Laminate material and method for manufacturing laminate material
The laminated material design with spaced or grooved layers effectively addresses gas retention issues, ensuring strength and design integrity by facilitating gas escape during bonding.
Patent Information
- Application Number
- JP2024018519
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-02-09
- Publication Date
- 2025-08-22
AI Technical Summary
Conventional laminated materials face issues such as air bubbles, air pockets, and gas retention due to thickness differences and chemical reactions, which affect strength and design integrity.
A laminated material design with alternating layers of fiber-reinforced composite and wood-based materials, incorporating spaces or grooves perpendicular to the lamination direction to facilitate gas escape during bonding, ensuring minimal gas retention.
The solution minimizes gas retention, maintaining strength and design integrity by allowing gas escape, thus enhancing bending rigidity and structural integrity.
Smart Images
Figure 2025122835000001_ABST
Abstract
Description
[Technical Field]
[0001] The present invention relates to a laminate and a method for manufacturing the laminate. [Background technology]
[0002] Since covers for covering water tanks and waterways, sleepers, etc. require strength, laminated materials made by stacking multiple flat plates made of fiber-reinforced composite materials, wood materials, etc. are used. As a laminated material, for example, Patent Document 1 discloses a synthetic sleeper in which a plurality of molded bodies containing reinforcing fibers oriented in a certain direction and foamed resin are laminated. Patent Document 2 discloses a cover that is configured with a face plate formed by stacking and joining a plurality of flat plates.
[0003] As shown in Figure 3, for example, a laminated material can be obtained by stacking the required number of rectangular flat plates of fiber-reinforced composite material, one of which is longitudinal in plan view, with a liquid adhesive applied to both sides or one side, pressing them together using a press or the like to push out excess adhesive from the sides, and then curing the material until the adhesive hardens. In designing for tensile strength and bending strength, when it is necessary to reinforce the laminate not only in the longitudinal direction but also in the direction perpendicular to the longitudinal direction in a plan view, as shown in Fig. 3, multiple flat plates 31a may be arranged in the planar direction so that the orientation direction of the reinforcing fibers of multiple flat plates 31a is perpendicular (Y direction in Fig. 3) to the longitudinal direction of the laminate 30 in a plan view (X direction in Fig. 3). The laminate 30 shown in Fig. 3 has a laminated structure in which two units are stacked: a first layer 31 made up of five flat plates 31a arranged so that the orientation direction of the reinforcing fibers is the Y direction of the laminate 30; a second layer 32 located on one side of the first layer 31 and made up of one flat plate 32a whose reinforcing fibers are oriented in the X direction of the laminate 30; and a third layer 33 located on the other side of the first layer 31 and made up of one flat plate 33a whose reinforcing fibers are oriented in the X direction of the laminate 30. In the laminated material 30 shown in FIG. 3, the second layer 32 of one unit also serves as the third layer 33 of the other unit. When reinforcement in one direction is sufficient, the flat plates 31a, 32a, and 33a are laminated and bonded together so that the orientation direction of the reinforcing fibers is the same. [Prior art documents] [Patent documents]
[0004] [Patent Document 1] Japanese Patent Application Publication No. 9-316801 [Patent Document 2] Japanese Patent Application Laid-Open No. 2002-88894 Summary of the Invention [Problem to be solved by the invention]
[0005] However, with conventional methods of laminating flat plates, there are problems such as air bubbles that are drawn in when the adhesive is applied, air pockets that remain in gaps that occur when there is a large difference in the thickness of the flat plates used at the same time, and gases such as carbon dioxide that are generated by chemical reactions depending on the material of the flat plates used not being able to escape completely and remaining in the laminated material, which can become the starting point and cause swelling when the laminated material is used. An object of the present invention is to provide a laminated material that minimizes the effect on strength design and that is less likely to retain gas, and a method for manufacturing the laminated material. [Means for solving the problem]
[0006] The present invention has the following aspects. [1] A laminate comprising a first layer, a second layer located on one side of the first layer and in contact with the first layer, and a third layer located on the other side of the first layer and in contact with the first layer, wherein the first layer has one or more flat plates selected from flat plates of a fiber-reinforced composite material containing a cured product of a resin composition and reinforcing fibers, flat plates of wood, and flat plates of a wood-based material, and has one or more spaces extending perpendicular to the lamination direction, and the second layer and the third layer are each a layer consisting of one or more flat plates selected from flat plates of a fiber-reinforced composite material containing a cured product of a resin composition and reinforcing fibers, flat plates of wood, and flat plates of a wood-based material. [2] The laminated material according to [1], wherein the width of the space is 3 to 20 mm. [3] The laminated material of [1] or [2] above, wherein the height of the space is 3 mm or more. [4] The laminate according to any one of [1] to [3], wherein the second layer and the third layer are layers made of flat plates of the fiber-reinforced composite material, the reinforcing fibers in the fiber-reinforced composite material are oriented in one direction, and the cured product is a foam. [5] The laminate according to any one of [1] to [4], wherein the laminate is rectangular with one longitudinal direction in a plan view, the second layer is located on one outermost surface of the laminate, the second layer located on one outermost surface of the laminate is a layer made of a flat plate of the fiber-reinforced composite material, and the reinforcing fibers in the fiber-reinforced composite material are oriented in the longitudinal direction of the laminate in a plan view. [6] A method for producing a laminated material according to any one of [1] to [5] above, comprising a step of laminating and bonding together the first layer, the second layer, and the third layer. [7] The method for manufacturing the laminated material of [6], wherein the first layer has a plurality of the flat plates, and the method includes a step of forming the first layer by arranging the plurality of flat plates constituting the first layer with gaps in the surface direction. [Effects of the Invention]
[0007] According to the present invention, it is possible to provide a laminated material and a method for manufacturing the laminated material that minimize the influence on strength design and that is less likely to leave gas. [Brief explanation of the drawings]
[0008] [Figure 1] 1 is a perspective view schematically showing an example of a laminated material of the present invention. [Figure 2] FIG. 2 is a perspective view schematically showing another example of the laminated material of the present invention. [Figure 3] FIG. 1 is a perspective view schematically showing an example of a conventional laminated material. DETAILED DESCRIPTION OF THE INVENTION
[0009] Hereinafter, with reference to the drawings, a form for carrying out the present invention will be described in detail. However, the following description is an example of an embodiment of the present invention, and the present invention is not limited to the contents of the following description within the scope of the gist described in the claims, and various modifications and changes are possible. In addition, in each drawing used in the following explanation, for convenience, characteristic parts may be shown enlarged to make the features easier to understand, and the dimensional ratios of each component may differ from the actual ones. In addition, in FIG. 2, the same components as those in FIG. 1 are denoted by the same reference numerals, and the description thereof will be omitted. In addition, in this specification, the use of "to" indicating a range of values means that the values before and after it are included as the lower and upper limits.
[0010] [Laminated wood] First Embodiment FIG. 1 is a perspective view showing a laminated material 10 according to a first embodiment of the present invention. The laminated material 10 of this embodiment has a laminated structure in which two units are stacked together: a first layer 11, a second layer 12 located on one side of the first layer 11 and in contact with the first layer 11, and a third layer 13 located on the other side of the first layer 11 and in contact with the first layer 11. In this embodiment, the second layer 12 of one unit also serves as the third layer 13 of the other unit. That is, the laminate 10 is a five-layer laminate in which the third layer 13, the first layer 11, the second layer 12 that also serves as the third layer 13, the first layer 11, and the second layer 12 are laminated in this order. The laminated material 10 of this embodiment is rectangular in plan view with one longitudinal side. In this specification, the longitudinal direction of the laminated material 10 is referred to as the "X direction", and the direction perpendicular to the longitudinal direction of the laminated material 10 in a plan view, ie, the lateral direction, is referred to as the "Y direction". In addition, in the present invention, the "stacking direction" refers to the stacking direction of the first layer 11, the second layer 12, and the third layer 13, that is, the thickness direction of the laminate 10, and is also called the "Z direction."
[0011] The thickness of the laminate 10, i.e., the length in the Z direction, is preferably 5 mm or more, and more preferably 10 mm or more. If the thickness of the laminate 10 is equal to or greater than the above-mentioned lower limit, the bending rigidity is further increased. There is no particular upper limit to the thickness of the laminate 10, and it may be set appropriately depending on the application of the laminate 10.
[0012] (First layer) The laminate 10 of this embodiment comprises two first layers 11 . Each of the first layers 11 in the illustrated example is a layer having five flat plates 11a arranged with gaps S1 in the X direction of the laminated material 10, and four spaces formed by the gaps S1 that extend through the laminated material 10 in the Y direction. The flat plate 11a in the illustrated example has a rectangular shape with one long side in plan view. The longitudinal direction of the flat plate 11a is parallel to the Y direction of the laminated material 10.
[0013] The flat plate 11a is one or more flat plates (P1) selected from a flat plate made of a fiber-reinforced composite material, a flat plate made of wood, and a flat plate made of a wood-based material. Among these, a flat plate made of a fiber-reinforced composite material is preferred. The five flat plates 11a constituting the first layer 11 may be the same type of flat plates or different types of flat plates.
[0014] The fiber-reinforced composite material contains a cured resin composition and reinforcing fibers. It is preferred that a part or all of the cured resin composition is attached to the reinforcing fibers. The cured product of the resin composition may be a foam or a non-foam. That is, the cured product of the resin composition may have voids derived from the foaming agent or may not have voids derived from the foaming agent. If the cured product of the resin composition is a foam, the specific gravity of the flat plate 11a is reduced. A fiber-reinforced composite material in which the cured product of the resin composition is a foam is also referred to as a "fiber-reinforced foamed composite material" or a "foamed resin molded product."
[0015] Examples of the resin component contained in the resin composition include thermosetting resins such as urethane resin, epoxy resin, vinyl ester resin, unsaturated polyester resin, phenol resin, etc. Among these, urethane resin is more preferred. The thermosetting resin may be used alone or in combination of two or more kinds. A resin composition containing a urethane resin is also referred to as a "urethane resin composition," and a fiber-reinforced composite material containing a cured product of the urethane resin composition and reinforcing fibers is also referred to as a "urethane resin molded article." Of these, a fiber-reinforced composite material in which the cured product of the urethane resin composition is a foam is also referred to as a "urethane resin foam molded article."
[0016] The resin composition includes, for example, the above-mentioned thermosetting resin. When the cured product of the resin composition is a foam, the resin composition contains a thermosetting resin and a foaming agent. The resin composition may further contain other additives as needed.
[0017] The foaming agent is not particularly limited, and any foaming agent known in the field of fiber reinforced composite materials can be used, such as water. The other additives are not particularly limited, and any additive known in the field of fiber-reinforced composite materials can be used. Examples of such additives include carbonate compounds such as calcium carbonate, magnesium carbonate, zinc carbonate, and barium carbonate; minerals such as dawsonite, hydrotalcite, mica, imogolite, sericite, and gypsum fiber; sulfate compounds such as calcium sulfate, barium sulfate, and magnesium sulfate; silicate compounds such as calcium silicate; clays such as talc, clay, montmorillonite, bentonite, activated clay, and sepiolite; nitrides such as aluminum nitride, boron nitride, and silicon nitride; carbon compounds such as carbon black, graphite, carbon balloons, and charcoal powder; titanium compounds such as potassium titanate and lead zirconate titanate; metal borate compounds such as aluminum borate; sulfides such as molybdenum sulfide; carbides such as silicon carbide; hydroxides such as aluminum hydroxide; ash such as fly ash, coal ash, and shirasu balloons; sand such as silica sand; pyroclastic materials such as pumice; perlite; glass balloons; wood chips; bamboo chips; starch; and rice bran. The other additives may be used alone or in combination of two or more.
[0018] Examples of reinforcing fibers include inorganic fibers such as glass fibers, carbon fibers, and metal fibers; and organic fibers such as natural fibers and synthetic fibers. Among these, glass fibers are preferred from the viewpoints of strength and economy. The reinforcing fibers may be used alone or in combination of two or more types.
[0019] Examples of glass fibers include glass roving, glass roving cloth, glass mat, and continuous strand mat. The glass fibers may be used alone or in combination of two or more types, and may be used as a mixture of long and short fibers.
[0020] The reinforcing fibers may be short fibers or long fibers (continuous fibers), but long fibers are preferred, and from the viewpoint of continuity and ease during production, it is more preferred that they are blended in one direction. When the reinforcing fibers are oriented in one direction, the orientation direction is not particularly limited, and the reinforcing fibers may be oriented in the X direction, the Y direction, a direction between the X and Y directions, or the Z direction. In particular, the reinforcing fibers are preferably oriented in the X or Y direction.
[0021] Furthermore, as will be described in more detail later, when the flat plate 12a constituting the second layer 12 or the flat plate 13a constituting the third layer 13 is a flat plate made of a fiber-reinforced composite material, it is preferable that the reinforcing fibers contained in the flat plate 11a are oriented in the same direction as the orientation direction of the reinforcing fibers contained in the flat plate 12a or the flat plate 13a, or in a direction perpendicular to the orientation direction of the reinforcing fibers contained in the flat plate 12a or the flat plate 13a when viewed in plan. As a preferred example, the reinforcing fibers contained in the flat plate 11a are oriented in the Y direction of the laminate, and the reinforcing fibers contained in the flat plates 12a and 13a are oriented in the X direction of the laminate; and the reinforcing fibers contained in the flat plates 11a, 12a, and 13a are oriented in the same direction, more preferably in the X direction of the laminate.
[0022] Wood-based materials are composite materials made by reconstructing wood fragments or thin plates using adhesives or other materials. In other words, they are newly manufactured materials that use wood as the main raw material and undergo various processes. Examples of wood-based materials include particle board and laminated plywood.
[0023] The thickness of the flat plate 11a is preferably 3 to 200 mm, more preferably 5 to 50 mm, and even more preferably 10 to 30 mm. If the thickness of the flat plate 11a is equal to or greater than the above lower limit, the flat plate 11a can be easily manufactured. If the thickness of the flat plate 11a is equal to or less than the above upper limit, the bending rigidity and strength of the laminate 10 are further increased.
[0024] The length of the flat plate 11a in the longitudinal direction (Y direction of the laminated material 10) is not particularly limited and may be set appropriately depending on the application of the laminated material 10, but is preferably 2000 mm or less, more preferably 1200 mm or less, and even more preferably 600 mm or less. The length of the flat plate 11a in the short side direction (X direction of the laminated material 10) is not particularly limited, and may be set appropriately depending on the application of the laminated material 10.
[0025] In the illustrated example, the gap S1 between the flat plates 11a is a space that the first layer 11 has. As will be described in detail later, the first layer 11, the second layer 12, and the third layer 13 are bonded together using an adhesive, and at that time, they are pressed together using a press or the like to push out excess adhesive from the sides of the laminated material 10. The first layer 11 has a space, which allows gas to escape during pressure bonding, making it less likely for gas to remain in the laminated material 10. In other words, the space provided in the first layer 11 is an escape route for the gas. Here, "gas" refers to, for example, air bubbles trapped when applying adhesive, air pockets remaining in gaps that occur when there is a large difference in thickness between the flat plates that make up each layer, and gases such as carbon dioxide that are generated by chemical reactions depending on the material of the flat plates used.
[0026] The width w1 of the gap S1 is preferably 3 to 20 mm, more preferably 5 to 20 mm, and even more preferably 5 to 10 mm. If the width w1 of the gap S1 is equal to or greater than the above-mentioned lower limit, gas can be sufficiently released during pressure bonding. If the width w1 of the gap S1 is equal to or less than the above-mentioned upper limit, the bending rigidity and strength of the laminated material 10 can be maintained at a good level.
[0027] The height h1 of the gap S1 is the same as the thickness of the flat plate 11a. That is, the height h1 of the gap S1 is preferably 3 mm or more. If the height h1 of the gap S1 is equal to or greater than the lower limit (i.e., the greater the height h1), the more gas can escape during pressure bonding. The smaller the height h1 of the gap S1, the better the bending rigidity and strength of the laminate 10 can be maintained.
[0028] (Second layer, third layer) The second layer 12 in the illustrated example is a layer made up of one flat plate 12a. The third layer 13 in the illustrated example is a layer made up of one flat plate 13a. The flat plates 12a and 13a in the illustrated example each have a rectangular shape with one longitudinal side in a plan view. The longitudinal directions of the flat plates 12a and 13a are parallel to the X direction of the laminated material 10.
[0029] The outermost layer of the laminate 10 may be a layer (another layer) other than the second layer 12 and the third layer 13, but as shown in Figure 1, it is preferable that the second layer 12 is located on the outermost surface of one side of the laminate 10, i.e., the outermost layer on one side of the laminate 10 is the second layer 12. It is also preferable that the third layer 13 is located on the outermost surface of the other side of the laminate 10, i.e., the outermost layer on the other side of the laminate 10 is the third layer 13.
[0030] The flat plate 12a is one or more flat plates (P2) selected from a flat plate made of a fiber-reinforced composite material, a flat plate made of wood, and a flat plate made of a wood-based material. Among these, a flat plate made of a fiber-reinforced composite material is preferred. The flat plate 13a is one or more flat plates (P3) selected from a flat plate made of a fiber reinforced composite material, a flat plate made of wood, and a flat plate made of a wood-based material. Among these, a flat plate made of a fiber reinforced composite material is preferred. The flat plates 11a, 12a, and 13a may be the same type of flat plate or different types of flat plates. Examples of the fiber reinforced composite material and the wood material include the fiber reinforced composite material and the wood material exemplified above in the description of the first layer 11, respectively.
[0031] When the flat plate 12a and the flat plate 13a are each a flat plate of a fiber-reinforced composite material, the reinforcing fibers contained in the fiber-reinforced composite material may be short fibers or long fibers, but long fibers are preferred, and from the viewpoint of continuity and ease during production, it is more preferred that they be blended in one direction. When the reinforcing fibers are oriented in one direction, the orientation direction is not particularly limited, and the reinforcing fibers may be oriented in the X direction, the Y direction, a direction between the X and Y directions, or the Z direction. In particular, it is preferable that the reinforcing fibers be oriented in the X direction or the Y direction. Furthermore, from the viewpoint of the bending rigidity and strength of the laminate 10, when the second layer 12 is located on one outermost surface of the laminate 10, it is preferable that the reinforcing fibers be oriented in the X direction of the laminate 10 in at least the flat plate 12a constituting the second layer 12 located on one outermost surface of the laminate 10. Furthermore, when the third layer 13 is located on the other outermost surface of the laminate 10, it is preferable that the reinforcing fibers be oriented in the X direction of the laminate 10 in the flat plate 13a constituting the third layer 13 located on the other outermost surface of the laminate 10.
[0032] The thickness of each of the flat plates 12a and 13a is preferably 3 to 200 mm, more preferably 5 to 50 mm, and even more preferably 10 to 30 mm. If the thicknesses of the flat plates 12a and 13a are equal to or greater than the above-mentioned lower limit values, the flat plates 12a and 13a can be easily manufactured. If the thicknesses of the flat plates 12a and 13a are equal to or less than the above-mentioned upper limit values, the bending rigidity and strength of the laminated material 10 are further increased.
[0033] The length of the flat plates 12a and 13a in the longitudinal direction (X direction of the laminated material 10) is not particularly limited, and may be set appropriately depending on the application of the laminated material 10. The lengths of flat plates 12a and 13a in the short direction (Y direction of laminated material 10) are not particularly limited and may be set appropriately depending on the application of laminated material 10, but for example, each is preferably 2000 mm or less, more preferably 1200 mm or less, and even more preferably 600 mm or less.
[0034] (Manufacturing method) The laminated material 10 is obtained by laminating and bonding together a first layer 11, a second layer 12, and a third layer 13. At this time, the first layer 11 is formed by arranging the five flat plates 11a that make up the first layer 11 with gaps S1 in the surface direction (the X direction of the laminated material 10 in the illustrated example). That is, the manufacturing method of the laminated material 10 includes a step of stacking and bonding the first layer 11, the second layer 12, and the third layer 13 together, and also a step of arranging the five flat plates 11a that make up the first layer 11 in the X direction of the laminated material 10 with a gap S1 between them to form the first layer 11.
[0035] An adhesive is used to bond the layers together. Examples of adhesives include epoxy resin adhesives, urethane resin adhesives, and polyester resin adhesives.
[0036] Specifically, the laminated material 10 is obtained as follows. First, adhesive is applied to both sides of the five flat plates 11a that make up the first layer 11. Next, five flat plates 11a coated with adhesive are placed on one flat plate 13a constituting the third layer 13, leaving a gap S1 in the X direction of the laminated material 10, to form the first layer 11, and then one flat plate 12a constituting the second layer 12 is stacked on the first layer 11 to obtain a precursor of the laminated material 10. Next, the flat plates 13a, 11a, and 12a are pressed together using a press or the like to push out excess adhesive from the side surfaces of the precursor of the laminated material 10. During the pressing, gas escapes from the gap S1 formed in the first layer 11. Thereafter, the laminate is cured until the adhesive hardens, and the laminate 10 is obtained.
[0037] When the flat plates 11a, 12a, and 13a are each made of a fiber-reinforced composite material, it is preferable to arrange the flat plates so that the orientation direction of the reinforcing fibers contained in each plate is in a desired direction. As an example, the flat plates are arranged so that the orientation direction of the reinforcing fibers contained in flat plate 12a and flat plate 13a is the X direction of the laminate 10, and the orientation direction of the reinforcing fibers contained in flat plate 11a is the Y direction or X direction of the laminate 10.
[0038] (Action and effect) As described above, in the laminated material 10 of this embodiment, the first layer 11 has a gap S1 (space), so that when the laminated material 10 is pressed, gas easily escapes from the gap S1 formed in the first layer 11, and gas is less likely to remain in the laminated material 10. Normally, when a plurality of flat plates are arranged in the surface direction, there is a concern that the strength may decrease, so as shown in FIG. 3, a plurality of flat plates 31a are arranged in the surface direction so that no gaps are formed. However, in the laminated material 10 of this embodiment, the second layer 12 is bonded to one surface of the first layer 11 having the gap S1, and the third layer 13 is bonded to the other surface of the first layer 11. Therefore, the laminated material 10 as a whole has a certain degree of thickness and can maintain its strength.
[0039] The laminated material 10 is suitable for use as a cover for covering a water tank or a waterway, a water cut-off wall, an earth retaining wall, a board for a sleeper, etc.
[0040] (Other aspects) The laminated material 10 of this embodiment is not limited to the above. In the illustrated example, the first layer 11, the second layer 12, and the third layer 13 each have a single-layer structure, but may have a laminated structure. However, it is preferable that at least the first layer 11 has a single-layer structure. When the second layer 12 has a laminated structure, two or more flat plates 12a are laminated and bonded together to form the second layer 12. Similarly, the third layer 13 is formed by laminating and bonding two or more flat plates 13a together to form the third layer 13. Furthermore, the laminated material 10 of this embodiment has two units each consisting of a first layer 11, a second layer 12, and a third layer 13, and the second layer 12 of one unit also serves as the third layer 13 of the other unit, but the second layer 12 of one unit and the third layer 13 of the other unit may be separate layers.
[0041] The second layer 12 is composed of one flat plate 12a, but two or more flat plates 12a may be arranged in the surface direction to form the second layer 12. However, when two or more flat plates 12a are arranged in the surface direction, the flat plates 12a are arranged so that no gaps are formed. The third layer 13 is composed of one flat plate 13a, but two or more flat plates 13a may be arranged in the surface direction to form the third layer 13. However, when two or more flat plates 13a are arranged in the surface direction, the flat plates 13a are arranged so that no gaps are formed.
[0042] When the second layer 12 has a laminated structure made up of a plurality of flat plates 12a or is made up of a plurality of flat plates 12a arranged in the planar direction, the plurality of flat plates 12a making up the second layer 12 may be of the same type or different types. When the third layer 13 has a laminated structure made up of a plurality of flat plates 13a or is made up of a plurality of flat plates 13a arranged in the planar direction, the plurality of flat plates 13a making up the third layer 13 may be of the same type or different types.
[0043] The first layer 11 in the illustrated example has five flat plates 11a, but the number of flat plates constituting the first layer 11 in this embodiment is not limited to five as long as it is two or more, and can be changed appropriately depending on the size of the flat plates 11a and the longitudinal length of the laminated material 10.
[0044] Furthermore, the gap S1 of the first layer 11 in the illustrated example extends in the Y direction of the laminate 10, but the extension direction is not particularly limited as long as it is perpendicular to the Z direction of the laminate 10, and may, for example, extend in the X direction of the laminate 10.
[0045] In addition, the flat plates 11a, 12a, and 13a in the illustrated example are rectangular with one longitudinal axis in a plan view, but the shape in a plan view is not particularly limited as long as they are plate-like, and may be square, circular, triangular, or polygonal with pentagons or more sides. In other words, the laminated material 10 may be square, circular, triangular, or polygonal with pentagons or more sides in a plan view.
[0046] Second Embodiment FIG. 2 is a perspective view showing a laminated material 20 according to a second embodiment of the present invention. The laminate 20 of this embodiment is similar to the laminate 10 of the first embodiment shown in Figure 1, except that each of the multiple flat plates 11a constituting the first layer 11 has two groove portions S2 extending through the laminate 10 in the Y direction, and other aspects and uses are also similar to the laminate 10 of the first embodiment. That is, in the illustrated example of the laminated material 20, the gaps S1 between the flat plates 11a and the grooves S2 formed in each flat plate 11a are the spaces that the first layer 11 has, and the gaps S1 and the grooves S2 extend in the same direction.
[0047] The groove S2 is composed of a bottom surface and a side surface extending from the bottom surface, and has an opening. Of the two grooves S2 formed in each flat plate 11a, the opening of one groove S2 faces the second layer 12 side, and the opening of the other groove S2 faces the third layer 13 side. The groove S2 is preferably formed approximately in the center of the flat plate 11a in the short side direction.
[0048] The width w2 of the groove S2 is preferably 3 to 20 mm, more preferably 5 to 20 mm, and even more preferably 5 to 10 mm. If the width w2 of the groove S2 is equal to or greater than the above-mentioned lower limit, gas can be sufficiently released during compression bonding. If the width w2 of the groove S2 is equal to or less than the above-mentioned upper limit, the bending rigidity and strength of the laminate 10 can be maintained at a good level.
[0049] The height h2 of the groove S2 is preferably 3 mm or more, more preferably 5 mm or more, and is preferably less than the thickness of the flat plate 11a, more preferably 10 mm or less. If the height h2 of the groove S2 is equal to or greater than the above-mentioned lower limit, gas can be sufficiently released during compression bonding. If the height h2 of the groove S2 is equal to or less than the above-mentioned upper limit, the bending rigidity and strength of the laminate 10 can be maintained at a good level.
[0050] When manufacturing the laminated material 20, it is preferable to form the grooves S2 in advance in each of the flat plates 11a.
[0051] In the illustrated example, the groove portion S2 extends in the Y direction of the laminate 10, but the extension direction is not particularly limited as long as it is perpendicular to the Z direction of the laminate 10, and it may, for example, extend in the X direction of the laminate 10.
[0052] Furthermore, although two groove portions S2 are formed in each of the flat plates 11a in the illustrated example, the flat plates 11a may have one groove portion S2 formed therein, or three or more groove portions S2 formed therein. For example, when manufacturing a laminated material 20 in which one groove portion S2 whose opening faces the second layer 12 side is formed in the flat plate 11a, the laminated material 20 may be manufactured as follows. First, an adhesive is applied to the other surfaces of the five flat plates 11a that make up the first layer 11. Next, five flat plates 11a coated with adhesive are placed on one flat plate 13a constituting the third layer 13 with gaps S1 formed in the surface direction (in the illustrated example, the X direction of the laminated material 10) so that the coated surfaces are in contact, and then grooves S2 are formed in each flat plate 11a to form the first layer 11. Thereafter, adhesive is applied to one surface of each flat plate 11a, and one flat plate 12a constituting the second layer 12 is laminated on top of them. Next, the flat plates 13a, 11a, and 12a are pressed together using a press or the like to push out excess adhesive from the sides of the laminated material 10. Thereafter, the adhesive is cured to harden, and the laminated material 20 is obtained.
[0053] <Other embodiments> The laminated material of the present invention is not limited to the above-described embodiments. For example, the first layer may be a layer consisting of a single flat plate having one or more grooves extending perpendicular to the stacking direction. Alternatively, the first layer may be a layer consisting of multiple flat plates arranged without gaps in the surface direction, each flat plate having one or more grooves extending perpendicular to the stacking direction of the laminate. In these cases, the grooves formed in the flat plates are the spaces that the first layer has. Furthermore, the flat plates constituting the second layer and the flat plates constituting the third layer may have one or more grooves extending perpendicular to the stacking direction. However, from the viewpoint of maintaining better strength, it is preferable that the flat plates constituting the second layer and the flat plates constituting the third layer do not have grooves. When the flat plates constituting the second layer have grooves, it is preferable that the flat plates constituting the second layer have grooves so that the openings of the grooves face the first layer side. When the flat plates constituting the third layer have grooves, it is preferable that the flat plates constituting the third layer have grooves so that the openings of the grooves face the first layer side. The grooves are similar to the grooves exemplified above in the description of the third embodiment. [Explanation of symbols]
[0054] 10 Laminated materials 11 First Layer 11a flat plate 12 Second Layer 12a flat plate 13 The Third Layer 13a flat plate 20 Laminated wood 30 Laminated wood S1 Gap between plates S2 groove X direction: Longitudinal direction in plan view of laminated material Y direction: Short side direction in plan view of laminate Z direction Stacking direction w1 Width of the gap between the plates h1 Height of the gap between the plates w2 groove width h2 Groove height
Claims
1. The first layer and a second layer located on one surface of the first layer and in contact with the first layer; a third layer located on the other surface of the first layer and in contact with the first layer; A laminate comprising: the first layer has one or more flat plates selected from a flat plate of a fiber-reinforced composite material containing a cured product of a resin composition and reinforcing fibers, a flat plate of wood, and a flat plate of a wood-based material, and has one or more spaces extending in a direction perpendicular to the lamination direction; The laminated material, wherein the second layer and the third layer are each a layer consisting of one or more flat plates selected from flat plates of a fiber-reinforced composite material containing a cured product of a resin composition and reinforcing fibers, flat plates of wood, and flat plates of a wood-based material.
2. 2. The laminate according to claim 1, wherein the width of the space is 3 to 20 mm.
3. 2. The laminate according to claim 1, wherein the height of the space is 3 mm or more.
4. 2. The laminate material according to claim 1, wherein the second layer and the third layer are layers consisting of flat plates of the fiber-reinforced composite material, the reinforcing fibers in the fiber-reinforced composite material are oriented in one direction, and the cured product is a foam.
5. The laminated material is rectangular in plan view with one side longer, the second layer is located on one outermost surface of the laminate; The laminate described in claim 1, wherein the second layer located on one outermost surface of the laminate is a layer consisting of a flat plate of the fiber-reinforced composite material, and the reinforcing fibers in the fiber-reinforced composite material are oriented in the longitudinal direction of the laminate when viewed in a plane.
6. A method for producing a laminate according to any one of claims 1 to 5, A method for manufacturing a laminated material, comprising a step of laminating and bonding the first layer, the second layer, and the third layer together.
7. the first layer having a plurality of the flat plates; The method for manufacturing a laminated material according to claim 6, further comprising the step of forming the first layer by arranging the plurality of flat plates constituting the first layer with gaps in the surface direction.
Citation Information
Patent Citations
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