Laminated material, method for producing intermediate sheet, and method for producing composite material

Abstract

In order to provide a composite material which has excellent formability for a three-dimensional shape and is easy to manufacture, in a laminated material (30) provided with a core material layer (20) and a skin material (31) laminated on the core material layer (20), the core material layer (20) has a plurality of plate-shaped sheets (13) arranged along the surface of the skin material (31), in the core material layer (20), adjacent plate-shaped sheets (13) form a single body with a gap (16) therebetween or through a notch (40), and in the core material layer (20), the adjacent plate-shaped sheets (13) form a single body with the gap (16) therebetween or through the notch (40). In the plurality of plate-shaped sheets (13), the cutting directions in the thickness direction, which are determined by cutting marks (13c, 13d) formed on the outer periphery, are the same.

Description

[0001] This invention application is a divisional application filed based on the Chinese invention application that entered the Chinese national phase of an international application with PCT application number PCT / JP2021 / 005898 and the subject matter of “Method for manufacturing a laminated material, an intermediate sheet, and a composite material”. The application number of the Chinese invention application is 202180004012.X and the application date is February 17, 2021. Technical Field

[0002] The present invention relates to a composite material having a core material layer, etc. Background Art

[0003] The general characteristics of structural materials formed into so-called sandwich structures (for example, see Patent Documents 1 to 2) are light weight and high rigidity. The essence of this characteristic is high rigidity per unit density. When bending stress occurs in a composite material, the stress burden of the skin material becomes large, and the stress burden of the core material becomes relatively small. Therefore, a material with low density and relatively high rigidity is used as the core material of the core material layer.

[0004] As a lightweight structural material formed of a single material, a profile called an I-beam is provided. This I-beam is used, for example, as a beam of a building structure. The I-beam is composed of a wide flange plate (plate material) arranged in an opposed manner up and down and a narrow web plate (plate material) connecting them in a symmetrical position, and is widely used as a lightweight structure formed of a single material that can achieve high rigidity. Both the sandwich structure and the I-beam structure can exponentially increase rigidity by increasing the thickness of the plate material.

[0005] Composite materials of sandwich structures are typically used as wall materials for prefabricated houses. In this case, for example, aluminum plates are used as surface materials and expanded polystyrene is used as core materials. Composite materials of sandwich structures are also used in aircraft and railway vehicles, etc. In this case, for example, fiber reinforced plastic materials (FRP) are used as surface materials and honeycomb structure materials formed of aluminum or aramid paper impregnated with resin are used as core materials. Composite materials of sandwich structures are also used as packaging boxes. In this case, for example, the surface material is made of paper and the core material is also made of paper. A truss structure formed into a corrugated shape is used as the core material.

[0006] The density of the core material of the sandwich structure is lower than that of the skin material. Therefore, since the thickness of the core material is increased in accordance with the degree of lightness of the core material, as a result, the specific stiffness (stiffness per unit specific gravity (density)) can be increased as a sandwich structure, achieving lightness and high stiffness. It is known that the bending stiffness of a structural material is increased exponentially by increasing the thickness of its cross section in the bending direction. In the case of a quadrilateral cross section, the bending stiffness increases in direct proportion to the cube of the thickness. In a sandwich structure, if the density of the core material is lower than that of the skin material, the specific stiffness will increase even if a resin foam is not used as the core material. This is the same when any material such as a metal material or a wood material is used as the core material. This is because, generally speaking, when examining the bending stiffness of a structural material, the closer to the center of the thickness relative to the bending direction, the less bending deformation there is, and the less contribution there is to the stiffness of the structural material. Therefore, reducing the density of the center part becomes beneficial for lightweighting while ensuring stiffness.

[0007] Here, Patent Document 1 Fig. 9 Disclosed are a core material, a sandwich structure composed of fiber-reinforced materials arranged on both sides of the core material, and an island structure of the core material. The core material is formed by punching a film obtained by pressing a polypropylene resin into a disc-shaped plate, and then arranging the disc-shaped plates in a manner of forming a predetermined interval.

[0008] In addition, Patent Document 2 discloses a reinforcement structure made of a sheet-like base material. In this reinforcement structure, there is a material attenuation portion that divides the base material into a plurality of material islands. The material islands are separated by the material attenuation portion but are connected to each other.

[0009] Prior art literature

[0010] Patent Literature

[0011] Patent Document 1: Japanese Patent No. 5151535

[0012] Patent Document 2: U.S. Patent Application Publication No. 2019 / 0099964A1 Summary of the invention

[0013] Technical problem to be solved by the invention

[0014] In the sandwich structure described in Patent Document 1, a plurality of disc-shaped plates produced by press working are arranged one by one on the fiber-reinforced material in order to provide the island structure of the core material on the fiber-reinforced material. However, it is not easy to arrange the disc-shaped plates one by one.

[0015] On the other hand, in the reinforcement structure described in Patent Document 2, a plurality of material islands are interconnected and integrated. Therefore, it is relatively easy to stack the reinforcement structure on the covering layer. However, when the composite material is formed into a three-dimensional shape, the range of bending the reinforcement structure is limited due to the presence of the connection between the material islands. In addition, when the composite material is formed into a complex three-dimensional shape, the deformation of each material island cannot be tolerated, and there is a risk of damage around the connection. In the reinforcement structure described in Patent Document 2, as the demand for composite materials increases, it is difficult to provide a composite material with excellent formability for three-dimensional shapes.

[0016] The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a composite material which has excellent moldability into a three-dimensional shape and is easy to manufacture.

[0017] Solutions for solving the above technical problems

[0018] In order to solve the above technical problems, the inventor of the present application has come up with a method, in which a material sheet that will become the raw material of a plurality of plate-like sheets is pasted on a substrate sheet, the material sheet is cut and processed, and an intermediate sheet obtained by pasting a plurality of plate-like sheets on the substrate sheet is produced, and the intermediate sheet is used as a transfer sheet, a core sheet for bonding, or a sheet for composite material manufacturing, etc., which will be described later, to produce a composite material. As a composite material or intermediate sheet obtained by the manufacturing method, the first invention is a laminated material, which has a core material layer and a skin material laminated on the core material layer, and the core material layer has a plurality of plate-like sheets arranged along the surface of the skin material, in the core material layer, adjacent plate-like sheets are separated by a gap or become a single body by an incision, and in the plurality of plate-like sheets, the cutting directions in the thickness direction determined by the cutting marks formed on the periphery are the same as each other. In addition, in this specification, "intermediate sheet (intermediate material)" refers to a sheet made in an intermediate process in the manufacturing process of a composite material. In addition, "core material layer" refers to a component forming the center layer of a sandwich structure. Among them, in the laminated material before being formed into a composite material, even in the case of a canapé structure, the part corresponding to the center layer in the composite material after forming is referred to as a "core material layer".

[0019] A second invention is the first invention, wherein in the core material layer, a ratio of a total area of ​​the plate-like pieces to a total area in a plan view is 50% or more.

[0020] The third invention is that in the first or second invention, in the skin material stacked on the main surface of the plate-like sheets, which is located on the cutting advancement side as the main surface in the thickness direction of the cutting direction, there is no cut mark on the surface on the core material layer side that would be formed if a plurality of plate-like sheets were formed by cutting on the skin material.

[0021] A fourth invention is the invention according to any one of the first to third inventions, wherein each of the plurality of plate-like pieces is made of a hard foam.

[0022] A fifth invention is the invention according to any one of the first to third inventions, wherein each of the plurality of plate-like pieces is made of wood.

[0023] The sixth invention is any one of the first to fifth inventions, wherein the skin material is a first skin material, and further comprises a second skin material which is arranged on the opposite side of the first skin material in the core material layer and sandwiches the core material layer together with the first skin material.

[0024] The seventh invention is in the sixth invention, with the core material layer as the first core material layer, and further comprising: a second core material layer having a plurality of plate-like pieces arranged along the surface of the second skin material; an intermediate adhesive layer, which is arranged between the first core material layer and the second core material layer and bonds the first core material layer to the second core material layer, and the first skin material, the first core material layer, the intermediate adhesive layer, the second core material layer, and the second skin material are stacked in sequence.

[0025] The eighth invention is the seventh invention, wherein the intermediate adhesive layer is formed of a sheet-like adhesive.

[0026] A ninth invention is the invention according to any one of the first to eighth inventions, wherein the intermediate adhesive layer is formed of a sheet-like adhesive.

[0027] A tenth invention is the invention according to any one of the sixth to ninth inventions, wherein the gaps between the adjacent plate-like pieces are filled with cured resin.

[0028] The eleventh invention is any one of the first to fifth inventions, wherein the surface material is a sheet-like adhesive.

[0029] A twelfth invention is any one of the first to fifth inventions, wherein the skin material is a prepreg in a semi-cured state.

[0030] The 13th invention is the first, second, fourth or fifth invention, wherein the plurality of plate-like sheets are releasably attached to the surface material and used as a transfer sheet capable of transferring the plurality of plate-like sheets from the surface material to another structural material.

[0031] The 14th invention is the 13th invention, wherein the plurality of plate-like pieces are bonded to the surface material with a temperature-sensitive adhesive.

[0032] The fifteenth invention is the invention according to any one of the first to thirteenth inventions, wherein a sticky layer or adhesive layer for holding the position of the plate-like sheet is provided between the surface material and the plate-like sheet.

[0033] A sixteenth invention is the invention according to any one of the first to fifteenth inventions, wherein a partitioned space composed of a through hole is formed in the plate-like piece.

[0034] The 17th invention is a method for manufacturing an intermediate sheet of multiple plate-like sheets used in a core material to which a composite material is pasted, wherein a cutting step is performed to divide the material sheet into multiple plate-like sheets by cutting the material sheet in a state of being pasted to a substrate sheet, thereby obtaining an intermediate sheet in which multiple plate-like sheets are pasted to a substrate sheet, wherein the intermediate sheet is used as a transfer sheet or a core sheet for bonding, wherein the transfer sheet can transfer multiple plate-like sheets from the substrate sheet to other structural materials, and the core sheet for bonding is obtained by melting the substrate sheet in a state of being stacked on a sheet of skin material that becomes a skin material of a composite material in order to use the substrate sheet as an adhesive.

[0035] The 18th invention is that in the 17th invention, the following steps are performed: a pasting step, pasting a sheet-like adhesive or a prepreg on the plate-like sheet side of the transfer sheet as the surface material of the intermediate sheet; a transfer step, after the pasting step, transferring multiple plate-like sheets to the surface material of the intermediate sheet by peeling off the base material sheet from the multiple plate-like sheets.

[0036] The 19th invention is a method for manufacturing a composite material, which comprises the following steps: a pasting step, in which a sheet for a skin material which becomes the skin material of the composite material is pasted to the plate-like sheet side of the transfer sheet obtained by the manufacturing method of the 17th invention; a transfer step, in which, after the pasting step, a plurality of plate-like sheets are transferred to the sheet for a skin material by peeling off the base material sheet from the plurality of plate-like sheets.

[0037] The 20th invention is the 19th invention, wherein a stretchable sheet is used as the surface material, and in the transfer step, the plate-like sheet to be transferred is transferred by pressing the plate-like sheet from the back side of the base sheet 10 while stretching the base sheet.

[0038] The 21st invention is that in the 20th invention, the following steps are performed after the transfer step: a stacking step, using a skin material sheet and a second skin material sheet to sandwich a plurality of plate-like sheets; a honeycomb forming step, after allowing resin to flow into the gaps in the core material layer composed of a plurality of plate-like sheets, the resin is solidified to form a honeycomb structure of the resin in the core material layer.

[0039] Effects of the Invention

[0040] In the present invention, when the laminated material is an intermediate sheet, as a trace of forming a plurality of plate-like pieces by cutting a surface material (e.g., a base sheet), the cutting directions in the thickness direction of the plurality of plate-like pieces, which are determined by the cutting marks formed on the periphery, are the same as each other. On the surface material of the intermediate sheet, a plurality of plate-like pieces are formed corresponding to the cutting shape in a plan view during the cutting process.

[0041] Furthermore, when the laminated material is a composite material, as a mark of manufacturing using the above-mentioned intermediate sheet, the cutting directions in the thickness direction of the plurality of plate-like sheets, which are determined by the cutting marks formed on the periphery, are the same as each other. On the surface material of the composite material, a plurality of plate-like sheets are arranged corresponding to the arrangement of the plate-like sheets in the intermediate sheet. Therefore, it is not necessary to arrange a plurality of plate-like sheets one by one on the material of the surface material (e.g., the sheet for the surface material), and a core material layer in which a plurality of plate-like sheets are arranged can be easily formed.

[0042] In addition, adjacent plate-like pieces are separated by gaps or cuts to form a single body. Therefore, when the composite material is formed into a three-dimensional shape, the range of bending the core material layer is less restricted than that of a composite material in which a plurality of material islands are connected to each other, and the formability to the three-dimensional shape is excellent. According to the present invention, a composite material that is excellent in formability to the three-dimensional shape and easy to manufacture can be provided. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Figure 1 It is a perspective view of the composite material according to the embodiment.

[0044] Figure 2 is a cross-sectional view of a composite material according to an embodiment.

[0045] Figure 3 This is a plan view of a side where a chamfered portion is formed on a core material layer of a composite material according to an embodiment.

[0046] Figure 4 This is a cross-sectional view of a transfer sheet according to an embodiment.

[0047] Figure 5 This is a cross-sectional view for explaining the first manufacturing step (the method for manufacturing the transfer sheet) of the embodiment.

[0048] Figure 6 It is a schematic configuration diagram of a production line used in the first manufacturing process of the embodiment.

[0049] Figure 7 This is a cross-sectional view for explaining a state in which a chamfered portion is formed on a plate-like piece during press cutting in the first manufacturing step of the embodiment.

[0050] Figure 8 It is a cross-sectional view for explaining the transfer step of the second manufacturing process of the embodiment.

[0051] Fig. 9 It is a cross-sectional view for explaining a stacking step of the second manufacturing process of the embodiment.

[0052] Fig.10 This is a cross-sectional view when a molding die having a curved cavity surface is used in the second manufacturing step of the embodiment.

[0053] Fig.11 This is a cross-sectional view of a composite material according to an embodiment when a cured resin is filled into gaps.

[0054] Fig.12 It is a cross-sectional view of the composite material according to the first modification.

[0055] Fig.13 It is a cross-sectional view of a laminated material in the manufacturing process of the composite material according to the second modification.

[0056] Fig.14 It is a cross-sectional view of the adhesive core sheet according to the third modified example.

[0057] Fig.15 This is a cross-sectional view for explaining a transfer step in the production process of the adhesive core sheet according to the third modification.

[0058] Fig.16 It is a cross-sectional view of the adhesive core sheet according to the fourth modified example.

[0059] Fig.17 This is a cross-sectional view showing a state in which a base sheet (Prepreg) having a plurality of plate-like sheets bonded thereto is set on a molding die in a fifth modification.

[0060] Fig.18 It is a cross-sectional view of a laminated material during the manufacturing process of the composite material according to the sixth modification.

[0061] Fig.19 It is a stereoscopic view of the composite material of the seventh variation.

[0062] Fig. 20 This is a cross-sectional view of a cylindrical body using the composite material according to the seventh modification.

[0063] Fig.21 (a) is a top view of the core material layer of the composite material of the eighth modification example, Fig.21 (b) is a cross-sectional view of the composite material of the eighth variant.

[0064] Fig. 22 It is a top view of the core material layer of the composite material according to the ninth modification.

[0065] Fig.23 (a) is a cross-sectional view of a transfer sheet according to a tenth variation. Fig.23 (b) is a cross-sectional view of the composite material of the tenth variant example, Fig.23 (c) is a plan view showing the state of the dot portion side of the transfer sheet for forming the adhesive layer being overlapped on the plate-like sheet in the production process of the transfer sheet according to the tenth variation.

[0066] Fig.24It is a cross-sectional view of another composite material according to the tenth modification.

[0067] Fig.25 This is a cross-sectional view showing a state of transferring a plate-shaped sheet using the transfer sheet according to the 11th modification.

[0068] Fig.26 (a) is a cross-sectional view of a transfer sheet of another modified example, Fig.26 (b) is a cross-sectional view of a composite material of another modified example.

[0069] Fig. 27 This is a cross-sectional view for explaining a state in which a cut is formed between adjacent plate-like pieces during press cutting in the first manufacturing step in a composite material according to another modified example. DETAILED DESCRIPTION

[0070] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. Note that the following embodiments are examples of the composite material, etc. of the present invention and are not intended to limit the scope of the present invention, its applications, or its uses.

[0071] [Composition of composite materials]

[0072] The composite material (laminated material) 30 of this embodiment will be described. Figure 1 and Figure 2 As shown, the composite material 30 is a sandwich structure panel. The composite material 30 includes: a core material layer (also called "middle layer") 20; a first skin material 31, which is stacked on the core material layer 20; and a second skin material 32, which is stacked on the opposite side of the first skin material 31 in the core material layer 20, and sandwiches the core material layer 20 together with the first skin material 31. The composite material 30 can be used, for example, as a panel material that places more emphasis on lightness and rigidity than strength. Specifically, the composite material 30 can be used as a structural material for mobile objects such as aircraft, automobiles or bicycles (sports bicycles, etc.), electrical equipment, electronic equipment, office equipment, household appliances, medical equipment, or building materials. In the case of a mobile object, the composite material 30 can be used as an aerodynamic component constituting the exterior.

[0073] Each skin material 31, 32 is made of a material different from the core material layer 20, such as a skin material or a panel material. As the material of each skin material 31, 32, any of metal, plastic or inorganic can be used. In the present embodiment, fiber reinforced plastic is used as the material of each skin material 31, 32. As the fiber reinforced plastic, fiber reinforced plastic reinforced by carbon fiber can be used. As the fiber reinforced resin, a prepreg in which a resin (matrix) is impregnated in carbon fiber (for example, "Pyrofil Prepreg (registered trademark)" manufactured by Mitsubishi Chemical Corporation) can be used. The matrix of the prepreg can use a thermosetting epoxy resin.

[0074] In addition, as the fiber of the fiber reinforced plastic, any of inorganic fibers, organic fibers or metal fibers can be used, for example, glass fiber, carbon fiber, aramid fiber, polyethylene fiber, polyester fiber, tungsten fiber, steel fiber, boron fiber, etc. can be used. In addition, as the matrix of the fiber reinforced plastic, any of thermosetting resins or thermoplastic resins can be used, for example, polyester resin, epoxy resin, phenolic resin, vinyl ester resin, polyimide resin, polypropylene resin, nylon resin, polyetheretherketone resin, polybutylene terephthalate resin, or bismaleimide resin can be used.

[0075] The core material layer 20 is stacked on each skin material 31, 32. In the core material layer 20, a plurality of plate-like sheets 13 of the same thickness are arranged on a two-dimensional plane as core materials. The plurality of plate-like sheets 13 are arranged along the surface of each skin material 31, 32. Each plate-like sheet 13 is a thin, flat piece. Each plate-like sheet 13 is made of the same material and has the same shape and size. In addition, in this specification, the "plurality" in "plurality of plate-like sheets" means more than 10. The number of plate-like sheets 13 in the stacked material 30 is at least 10 sheets. In addition, the number of sheets is sometimes more than 50 sheets.

[0076] The plate-like sheet 13 is made of, for example, a sheet material, a film material, or a resin foam. The plate-like sheet 13 can be made of a material with a lower density than the skin materials 31 and 32. For example, the plate-like sheet 13 can be made of a material with a density of 30 kg / m 3 Above 2000kg / m 3 The density of the plate-like piece 13 may be appropriately designed according to the physical properties or the intended use of the composite material 30 so as to be a value outside the above range.

[0077] As the material of the plate-like sheet 13, resin (resin foam, etc.), wood material (balsa wood, veneer, etc.), or metal foam (aluminum alloy, etc.) can be used. In the present embodiment, the plate-like sheet 13 is composed of a hard resin foam. The plate-like sheet 13 is composed of, for example, a polymethacrylimide (PMI) independent bubble foam (for example, "ROHACELL (registered trademark)" (Evonik Industries)). From the perspective of lightweight composite material 30, the density of the plate-like sheet 13 is set to 30 kg / m 3 Above 500kg / m 3 The following range of values ​​(e.g. 110 kg / m 3 ).

[0078] In addition, as a hard resin foam material used for the plate-like sheet 13, polystyrene foam, polyvinyl chloride foam, cellulose acetate foam, polyurethane foam, phenolic foam, epoxy resin foam, acrylic foam, polymethacrylimide foam, polypropylene foam, polyethylene terephthalate foam, polycarbonate foam, polyamideimide foam, or polyphenylene sulfide foam can be used.

[0079] like Figure 3 As shown, in the core material layer 20, the top view shape (peripheral shape) of the plate-like sheet 13 is a regular polygon (a regular hexagon in this embodiment). In addition, when a plurality of plate-like sheets 13 are evenly spread, the top view shape of the plate-like sheet 13 can be selected from a triangle, a quadrilateral, a hexagon or a regular pentagon. In addition, the top view shape of the plate-like sheet 13 can also be a shape other than these shapes, and other polygons, circles or ellipses can also be selected. When the top view shape of the plate-like sheet 13 is a polygon as the basic shape, chamfers or roundings can be formed at each corner when viewed from above.

[0080] The thickness of the plate-like piece 13 can be set, for example, to a range of 0.05 mm to 10 mm (e.g., 0.05 mm to 2 mm). In addition, regarding the top view size of the plate-like piece 13, the average value of the distance from the center of gravity to the periphery (the average value of 360 degrees, the radius in the case of a circle) can be set to a value in the range of 3 mm to 50 mm (e.g., 5 mm), and in the case where the plate-like piece 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). Among them, the size of the plate-like piece 13 can also be set to a value outside the range described in this paragraph.

[0081] In the core material layer 20, all the plate-like pieces 13 are separated from each other and become a single body. The entire circumference of each plate-like piece 13 is separated from all adjacent plate-like pieces 13 by a gap 16. Each plate-like piece 13 becomes an island structure independent of each other. Unlike the reinforcement structure of the above-mentioned patent document 2, the adjacent plate-like pieces 13 are not connected to each other by a connection part made of the same material as the plate-like piece 13. The composite material 30 is a multi-web panel in which each skin material 31, 32 functions as a flange plate in an I-beam structure and each plate-like piece 13 functions as a web plate, and is a panel of a sandwich structure in which each plate-like piece 13 functions as a core material.

[0082] One side of the adjacent plate-like pieces 13 is opposed to each other with a gap 16 therebetween. The width W of the gap 16 is changed according to the size of the gap between the adjacent blades 24 in the upper mold 23 described later. The width W of the gap 16 is constant along the opposite sides. In addition, in each plate-like piece 13, the width W of the gap 16 faced by all the sides is equal to each other. The size of the width W of the gap 16 is appropriately designed according to the size of the composite material 30, for example, it can be set to a range of more than 0 mm and less than 10 mm.

[0083] In the core material layer 20, the ratio R1 of the total area of ​​the plate-like sheets 13 to the total area of ​​the laminated material 30 in a plan view can be adjusted by the size of the gaps 16 between the adjacent plate-like sheets 13. The ratio R1 (%) can be expressed by Formula 1.

[0084] Formula 1: R1 = (S2 / S1) × 100

[0085] Here, S1 represents the total area of ​​the core layer 20 (the total area of ​​the plate-like pieces 13 and the gaps 16), and S2 represents the total area of ​​all the plate-like pieces 13 (the area when observed from the thickness direction). In the state where there is no filling in the gaps 16, the value obtained by subtracting R1 from 100 (%) is approximately equal to the porosity R2 (%) of the core layer 20. The ratio R1 can be set to less than 100%, 50% or more (70% or more depending on the situation). In addition, when the plan view shape of each plate-like piece 13 is a triangle, a quadrilateral, a hexagon or a regular pentagon, the space of the core layer 20 can be efficiently filled. When the plate-like pieces 13 of a regular hexagon with a side of 5 mm are evenly spread with a gap of 1 mm, the ratio R1 becomes 80%. In addition, when the plate-like pieces 13 of a regular hexagon with a side of 5 mm are evenly spread with a gap of 3 mm, the ratio R1 becomes 55%.

[0086] In the core material layer 20, a plurality of plate-like sheets 13 are regularly arranged. A plurality of plate-like sheets 13 are evenly spread. In the present embodiment, as the arrangement of the plate-like sheets 13, a staggered arrangement is adopted in which the positions of the plate-like sheets 13 are staggered by half a pitch between adjacent plate-like sheet columns 13L. In the present embodiment, the top view shape of each plate-like sheet 13 is a regular hexagon, and the arrangement of the plate-like sheets 13 can also be called a honeycomb arrangement in which gaps are formed between adjacent plate-like sheets 13.

[0087] On one main surface of each plate-like piece 13 (one of the two surfaces parallel to the arrangement surface of each plate-like piece 13, Figure 2 The outer circumference of the plate-like piece 13a (the lower surface in the figure) is formed with a chamfered portion 13c throughout the entire circumference. The chamfered portion 13c is a trace (cutting mark) indicating that the plate-like piece 13 is formed by stamping, and is an arc-shaped curved surface (for example, an R surface of about 0.05 mm), or a curved surface bulging outward like an arc. The shape of the chamfered portion 13c changes depending on the blade shape of the blade 24 used in the stamping process, etc. In each plate-like piece 13, the size of the chamfered portion 13c is roughly uniform throughout the entire circumference. In addition, in this specification, the "main surface" of the plate-like piece 13 refers to the surface on the front side or the back side.

[0088] In addition, in a plurality of plate-like sheets 13 (for example, all the plate-like sheets 13 of the core material layer 20), as a mark of manufacturing using the transfer sheet 10 described later, the cutting directions in the thickness direction determined by the cutting marks formed on the periphery are the same. Specifically, in the plurality of plate-like sheets 13, chamfered portions 13c are formed on the periphery of the main surfaces 13a that are on the same side in the thickness direction. In addition, as another mark of using the transfer sheet 10, in the main surfaces 13a, 13b stacked on the plate-like sheets 13, the main surface 13b that is located on the advancing side of the cutting as the cutting direction in the thickness direction of the skin material 32, there is no cut mark 43 on the inner surface (the surface on the core material layer 20 side), which would be formed if the plurality of plate-like sheets 13 were formed by cutting on the skin material 32. Specifically, in the second skin material 32 of the main surface 13b on the opposite side of the side having the chamfered portion 13c formed on the outer periphery of the main surfaces 13a and 13b of the plate-like sheet 13, there is no cut mark 43 on the inner surface. When the cut is performed by the blade 24 of the upper mold 23 described later, the cut mark 43 becomes a V-shaped groove. In addition, in order to avoid the cut mark 43, a modified example in which a burr 13d is formed on the outer periphery of the plate-like sheet 13 (see Fig.25 The same is true for (b)).

[0089] [Constitution of transfer sheet]

[0090] Next, the transfer sheet 10 used for producing the composite material 30 will be described. The transfer sheet 10 is a sheet that can transfer a plurality of plate-like pieces 13 from the base sheet 11 to another structural material (a structure having adhesive or tacky properties on the surface).

[0091] like Figure 4 As shown, the transfer sheet 10 includes a core material layer 20 and a base material sheet 11 stacked on the core material layer 20. On the surface of the base material sheet 11 on the side of the core material layer 20, there remain cut marks (scratches) 43 when the plurality of plate-like sheets 13 are cut. In the core material layer 20, adjacent plate-like sheets 13 are separated by gaps 16. In addition, in the plurality of plate-like sheets 13, in the thickness direction, chamfered portions 13c are formed on the periphery of the main surface 13a on the same side of each plate-like sheet 13. In addition, the transfer sheet 10 is equivalent to a "stacked material", and the base material sheet 11 is equivalent to a "skin material".

[0092] The substrate sheet 11 uses, for example, a sheet or film made of resin (thermoplastic resin sheet, etc.). As the resin used for the substrate sheet 11, various resins such as polyethylene, polypropylene, polyurethane, polyester, polyethylene terephthalate (PET) or polycarbonate can be used. In the present embodiment, polyethylene terephthalate (for example, "Micro-adhesive sheet PET75 series for processing process" manufactured by Nichiei Chemical Co., Ltd.) is used as the material of the substrate sheet 11. The thickness of the substrate sheet 11 can be set to a value in the range of 0.01 mm to 0.5 mm (for example, 0.075 mm). In addition to resin, the substrate sheet 11 can also use a sheet (or film) made of rubber or paper.

[0093] On one side of the substrate sheet 11 ( Figure 4 An adhesive layer 18 is formed by applying an adhesive (pressure-sensitive adhesive, which does not cure at room temperature) on the upper surface of the substrate 11. As the adhesive, various types such as acrylic, polyurethane, or silicone can be used. In the case of the substrate sheet 11 of the micro-adhesive sheet PET75 series used in the above-mentioned processing step, an adhesive layer 18 is pre-formed on one side by applying an acrylic adhesive. However, in the case of using a substrate sheet 11 on which an adhesive layer 18 is not pre-formed, the adhesive layer 18 is formed by an adhesive such as spray glue. In this case, a spray glue such as an acrylic adhesive (for example, the "Spray Glue Series" manufactured by 3M Japan Co., Ltd.) can be used. In addition, the substrate sheet 11 can also use a sheet obtained by bonding adhesive films on both sides to a resin film.

[0094] A plurality of plate-like sheets 13 are attached to the surface of the base sheet 11 in a releasable manner. Each plate-like sheet 13 is held to the base sheet 11 with a constant adhesive force by the adhesive layer 18. The side opposite to the side having the chamfered portion 13c formed on the periphery of each plate-like sheet 13 is attached to the base sheet 11. In addition, when the surface of the base sheet 11 has adhesiveness, the adhesive layer 18 may be omitted.

[0095] The arrangement of the plate-like pieces 13 on the substrate sheet 11 becomes the basis for the arrangement of the plate-like pieces 13 in the core material layer 20 of the composite material 30. The top view of the core material layer 20 of the transfer sheet 10 is similar to the top view of the transfer sheet 10. Figure 3 same.

[0096] Specifically, if Figure 3 As shown, in the core material layer 20, the planar shape (peripheral shape) of the plate-like piece 13 is a regular polygon (a regular hexagon in this embodiment). In the core material layer 20, all the plate-like pieces 13 are separated from each other and become a single body. Each plate-like piece 13 becomes an island structure independent of each other.

[0097] Adjacent plate-like sheets 13 are opposed to each other with a gap 16 on one side. The width W of the gap 16 is constant along the opposing sides. In addition, in each plate-like sheet 13, the width W of the gap 16 facing all the sides is equal to each other. In addition, in the core material layer 20, the ratio R1 of the total area of ​​the plate-like sheets 13 to the total area of ​​the laminated material 30 when viewed from above is less than 100% and greater than 50% (or greater than 70% depending on the situation). In addition, the width W of the gap 16 may not be constant along the opposing sides, and in each plate-like sheet 13, the width W of the gap 16 facing all the sides may not be equal to each other.

[0098] On one main surface 13a (on Figure 4 The outer periphery of the plate-like piece 13 (the upper surface in the middle) is formed with a chamfered portion 13c over the entire periphery. In each plate-like piece 13, the size of the chamfered portion 13c is substantially uniform over the entire periphery.

[0099] [Method for producing composite material]

[0100] The method for manufacturing the composite material 30 sequentially performs the following steps: a first manufacturing step of manufacturing the transfer sheet 10; and a second manufacturing step of manufacturing the composite material 30 using the transfer sheet 10 obtained in the first manufacturing step. The transfer sheet 10 corresponds to an intermediate sheet.

[0101] In the first manufacturing process, the following steps are performed in order: a pasting step of pasting the material sheet 14 to the base sheet 11; and a cutting step of dividing the material sheet 14 into a plurality of plate-like pieces 13 by punching (press cutting) the material sheet 14 pasted to the base sheet 11. The material sheet 14 is a sheet of material that becomes the plate-like piece 13, and for example, a sheet of a polymethacrylimide (PMI) closed-cell foam that is sliced ​​to a predetermined thickness of 0.05 mm or more and 10 mm or less can be used.

[0102] In the pasting step, a laminated sheet 19 is prepared by pasting a long material sheet 14 to a long base sheet 11 using an adhesive layer 18 (see Figure 5 The laminated sheet 19 is wound into a roll and placed on a reel 51 of a production line 50 (see Figure 6 ). Then, the laminated sheet 19 is unfolded in the longitudinal direction and passed through the pressurizing device 15. In addition, the bonding of the base sheet 11 and the material sheet 14 can be performed by a press, a roller, or an ultrasonic horn that can apply pressure or heat and pressure.

[0103] In the cutting step, the material sheet 14 is press-cut by vertically cutting into the laminated sheet 19 on the lower die 22 of the press device 15 using the blade 24 of the upper die 23. Figure 5 As shown in (b), the substrate sheet 11 is not cut, but is so-called half-cut (i.e., cut to a degree that it does not penetrate). In this embodiment, a plurality of plate-like pieces 13 are formed on the substrate sheet 11 to manufacture the transfer sheet 10 (refer to Figure 5 (c)). In addition, the top view shape of the blade 24 uses a shape corresponding to the outer peripheral shape of the plate-like piece 13. For example, in the case of the plate-like piece 13 formed into a regular hexagon, a blade 24 that is a regular hexagon in top view is used. In the upper mold 23, a plurality of blades 24 are arranged on a two-dimensional plane with gaps therebetween.

[0104] Here, if Figure 7 As shown in (a), during the punching process, a portion 29 of the surface of the material sheet 14 that first contacts the front end of the blade 24 is pushed in. Then, the periphery of the portion 29 undergoes plastic deformation. Therefore, after the material sheet 14 is cut by the blade 24, as shown in FIG. Figure 7 As shown in (b), as a mark of plastic deformation, a chamfered portion 13c is formed on the outer periphery of the plate-like piece 13. As described above, the chamfered portion 13c is a curved surface in the shape of an arc or a curved surface bulging outward like an arc. In addition, chips 39 are formed between the blades 24. In addition, during the stamping process, depending on the cutting conditions, burrs 13d are sometimes formed on the outer periphery of the main surface 13a of each plate-like piece 13 (see Fig.25(b)) instead of the chamfered portion 13c. However, no matter which one is formed, a cutting mark that can identify the cutting direction in the thickness direction remains on the outer periphery of the main surface 13a of the plate-like piece 13.

[0105] In the present embodiment, the upper die 23 moves up and down relative to the lower die 22 during press cutting. However, press cutting may be performed by pressurization by rotation of a rotary die (die cutting roller).

[0106] The scraps 39 of the material sheet 14 cut by the pressurizing device 15 become a mesh sheet 38 connected to each other. The mesh sheet 38 composed of the scraps 39 is taken up and removed by the take-up reel 25 (see Figure 6 ). In addition, a protective film 27 unrolled from a roller provided on another reel 26 is stacked on the plate-like sheet 13 side of the transfer sheet 10. A plurality of plate-like sheets 13 are covered with the protective film 27. In addition, in the present embodiment, the long transfer sheet 10 is cut into a predetermined length by a cutter 28 to be divided into a plurality of transfer sheets 10. In addition, the winding of the winding reel 25, the covering of the protective film 27, and the cutting of the cutter 28 may be omitted.

[0107] In the second manufacturing process, the following steps are performed in sequence: a transfer step of transferring the plurality of plate-like pieces 13 on the transfer sheet 10 to the first skin material sheet 31A; and a laminating step of laminating the second skin material sheet 32A to the plurality of plate-like pieces 13. Each skin material sheet 31A, 32A is the skin material 31, 32 (see Figure 2 ) material, for example, a prepreg (prepreg sheet) in a semi-cured state can be used.

[0108] In the transfer step, first, the first skin material sheet 31A is placed on a molding die (eg, mold) 33. Figure 8 As shown in (a), the transfer sheet 10 obtained by the first manufacturing step is arranged so that the plate-like sheet 13 side faces the first skin material sheet 31A on the forming mold 33. Figure 8 As shown in (b), the plurality of plate-like pieces 13 of the transfer sheet 10 are pressed against the first surface material sheet 31A. The surface of the first surface material sheet 31A has adhesiveness. Therefore, the plurality of plate-like pieces 13 are attached to the first surface material sheet 31A. Then, as shown in Figure 8 As shown in (c), the base sheet 11 is peeled off from the plurality of plate-like sheets 13. In this way, since the adhesive force of the first surface material sheet 31A to the plurality of plate-like sheets 13 is greater than the adhesive force of the adhesive layer 18 to the plurality of plate-like sheets 13, the plurality of plate-like sheets 13 can be transferred from the base sheet 11 to the first surface material sheet 31A.

[0109] In addition, a thermosensitive adhesive may be used as the adhesive of the adhesive layer 18. For example, when a thermal release adhesive whose adhesive force decreases above a predetermined transition temperature (e.g., "Thermosensitive Adhesive Sheet Intelimer Tape Thermal Release" manufactured by Nitta Co., Ltd., for example, a transition temperature of 50 degrees) is used for the adhesive layer 18, Figure 8 In the state shown in (b), the substrate sheet 11 is placed from the back side (at Figure 8 On the other hand, when a cold release adhesive whose adhesive force decreases below a predetermined transition temperature (e.g., "Intelimer tape cold release type" manufactured by Nitta Co., Ltd., for example, a transition temperature of 25 degrees) is used for the adhesive layer 18, the substrate sheet 11 is peeled off when the adhesive layer 18 is at or above the transition temperature. Figure 8 The substrate sheet 11 is cooled from the back side in the state shown in (b), and the substrate sheet 11 is peeled off when the adhesive layer 18 is below the transition temperature. When a temperature-sensitive adhesive is used, the substrate sheet 11 can be easily peeled off from the plate-like sheet 13. In addition, when the substrate sheet 11 is peeled off, the influence on the bonding state between each plate-like sheet 13 and the first skin material sheet 31A is also small.

[0110] Then, if Fig. 9 As shown in (a), in the laminating step, first, the second skin material sheet 32A is separately arranged in a manner opposite to the plate-like sheet 13 side of the laminated material 30A obtained by the transfer step. Then, as Fig. 9 As shown in (b), the second surface material sheet 32A is stacked on the plate-like sheet 13 side of the stacking material 30A. The surface of the second surface material sheet 32A has adhesiveness. Therefore, a plurality of plate-like sheets 13 are attached to the second surface material sheet 32A. As described above, a stacking material 30B in which a plurality of plate-like sheets 13 are sandwiched by a pair of surface material sheets 31A and 32A can be obtained.

[0111] Then, in the case where the matrix of the prepreg used in each skin material sheet 31A, 32A is a thermosetting resin (e.g., epoxy resin), a forming step is performed. In the forming step, the laminated material 30B obtained by the lamination step is sealed with a bagging film. 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, 32A become fully cured skin materials 31, 32. As a result, the laminated material 30B is formed into a specified shape ( Fig. 9 In the case of (b), the composite material 30 is in a flat plate shape and cured.

[0112] In addition, when the matrix of the prepreg used in each skin material sheet 31A, 32A is a thermoplastic resin (such as polyamide resin, polypropylene resin, polyetheretherketone resin), after the molding steps such as pressurized heating and pressing molding, the stacked material 30B is cooled in an atmosphere at a temperature lower than the curing temperature of the matrix (such as room temperature), thereby performing a curing step to complete the composite material 30.

[0113] [Effects of this embodiment, etc.]

[0114] In the transfer sheet 10 of the present embodiment, as a mark of forming the plurality of plate-like pieces 13 by punching the base sheet 11, the cutting directions in the thickness direction are the same as each other, which are determined by the cutting marks formed on the periphery of the plurality of plate-like pieces 13. Specifically, the chamfered portion 13c (or burr 13d) is formed on the same side in the thickness direction of the plurality of plate-like pieces 13. On the base sheet 11 of the transfer sheet 10, the plurality of plate-like pieces 13 are formed according to the cutting shape (punching shape) in the plan view during the punching process.

[0115] Furthermore, in the composite material 30 of the present embodiment, as a trace of manufacturing using the transfer sheet 10, chamfered portions 13c are formed on the same side in the thickness direction in the plurality of plate-like sheets 13. On the first skin material 31 of the composite material 30, a plurality of plate-like sheets 13 are arranged corresponding to the arrangement of the plate-like sheets 13 in the transfer sheet 10. Therefore, it is possible to easily form a core material layer 20 in which a plurality of plate-like sheets 13 are arranged without arranging a plurality of plate-like sheets 13 one by one on the skin material sheet 31A. Fig. 9 In the case of , it is difficult to densely arrange the disk-shaped plates, but according to the present embodiment, it is also easy to densely arrange a plurality of plate-shaped pieces 13 on the skin material sheet 31A.

[0116] In addition, in the composite material 30 of the present embodiment, adjacent plate-like sheets 13 are separated by gaps 16 to form a single body. Here, in the case of using a rigid foam body in the plate-like sheet 13, the composite material of the conventional sandwich structure has achieved light weight and high rigidity by having a core material layer composed of a foam body, a honeycomb structure, or a plurality of interconnected material islands. However, the conventional composite material has a continuous structure in the core material layer, so if the rigid foam body lacking toughness is bent, it is easy to be damaged, and it is difficult to form into a complex three-dimensional shape. When the shape of the composite material is bent, the bending range is limited.

[0117] In contrast, in this embodiment, if Fig.10As shown, even when a forming mold 33 with a curved cavity surface is used, adjacent plate-like pieces 13 are separated by the gap 16, and interference between adjacent plate-like pieces 13 is suppressed by the gap 16. Therefore, compared with conventional composite materials, the core material layer 20 is less likely to be damaged even if it is bent, and the bending range is less restricted when formed into a three-dimensional shape. According to this embodiment, a composite material 30 that is excellent in formability for three-dimensional shapes and easy to manufacture can be provided. Furthermore, a composite material 30 with a complex three-dimensional shape and a composite material 30 with a larger bend can be realized.

[0118] In addition, when using Fig.10 In the case of the forming mold 33 shown in FIG. 3 , a composite material 30 having a three-dimensional shape curved along the cavity surface of the forming mold 33 can be obtained. Fig.10 In the case of a convex surface as shown, even in the case of a concave surface, interference between adjacent plate-like pieces 13 can be suppressed. In addition, when using a forming die 33 with a curved cavity surface, the followability to the forming die 33 changes according to the width W of the gap 16. Therefore, the width W of the gap 16 can be appropriately designed according to the curvature of the forming die 33.

[0119] In addition, in the composite material 30 of the present embodiment, prepreg is used as the material of each skin material 31, 32. Therefore, when the heat treatment is performed, the curable resin (matrix) of the prepreg flows into the gap 16 between the plate-like sheets 13 and fills the gap 16 of the core material layer 20. The inflowing curable resin is cured in the gap 16. The resin cured in the gap 16 contains short fibers that flow from the prepreg together with the resin. Thus, it is possible to suppress the local strength reduction of the composite material 30. In addition, sometimes the gap 16 of the core material layer 20 is filled with the resin of the prepreg, and sometimes a fillet is formed at the corner between the side of the plate-like sheet 13 and the inner surface of the skin material 31, 32, or the gap 16 is filled in a state containing bubbles. In addition, when the gap 16 is large, the prepreg used as the material of each skin material 31, 32 can use a prepreg with a large amount of resin per unit area.

[0120] In addition, a curable resin (e.g., a thermosetting, two-liquid reactive, moisture reactive adhesive, etc.) may be injected into the gap 16 of the plate-like sheet 13 by using a pressure difference separately from the matrix of the prepreg. The injected curable resin is cured in the gap 16. In addition, a film-like adhesive may be added between the two sheets of skin material 31, 32. In this case, the film-like adhesive melts during the heat treatment, and the melted adhesive (curable resin) flows into the gap 16 and finally cures. In these cases, as Fig.11As shown, the gaps 16 between the adjacent plate-like sheets 13 are filled with the cured resin 6, which can suppress the local strength reduction of the composite material 30 and improve the rigidity. In addition, these steps correspond to the honeycomb forming step, and after the curable resin is flowed into the gaps 16 of the core material layer 20 composed of a plurality of plate-like sheets 13, the honeycomb structure of the resin 6 is formed in the core material layer 20 by curing the resin. In addition, the filling of the curable resin can also be performed without using prepreg in the material of the skin materials 31 and 32.

[0121] In addition, in this embodiment, since the density of the plate-like sheet 13 is low, a composite material 30 having light weight and excellent specific stiffness can be realized. In addition, in this embodiment, in addition to the density of the plate-like sheet 13, the density of the core material layer 20 can also be adjusted by adjusting the thickness of the plate-like sheet 13 and the gap 16.

[0122] <First Modification>

[0123] In this variation, if Fig.12 As shown, the composite material 130 also includes: a second core material 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 material layer 20 and the second core material layer 21. The intermediate adhesive layer 17 is formed by a sheet-like adhesive (also referred to as a film-like adhesive or an adhesive sheet) that is directly heat-cured by heating and melting, and bonds the first core material layer 20 to the second core material layer 21. In the composite material 130, the first skin material 31, the first core material layer 20, the intermediate adhesive layer 17, the second core material layer 21, and the second skin material 32 are stacked in this order. In addition, the intermediate adhesive layer 17 may also be composed of an adhesive layer obtained by melting the sheet-like adhesive. In addition, the gap 16 between each core material layer 20, 21 may be filled with a cured resin 6.

[0124] In this variation, the position of each plate-like piece 13 of the first core layer 20 is made consistent with the position of each plate-like piece 13 of the second core layer 21 when viewed from above, but the position of each plate-like piece 13 of the first core layer 20 and the position of each plate-like piece 13 of the second core layer 21 can also be staggered with each other.

[0125] In this modification, the core material layers 20 and 21 are provided as two layers, but the core material layers 20 and 21 may be provided as three or more layers. In this case, the intermediate adhesive layer 17 may be provided between the core material layers 20 and 21 adjacent to each other in the thickness direction.

[0126] In addition, a prepreg or a thermosetting resin sheet (epoxy resin, etc.) may be used instead of a sheet-shaped adhesive in the intermediate adhesive layer 17. In this case, the composite material 130 may be manufactured by laminating a plurality of laminated materials 10 having a laminated structure of a substrate sheet (prepreg) 11 and a plurality of plate-shaped sheets 13 attached to the substrate sheet 11. In this case, since the resin flows and flows into the gaps 16 between the plate-shaped sheets 13 during the heating step, it is possible to suppress a local decrease in the strength of the composite material 30. In addition, since the surface of the substrate sheet 11 has adhesiveness, an adhesive for holding the plate-shaped sheets 13 can be omitted.

[0127] In this variation, in the core material layer 20, the plate-like sheet 13 has a two-layer structure. Here, when the curved composite material 30 is formed, the greater the thickness of the plate-like sheet 13, the greater the tensile deformation in one side of the plate-like sheet 13, and depending on the thickness of the plate-like sheet 13 and the size of the bend, one side of the plate-like sheet 13 may be damaged due to the tensile deformation. In contrast, when comparing composite materials of the same thickness, in this variation, each plate-like sheet 13 is thinner than the composite material 30 in which the plate-like sheet 13 is a one-layer structure. Therefore, the tensile deformation generated on one side of each plate-like sheet 13 becomes smaller, and it is difficult to cause damage even when a low-toughness hard resin foam is used for the plate-like sheet 13. According to this variation, a composite material 30 with better formability in three-dimensional shapes can be provided.

[0128] <Second Modification>

[0129] In this modification, the intermediate sheet manufactured in the first manufacturing step is not used as the transfer sheet 10, but is used as the core sheet 60 for bonding (see Fig.13 ), the adhesive core sheet 60 is obtained by melting the substrate sheet 111 in a state where it is stacked on the surface material sheet 31A in order to use the substrate sheet 111 as an adhesive. In addition, the adhesive core sheet 60 can use a sheet having the same structure as the above-mentioned transfer sheet 10. However, in the case of the transfer sheet 10, an adhesive that can peel off each plate-like sheet 13 from the substrate sheet 11 is used for the adhesive layer 18, but in the case of the adhesive core sheet 60, it is not necessary to make each plate-like sheet 13 peelable, but the material sheet 14 can be attached to the substrate sheet 111 by an adhesive or an adhesive.

[0130] For example, when the plate-like sheet 13 is a single layer, in the second manufacturing process of manufacturing the composite material 30, the first skin material sheet 31A on the forming die 33 is sequentially laminated with the adhesive core sheet 60 and the second skin material sheet 32A. Fig.13As shown, the plate-like sheet 13 side can be pasted to the first surface material sheet 31A. In addition, the substrate sheet 111 side can also be pasted to the first surface material sheet 31A (omitted from the figure). Then, the result of laminating the second surface material sheet 32A is that a laminated material 30B can be obtained. Since the method for manufacturing the composite material 30 by the laminated material 30B is the same as the above-mentioned embodiment, the description is omitted. In addition, when the amount of resin buried in the gap 16 is insufficient, a resin sheet (a sheet of the same properties as the intermediate adhesive layer 17, such as a sheet-like adhesive, a prepreg, etc.) can also be laminated on one side or both sides of the core layer 20.

[0131] In addition, multiple adhesive core sheets 60 may be used in the manufacture of one composite material 30. In this case, multiple adhesive core sheets 60 may be stacked in such a manner that the plate-like sheets 13 face the same side in the thickness direction. In addition, with respect to the adhesive core sheets 60 adjacent in the thickness direction, the base material sheets 111 may be bonded to each other, and the core material layers 20 may be bonded to each other.

[0132] <Third Modification>

[0133] In this modification, the transfer sheet (first intermediate sheet) 10 is used to manufacture Fig.14 The illustrated bonding core sheet (second intermediate sheet) 60. The surface material 111 of the bonding core sheet 60 is a sheet-like adhesive.

[0134] In the method for manufacturing the adhesive core sheet 60, a pasting step and a transfer step are sequentially performed after the first manufacturing step. In the pasting step, Fig.15 (a) and Fig.15 As shown in (b), the surface material 111 is attached to the plate-like sheet 13 side of the transfer sheet 10. In addition, as the sheet-like adhesive of the surface material 111, an adhesive having the independent sheet 141 laminated on the back surface can be used.

[0135] In the transfer step, Fig.15 As shown in (c), by peeling off the base sheet 11 from the plurality of plate-like sheets 13, the plurality of plate-like sheets 13 are transferred to the surface material 111. Thus, the adhesive core sheet 60 can be obtained. In addition, the process of laminating the protective film 27 can also be performed on the plate-like sheet 13 side of the adhesive core sheet 60.

[0136] <Fourth Modification>

[0137] In this modification, the transfer sheet (first intermediate sheet) 10 is used to manufacture Fig.16 The composite material manufacturing sheet (second intermediate sheet) 70 shown in FIG. The composite material manufacturing sheet 70 is similar to the composite material manufacturing sheet except that the surface material 61 is a prepreg (semi-cured state). Fig.14 The prepreg of the skin material 61 can be a prepreg having the independent sheet 41 laminated on the back. The method of manufacturing the sheet 160 for manufacturing a composite material is the same as that of the third modification except for the skin material, so the description is omitted.

[0138] <Fifth Modification>

[0139] In this modification, the intermediate sheet manufactured by the first manufacturing step is a sheet 70 for manufacturing a composite material using a prepreg as the base sheet 61. In this case, in the manufacturing method of the composite material 30, Fig.17 As shown, a base sheet 61 having a plurality of plate-like pieces 13 attached thereto is placed on a mold 33. Then, the second skin material sheet 32A is laminated on the plurality of plate-like pieces 13 of the base sheet 61 to produce a laminated material 30B (not shown).

[0140] The laminated material 30B is heated in an autoclave at a predetermined temperature and pressure for a predetermined time as in the above embodiment. As a result, the laminated material 30B is fired to complete the composite material 30 of a predetermined shape by completely curing the base sheet 61 and the second skin material sheet 32A.

[0141] According to this modification, there is no need to perform the peeling operation of the base sheet 61 , and the composite material 30 can be manufactured with fewer steps than in the above-described embodiment.

[0142] <Sixth Modification>

[0143] In this variation, if Fig.18 As shown in FIG. 1 , in the transfer sheet 10 , an independent sheet 41 is laminated on the back surface of the base sheet 11 . The independent sheet 41 covers the back surface of the base sheet 11 .

[0144] The independent sheet 41 can be made of a sheet material or a film material such as polypropylene, polyolefin, polyester, polyethylene, polyethylene terephthalate, polyurethane, tetrafluoroethylene, polytetrafluoroethylene, polyphenylene sulfide, polyimide, polyetheretherketone, or paper.

[0145] When prepreg is used as the base sheet 11, the independent sheet 41 is provided on the base sheet 11 so as to be releasable by utilizing the adhesiveness of the prepreg. Also, when a thermoplastic resin sheet is used as the base sheet 11, the independent sheet 41 is provided on the base sheet 11 so as to be releasable.

[0146] In this modification, the independent sheet 41 is provided, so that the transfer sheet 10 can be easily handled in the transfer step. Therefore, the base sheet 11 and the plate-like sheet 13 can be easily positioned, and the molding operation of the composite material 30 can be easily performed.

[0147] <Seventh Modification>

[0148] In this variation, if Fig.19 As shown, the composite material 131 is a laminated structure. In addition, in the core material layer 20 on the skin material 31, the strip-shaped plate-like sheets 13 are arranged in a constant direction. A gap 16 is formed between adjacent plate-like sheets 13. Fig.19 In the embodiment, the plate-like piece 13 is not divided along its length direction, but the plate-like piece 13 may be divided along its length direction. In addition, the chamfered portion 13c is formed on the outer periphery of the main surface 13a on the side of the skin material 31 in each plate-like piece 13. Fig.19 and Fig. 20 The record is omitted.

[0149] The composite material 131 can be wound into a cylindrical shape to produce the cylindrical body 100. When the composite material 131 is wound with the skin material 31 side as the inner side, the cylindrical body 100 can be obtained. Fig. 20 The cylindrical body 100 shown. In this case, the two end portions 31a of the skin material 31 are not laminated with the core material layer 20, and the end portion 31a of one side becomes a sticky strip on the inner circumference (sticked to a sticking portion of the skin material 31 on the outside), and the end portion 13a of the other side is laminated in a manner covering the outermost plate-like sheet 13. In addition, in the case where the composite material 131 is wound with the skin material 31 side as the outer side, a cylindrical body 100 can be obtained. In this case, the end portion 31a of one side is laminated in a manner covering the innermost plate-like sheet 13, and the end portion 13a of the other side becomes a sticky strip on the outer circumference (sticked to a sticking portion of the skin material 31 on the inside). On the innermost side, the end portion 31a of the skin material 31 is laminated in a manner covering multiple plate-like sheets 13.

[0150] <Eighth Modification>

[0151] In this modified example, a partition space 53 consisting of a through hole is formed in each plate-like piece 13 of the core material layer 20. The partition space 53 divides the surrounding space in a top view. In addition, the number of partition spaces 53 in one plate-like piece 13 can be one or more. In addition, the partition space 53 can be formed in all the plate-like pieces 13 in the composite material 30, or the partition space 53 can be formed only in a part of the plate-like pieces 13.

[0152] The outer peripheral shape of the plate-like piece 13 is the same as that of the above-mentioned embodiment, and is a regular polygon (in Fig.21(a) is a regular hexagon). However, the plan view shape of the plate-like piece 13 may be a shape other than a regular polygon (for example, a polygon other than a regular polygon, a circle, an ellipse, etc.). In addition, the plan view shape of the partition space 53 is the same as the outer peripheral shape of the plate-like piece 13. However, the plan view shape of the partition space 53 may be different from the outer peripheral shape of the plate-like piece 13.

[0153] The partitioning spaces 53 can be formed during the press cutting of the material sheet 14 into a plurality of plate-like pieces 13 in the cutting step of the first manufacturing process. In this case, in the upper die 23 used for press cutting, a blade (not shown) corresponding to the top view shape of the partitioning spaces 53 is provided inside the blade 24 corresponding to the top view shape of the plate-like piece 13. Fig.21 As shown in (b), on the same side as the chamfered portion 13c (or burr 13d) in the thickness direction, an inner chamfered portion 13e (or inner burr) is formed as a trace (cut mark) showing that the partition space 53 is formed by stamping. Fig.21 In (a), the chamfered portion 13c and the inner chamfered portion 13e are omitted. In addition, after the partition space 53 is formed in the material sheet 14, the material sheet 14 is pasted to the base sheet 11, and the material sheet 14 is divided into a plurality of plate-like pieces 13 by pressing and cutting in a manner that matches the position of the partition space 53.

[0154] In the composite material 30, as Fig.21 As shown in (b), the gap 16 of the core material layer 20 is filled with a cured resin 6. The resin 6 is a resin obtained by injecting a curable resin (such as a thermosetting, two-liquid reactive, moisture-reactive adhesive, etc.) into the gap 16 using a pressure difference and curing it. The curable resin can be injected using, for example, the RTM (Resin Transfer Molding) molding method. In this case, for example, the skin material sheets 31A and 32A sandwiching the core material layer 20 can use fiber fabrics that do not contain resin (carbon fiber or glass fiber fabrics, or carbon fiber or glass fiber non-woven fabrics, etc.), resin plates or metal plates, and between each skin material sheet 31A and 32A and the core material layer 20, a resin sheet 54 made of a raw material that prevents the curable resin from passing can be stacked.

[0155] The resin sheet 54 can be a perforated sheet 54A having a plurality of through holes 54a formed therein, or a non-porous sheet 54B having no through holes 54a. Fig.21As shown in (b), one side can be set as an open-pored sheet 54A and the other side can be set as a non-porous sheet 54B, or both sides can be set as an open-pored sheet 54A, or both sides can be set as a non-porous sheet 54B. In the case of using the open-pored sheet 54A, by overlapping at least a portion of the through-holes 54a of the resin sheet 54 with the gap 16, it becomes easy to fill the gap 16 with a low-fluidity curable resin. In addition, at least a portion of the through-holes 54a of the resin sheet 54 can be overlapped with the divided space 53. In this case, the divided space 53 overlapping with the through-holes 54a is injected with curable resin, and the divided space 53 other than this is not injected with curable resin. In addition, in the case where any through-hole 54a of the resin sheet 54 does not overlap with the divided space 53, or in the case where both sides use the non-porous sheet 54B, curable resin is not injected into any divided space 53. In either case, it is possible to control whether the divided space 53 flows into the curable resin. Therefore, the porosity in the core material layer 20 can be adjusted according to the size of the divided space 53. In addition, the curable resin may not be injected into the gap 16. Even in this case, by providing the divided space 53 in each plate-like piece 13, each plate-like piece 13 becomes easy to follow the three-dimensional shape.

[0156] <9th Modification>

[0157] This modification is the same as the eighth modification in that a partition space 53 is formed in the plate-like piece 13. Fig. 22 As shown, a honeycomb structure partition space 53 is formed in the plate-like piece 13. The number of partition spaces 53 in one plate-like piece 13 may be one or more. Fig. 22 In the figure, the dotted line indicates the cutting part (the position of the pressure cutting described later). The plan view shape of the cutting part relative to one plate-like piece 13 is a polygon (hexagon). However, the plan view shape of the cutting part may be a shape other than a polygon.

[0158] In the manufacture of the core material layer 20, in the first manufacturing step, after the material sheet 14 of the honeycomb structure is attached to the base material sheet 11, the material sheet 14 is punched (press-cut) while being attached to the base material sheet 11, so that the material sheet 14 is divided into a plurality of plate-like pieces 13. Then, the cuttings are removed as needed to obtain the core material layer 20. In addition, as the material sheet 14, a sheet in which thin films are integrated on both sides of a layer of a honeycomb structure in such a manner as to block each through hole of the honeycomb structure can be used, and a sheet consisting only of a layer of a honeycomb structure can also be used.

[0159] exist Figure 2 Composite materials such as 30, Figure 4 Transfer sheet 10, etc. Fig.13The bonding core sheet 60, etc., and Fig.16 In the laminated materials of all the above-mentioned embodiments and variants such as the sheet material 70 for manufacturing composite materials, the core layer 20 of the 8th variant and the 9th variant can be used instead of the core layer 20 without the partitioning space 53. With regard to the technical problem of making each plate-like piece 13 easy to follow a three-dimensional shape, when the laminated material is an intermediate sheet such as a transfer sheet 10, the laminated material 10 comprises a core layer 20 and a skin material 11 laminated on the core layer 20, the core layer 20 has a plurality of plate-like pieces 13 arranged along the surface of the skin material 11, in the core layer 20, adjacent plate-like pieces 13 are separated by gaps or cuts to form a single body, and the partitioning space 53 is formed in the plate-like piece 13. In addition, in the case where the laminated material is a composite material 30 such as a sandwich structure panel, the laminated material 30 has a skin material 11 as a first skin material, and further has a second skin material 12, which is arranged on the opposite side of the first skin material 11 in the core layer 20, and sandwiches the core layer 20 together with the first skin material 11. In addition, in order to realize a technical problem such as a laminated material capable of adjusting the porosity in the core layer 20, in the laminated materials 10, 30, a resin sheet 54 that prevents curable resin from passing is stacked between each skin material sheet 31A, 32A and the core layer 20.

[0160] <10th Modification>

[0161] In this modification, a holding portion 80 for holding the planar position of the plate-like sheet 13 is stacked on the main surfaces 13a and 13b of the plate-like sheet 13 of the core layer 20. The holding portion 80 is an adhesive layer or bonding layer having a gap formed partially therein.

[0162] exist Fig.23 In the embodiment, the adhesive layer 80 is composed of a plurality of dot portions 80a each composed of an adhesive film. In the adhesive layer 80, for example, the plurality of dot portions 80a are regularly arranged. The adhesive layer 80 is laminated on at least one of the main surface 13a and the main surface 13b of the plate-like sheet 13. Fig.23 (a) The transfer sheet 10 and Fig.23 In the composite material 30 of (b), the adhesive layer 80 is laminated on both the main surface 13a and the main surface 13b of the plate-like sheet 13. However, the adhesive layer 80 may be laminated only on the main surface 13a of the plate-like sheet 13, or may be laminated only on the main surface 13b of the plate-like sheet 13. According to this modified example, when the curable resin is injected into the gap 16 by using the pressure difference, the position deviation of the plate-like sheet 13 can be suppressed, and the position deviation of the plate-like sheet 13 can also be suppressed in the finished product of the composite material 30.

[0163] The method of providing the adhesive layer 80 on the plate-like sheet 13 may be, for example, printing a plurality of dot portions 80a on one or both sides of a material sheet 14 that is a material of the core material layer 20 in a preparation process performed before the first manufacturing process. In this case, in the first manufacturing process, the material sheet 14 printed with a plurality of dot portions 80a is attached to the base sheet 11, and then the material sheet 14 is divided into a plurality of plate-like sheets 13 by punching.

[0164] As another method, a transfer sheet 85 for forming an adhesive layer on which a plurality of dot portions 80a are printed can be used (see Fig.23 (c)). In this case, the base sheet 86 on which the plurality of dot portions 80a are printed in the transfer sheet 85 can be made of an easily removable sheet such as a resin sheet of a PET film treated with silicone. The adhesive force of the dot portion 80a to the plate-like sheet 13 is greater than the adhesive force of the dot portion 80a to the base sheet 86. In this method, after the cutting step in the first manufacturing process, the dot portion 80a side of the transfer sheet 85 is set to overlap with the main surface 13a of the plate-like sheet 13 ( Fig.23 Then, by peeling off the base sheet 86, the plurality of dots 80a can be transferred to the main surface 13a of the plate-like sheet 13. In addition, in the above-mentioned preparation process, instead of printing the plurality of dots 80a on the material sheet 14, the plurality of dots 80a can be transferred to the main surfaces 13a and 13b of the plate-like sheet 13 using the transfer sheet 85.

[0165] In addition, the dot portion 80a may be formed of an adhesive film instead of an adhesive. In this case, the dot portion 80a fixed to each plate-like piece 13 functions as an anchor, thereby suppressing positional deviation of the plate-like piece 13.

[0166] In addition, instead of the plurality of dot portions 80a, Fig.24 As shown, an adhesive sheet (or bonding sheet) 87 having a plurality of gaps formed in the thickness direction is laminated on the main surfaces 13a and 13b of the plate-like sheet 13. The adhesive sheet 87 can be a mesh sheet using an adhesive as a material, or a nonwoven fabric interwoven with fibers of an adhesive, etc. The bonding sheet 87 can be a mesh sheet using an adhesive as a material, or a nonwoven fabric interwoven with fibers of an adhesive, etc. In these cases, the positional deviation of the plate-like sheet 13 can also be suppressed.

[0167] The holding portion 80 of this modification can be applied to Figure 2 Composite materials such as 30, Figure 4 Transfer sheet 10, etc. Fig.13 The bonding core sheet 60, etc., and Fig.16The laminated materials of all the above-mentioned embodiments and variations thereof, such as the sheet material 70 for manufacturing composite materials, etc. For realizing a laminated material capable of suppressing positional deviation of the plate-like pieces 13, when the laminated material is an intermediate sheet such as a transfer sheet 10, the laminated material 10 comprises a core material layer 20 and a skin material 11 laminated on the core material layer 20, the core material layer 20 comprises a plurality of plate-like pieces 13 arranged along the surface of the skin material 11, in the core material layer 20, adjacent plate-like pieces 13 are separated by gaps or cuts to form a single body, and between the skin material 11 and the plate-like pieces 13, a retaining portion 80 for retaining the planar position of the plate-like pieces 13 is laminated. In addition, in the case where the laminated material is a composite material 30 such as a panel with a sandwich structure, the laminated material 30 has a skin material 11 as a first skin material, and further has a second skin material 12, which is arranged on the opposite side of the first skin material 11 in the core material layer 20, and sandwiches the core material layer 20 together with the first skin material 11, and a retaining portion 80 is stacked between the skin materials 11, 12 and the plate-like sheet 13.

[0168] <11th Modification>

[0169] In this modification, a sheet material having stretchability is used as the base sheet 11 of the transfer sheet 10. A resin sheet such as a CPP film (unstretched polypropylene) can be used as the base sheet 11. As an example of the physical property values ​​of the base sheet 11, for example, the tensile strength is 100 MPa (JIS K 7127) or less, and the tensile elongation is 200% (JIS K 7127) or more.

[0170] In this modification, in the transfer step of transferring the plate-like sheet 13, an operator or a machine uses Fig.25 While the substrate sheet 11 is stretched in the direction of the arrow shown, the plate-like sheet 13 to be transferred is pressed from the back of the substrate sheet 11 by a pressing object 55 such as a rod or a finger of the operator, so that the plate-like sheet 13 is transferred to the surface material sheet 31A. According to this modification, since the adhesive force between the plate-like sheet 13 to be transferred and the substrate sheet 11 is reduced by stretching the substrate sheet 11, the transfer of the plate-like sheet 13 becomes easy. For example, when transferring to the surface material sheet 31A placed on a convex curved surface, since the close contact area of ​​the plate-like sheet 13 with respect to the surface material sheet 31A becomes small, the transfer of the plate-like sheet 13 becomes easy.

[0171] <Another Modification>

[0172] In the above embodiment, the material sheet 14 may be cut into a plurality of plate-like pieces 13 by laser cutting instead of press cutting. Fig.26As shown in (a) of FIG. 1 , in the intermediate sheet 10, burrs 13d are formed on the periphery of the main surface 13a of each plate-like sheet 13 as cutting marks that can identify the cutting direction in the thickness direction. Fig.26 As shown in (b), burrs 13d remain on the periphery of the main surface 13a of each plate-like piece 13 in the composite material 30. In addition, when laser cutting is performed, chamfered portions 13c are sometimes formed on the periphery of the main surface 13a of each plate-like piece 13 as the above-mentioned cutting marks. In addition, the state of the cut surface can be controlled by adjusting the focus, output, or feed speed of the laser during laser cutting.

[0173] In the above embodiment, instead of press cutting or laser cutting, a cutting device (cutting plotter) that moves a blade along the shape to be cut may be used to cut the material sheet 14 to separate it into a plurality of plate-like pieces 13. In this case, a chamfer 13c or a burr 13d is formed on the outer periphery of the main surface 13a of each plate-like piece 13 as a cutting mark that can identify the cutting direction in the thickness direction.

[0174] In the above embodiment, in the core material layer 20, the adjacent plate-like pieces 13 are separated by the gap 16 and become a single body, but the adjacent plate-like pieces 13 may also become a single body through the cutout 40. In this case, Fig. 27 (a) and Fig. 27 As shown in (b), adjacent plate-like pieces 13 are cut by the same blade 24. For example, in the case of a plate-like piece 13 formed into a regular hexagon, a blade 24 with a regular hexagonal arrangement pattern is used. Then, as shown in FIG. Fig. 27 As shown in (c), when the blade 24 is pulled out, Fig. 27 In the state (b), the plate-like pieces 13 that have been elastically deformed are restored, and the cutouts 40 remain between the adjacent plate-like pieces 13 .

[0175] In the above-mentioned embodiment, as the material of the skin material 31, 32, a metal material can be used. In this case, each plate-like sheet 13 is joined to the skin material 31, 32 by an adhesive. As the adhesive, for example, vinyl acetal / phenolic resin adhesive, nitrile rubber / phenolic resin adhesive, chloroprene rubber / phenolic resin adhesive, epoxy resin adhesive, recycled rubber adhesive, polybenzimidazole (PBI) adhesive, polyimide (PI) adhesive, etc. can be used. In addition, from the perspective of the efficiency of the bonding operation (stability and workability of the coating amount of the adhesive), a sheet-like adhesive (film-like adhesive) can also be used. The resin that becomes the base of the sheet-like adhesive is, for example, epoxy resin, nylon / epoxy resin, nitrile / epoxy resin, acrylic / epoxy resin, vinyl / epoxy resin, modified epoxy resin, epoxy resin / phenolic resin, polyimide, nylon, or modified polypropylene, etc.

[0176] In the above embodiment, when the composite material 30 is used for a huge structure such as a ship hull panel, the size of each plate-like piece 13 becomes larger, and the width W of the gap 16 between adjacent plate-like pieces 13 also becomes larger. For example, when the outer shape of the plate-like piece 13 is a deformed circle with a major axis dimension of 100 mm, the width W of the gap 16 can be set to 10 mm or more.

[0177] In the above embodiment, the shapes of all the plate-like pieces 13 in the core material layer 20 may be different. For example, the planar shape of the plate-like piece 13 at a location in the composite material 30 may be determined based on the curvature of the location.

[0178] In the above embodiment, Figure 2 The composite material 30 shown may be a laminated structure without the second skin material 32. In this case, the plate-like sheet 13 side of the composite material 30 is attached to the structural material to be reinforced. The core material layer 20 is sandwiched between the first skin material 31 and the structural material to be reinforced.

[0179] In the above embodiment, the core material layer 20 is composed of a plurality of plate-like sheets 13 arranged along the surface of the skin materials 11, 12, but in intermediate sheets such as the transfer sheet 10, the adhesive core sheet 60, and the composite material manufacturing sheet 70, the core material layer 20 may also be composed of a sheet material having a plurality of through holes (e.g., a sheet material having a honeycomb structure).

[0180] [Example]

[0181] right Figure 1 and Figure 2 The present invention is not limited to this embodiment unless otherwise specified. In addition, the units and measurement methods described in this embodiment are based on the JIS standard unless otherwise specified.

[0182] The plate-like sheet 13 is made of a closed-cell polymethacrylimide (PMI) foam with a trade name of "ROHACELL (registered trademark)" (Evonik Industries AG). The density of the plate-like sheet 13 is 110 kg / m 3. In addition, the plan view shape of the plate-like piece 13 is a shape with a regular hexagon as the basic shape and six corners being chamfered respectively. Regarding the size of the plate-like piece 13, the thickness is 1.0 mm, the length of one side of the regular hexagon is 5 mm, and the radius of the chamfer of each of the above-mentioned corners is 0.5 mm. In addition, the width W of the gap 16 between adjacent plate-like pieces 13 is 1 mm. A plurality of plate-like pieces 13 are evenly arranged in the above-mentioned honeycomb arrangement. In addition, as a cutting mark of the stamping process, a chamfered portion 13c with a radius of about 0.05 mm is formed on the outer periphery of the main surface (one side) 13a of the plate-like piece 13. In a plan view, the area ratio R1 of the plate-like piece 13 to the total area is 80.3% (a calculated value reflecting the area reduction caused by the chamfering of each corner).

[0183] The skin materials 31 and 32 are made of a prepreg with a trade name of "Pyrofil Prepreg (registered trademark) TR3110381GMX" (manufactured by Mitsubishi Chemical Corporation). The specification of the prepreg is a total weight per unit area of ​​333 g / m 2 , a carbon fiber plain cloth material with a tensile elastic modulus of 240 GPa, and a matrix of thermosetting epoxy resin.

[0184] In the heating step, the laminated material 30B was heated at 0.2 MPa and 130° C. for 2 hours. As a result, the laminated material 30B was formed into a material with a thickness of 1.49 mm and a density of 503 kg / m 3 Composite material 30.

[0185] In order to evaluate the physical properties of the composite material 30, a bending test was conducted based on JIS standard K7074 (bending test method for carbon fiber reinforced plastics). The results showed that the bending elastic modulus was 18.9 GPa and the density was 503 kg / m 3 , the elastic modulus per unit density becomes a very high value. According to the embodiment, it can be confirmed that a composite material 30 having light weight and high rigidity can be obtained.

[0186] Industrial Applicability

[0187] The present invention can be applied to composite materials having a core material layer, etc.

[0188] Description of Reference Numerals

[0189] 10 Transfer sheet (laminated material, intermediate sheet)

[0190] 11 Base sheet (surface material)

[0191] 13 plates

[0192] 13a, 13b main surface

[0193] 13c chamfered part

[0194] 13d burr

[0195] 16 Clearance

[0196] 18 Adhesive layer

[0197] 20 core layers

[0198] 30 Composite materials (laminated materials)

[0199] 31, 32 Surface material

[0200] 40 incision

[0201] 60 Core sheet for bonding (laminated material, intermediate sheet)

[0202] 70 Sheets for composite material manufacturing (laminated materials, intermediate sheets).

Claims

1. A method for producing an intermediate sheet having a plurality of plate-like sheets bonded together and used as a core material of a composite material used as a structural material, characterized in that: A cutting step is performed to cut a material sheet in a state where the material sheet is adhered to a substrate sheet by an adhesive, so as to divide the material sheet into a plurality of plate-like pieces, thereby obtaining an intermediate sheet in which the plurality of plate-like pieces are adhered to the substrate sheet via an adhesive layer. The intermediate sheet is used as a transfer sheet for transferring the plurality of plate-shaped pieces from the base sheet and the adhesive layer to a skin material sheet that becomes a skin material in the composite material.

2. The method for manufacturing an intermediate sheet according to claim 1, characterized in that: The skin material sheet has a fiber reinforcement material.

3. The method for manufacturing an intermediate sheet according to claim 1, wherein: In the cutting step, the cutting process is performed by laser cutting.

4. The method for manufacturing an intermediate sheet according to claim 1, wherein: In the cutting step, the cutting process is performed by press cutting.

5. The method for manufacturing an intermediate sheet according to claim 1, wherein: As the material of the material sheet, a hard resin foam is used.

6. A transfer sheet comprising a core material layer and a skin material laminated on the core material layer, characterized in that: The core material layer has a plurality of plate-like pieces arranged along the surface of the skin material. In the core material layer, adjacent plate-like sheets are separated by gaps or cuts to form a single body. The plurality of plate-like sheets are releasably attached to the surface material via an adhesive layer. The plurality of plate-like pieces are transferred from the skin material and the adhesive layer to a skin material sheet that becomes a skin material in a composite material used as a structural material.

Images