to claim 1, wherein the surface material is a wood-based material, a metal-based material, a plastic-based material, or a composite system of two or more thereof.
フェノール樹脂を散布し加熱融着させた発泡性フェノー
ル樹脂複合物とハニカムコアとを発泡性フェノール樹脂
がハニカムコアのセル内に充填されるように積層し、更
にマット状繊維物と異なる材質の表面材を同時に積層し
１段又は多段プレスにより加熱発泡成形するか、又は表
面材なしで成形した後、表面材を接着することを特徴と
する請求項１〜４記載のトラックボデー用ハニカム複合
成形体の成形方法。5. A foamable phenol resin composite in which a foamable phenol resin is sprayed and heat-sealed on at least one surface of a mat-like fiber material and a honeycomb core are filled with the foamable phenol resin in the cells of the honeycomb core. And the surface material made of a material different from that of the mat-like fibrous material are laminated at the same time, and heat foaming is performed by a single-stage or multi-stage press, or after molding without the surface material, the surface material is bonded. The method for forming a honeycomb composite formed article for a track body according to claim 1.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP7350701A JPH09150472A (en) | 1995-11-28 | 1995-11-28 | Honeycomb composite molded object for truck body and molding thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP7350701A JPH09150472A (en) | 1995-11-28 | 1995-11-28 | Honeycomb composite molded object for truck body and molding thereof |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH09150472A true JPH09150472A (en) | 1997-06-10 |
Family
ID=18412266
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP7350701A Pending JPH09150472A (en) | 1995-11-28 | 1995-11-28 | Honeycomb composite molded object for truck body and molding thereof |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH09150472A (en) |
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2006132184A1 (en) | 2005-06-08 | 2006-12-14 | Kabushiki Kaisha Shizuka | Sandwich panel including honeycomb structure body and method of producing the sandwich panel |
| JP2007517687A (en) * | 2004-01-19 | 2007-07-05 | エラコ ピーティーワイ リミテッド | High impact strength elastic mixed fiber metal laminate |
| JP2010036848A (en) * | 2008-08-08 | 2010-02-18 | Tomei Giken Kk | Door material for truck |
| CN103211521A (en) * | 2011-12-06 | 2013-07-24 | 膳魔师（中国）家庭制品有限公司 | Electric pressurizing injection-out type liquid container |
| CN105015047A (en) * | 2014-04-24 | 2015-11-04 | 沈阳航空航天大学 | Preparation method for resin honeycomb sandwich structure and composite material structure thereof |
| KR20160094209A (en) * | 2015-01-30 | 2016-08-09 | 한국차체 주식회사 | Composite material cargo box for truck |
| KR20160094210A (en) * | 2015-01-30 | 2016-08-09 | 한국차체 주식회사 | Composite material cargo box for truck |
-
1995
- 1995-11-28 JP JP7350701A patent/JPH09150472A/en active Pending
Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2007517687A (en) * | 2004-01-19 | 2007-07-05 | エラコ ピーティーワイ リミテッド | High impact strength elastic mixed fiber metal laminate |
| WO2006132184A1 (en) | 2005-06-08 | 2006-12-14 | Kabushiki Kaisha Shizuka | Sandwich panel including honeycomb structure body and method of producing the sandwich panel |
| EP1829674A1 (en) * | 2005-06-08 | 2007-09-05 | Kabushiki Kaisha Shizuka | Sandwich panel including honeycomb structure body and method of producing the sandwich panel |
| EP1829674A4 (en) * | 2005-06-08 | 2012-05-30 | Shizuka Kk | Sandwich panel including honeycomb structure body and method of producing the sandwich panel |
| JP2010036848A (en) * | 2008-08-08 | 2010-02-18 | Tomei Giken Kk | Door material for truck |
| CN103211521A (en) * | 2011-12-06 | 2013-07-24 | 膳魔师（中国）家庭制品有限公司 | Electric pressurizing injection-out type liquid container |
| CN105015047A (en) * | 2014-04-24 | 2015-11-04 | 沈阳航空航天大学 | Preparation method for resin honeycomb sandwich structure and composite material structure thereof |
| KR20160094209A (en) * | 2015-01-30 | 2016-08-09 | 한국차체 주식회사 | Composite material cargo box for truck |
| KR20160094210A (en) * | 2015-01-30 | 2016-08-09 | 한국차체 주식회사 | Composite material cargo box for truck |
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