JP2007301888

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DESCRIPTION JP2007301888
To provide a new lightweight, highly rigid plate material replacing conventional honeycomb
structure materials. [Solution] A plurality of tube materials having hollow inside and a pair of
surface materials provided so as to seal the hollow portions of each of the plurality of tubes at
both ends of the plurality of tube materials are lightweight. Manufacture and construct
composite plate materials. [Selected figure] Figure 1
Lightweight composite plate, method of manufacturing the same, and speaker using the same
[0001]
The present invention relates to a lightweight composite plate material, a method of
manufacturing the same, and a speaker using the same.
[0002]
Conventionally, honeycomb structural materials have been applied to flat speakers and the like
as well as moving devices such as aircrafts and Shinkansen, taking advantage of features such as
lightness and high rigidity.
[0003]
At present, such honeycomb structured materials are manufactured through complicated and
many processes.
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Typically, first, a thermosetting epoxy adhesive is linearly applied in the longitudinal direction at
regular intervals on the front and back of the aramid non-woven fabric and paper forming the
honeycomb partition walls, and this adhesive is applied. The aramid non-woven fabric and the
sheet are shifted so that a honeycomb structure can be formed, and after overlapping, the
adhesive is cured by heating.
Next, the lowermost aramid nonwoven fabric or paper is fixed, and the uppermost aramid
nonwoven fabric or paper is uniformly pulled up to form a hexagonally laid sideways honeycomb
structure.
[0004]
Then, the intermediate member constituting the above-mentioned honeycomb structure is
impregnated with a phenol resin, and the resultant is heated and cured to obtain a honeycomb
structure. Next, slice cutting is performed on the honeycomb structure to obtain a planar
honeycomb material. Then, a thin glass epoxy laminate or a glass phenol laminate is attached to
both ends of the honeycomb material with an epoxy resin or the like to obtain the desired
honeycomb structure material.
[0005]
However, the conventional honeycomb structure material as described above is complicated in
the manufacturing process and expensive, and sometimes it can not be said that the rigidity is
sufficient.
[0006]
An object of the present invention is to provide a novel, lightweight, highly rigid plate material
replacing conventional honeycomb structure materials in view of the above-mentioned problems.
[0007]
In order to achieve the above object, according to the present invention, there are provided a
plurality of tubes having a hollow inside, and sealing the hollow portion of each of the plurality of
tubes at both ends of the plurality of tubes. The present invention relates to a lightweight
composite plate material, comprising: a pair of surface materials.
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[0008]
The lightweight composite plate material of the present invention is composed of a plurality of
tube materials constituting the central portion, and a pair of surface materials provided at both
ends so as to seal the hollow portions of these tube materials. It has a very simple structure.
Therefore, as described in detail below, the method of manufacturing the lightweight composite
plate can be extremely simplified, and the manufacturing cost can be significantly reduced.
[0009]
In addition, by appropriately controlling the number and arrangement density of the tube
materials, and further appropriately controlling the material components and the like, and by
appropriately controlling the material components and the thickness of the surface material, the
inside of the tube material The mechanical properties, in particular the rigidity etc., can be
arbitrarily controlled while ensuring the lightness because of the hollow structure.
As a result, a lightweight and highly rigid plate material can be easily provided.
[0010]
As described above, according to the present invention, it is possible to easily provide a novel,
lightweight, high-rigidity plate material replacing the conventional honeycomb structure
material.
[0011]
Hereinafter, other features and advantages of the present invention will be described in detail
based on the best mode for carrying out the invention.
[0012]
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(Tube material) The lightweight composite board material of the present invention comprises a
plurality of tube materials whose inside is hollow.
This tube material exists so that both ends are pinched by the surface material, and constitutes
the central part of the light weight composite plate material.
Moreover, since the said tube material is hollow inside, the lightweight property of the said
lightweight composite board material is ensured.
[0013]
As described above, since the tube material constitutes the central portion of the light weight
composite plate material, the number of arrangement, the arrangement density, the material
components, etc. impart desired characteristics, particularly high rigidity, to the light weight
composite plate material. Select and control as appropriate.
[0014]
For example, by forming the tube material from an impregnated member configured to include a
sleeve made of a woven fiber fabric or a non-woven fabric fiber and a resin composition
impregnated in the sleeve, the lightweight composite plate material can be obtained. It becomes
possible to easily impart high rigidity.
Under the present circumstances, by comprising the said resin composition from a phenol resin
especially, while being able to provide high rigidity easily with respect to the said tube material,
ie, the said lightweight composite board material, a flame retardance can be provided. .
[0015]
Further, as the fiber woven fabric, in addition to highly crystalline organic fibers such as nylon,
aramid, carbon and polyester, glass cloth can be used.
In particular, when the organic fiber is used, the lightness of the tube material, that is, the
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lightweight composite plate material can be ensured more reliably, and rigidity can be improved.
[0016]
In addition, as said fiber non-woven fabric, non-woven fabric based on general purpose, for
example, carbon, aramid, nylon and phenol woven paper can be used.
[0017]
(Surface Material) The lightweight composite plate material of the present invention comprises a
pair of surface materials at both ends of the tube material constituting the central part.
The pair of surface members are disposed to seal the internal cavity of the tube material in order
to constitute the lightweight composite plate material.
[0018]
The material component, thickness, and the like of the surface material are appropriately
selected and controlled so as to impart desired characteristics, particularly high rigidity, to the
lightweight composite plate material. For example, by forming the surface material from an
impregnated member including a board made of a woven fiber fabric or a non-woven fabric fiber
and a resin composition impregnated in the board, the weight of the lightweight composite plate
can be increased. Stiffness can be easily given. Under the present circumstances, by comprising
the said resin composition from a phenol resin especially, while being able to provide high
rigidity easily with respect to the said surface material, ie, the said lightweight composite board
material, a flame retardance can be provided. .
[0019]
Moreover, as the fiber woven fabric and the fiber non-woven fabric, the same as the abovementioned tube material can be used.
[0020]
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(Light-Weight Composite Plate Material) As described above, the light-weight composite plate
material of the present invention includes the plurality of tube materials and the surface material
provided to seal the internal cavity of the tube material at both ends thereof. .
The lightweight composite plate material can be made into any form according to the application
by appropriately controlling the arrangement configuration and arrangement density of the tube
material, and the form of the surface material.
[0021]
FIG. 1 is a block diagram showing an example of the lightweight composite plate material of the
present invention. Fig.1 (a) is a side sectional view of a lightweight composite board material,
FIG.1 (b) is a surface view of a lightweight composite board material. In addition, in this surface
view, in order to clearly show the arrangement configuration of the tube material, the surface
material is omitted.
[0022]
In the lightweight composite plate 10 shown in FIG. 1, a plurality of tube materials 11 are closely
arranged in a honeycomb shape so as to contact each other, and a pair of surface materials 12
substantially parallel to each other are provided at both ends thereof The plate member 10 is
configured to have a flat plate shape. As shown in FIG. 1, the rigidity of the lightweight composite
plate material 10 can be further improved by arranging the tube materials 11 in close contact
with each other. In addition, by reducing the arrangement ¦ positioning density of the tube
material 11, the rigidity of the lightweight composite board ¦ plate material 10 can be naturally
reduced.
[0023]
Moreover, the lightness of the tube material 11, that is, the lightweight composite plate material
10 is secured by the cavity 13 formed in the tube material 11.
[0024]
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FIG. 2 is a block diagram showing another example of the lightweight composite plate material of
the present invention.
Fig.2 (a) is a side sectional view of a lightweight composite board material, FIG.2 (b) is a surface
view of a lightweight composite board material. Also in this surface view, the surface material is
omitted to clearly show the arrangement configuration of the tube material.
[0025]
In the lightweight composite plate 20 shown in FIG. 2, the plurality of tube materials 21 are
closely arranged in a honeycomb shape so as to be in contact with each other in the surface
material 22 composed of curved members substantially parallel to each other. Are configured to
exhibit a curved variant. Also in this case, as shown in FIG. 2, the rigidity of the lightweight
composite plate material 20 can be further improved by arranging the tube materials 21 in close
contact with each other. The rigidity of the lightweight composite plate material 20 can naturally
be reduced by reducing the arrangement density of the tube material 21.
[0026]
Moreover, the surface shape of the surface material 22 is exhibiting substantially elliptical shape.
Therefore, the lightweight composite plate 20 shown in FIG. 2 can be used for applications such
as radome. In addition, it may replace with substantially elliptical shape and can also be made
circular suitably.
[0027]
FIG. 3 is an enlarged view of the arrangement of the tube members 11 and 21 of the lightweight
composite plates 10 and 20 shown in FIGS. 1 and 2. In the example shown in FIG. 3A, the crosssectional shape of the tube material has a circular shape, whereas in the example shown in FIG.
3B, the cross-sectional shape of the tube material is hexagonal due to the internal force of the
foaming agent. It has a shape. Generally, when the tube materials are closely arranged, the tube
materials become hexagonal as shown in FIG. 3 (b) due to the manufacturing method shown
below, etc., and the arrangement density of the tube materials decreases As it does, as shown to
Fig.3 (a), a tube material comes to exhibit circular shape.
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[0028]
(Method for Producing Light-Weight Composite Plate Material) The method for producing the
light-weight composite plate material of the present invention is not particularly limited, but
preferably it is produced by the following method.
[0029]
First, a plurality of prepreg tubes for the plurality of tubes described above are prepared.
The prepreg tube can be composed of, for example, an impregnated member configured to
include a sleeve made of the above-described fiber woven fabric or non-woven fabric and a resin
composition impregnated in the sleeve. In addition, about sizes, such as length of the said
prepreg tube, it sets beforehand so that the said target tube material may be obtained.
[0030]
Next, a gas generating agent is attached to the inner wall of the prepreg tube. The gas generating
agent generates a predetermined gas in a heating process described below, forms a cavity in the
prepreg tube, and forms a target tube material. Examples of the gas generating agent include
sodium bicarbonate and the like.
[0031]
Then, a pair of prepreg boards for the pair of surface materials are provided in close contact with
both ends of the plurality of prepreg tubes. This prepreg board can also be constituted of, for
example, an impregnated member including a board made of the above-described fiber woven
fabric or fiber non-woven fabric and a resin composition impregnated in the board.
[0032]
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Under the present circumstances, although the said prepreg board can also be used as a single ¦
mono layer, it can also be used, laminating two or more. For example, three-layered prepreg
boards can be prepared, and these can be laminated and used.
[0033]
Then, the prepreg tube and the pair of prepreg boards are heated under pressure to adhere to
each other. At this time, as described above, the prepreg tube is hardened and strained by the gas
generated from the gas generating agent, and both ends of the tube material are sandwiched by
the surface material in conjunction with the curing process by the heating. The lightweight
composite plate material of the present invention can be obtained.
[0034]
In the light-weight composite plate material, when arranging the tube materials in a honeycomb
shape, for example, the corresponding prepreg tubes need to be arranged in the same manner.
Such an arrangement is performed by preparing a predetermined mold and arranging to fill the
prepreg tube in the mold. As the mold, a wood mold, a mold or the like can be used.
[0035]
Moreover, when manufacturing the lightweight composite member of a structure as shown in
FIG. 1, a square-shaped thing is used as said type ¦ mold. Moreover, in manufacturing the
lightweight composite member of a structure as shown in FIG. 2, a ring-shaped form is used. In
the mold, a wax such as carnauba wax can be applied as appropriate for release.
[0036]
In the heating operation, when the adhesion is not sufficient, the degree of adhesion can be
adjusted appropriately using an adhesive.
[0037]
Furthermore, when producing a modified lightweight composite plate material having a curved
shape as shown in FIG. 2, as shown in FIG. 4, in addition to the mold 31 serving as the base, it fits
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into the curved shape of the lightweight composite plate material to be formed. Additional molds
32 and 33 of combined curved shape are used in combination.
[0038]
FIG. 5: is a block diagram which shows an example of the apparatus which manufactures the
lightweight composite board material of this invention continuously.
The lightweight composite member manufacturing apparatus 40 shown in FIG. 5 includes a
hopper 41 for holding and supplying the prepreg tubes 11A and 22A, and rollers 42 and 43 for
supplying prepreg boards as appropriate.
The roller 42 supplies a prepreg board for sealing the hollow of the tube material from below,
and the roller 43 supplies the prepreg board for sealing the hollow of the tube material from
above.
[0039]
Further, the device 40 includes a belt 44 for transporting the prepreg tube and the prepreg
board, and is configured to be transported and driven by the support roll 45 and the guide roll
46. The device 40 also includes a heating and pressing press 47 at the leading end of the belt 44
in the transport direction.
[0040]
In the apparatus 40 shown in FIG. 5, the prepreg tubes 11A and 22A are continuously supplied
from the hopper 44 into a mold (not shown), and the whole mold is conveyed by the belt 44
toward the heating and pressing press 47. On the other hand, prepreg boards are appropriately
transported from the rollers 42 and 43, and the prepreg boards are positioned on the upper and
lower surfaces of the prepreg tubes 11A and 22A housed and disposed in the mold. Next, the
laminate obtained in this manner is conveyed by the belt 44 and heated under pressure by the
heating and pressing press 47 to obtain the light weight composite plate materials 10 and 20 as
described above.
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[0041]
If such an apparatus 40 is used, the target lightweight composite plate material can be
manufactured continuously and efficiently.
[0042]
(Speaker) Next, a speaker will be described as a specific application example using the
lightweight composite plate material of the present invention.
When the lightweight composite plate material is used in the speaker, the lightweight composite
plate material is used as a diaphragm.
[0043]
FIG. 6 is a configuration diagram in the case where the lightweight composite plate material of
the present invention is applied to a speaker. As shown in FIG. 6, by providing the sound
generating excitation device 50 on the lightweight composite plate 10, the lightweight composite
plate 10 is made to function as a diaphragm to constitute a speaker. According to the
configuration as shown in FIG. 6, it is possible to provide a high-rigidity and lightweight speaker
at low cost.
[0044]
As mentioned above, although the present invention was explained in detail based on the abovementioned example, the present invention is not limited to the above-mentioned example, and
various modification and change are possible unless it deviates from the category of the present
invention.
[0045]
The lightweight composite plate material of the present invention can be used in all fields such as
architecture, furniture, various housings, play boards, aircraft, ships, vehicles, automobiles, etc.
other than the above-mentioned speakers.
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[0046]
It is a block diagram which shows an example of the lightweight composite board material of this
invention.
It is a block diagram which shows the other example of the lightweight composite board material
of this invention.
It is the figure which expanded and showed the arrangement configuration of the tube material
of the lightweight composite board ¦ plate material shown to FIG. 1 and FIG. It is a figure which
shows an example of the type ¦ mold used when manufacturing the lightweight composite board
¦ plate material shown in FIG. It is a block diagram which shows an example of the apparatus
which manufactures the lightweight composite board material of this invention continuously. It is
a block diagram at the time of applying the lightweight compound board material of the present
invention to a speaker.
Explanation of sign
[0047]
10, 20 Lightweight composite plate material 11, 21 Tube material 12, 22 Surface material 13, 23
Cavity in tube material 31-33 type 40 Lightweight composite material manufacturing device 41
Hopper 42, 43 Roller for supplying prepreg board 44 Belt 45 Support roll 46 Guide roll 47 Press
machine for heating and pressing 50 Excitation machine for sound generation
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