Method for manufacturing long foamed sheet, method for manufacturing composite material, and long foamed sheet

Abstract

The present application provides a long foam sheet manufacturing method capable of manufacturing a long foam sheet with high precision in thickness without being limited by the material and thickness of the foam, in the long foam sheet manufacturing method, the following steps are performed: a slicing step of slicing a foam block (35) to thereby manufacture foam sheets (14); and a sheet pasting step of pasting a plurality of the foam sheets (14) manufactured in the slicing step on one side of a long base sheet (11A) in an array to thereby manufacture a long foam sheet (12) in which the plurality of the foam sheets (14) are connected in the length direction of the base sheet (11A).

Description

Technical Field

[0001] This invention relates to a method for manufacturing long strip foam sheets used in composite materials and the like. Background Technology

[0002] Previously, composite materials with a core material disposed between skin materials were known. Foamed materials are preferably used as the core material. Patent Document 1 describes a fiber-reinforced composite laminate comprising a core containing foamed resin and a surface layer containing a thermosetting resin containing carbon fibers.

[0003] On the other hand, Patent Document 2 describes a method for manufacturing a thermoplastic resin foam film laminated on aluminum foil, which involves using a cutting machine to cut (slice) a square-shaped foam body. Furthermore, Patent Document 3 describes a method for manufacturing a foam sheet from a cylindrical foam block. In this method, the cylindrical foam block is continuously sliced ​​using a slicing blade, peeling it from its outer peripheral surface, thereby producing a long, thin foam sheet.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2019-6037

[0007] Patent Document 2: International Publication No. WO2010 / 047274

[0008] Patent Document 3: Japanese Patent Application Publication No. 63-19235 Summary of the Invention

[0009] The technical problem that the invention aims to solve

[0010] However, while some foam sheets are manufactured into thinner sheets during foaming processes, such as through extrusion foaming, most foam sheets are produced by cutting foam blocks to a specified thickness. In this case, the foam sheet inevitably becomes paper-like. Foam films (foam sheets) manufactured using the thermoplastic resin foam film manufacturing method described in Patent Document 2 also become paper-like.

[0011] On the other hand, the inventors of this application have completed an invention relating to composite materials with an island-like structure in which the core layer is composed of multiple plate-like sheets, and have filed a patent application (Japanese Patent Application No. 2020-24756). As a method for obtaining a core layer composed of multiple plate-like sheets, for example, there is a method for stamping foam sheets. However, when the foam sheet is in the form of paper, it is difficult to perform continuous stamping. Furthermore, when the foam sheet is in the form of paper, it is also difficult to perform continuous processing when continuously bonding the foam sheet to long rolls of materials such as metal films or fiber-reinforced resins.

[0012] Therefore, in order to improve productivity through continuous processing, the inventors of this application considered preparing long strip foam sheets. However, in the method for manufacturing long strip foam sheets described in Patent Document 3, the foam needs to be formed into a cylindrical shape. Consequently, in processing using a slicing machine that matches the cylindrical foam, the material, thickness, and precision of the foam that can be processed are very limited.

[0013] The present invention was made in view of the following circumstances, and its object is to provide a method for manufacturing elongated foam sheets, which can manufacture elongated foam sheets with high precision thickness without being limited by the material or thickness of the foam.

[0014] Solution to the above technical problems

[0015] The first solution to solve the above-mentioned technical problem is a method for manufacturing a strip of foam sheet, which involves performing a sheet bonding process in which multiple foam sheets are arranged and bonded to one side of a strip of substrate sheet, thereby manufacturing a strip of foam sheet formed by connecting multiple foam sheets together in the length direction of the substrate sheet.

[0016] The second option is that, in the first option, before the sheet bonding process, the following processes are performed: a slicing process, in which foam blocks are sliced ​​to produce foam sheets; a sheet stretching process, in which the curling characteristics of the foam sheets produced by the slicing process are reduced; and in the sheet bonding process, the foam sheets with reduced curling characteristics produced by the sheet stretching process are bonded to the substrate sheet.

[0017] The third option is that, in the first option, before the sheet bonding process, the following process is performed: a slicing process, in which foamed blocks are sliced ​​to produce foamed sheets; an inspection process, in which the foamed sheets produced by the slicing process are inspected for at least one of weight or thickness, and foamed sheets that meet the screening criteria are selected; and in the sheet bonding process, the foamed sheets that meet the screening criteria in the inspection process are bonded to the substrate sheet.

[0018] Option 4 is that, in any one of Options 1 to 3, the foam sheet is a rigid foam sheet.

[0019] The fifth embodiment is a method for manufacturing a composite material, comprising the following steps: a cutting step, wherein the foam sheet constituting the long foam sheet manufactured by any one of the manufacturing methods of the first to fourth embodiments is divided into multiple plate-shaped sheets by cutting processing; and a lamination step, wherein the multiple plate-shaped sheets obtained by the cutting step are sandwiched between a pair of skin material sheets, thereby manufacturing a composite material.

[0020] The sixth option is to perform a sheet bonding process after the sheet bonding process and before the cutting process, in addition to the fifth option, using a connecting component to connect adjacent foam sheets on the substrate sheet.

[0021] The seventh option is to remove, in the sixth option, chips other than the multiple sheet-like pieces in the cut foam sheet by winding.

[0022] The eighth embodiment is that, in any one of the fifth to seventh embodiments, in the cutting process, an intermediate sheet is made by bonding multiple plate-shaped sheets to a substrate sheet; after the cutting process, a transfer process is performed to transfer the multiple plate-shaped sheets on the intermediate sheet to one of a pair of skin material sheets; and in the lamination process, the other of the pair of skin material sheets is laminated to the multiple plate-shaped sheets after the transfer process.

[0023] The ninth embodiment is that, in any one of the fifth to seventh embodiments, in the cutting process, an intermediate sheet is formed by bonding multiple plate-shaped sheets to a substrate sheet, and in the lamination process, the intermediate sheet is sandwiched between a pair of skin material sheets.

[0024] The 10th embodiment is a method for manufacturing a long strip of foam sheet, which involves performing a sheet connecting process, arranging multiple foam sheets in a certain direction and connecting them using connecting components, thereby manufacturing a long strip of foam sheet formed by connecting multiple foam sheets.

[0025] The 11th embodiment is a long strip of foam sheet wound into a roll, comprising: a long strip of substrate sheet; and multiple foam sheets arranged and pasted on one side of the substrate sheet along the length direction of the substrate sheet.

[0026] Invention Effects

[0027] In this invention, multiple foam sheets are arranged and bonded to one side of a long strip of substrate sheet, thereby manufacturing a long strip of foam sheet. While it is difficult to manufacture long strips of foam sheet with high-precision thickness from a cylindrical foam block without being limited by the material and thickness of the foam, it is possible to prepare large quantities of short foam sheets with high-precision thickness. Therefore, by arranging and bonding multiple foam sheets, long strips of foam sheet can be manufactured with high-precision thickness without being limited by the material and thickness of the foam. Attached Figure Description

[0028] Figure 1 This is a perspective view of the composite material used in the implementation method.

[0029] Figure 2 This is a cross-sectional view of the composite material used in the embodiment.

[0030] Figure 3 This is a top view of the side of the composite material core layer with the chamfered portion formed according to the embodiment.

[0031] Figure 4 This is a cross-sectional view of the transfer sheet used in the implementation method.

[0032] Figure 5 This is a cross-sectional view used to explain the slicing process of the first manufacturing process in the embodiment.

[0033] Figure 6 This is a schematic diagram illustrating the sheet stretching process of the first manufacturing step in the embodiment.

[0034] Figure 7 This is a perspective view used to explain the sheet bonding process of the first manufacturing process of the embodiment.

[0035] Figure 8 This is a schematic diagram of the production line used in the second manufacturing process of the implementation method.

[0036] Figure 9 This is a cross-sectional view used to explain the cutting process of the second manufacturing process in the embodiment.

[0037] Figure 10 This is a cross-sectional view used to explain the transfer process of the third manufacturing process in the embodiment.

[0038] Figure 11 This is a cross-sectional view used to explain the lamination process of the third manufacturing step in the embodiment.

[0039] Figure 12 This is a cross-sectional view of the composite material in the embodiment, where the cured resin fills the gaps.

[0040] Figure 13 This is a cross-sectional view of the laminated material during the manufacturing process of the composite material in the first modified example.

[0041] Figure 14 This is a cross-sectional view used to illustrate the transfer process in the manufacturing process of the adhesive core sheet of the second modified example.

[0042] Figure 15 This is a cross-sectional view of the composite material sheet used in the third variation.

[0043] Figure 16 This is a cross-sectional view of the composite material in the fourth variation.

[0044] Figure 17 This is a perspective view of the composite material in the fifth variation.

[0045] Figure 18 This is a cross-sectional view of the cylindrical body using the composite material of the fifth variation.

[0046] Figure 19 It is a cross-sectional view used to illustrate the situation in which slits are formed between adjacent plate-like sheets during compression cutting in composite materials of other variations.

[0047] Figure 20 This is a perspective view of the sheet joining process in the first manufacturing step of the method for manufacturing long strip foam sheets for other variations.

[0048] Figure 21 This is a diagram used to illustrate the slicing process of the first manufacturing step in other variations. Detailed Implementation

[0049] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Furthermore, the following embodiments are merely examples of the present invention and do not limit the scope of the present invention, its applications, or its uses.

[0050] This embodiment describes a method for manufacturing a composite material 30 using the manufacturing method of the elongated foam sheet (elongated foam film) 12 of the present invention. Hereinafter, the composition of the composite material 30 and the composition of the transfer sheet 10 used in the manufacturing of the composite material 30 will be explained, followed by a description of the manufacturing method of the composite material 30.

[0051] [Composition of Composite Materials]

[0052] like Figure 1 and Figure 2As shown, composite material 30 is a sandwich-structured panel. Composite material 30 comprises: a core layer (also called an "intermediate layer") 20; a first skin material 31 laminated to the core layer 20; and a second skin material 32 laminated to the opposite side of the first skin material 31 within the core layer 20, sandwiching the core layer 20 together with the first skin material 31. Composite material 30 can be used, for example, as a panel material where lightweight and stiffness are prioritized over strength. Specifically, composite material 30 can be used as a structural material for mobile bodies such as aircraft, automobiles, or bicycles (sports bicycles, etc.), electrical equipment, electronic equipment, office equipment, home appliances, medical equipment, or building materials. In the case of mobile bodies, composite material 30 can be used as an aerodynamic component constituting the exterior.

[0053] Each skin material 31 and 32 is made of a different type of material than the core layer 20, such as a skin material or a panel material. As the material for each skin material 31 and 32, any type of metal, plastic, or inorganic material can be used. In this embodiment, the material for each skin material 31 and 32 is fiber-reinforced plastic. As the fiber-reinforced plastic, fiber-reinforced plastic reinforced with carbon fibers can be used. As the fiber-reinforced resin, a prepreg (e.g., "Pyrofil Prepreg" (registered trademark) manufactured by Mitsubishi Chemical Corporation) impregnated with resin (matrix) can be used. The matrix of this prepreg is a thermosetting epoxy resin.

[0054] Furthermore, the fibers used as the reinforcing fibers in fiber-reinforced plastics can be any type of inorganic fiber, organic fiber, or metallic fiber, such as glass fiber, carbon fiber, aramid fiber, polyethylene fiber, polyester fiber, tungsten fiber, steel fiber, boron fiber, etc. Additionally, the matrix used as the reinforcing fiber can be any type of thermosetting resin or thermoplastic resin, such as polyester resin, epoxy resin, phenolic resin, vinyl ester resin, polyimide resin, polypropylene resin, nylon resin, polyetheretherketone resin, polybutylene terephthalate resin, or bismaleimide resin, etc.

[0055] A core material layer 20 is stacked on each of the outer skin materials 31 and 32. In the core material layer 20, multiple plate-shaped sheets 13 of equal thickness are arranged as core material on a two-dimensional plane. The multiple plate-shaped sheets 13 are arranged along the surfaces of each of the outer skin materials 31 and 32. Each plate-shaped sheet 13 is a thin, flat fragment. All plate-shaped sheets 13 are of the same material, shape, and size. Furthermore, in this specification, "multiple plate-shaped sheets" means 10 or more. The number of plate-shaped sheets 13 in the core material layer 20 is at least 10. In some cases, this number is 50 or more.

[0056] The sheet 13 can be made of a material with a lower density than the skin materials 31 and 32. In this embodiment, a rigid resin foam is used as the material for the sheet 13. The density of the sheet 13 is, for example, 30 kg / m³. 3 Above 500kg / m 3 The following range of values.

[0057] Examples of rigid resin foams used as materials for sheet-like sheets 13 include polystyrene foams, polyvinyl chloride foams, cellulose acetate foams, polyurethane foams, phenolic foams, epoxy resin foams, acrylic foams, polymethacrylamide foams, polypropylene foams, polyethylene terephthalate foams, polycarbonate foams, polyamide-imide foams, and polyphenylene sulfide foams. For example, for polymethacrylamide foams, polymethacrylamide (PM I) individually bubbled foams (e.g., "ROHACELL (registered trademark)" (Evonik Industries)) can be used.

[0058] like Figure 3 As shown, in the core layer 20, the top view shape (outer periphery shape) of the plate-shaped sheet 13 is a regular polygon (a regular hexagon in this embodiment). Furthermore, when multiple plate-shaped sheets 13 are evenly distributed, the top view shape of the plate-shaped sheet 13 can be a triangle, quadrilateral, hexagon, or regular pentagon. In addition, the top view shape of the plate-shaped sheet 13 can also be other shapes besides these, such as polygons, circles, or ellipses. When the top view shape of the plate-shaped sheet 13 is based on a polygon, chamfers can also be formed at each corner.

[0059] The thickness of the plate-shaped sheet 13 can be set to a range of 0.05 mm to 10 mm (e.g., 0.05 mm to 2 mm). Furthermore, regarding the top-view dimensions of the plate-shaped sheet 13, the average distance from the center of gravity to the outer perimeter (average over 360 degrees; in the case of a circle, the radius) can be set to a value in the range of 3 mm to 50 mm (e.g., 5 mm). If the plate-shaped sheet 13 is a regular hexagon, the length of one side can be set to a value in the range of 3 mm to 10 mm (e.g., 5 mm). The dimensions of the plate-shaped sheet 13 can also be set to values ​​outside the ranges described in this paragraph.

[0060] In the core layer 20, all the plate-like sheets 13 are separated from each other and become individual units. The entire circumference of each plate-like sheet 13 is separated from all adjacent plate-like sheets 13 by a gap 16. Each plate-like sheet 13 becomes an independent island-like structure. Adjacent plate-like sheets 13 are not connected to each other by a connector made of the same material as the plate-like sheets 13. The composite material 30 is a multi-web panel where each skin material 31, 32 functions as a flange in an I-beam structure and each plate-like sheet 13 functions as a web, and it is a sandwich structure panel where each plate-like sheet 13 functions as a core material.

[0061] Adjacent plate-shaped sheets 13 face each other with a gap 16 between their edges. The width W of the gap 16 varies depending on the size of the gap between adjacent blades 24 in the upper die 23, as described later. The width W of the gap 16 is constant along the opposing edges. Furthermore, in each plate-shaped sheet 13, the width W of the gap 16 faced by each edge is equal to each other. The dimension of the width W of the gap 16 is appropriately designed according to the dimensions of the composite material 30, and for example, it can be set to a range of 0 mm to 10 mm.

[0062] In the core layer 20, a plurality of plate-shaped sheets 13 are arranged regularly. The plurality of plate-shaped sheets 13 are evenly distributed. In this embodiment, the plate-shaped sheets 13 are arranged in an alternating configuration where the positions of the plate-shaped sheets 13 are staggered by half a spacing between adjacent rows of plate-shaped sheets 13L. In this embodiment, the top view shape of each plate-shaped sheet 13 is a regular hexagon, and the arrangement of the plate-shaped sheets 13 can also be described as forming a honeycomb configuration with gaps between adjacent plate-shaped sheets 13.

[0063] On one main surface of each plate 13 (one of the two surfaces 13a and 13b parallel to the arrangement surface of each plate 13) 13a (in Figure 2 The outer periphery of the plate-shaped sheet 13 (the lower surface) is chamfered 13c, which is formed throughout the entire circumference. The chamfered portion 13c is a mark (cutting mark) indicating that the plate-shaped sheet 13 was formed by stamping. It is an arc-shaped curved surface (e.g., an R-surface of about 0.05 mm) or a curved surface that bulges outward like an arc. The shape of the chamfered portion 13c varies depending on the shape of the cutting edge 24 used in the stamping process. In each plate-shaped sheet 13, the size of the chamfered portion 13c is approximately uniform throughout the entire circumference. In this specification, the "main surface" of the plate-shaped sheet 13 refers to the front or back surface.

[0064] Furthermore, in the plurality of plate-shaped sheets 13 (e.g., all plate-shaped sheets 13 of the core material layer 20), the cutting directions in the thickness direction, as traces created using the transfer sheet 10 described later, are the same as each other, as determined by the cutting marks formed on the outer periphery. Specifically, in the plurality of plate-shaped sheets 13, a chamfered portion 13c is formed on the outer periphery of the main surface 13a on the same side in the thickness direction.

[0065] [Composition of transfer sheet]

[0066] Next, the transfer sheet 10 used in the manufacture of composite material 30 will be described. The transfer sheet 10 is a sheet from which multiple plate-shaped sheets 13 can be transferred from the substrate sheet 11 to other structural materials (structures with adhesive or bonding properties on their surfaces). The transfer sheet 10 is equivalent to an intermediate sheet. Furthermore, in this specification, "intermediate sheet (intermediate material)" refers to a sheet produced in an intermediate step during the manufacture of composite material 30.

[0067] like Figure 4 As shown, the transfer sheet 10 includes a core layer 20 and a substrate sheet 11 on which the core layer 20 is laminated. The substrate sheet 11 is made by cutting a long strip of substrate sheet 11A, which will be described later. Cutting marks (V-shaped grooves) 43 (see reference) remain on the surface of the substrate sheet 11 on the side of the core layer 20, which were formed when cutting the plurality of plate-shaped sheets 13. Figure 9 Furthermore, in the core material layer 20, adjacent plate-shaped sheets 13 are separated by a gap 16. In the core material layer 20, in the thickness direction, a chamfered portion 13c is formed on the outer periphery of the main surface 13a on the same side of each plate-shaped sheet 13.

[0068] Multiple sheet-like pieces 13 are peelably adhered to the surface of the substrate sheet 11. Each sheet-like piece 13 is held to the substrate sheet 11 with a certain adhesive force by an adhesive layer 18. The main surface 13b of each sheet-like piece 13, opposite to the main surface 13a on the chamfered portion 13c side, is adhered to the substrate sheet 11. Alternatively, if the surface of the substrate sheet 11 is adhesive, the adhesive layer 18 may be omitted.

[0069] The arrangement of the plate-shaped sheets 13 on the substrate sheet 11 forms the basis for the arrangement of the plate-shaped sheets 13 in the core layer 20 of the composite material 30. A top view of the core layer 20 of the transfer sheet 10 and... Figure 3 same.

[0070] [Manufacturing methods for composite materials]

[0071] In the manufacturing method of composite material 30, the following steps are performed sequentially: a first manufacturing step, manufacturing a foam roll 12; a second manufacturing step, using the foam roll 12 obtained in the first manufacturing step to manufacture a transfer sheet 10; and a third manufacturing step, using the transfer sheet 10 obtained in the second manufacturing step to manufacture composite material 30. Furthermore, the foam roll 12 is equivalent to a long strip of foam sheet.

[0072] In the first manufacturing process, the following steps are performed sequentially: a slicing process, in which foam blocks 35 are sliced ​​to produce foam sheets 14; and a sheet bonding process, in which multiple foam sheets (paper-like foam sheets) 14 produced by the slicing process are continuously arranged and bonded to the surface of a strip of substrate sheet 11A, thereby creating a foam roll 12 in which multiple foam sheets 14 are connected along the length of the substrate sheet 11A. In addition, in this embodiment, a sheet stretching process and an inspection process are performed between the slicing process and the sheet bonding process, in addition to these steps. Furthermore, in this specification, "multiple" in "multiple foam sheets" means 5 or more. That is, the number of foam sheets 14 in the foam roll 12 is at least 5 (when using foam blocks 35 of the dimensions described in the next paragraph, the length of the foam roll 12 is 5000 mm or more). In addition, there are cases where the number of sheets is 10 or more (the length of the foam roll 12 is 10000mm or more).

[0073] In the first manufacturing process, foam block 35 and substrate sheet 11A are prepared as materials. As foam block 35, a rigid resin foam (e.g., polymethacrylamide (PM I) free-float foam) in a generally rectangular shape can be used. The dimensions of foam block 35 are, for example, 2000 mm in length, 1000 mm in width, and 50 mm in thickness.

[0074] On the other hand, the substrate sheet 11A is a long strip of sheet wound into a roll. The substrate sheet 11A has a uniform thickness along its entire length, and its thickness is, for example, in the range of 0.01 mm to 0.5 mm. The width of the substrate sheet 11A needs to be greater than or equal to the width of the foam sheet 14, and in this embodiment, it is equal to the width of the foam sheet 14.

[0075] The substrate sheet 11A can be made of resin, such as a sheet or film (thermoplastic resin sheet, etc.). Various resins such as polyethylene, polypropylene, polyurethane, polyester, polyethylene terephthalate (PET), or polycarbonate can be used as the resin for the substrate sheet 11A. In this embodiment, an adhesive such as an acrylic, polyurethane, or silicone adhesive is applied to one side of the substrate sheet 11A. That is, the strip substrate sheet 11A is an adhesive tape (or micro-adhesive tape). Furthermore, the substrate sheet 11A can be a substrate sheet with a separate sheet (not shown) laminated on the back side. In addition to resin, the substrate sheet 11 can also be made of rubber or paper (or film).

[0076] In the slicing process, the foam block 35 is sliced ​​to a uniform thickness (a value in the range of 0.05 mm to 10 mm, for example, 0.05 mm to 2 mm). During this slicing process, the foam block 35 is sliced ​​using the slicing tool 36 while at least one of the foam block 35 and the slicing tool 36 moves in a certain direction. Figure 5 In this process, the slicing tool 36 moves alongside the foam block 35 within the foam block 35 while cutting. During the slicing process, multiple foam blocks 35 are repeatedly sliced ​​to produce multiple foam sheets 14 of equal thickness. Furthermore, in... Figure 5 The description of the component for fixing the slicing tool 36 is omitted.

[0077] Here, each foam sheet 14 obtained through slicing retains curling characteristics, remaining rolled up in the slicing direction. Therefore, in this embodiment, a sheet stretching process to reduce the curling characteristics of the foam sheet 14 is performed before the sheet bonding process. Furthermore, the density of the foam block 35 is typically uneven, and weight variations may occur between the multiple foam sheets 14 produced in the slicing process. Moreover, the density variation of the foam block 35 causes variations in its rigidity, thus thickness variations may also occur between the multiple foam sheets 14 produced in the slicing process. Therefore, in this embodiment, an inspection process is performed before the sheet bonding process to screen the foam sheets 14 by checking at least one of weight or thickness.

[0078] Furthermore, for the sheet stretching and inspection processes, both processes can be omitted, or only one process can be performed. Additionally, regarding the inspection process, only the weight and thickness checks can be performed. Furthermore, the order of the sheet stretching and inspection processes can be either performed first or first. Alternatively, the sheet stretching process can be performed between the weight check and the thickness check.

[0079] In the sheet stretching process, foam sheets 14 with curling properties are fed one by one into the... Figure 6 The stretching device 55 shown extends the foam sheet 14. The stretching device 55 is a device that drives a conveyor belt 56 to transport the foam sheet 14 fed between adjacent rollers 72 and 74, while simultaneously causing the foam sheet 14 to pass between the conveyor belt 56 and rollers 74, and between adjacent rollers 73 and 74, thereby extending the foam sheet 14. In the stretching device 55, some of the rollers 73 and 74 are heated rollers; by heating the foam sheet 14 using the rollers 73 and 74, the curling characteristics of the foam sheet 14 are effectively removed.

[0080] Specifically, the stretching device 55 includes multiple rollers 71-74, a conveyor belt 56 consisting of an annular conveyor belt, and a drive motor (not shown) for rotating at least one roller 71 to drive the conveyor belt 56. The conveyor belt 56 is wound around the first roller 71 and the second roller 72 and the third roller 73, which are arranged separately from the first roller 71. Furthermore, the conveyor belt 56 uses a fourth roller 74 arranged between the second roller 72 and the third roller 73 to make the travel track recessed inward. The second roller 72, the third roller 73, and the fourth roller 74 are arranged adjacent to each other in the vertical direction with gaps. In the stretching device 55, the foam sheet 14, which is fed between the second roller 72 and the fourth roller 74, is stretched while being sandwiched between the fourth roller 74 and the conveyor belt 56, and then passes through the gap between the third roller 73 and the fourth roller 74, and is stretched while being conveyed around the third roller 73. Then, the foam sheet 14, which is stretched roughly in a straight line, is conveyed to the side of the first roller 71 and picked up by the operator.

[0081] In the inspection process, the foam sheet 14 is inspected for both weight and thickness to screen out the foam sheets 14. In this screening, predetermined screening criteria are used for both weight and thickness. The weight screening criterion is that the measured weight of the foam sheet 14 is within an error range (e.g., ±10%) relative to the designed weight value. Similarly, the thickness screening criterion is that the measured thickness of the foam sheet 14 is within an error range (e.g., ±10%) relative to the designed thickness value. In the inspection process, each foam sheet 14 is subjected to both weight and thickness measurements. Foam sheets 14 that do not meet the screening criteria for either weight or thickness are excluded, and only those that meet both screening criteria are selected.

[0082] Next, in the sheet bonding process, such as Figure 7 As shown, a roll of substrate sheet 11A, located on the first reel 81, is unrolled and wound onto the second reel 82. In this state, when the second reel 82 is used to wind up the substrate sheet 11A, the substrate sheet 11A moves between the two reels 81 and 82. During the sheet bonding process, the substrate sheet 11A is repeatedly moved and stopped, and during the period when the substrate sheet 11A is stopped, foam sheets 14 are bonded to the substrate sheet 11A between the two reels 81 and 82. In the sheet bonding process, multiple foam sheets 14 are arranged and bonded along the length direction of the substrate sheet 11A without gaps (or with only slight gaps) in a non-overlapping manner. Then, the substrate sheet 11A with multiple foam sheets 14 bonded thereto is gradually wound up onto the second reel 82, thereby completing the foam roll 12.

[0083] Additionally, after the sheet bonding process, it can also be combined with... Figure 20Similarly, the sheet bonding process is further performed by using tape 85 to bond adjacent foam sheets 14 on the long substrate sheet 11A. In this case, the tape 85 acts as a bonding component, adhering along the seam of adjacent foam sheets 14 to bond the adjacent foam sheets 14 to each other.

[0084] Next, the second manufacturing process will be explained.

[0085] In the second manufacturing process, a cutting process is performed, in which the foam sheets 14 constituting the foam roll 12 are divided into multiple plate-shaped sheets 13 by cutting. In the cutting process, the foam sheets 14, which are bonded to the substrate sheet 11A, are stamped (press-cut), thereby manufacturing... Figure 4 The transfer sheet 10 shown.

[0086] During the cutting process, the foam roll 12 is set in... Figure 8 The production line 50 shown has a reel 51. Furthermore, the foam sheet 14 is unwound along its length from the foam roll 12 together with the substrate sheet 11A and passed through... Figure 9 The pressurizing device 15 is shown in (a). Furthermore, the foam sheet 14 is press-cut by vertically cutting the foam sheet 14 on the lower die 22 of the pressurizing device 15 using the blade 24 of the upper die 23. At this time, as shown... Figure 9 As shown in (b), the substrate sheet 11A is not cut, but rather so-called half-cut (i.e., cut to a non-through degree). Chips 39 are formed between the blades 24 (see Figure 1). Figure 9 (c)). In this embodiment, a plurality of plate-shaped sheets 13 are formed on a substrate sheet 11A to manufacture a transfer sheet 10. Furthermore, the top-view shape of the cutting edge 24 uses a shape corresponding to the outer peripheral shape of the plate-shaped sheet 13. For example, in the case where the plate-shaped sheet 13 is formed into a regular hexagon, a cutting edge 24 that is a regular hexagon in top view is used. In the upper die 23, the plurality of cutting edges 24 are arranged in a two-dimensional plane with gaps between them. Moreover, in the stamping process, depending on the cutting conditions, sometimes burrs are formed on the outer periphery of the main surface 13a of each plate-shaped sheet 13 instead of chamfered portions 13c.

[0087] In this embodiment, the chips 39 other than the multiple plate-shaped sheets 13 in the cut foam sheet 14 become a mesh sheet 38. The mesh sheet 38 composed of the chips 39 is wound up and removed by the winding reel 25 (see reference). Figure 8Furthermore, a protective film 27, which unfolds from another reel 26, is stacked on the plate-shaped sheet 13 side of the transfer sheet 10. Multiple plate-shaped sheets 13 are covered by the protective film 27. In this embodiment, the long strip of transfer sheet 10 is cut to a predetermined length using a cutter 28, dividing it into multiple transfer sheets 10. Alternatively, the winding of the take-up reel 25, the covering of the protective film 27, and the cutting of the cutter 28 can be omitted.

[0088] In addition, in this embodiment, the upper die 23 moves up and down relative to the lower die 22 during die cutting, but die cutting can also be performed by applying pressure through the rotation of a rotary die (die cutting roller).

[0089] Next, the third manufacturing process will be explained.

[0090] In the third manufacturing process, the following steps are performed sequentially: a transfer process, in which multiple sheet-like sheets 13 on the transfer sheet 10 are transferred to the first skin material sheet 31A; a lamination process, in which the second skin material sheet 32A is laminated onto the multiple sheet-like sheets 13 transferred in the transfer process, thereby producing a laminated material 30B with multiple sheet-like sheets 13 sandwiched between a pair of skin material sheets 31A and 32A, thus manufacturing the composite material 30. Each skin material sheet 31A and 32A is the aforementioned skin material 31 and 32 (refer to...). Figure 2 Materials that can be used, such as prepregs in a semi-cured state (prepreg sheets).

[0091] In the transfer process, firstly, a sheet 31A for the first skin material is placed on a forming mold (e.g., a mold) 33. Then, as... Figure 10 As shown in (a), the transfer sheet 10 obtained through the second manufacturing process is configured such that the plate-shaped sheet 13 faces the first skin material sheet 31A on the forming mold 33. Next, as... Figure 10 As shown in (b), a plurality of plate-shaped sheets 13 of the transfer sheet 10 are pressed onto the first skin material sheet 31A. The surface of the first skin material sheet 31A is adhesive. Therefore, the plurality of plate-shaped sheets 13 are adhered to the first skin material sheet 31A. Then, as... Figure 10 As shown in (c), the substrate sheet 11 is peeled off from the plurality of sheet-like sheets 13. In this way, since the adhesive force of the first skin material sheet 31A to the plurality of sheet-like sheets 13 is greater than the adhesive force of the adhesive layer 18 to the plurality of sheet-like sheets 13, the plurality of sheet-like sheets 13 can be transferred from the substrate sheet 11 to the first skin material sheet 31A.

[0092] Next, as Figure 11 As shown in (a), in the lamination process, the second skin material sheet 32A is first arranged separately from the plate-shaped sheet 13 of the laminated material 30A obtained through the transfer process. Then, as... Figure 11 As shown in (b), a second skin material sheet 32A is laminated onto the plate-shaped sheet 13 side of the laminated material 30A. The surface of the second skin material sheet 32A is adhesive. Therefore, multiple plate-shaped sheets 13 are adhered to the second skin material sheet 32A. As described above, a laminated material 30B in which multiple plate-shaped sheets 13 are sandwiched between a pair of skin material sheets 31A, 32A can be obtained.

[0093] Then, when the matrix of the prepreg used in the skin material sheets 31A and 32A is a thermosetting resin (e.g., epoxy resin), a molding process is performed. In the molding process, a bagging film is used to seal the laminated material 30B obtained through the lamination process. Then, the laminated material 30B sealed with the bagging film is heated in an autoclave at a specified temperature and pressure (e.g., 0.2 MPa, 130°C) for a specified time (e.g., 2 hours). Through this heating process, the semi-cured skin material sheets 31A and 32A become fully cured skin materials 31 and 32. As a result, they are molded into a specified shape ( Figure 11 In case (b), the composite material 30 is flat and cured.

[0094] Furthermore, during the molding process, when the laminated material 30B is heated, the resin (matrix) of the prepreg flows into the gaps 16 between the sheet-like sheets 13, filling the gaps 16 of the core material layer 20. The flowing resin cures in the gaps 16. As a result, localized strength reduction in the composite material 30 is suppressed. In addition, when the gaps 16 are large, a larger amount of resin per unit area can be used in the prepreg used as the material for each skin material 31, 32.

[0095] Alternatively, a curing resin (e.g., thermosetting, two-component reactive, or moisture-reactive adhesive) can be injected separately from the prepreg matrix into the gap 16 of the sheet 13 using a pressure difference. The injected resin then cures in the gap 16. Alternatively, a thin-film adhesive can be added between the two skin materials 31 and 32. In this case, the thin-film adhesive melts when the laminated material 30B is heated, and the melted adhesive (resin) flows into the gap 16, eventually curing. In these cases, such as... Figure 12 As shown, the gaps 16 between adjacent plate-shaped sheets 13 are filled with cured resin 6, suppressing localized strength reduction and improving stiffness of the composite material 30. The filling with cured resin can also be carried out without the use of prepreg in the materials of the skin materials 31 and 32.

[0096] In addition, when the matrix of the prepreg used in the sheets 31A and 32A of each skin material is a thermoplastic resin (e.g., polyamide resin, polypropylene resin, polyetheretherketone resin), after the molding process such as pressing and heating, the laminated material 30B is cooled in an atmosphere at a temperature lower than the curing temperature of the matrix (e.g., room temperature) to carry out the curing process and complete the composite material 30.

[0097] [Effects of this implementation method, etc.]

[0098] In this embodiment, a long strip of foam sheet 12 is manufactured by arranging and bonding multiple foam sheets 14, which are produced by a slicing process, onto one side of a long strip of substrate sheet 11A. As described above, as long as the foam sheets 14 are relatively short, it is possible to prepare a large quantity of foam sheets with approximately uniform thickness. Therefore, by arranging and bonding multiple foam sheets 14, it is possible to manufacture a long strip of foam sheet 12 with approximately uniform thickness in the length direction.

[0099] Furthermore, in this embodiment, the curling characteristics of the foam sheet 14 are reduced by the sheet stretching process, so the foam sheet 14 can be glued to the correct position in the sheet bonding process.

[0100] Furthermore, in this embodiment, by inspecting the foam sheet 14 that meets the screening criteria in terms of weight and thickness, only the foam sheet 14 is pasted onto the substrate sheet 11A. Therefore, for the foam sheet 14 layer of the long strip foam sheet 12, the weight and thickness in the length direction can be further homogenized.

[0101] Furthermore, in this embodiment, the chips 39 are made into a mesh sheet 38 and can be easily removed, thus enabling efficient manufacturing of the intermediate sheet 10 and the composite material 30.

[0102] Furthermore, in this embodiment, a plurality of plate-shaped sheets 13 in the core material layer 20 are configured using the transfer sheet 10. Therefore, the core material layer 20 can be easily formed without configuring the plurality of plate-shaped sheets 13 one by one.

[0103] <First Variation>

[0104] In this variation, the transfer process is not performed; instead, the intermediate sheet 10 is directly sandwiched between a pair of outer skin material sheets 31A and 32A during the lamination process, thereby manufacturing... Figure 13The laminated material 30B is shown. In this case, the intermediate sheet 10 is used as an adhesive core sheet to melt the substrate sheet 11. Furthermore, when the intermediate sheet 10 is used as a transfer sheet, an adhesive is used so that each sheet 13 can be peeled from the substrate sheet 11. However, when used as an adhesive core sheet, in the bonding of the foam sheet 14 to the substrate sheet 11, an adhesive agent can be used in addition to the adhesive.

[0105] Specifically, in the third manufacturing step, the intermediate sheet 10 and the second skin material sheet 32A are sequentially layered onto the first skin material sheet 31A on the forming mold 33. Here, regarding the layering of the intermediate sheet 10, as follows... Figure 13 As shown, the sheet 13 side can be adhered to the first skin material sheet 31A. Alternatively, the substrate sheet 11 side can be adhered to the first skin material sheet 31A (illustration omitted). Then, by laminating the second skin material sheet 32A, a laminated material 30B can be obtained. Since the method for manufacturing the composite material 30 using the laminated material 30B is the same as in the above embodiment, description is omitted. Furthermore, if the amount of resin filling the gap 16 is insufficient, resin sheets (e.g., sheet adhesives, prepregs, etc.) can be laminated on one or both sides of the core layer 20. Additionally, multiple intermediate sheets 10 can be used as bonding core sheets in the manufacture of a single composite material 30.

[0106] <Second Variation>

[0107] In this modified example, during the transfer process, the plurality of plate-shaped sheets 13 on the transfer sheet 10 are transferred to the sheet-shaped adhesive 111 instead of being transferred to the first skin material sheet 31A.

[0108] Specifically, in the transfer process, such as Figure 14 (a) and Figure 14 As shown in (b), a sheet-like adhesive 111 is adhered to the plate-like sheet 13 side of the transfer sheet 10 (first intermediate sheet). The sheet-like adhesive 111 uses an adhesive on which individual sheets 141 are laminated on their back side. Then, as... Figure 14 As shown in (c), by peeling the substrate sheet 11 from the plurality of plate-shaped sheets 13, the plurality of plate-shaped sheets 13 are transferred to the sheet-shaped adhesive 111 to manufacture an adhesive core sheet 60 as a second intermediate sheet. Then, in the lamination process, similar to the adhesive core sheet 10 in the first modification, the adhesive core sheet 60 is sandwiched between a pair of skin material sheets 31A, 32A, thereby manufacturing a laminated material 30B.

[0109] <3rd Variation>

[0110] In this modified example, during the transfer process, a plurality of plate-shaped sheets 13 on the transfer sheet (first intermediate sheet) 10 are transferred to the prepreg 31A, thereby manufacturing... Figure 15 The composite material manufacturing sheet (second intermediate sheet) 70 shown is used in this second intermediate sheet. Specifically, a semi-cured prepreg 31A is used instead of the sheet adhesive 111 of the second modified example. The prepreg 31A can be a prepreg with individual sheets 141 laminated on the back side. The prepreg 31A corresponds to the skin material sheet. Then, in the lamination process, the prepreg 31A is placed on the lower side while the composite material manufacturing sheet 70 is placed on the mold, and the prepreg 31B, corresponding to the skin material sheet, is laminated from the upper side.

[0111] <4th Variation>

[0112] In this variation, such as Figure 16 As shown, the composite material 130 further comprises: a second core layer 21 having a plurality of plate-like sheets 13 arranged along the surface of the second skin material 32; and an intermediate adhesive layer 17 disposed between the first core layer 20 and the second core layer 21. The intermediate adhesive layer 17 is constructed using a sheet-like adhesive (also called a film-like adhesive or adhesive sheet) that is directly thermosetting by heating and melting, and bonds the first core layer 20 and the second core layer 21.

[0113] Regarding the manufacturing method of the composite material 130 of this modified example, the laminated material before the molding process can be manufactured through the following process: after laminating the first core material layer 20 and the intermediate adhesive layer 17 into an adhesive core material sheet that is integrally formed with the first skin material sheet 31A on the mold, a plurality of plate-shaped sheets 13 are transferred from the transfer sheet 10 to the intermediate adhesive layer 17, and then the second skin material sheet 32A is laminated. Alternatively, it can be manufactured by placing the composite material manufacturing sheet 70 of the third modified example on the mold with the prepreg 31A on the underside, and then sequentially laminating the adhesive core material sheet 10 and the prepreg 32A of the first modified example on it.

[0114] Furthermore, in this modified example, the core material layers 20 and 21 are provided as two layers, but they can also be provided as three or more layers. In this case, an intermediate adhesive layer 17 is also provided between adjacent core material layers 20 and 21 in the thickness direction. Alternatively, a prepreg or thermosetting resin sheet (epoxy resin, etc.) can be used in the intermediate adhesive layer 17 instead of a sheet adhesive.

[0115] In this modified example, the sheet 13 in the core layer 20 has a two-layer structure. Here, when forming the bent composite material 30, the greater the thickness of the sheet 13, the greater the tensile deformation on one side of the sheet 13. Depending on the thickness of the sheet 13 and the degree of bending, one side of the sheet 13 may break due to tensile deformation. In contrast, when comparing composite materials of the same thickness, this modified example has thinner sheet 13 compared to the composite material 30 with a single-layer structure. Therefore, the tensile deformation on one side of each sheet 13 is smaller, and breakage is less likely even when a low-toughness rigid resin foam is used in the sheet 13. According to this modified example, a composite material 30 with excellent formability in three-dimensional shapes can be provided.

[0116] <5th Variation>

[0117] In this variation, such as Figure 17 As shown, the composite material 131 has a layered structure. Furthermore, in the core layer 20 on the outer skin material 31, strip-shaped plate-like sheets 13 are arranged in a certain direction. Gap 16 is formed between adjacent plate-like sheets 13. Additionally, in... Figure 17 In this case, the plate-shaped sheet 13 is not divided along its length direction, but it can also be divided along its length direction.

[0118] In this modified example, during the cutting process, the foam sheet 14, which is adhered to the substrate sheet 11A, is stamped (press-cut) to produce a transfer sheet (not shown) in which strip-shaped plates 13 are arranged in a certain direction on the substrate sheet 11A. Then, in the transfer process, the multiple plates 13 on the transfer sheet are transferred to a sheet 31A for skin material such as prepreg.

[0119] Furthermore, the cylindrical body 100 can be manufactured by winding the composite material 131 into a cylindrical shape. When the composite material 131 is wound with the skin material 31 side as the inner side, the following can be obtained: Figure 18 The cylindrical body 100 is shown. In this case, the two ends 31a of the skin material 31 are not laminated with the core material layer 20. One end 31a becomes an adhesive strip on the inner circumferential surface (adhesive portion to an outer skin material 31), and the other end 31a is laminated to cover the outermost plate-like sheet 13. Furthermore, a cylindrical body 100 can also be obtained when the composite material 131 is wound with the skin material 31 side as the outer side. In this case, one end 31a is laminated to cover the innermost plate-like sheet 13, and the other end 31a becomes an adhesive strip on the outer circumferential surface (adhesive portion to an inner skin material 31). At the innermost side, the end 31a of the skin material 31 is laminated to cover multiple plate-like sheets 13.

[0120] <Other variations>

[0121] In the above embodiments, the foam sheet 14 can also be cut into multiple plate-shaped pieces 13 by laser cutting instead of pressure cutting. Alternatively, a cutting device that moves the blade along the shape to be cut can be used to cut the foam sheet 14 into multiple plate-shaped pieces 13.

[0122] In the above embodiment, in the core layer 20, adjacent plate-shaped sheets 13 are separated by a gap 16 to form a single unit, but adjacent plate-shaped sheets 13 can also be separated by a cut 40 to form a single unit. In this case, as Figure 19 (a) and Figure 19 As shown in (b), adjacent plate-shaped sheets 13 are cut by the same cutting edge 24. For example, in the case of plate-shaped sheets 13 shaped as regular hexagons, cutting edges 24 with a regular hexagonal arrangement pattern are used. Then, as... Figure 19 As shown in (c), when the blade 24 is pulled out, at Figure 19 The plate-shaped sheet 13 that underwent elastic deformation in state (b) is restored, and a cut 40 remains between adjacent plate-shaped sheets 13.

[0123] In the above embodiment, a long substrate sheet 11 is used in the manufacture of the long foam sheet, but the substrate sheet 11 may be omitted. That is, in the method for manufacturing the long foam sheet, a sheet connecting process is performed where multiple foam sheets 14 are arranged in a certain direction and connected using a connecting component (tape) 85, thereby manufacturing a long foam sheet formed by connecting multiple foam sheets 14 (see reference). Figure 20 ).

[0124] In the above embodiment, after connecting multiple (e.g., 2 to 10) foam sheets 14 are arranged in a certain direction by using connecting member 85, the multiple foam sheets 14 can be glued to the substrate sheet 11.

[0125] In the above embodiment, the inner portion of the blade 24 used for stamping in the foam sheet 14 of the elongated foam sheet 12 is used as the core material, thereby forming an island-shaped core layer 20. However, the inner portion of the blade 24 can also be used as a chip, and the outer portion of the blade 24 can be used as the core material. In this case, during stamping, the aforementioned half-cut is not performed; instead, a full cut is made using the blade 24 to cut the foam sheet 14 and the substrate sheet 11 together along the entire thickness direction. The core layer 20 becomes a structure with multiple small chambers (the chambers in the planar shape of the blade 24), and when the planar shape of the blade 24 is a regular hexagon, it becomes a honeycomb structure.

[0126] In the above embodiments, thinning can also be used as a slicing process in the slicing step. In thinning, such as... Figure 21 As shown in (a), the foam block 35 is sliced ​​to form a foam sheet 14 by passing the straight portion of the rotating annular and thinner strip cutter 80 relative to the width direction of the strip cutter 80. In this case, as Figure 21 As shown in (b), the foam block 35 can be fed into the belt cutter 80 by roller 81, or as shown in (b). Figure 21 As shown in (c), the worktable 82, on which the foam block 14 is placed, is moved to feed the foam block 35 into the belt cutter 80. In the case of thinning, since the foam sheet 14 exhibits almost no curling characteristics, the sheet stretching process can be omitted. Furthermore, Figure 21 (a) is a 3D diagram. Figure 21 (b) and Figure 21 (c) is a cross-sectional view. Furthermore, in Figure 21 In (a), the description of pulleys and the like used to rotate the belt cutter 80 is omitted.

[0127] In the above embodiment, metallic materials can be used as the materials for the skin materials 31 and 32. In this case, each plate-shaped sheet 13 is bonded to the skin materials 31 and 32 by an adhesive.

[0128] In the above embodiment, a rigid resin foam was used in the material of the sheet 13. However, when performing a slicing process, any type of foam that can be molded into a generally rectangular parallelepiped shape by foaming can be used, and foams other than rigid resin foams can also be used. Furthermore, even when not performing a slicing process, foams other than rigid resin foams can be used.

[0129] In the above embodiments, the shapes of all the plate-like sheets 13 in the core layer 20 may be different. For example, the top view shape of the plate-like sheet 13 in a certain part can be determined according to the curvature of that part in the composite material 30.

[0130] In the above embodiments, Figure 2 The composite material 30 shown can be configured as a laminated structure by omitting the second skin material 32. In this case, the plate-like sheet 13 side of the composite material 30 is bonded to the structural material of the reinforced object. The core layer 20 is sandwiched between the first skin material 31 and the structural material of the reinforced object. Furthermore, unlike a sandwich structure, the core layer 20 of the laminated structure does not form a central layer, but rather forms a central layer between the first skin material 31 and the structural material of the reinforced object after being bonded to the reinforced object.

[0131] Industrial applicability

[0132] This invention can be applied to methods for manufacturing long, foamed sheets used in composite materials and other materials.

[0133] Explanation of reference numerals in the attached figures

[0134] 10-transfer printing sheet (intermediate sheet)

[0135] 11 Substrate Sheets

[0136] 11A long strip of substrate sheet

[0137] 12 rolls of foam (long strips of foam sheet)

[0138] 13 plates

[0139] 14 Foamed Sheets

[0140] 20 core layers

[0141] 30 composite materials

[0142] 31, 32 Surface material

[0143] 31A and 32A sheet materials for skin

[0144] 35 foam blocks

[0145] 36. Slicing knife.

Claims

1. A method for manufacturing a long strip of foamed sheet, characterized in that, The process involves arranging multiple rectangular foam sheets without gaps along the length of a long strip of substrate sheet and then bonding them to one side of the long strip of substrate sheet. This process manufactures a long strip of foamed material formed by connecting the plurality of foamed sheets along the length of the substrate sheet. In the sheet bonding process, an adhesive is used to bond the foam sheet to the substrate sheet. In the elongated foam sheet, the foam sheet is adhered to the substrate sheet in a transferable manner using the adhesive. Prior to the sheet bonding process, the following processes are also performed: a slicing process, in which the foam block is sliced ​​to produce a foam sheet; and a sheet stretching process, in which a stretching device for the foam sheet is used to reduce the curling characteristics of the foam sheet produced by the slicing process. In the sheet bonding process, a foam sheet whose curling characteristics have been reduced through the sheet stretching process is bonded to the substrate sheet. The stretching device includes multiple rollers that convey and stretch the foam sheet simultaneously. The plurality of rollers includes heated rollers for heating the foam sheet.

2. A method for manufacturing a long strip of foamed sheet, characterized in that, The process involves arranging multiple rectangular foam sheets without gaps along the length of a long strip of substrate sheet and then bonding them to one side of the long strip of substrate sheet. This process manufactures a long strip of foamed material formed by connecting the plurality of foamed sheets along the length of the substrate sheet. In the sheet bonding process, an adhesive is used to bond the foam sheet to the substrate sheet. In the elongated foam sheet, the foam sheet is adhered to the substrate sheet in a transferable manner using the adhesive. Before the sheet bonding process, the following processes are performed: a slicing process, in which the foam block is sliced ​​to produce foam sheets; and an inspection process, in which the foam sheets produced by the slicing process are inspected for at least one of weight or thickness, and foam sheets that meet the screening criteria are selected. In the sheet bonding process, the foam sheet that meets the screening criteria in the inspection process is bonded to the substrate sheet.

3. The method for manufacturing the elongated foam sheet as described in claim 1 or 2, characterized in that, The foam sheet is a rigid foam sheet.

4. A method for manufacturing a composite material, characterized in that, The sheet bonding process involves arranging and bonding multiple foam sheets onto one side of a long strip of substrate sheet. This process manufactures a long strip of foamed material formed by connecting the plurality of foamed sheets along the length of the substrate sheet. In the sheet bonding process, an adhesive is used to bond the foam sheet to the substrate sheet. In the elongated foam sheet, the foam sheet is adhered to the substrate sheet in a transferable manner using the adhesive. It also performs a cutting process, which divides the foam sheet that constitutes the long foam sheet manufactured by the sheet bonding process into multiple plate-shaped sheets through cutting processing; In the lamination process, the plurality of plate-shaped sheets obtained by the cutting process are sandwiched between a pair of sheets for the outer skin material. This allows for the manufacture of composite materials.

5. The method for manufacturing the composite material as described in claim 4, characterized in that, After the sheet bonding process and before the cutting process, a sheet connecting process is also performed, in which adjacent foam sheets on the substrate sheet are connected using connecting components.

6. The method for manufacturing the composite material as described in claim 5, characterized in that, The chips other than the plurality of plate-shaped sheets in the foamed sheet after the cutting process are removed by winding.

7. The method for manufacturing the composite material according to any one of claims 4 to 6, characterized in that, In the cutting process, an intermediate sheet is formed by bonding the plurality of plate-shaped sheets to the substrate sheet. Following the cutting process, a transfer process is performed to transfer the plurality of plate-shaped sheets from the intermediate sheet to one of the pair of outer skin material sheets. In the lamination process, the other of the pair of skin materials is laminated onto the plurality of plate-shaped sheets after being transferred by the transfer process.

8. The method for manufacturing the composite material according to any one of claims 4 to 6, characterized in that, In the cutting process, an intermediate sheet is formed by bonding the plurality of plate-shaped sheets to the substrate sheet. In the lamination process, the intermediate sheet is sandwiched between the pair of outer skin material sheets.

9. A method for manufacturing a composite material, characterized in that, implement: The long strip foam sheet manufacturing process involves performing a sheet connecting process that connects multiple foam sheets arranged in a certain direction using connecting components to produce a long strip foam sheet. The cutting process involves dividing the long foam sheet, which is manufactured through the long foam sheet manufacturing process, into multiple plate-shaped sheets using a cutting process. In the lamination process, the plurality of plate-shaped sheets obtained by the cutting process are sandwiched between a pair of sheets for the outer skin material. This allows for the manufacture of composite materials.

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