JP4407232B2 - Manufacturing method of honeycomb structure - Google Patents

Description

The present invention is a wall material, a door material, heat insulating material, a method of manufacturing a suitable honeycomb structure for use as various civil engineering construction materials such as sound insulating materials.

  Conventionally, there has been known a honeycomb structure in which a heat insulating material made of foam, a sound absorbing material, or the like is filled in the entire area of the honeycomb core or in an intermediate region in the thickness direction. As a manufacturing method thereof, Patent Document 1 (Japanese Patent Publication No. 5-68431) discloses foaming made of a lightweight aggregate, an alkali silicate, a metal-based foaming agent, a curing agent, and water in each honeycomb space of the honeycomb core. A method for filling and curing a curable composition is described. Patent Document 2 (Japanese Patent Publication No. 3-79183) discloses that an inorganic aggregate, an inorganic aggregate coated with a foamable phenol resin, and an inorganic aggregate are placed in this order in each honeycomb space of the honeycomb core. , Forming an inorganic aggregate layer in the bottom area, foamable phenolic resin-coated inorganic aggregate layer in the middle area, and forming an inorganic aggregate layer in the upper area, and then heating the whole to foam and cure the foamable phenolic resin, A method of manufacturing a honeycomb structure having a heat insulating intermediate layer in an intermediate region of the honeycomb space by removing inorganic aggregate remaining in the bottom region and the upper region of the honeycomb space is described.

However, each of the above-described methods for manufacturing a honeycomb structure has problems. That is, in the method described in Patent Document 1, since the entire honeycomb space of the honeycomb core is filled with the foam, the foam overflows from the surface of the honeycomb core after the foam curing of the foam curable composition. Therefore, there has been a problem that the surface of the honeycomb core has to be cut and flattened, and the processing is costly. In many cases, a surface panel is attached to the surface of the honeycomb core, and in this case, usually, an adhesive is applied to both sides of the honeycomb core at the same time using a roller coater. Instead, it is also applied to the surface of the foam filling the honeycomb space. For this reason, there is a problem that the consumption of the adhesive increases, which is uneconomical, and that heat drying or the like is required for a long time to remove the moisture or solvent content of the adhesive. In order to avoid this problem, the roller coater application may be stopped and the adhesive may be extruded in a stripe form from nozzles arranged at a constant pitch. Since it can only be applied, the surface panels must be bonded one by one, resulting in a problem that the productivity is remarkably deteriorated. On the other hand, in the method described in Patent Document 2, an inorganic aggregate, a foamable phenol resin-coated inorganic aggregate, and an inorganic aggregate are placed in this order in the honeycomb space of the honeycomb core, and the inorganic aggregate layer and the foamable phenol resin are coated. It is necessary to form an inorganic aggregate layer and an inorganic aggregate layer, and this work is troublesome and it is possible to uniformly supply each aggregate for each honeycomb space to form an aggregate layer having an equal thickness. There is a problem that it is difficult, and the work of removing the bottom and upper inorganic aggregates after the foam curing is troublesome. In addition, there is a problem that heating is required for foam curing, which also takes time.
Japanese Patent Publication No. 5-68431 Japanese Patent Publication No. 3-79183

The present invention has been made in view of the above problems, and enables the foam to be filled in the honeycomb space of the honeycomb core in a form in which the foam does not overflow from the surface of the honeycomb core by a simple operation. and to provide a manufacturing how the honeycomb structure.

  In the invention according to claim 1, in order to manufacture the honeycomb structure by filling the foam into a form in which the foam does not overflow from the surface of the honeycomb core by a simple operation, Laminating a sheet-like support having a plurality of openings, and placing the first honeycomb core in a horizontal state with the sheet-like support facing up, and placing the foam curable composition on the sheet-like support. And a foam curing property of coating so that the thickness after foam curing is not more than the total thickness of the first honeycomb core and the second honeycomb core described later. And a step of inserting the second honeycomb core into the composition from above with the opening end facing downward, and a step of foam-curing the foam-curable composition, and further comprising the step of opening the sheet-like support. Size and foam curable When the foam curable composition is foam-cured, part of the viscosity of the composition penetrates the sheet-like support and enters the first honeycomb core, and the foam after completion of foaming is the first The honeycomb core is determined so as to be filled in an intermediate region excluding the lower end portion of the honeycomb core and the upper end portion of the second honeycomb core.

  According to a second aspect of the present invention, in the method according to the first aspect, when the second honeycomb core is inserted into the foam curable composition, the opening is shifted with respect to the first honeycomb core. It is set as the structure inserted in.

  The invention according to claim 3 is the method according to claim 1 or 2, wherein the sheet-like support is a plastic mesh.

  The invention according to claim 4 is the method according to any one of claims 1 to 3, further comprising a step of bonding the surface panel to the outer surface of the laminated first honeycomb core and the second honeycomb core. It is a thing.

  The invention according to claim 5 is the method according to any one of claims 1 to 4, wherein the foam-curable composition is a foam-curable inorganic composition that is foam-cured at room temperature.

  In the invention according to claim 1, a sheet-like support is laminated on one side of the first honeycomb core, and the foam curable composition is applied thereon to a uniform thickness. The foam can be filled into the intermediate region excluding the lower end portion of the first honeycomb core and the upper end portion of the second honeycomb core by simply inserting the foam and then foam-curing the foam curable composition. And the 1st honeycomb core and the 2nd honeycomb core can be integrated with the foam, and the honeycomb structure in which the foam does not overflow on both surfaces can be manufactured at low cost.

  In the invention according to claim 2, when the second honeycomb core is inserted into the foam curable composition, the opening is shifted with respect to the first honeycomb core. The foam is not separated for each cell of the honeycomb core, but has a continuous form as a whole, whereby the strength of the honeycomb structure can be further increased.

  In the invention according to claim 3, the honeycomb structure can be formed by using a low-cost material by forming the sheet-like support body as a plastic network.

  In the invention according to claim 4, a honeycomb structure having a surface panel on both sides is manufactured by providing a step of bonding the surface panel to the outer surfaces of the laminated first honeycomb core and the second honeycomb core. it can.

  In the invention according to claim 5, by making the foam curable composition a foam curable inorganic composition that is foam-cured at room temperature, the foam curing operation is facilitated, and the manufactured honeycomb structure is an inorganic composition. Since the formed foam is provided, it has excellent fire resistance, fire resistance, heat insulation, sound absorption, sound insulation, and the like.

  As the first and second honeycomb cores used in the present invention, those used in the field of civil engineering and construction can be used as appropriate, and the thickness, overall planar shape, size, etc. of the honeycomb core are determined by the honeycomb structure to be manufactured. It may be set appropriately in consideration of the required characteristics. Moreover, the cross-sectional shape of the honeycomb space formed in the honeycomb core can also be various, for example, any shape such as a hexagon, a triangle, a quadrangle, and a circle. Examples of the material of the honeycomb core include metals such as aluminum, steel plate and stainless steel, non-metals such as paper and plastic, and laminated materials such as metal, paper and plastic. The first honeycomb core and the second honeycomb core constituting one honeycomb structure may be the same in shape, size, material, or the like, or may be different.

  The sheet-like support used in the present invention can be supported so that the foam curable composition does not permeate so much when the foam curable composition is applied thereon. It is provided with a large number of small openings so that a part of the composition can gradually permeate the sheet-like support and spread downward, and various types of reticulates can be exemplified as a preferable one. A reticulated product is preferred. The plastic network is low in cost and hardly used for deterioration due to reaction with the foam curable composition. The roughness of the mesh used for the sheet-like support varies depending on the viscosity of the foam curable composition, but the viscosity of the foam curable composition should be about 10 to 20 mesh with respect to 40 to 100 poise. Is preferred.

  The foaming curable composition used in the present invention can be applied so as to form a layer having a uniform thickness on a sheet-like support, and after application, the second honeycomb core is pushed into it. It is fluid and can be foam-cured. The viscosity is preferably about 40 to 100 poise. The foam curable composition may be foamed by heating, but it is preferable to use a foam curable inorganic composition that foams and cures at room temperature. A typical foam-curable inorganic composition with this property is a filling to improve physical properties as needed by adding a metal-based foaming agent to the reaction system of inorganic powder and silicate. The thing which mixed the material can be mentioned. Further, the foam curable inorganic composition suitable for the present invention includes aluminum silicate-based reactive inorganic powder, alkali metal silicate, hydrogen peroxide, and infrared-impermeable powder. The proportion of hydrogen and infrared-impermeable powder is 10 to 100 parts by weight, 0.2 to 3 parts by weight, and 4 to 40 parts by weight, respectively, with respect to 100 parts by weight of the aluminum silicate-based reactive inorganic powder. (Hereinafter, referred to as a preferred foam-curable inorganic composition).

Hereinafter, this suitable foaming curable inorganic composition will be described. “Aluminum silicate-based reactive inorganic powder” refers to a reactive inorganic powder containing an aluminum silicate component, which can be reacted and cured with a water-soluble alkali silicate. Specific examples include fly ash, mineralized pulp sludge, blast furnace slag, and the like. The fly ash preferably has a composition of SiO ₂ : Al ₂ O ₃ = 45 to 60:20 to 28 (weight ratio) and an average particle diameter of 5 to 30 μm from the viewpoint of heat resistance. The mineralized pulp sludge preferably has a composition of SiO ₂ : Al ₂ O ₃ = 30 to 50:25 to 35 (weight ratio) and an average particle diameter of 5 to 30 μm from the viewpoint of heat resistance. The blast furnace slag, from the viewpoint of heat _{resistance, SiO 2: Al 2 O 3} = 31~35: 13~16 an average particle size of and 5~30μm a composition (weight ratio) is preferable. In addition to these, inorganic powders containing 10 to 80% by weight of SiO ₂ and 90 to 10% by weight of Al ₂ O ₃ as chemical compositions can be used as aluminum silicate-based reactive inorganic powders. It is. Examples of such powders include kaolin minerals such as metakaolin, mica clay minerals, wollastonite, and talc.

The alkali metal silicate can be expressed as M ₂ O · nSiO ₂ (one or more metals selected from M = K, Na, and Li). Here, “n” is preferably in the range of 0.5 to 4, more preferably 1.0 to 2.5. If the value of n is smaller than this, the reaction is too fast, and the foam cell becomes open-celled and the heat insulation performance decreases. Conversely, if the value of n becomes too large, the reaction becomes difficult to proceed. In addition, it is preferable to mix | blend alkali metal silicate as aqueous solution. The concentration of the aqueous solution is preferably 10 to 60% by weight because the reactivity with the reactive powder decreases as the concentration decreases and the alkali metal silicate tends to precipitate when the concentration increases. The alkali metal silicate aqueous solution may be prepared by dissolving the alkali metal silicate as it is in water under pressure and heating, but first, the alkali metal silicate is mixed with SiO ₂ such as silica sand and silica powder. The components may be added to make n a predetermined value, and then dissolved under pressure and heating to obtain an alkali metal silicate aqueous solution. Hydrogen peroxide is also preferably formulated as an aqueous solution (hydrogen peroxide solution), and the concentration is preferably in the range of 5 to 40% by weight. The “infrared impervious powder” is a material that is opaque to infrared transmission and scatters and blocks radiant heat, and specifically includes zirconium oxide, titanium oxide, and the like. Zirconium oxide preferably has an average particle diameter of 1 to 80 μm, more preferably 1 to 50 μm, from the viewpoints of heat reflectivity and heat insulation at high temperatures. As the titanium oxide, those having an average particle diameter of 0.1 μm or more are preferable from the viewpoint of heat reflectivity, and more preferably 0.2 μm or more.

  The preferred foam-curable inorganic composition having the above composition is foam-cured at room temperature and becomes a foam having fine and closed cells. The foam having such fine and closed cells has excellent heat insulating properties by preventing convection of the gas in the material. Moreover, since the infrared impermeable powder spreads over the entire cell wall while being oriented along the foam cell wall surface during the foaming process, the infrared impermeable powder extends along the cell wall surface within the foam. The heat transfer due to radiation can be reduced. Thus, with this foam, the fire insulation at high temperatures can be more effectively enhanced. If the foam temperature is 400 ° C. or higher, microcracks may be generated in the cell walls due to shrinkage of the foam. When microcracks are generated, closed cells are communicated with each other. Therefore, when it is desired to prevent the occurrence of such microcracks, it is preferable to add heat-resistant fibers. As the heat-resistant fibers, inorganic fibers such as potassium titanate fibers, boron fibers, and silica fibers are preferable.

  The amount of each component constituting the above-mentioned preferred foam curable inorganic composition is preferably determined as follows. First, the amount of the alkali metal silicate is preferably 10 to 100 parts by weight, more preferably 20 to 60 parts by weight with respect to 100 parts by weight of the aluminum silicate-based reactive inorganic powder. When the amount of the alkali metal silicate is larger than this, the foam tends to be brittle, while when the amount of the alkali metal silicate is small, the curing reaction with the aluminum silicate-based reactive inorganic powder is delayed. The amount of hydrogen peroxide is preferably 0.2 to 3 parts by weight, more preferably 0.5 to 2 parts by weight with respect to 100 parts by weight of the aluminum silicate-based reactive inorganic powder. When the amount of hydrogen peroxide is larger than this, foaming progresses due to abnormal foaming, and the cells of the foam become open-celled and the heat insulation performance is lowered. Moreover, since it becomes a density smaller than a suitable density, the foam which has sufficient intensity | strength cannot be obtained. On the other hand, when the amount of hydrogen peroxide is small, foaming is small and the density of the foam becomes high, and strength and closed cells can be secured, but the lightness is impaired and the heat insulation performance is inferior. The amount of the infrared-impermeable powder is preferably 4 to 40 parts by weight, more preferably 10 to 30 parts by weight with respect to 100 parts by weight of the aluminum silicate reactive inorganic powder. If the amount is less than 4 parts by weight, heat transfer due to radiation cannot be sufficiently suppressed. Conversely, if the amount exceeds 40 parts by weight, the strength of the resulting foam is weakened, and cracking may occur at high temperatures. In addition, when adding heat-resistant fiber (inorganic fiber), it is preferable to add 0.3 to 5 parts by weight of heat-resistant fiber with respect to 100 parts by weight of aluminum silicate-based reactive inorganic powder. If the amount of heat-resistant fiber is too small, the effect of preventing the occurrence of microcracks at high temperatures cannot be obtained, and if too large, kneading cannot be performed well. Moreover, you may mix | blend inorganic heat-resistant hollow particles, such as a shirasu balloon and a ceramic balloon, with the above-mentioned suitable foaming curable inorganic composition as needed.

Next, embodiments of the present invention will be described in more detail with reference to the drawings. FIG. 1 shows an example of a honeycomb structure manufactured by the method of the present invention. (A) is a schematic perspective view of the entire honeycomb structure, (b) is a schematic cross-sectional view thereof, and (c) is an enlarged view. It is a schematic sectional drawing shown. The entire honeycomb structure denoted by reference numeral 1 has a rectangular plate shape as a whole, and includes a first honeycomb core 2a and a second honeycomb core 2b laminated via a sheet-like support 6. A foam 3 filled in a region excluding both end portions 5a and 5b in the thickness direction of the first and second honeycomb cores 2a and 2b in a laminated state, and a surface panel 4a bonded to the surfaces on both sides, 4b.

Next, a method for manufacturing the honeycomb structure 1 will be described. First, as shown in FIG. 2A, the first honeycomb core 2a is placed horizontally, and a sheet-like support 6 such as a plastic net is placed on the upper surface thereof. If necessary, the sheet-like support 6 may be attached to the upper surface of the first honeycomb core 2a using an appropriate adhesive. Next, as shown in FIG. 2B, the foam curable composition 7 is applied to the upper surface of the sheet-like support 6 so as to have a uniform thickness. The foam curable composition 7 is foam-cured to form the foam 3, and various types can be used as described above. In this embodiment, the above-mentioned preferred foam-curable inorganic composition is used. use. The thickness t of the applied foamed curable composition 7, so that the thickness after foaming is less than the sum of the thickness w ₂ of the thickness w ₁ of the first honeycomb core 2a second honeycomb core 2b The thickness is preferably selected so as to be about 10 to 20% smaller than the thickness w ₁ + w ₂ . If necessary, when the foam curable composition 7 is applied, the first honeycomb core 2a and the sheet-like support 6 on the upper surface thereof are placed in a suitable mold, and the applied foam curable composition 7 is applied. It may be prevented from flowing down to the surroundings.

  Next, as shown in FIGS. 2 (c) and 2 (d), the second honeycomb core 2 b is placed from above into the foam curable composition 7 applied on the sheet-like support 6, and the open end faces downward. Then, the honeycomb core 2b is pushed in until the lower end of the honeycomb core 2b hits the sheet-like support 6. In addition, since the applied foaming curable composition 7 starts foaming curing immediately after the application, the pushing of the honeycomb core 2b is completed before the curing progresses so much. Thereafter, as shown in FIG. 2 (e), the foam curable composition 7 foams and hardens while increasing in volume, and a part of the foam curable composition 7 fills the inside of the first honeycomb core 2b on the upper stage side. Go. Further, a part thereof passes through the opening of the sheet-like support 6 and fills the lower honeycomb core 2a. Finally, a foam 3 is formed which fills most of the laminated first and second honeycomb cores 2a and 2b and is joined to the honeycomb cores 2a and 2b. 2a, 2b will be joined integrally through the foam 3. Here, by appropriately setting the viscosity of the foam curable composition 7 and the size and opening ratio of the opening of the sheet-like support 6, an appropriate amount of the foam curable composition 7 is set to the sheet-like support. 6 and enters the lower first honeycomb core 2a. As shown, the foam 3 excludes the lower end portion 5a of the first honeycomb core 2a and the upper end portion 5b of the second honeycomb core 2b. The intermediate area will be filled. As described above, the first honeycomb core 2a and the second honeycomb core 2b are integrated with the foam 3, and the honeycomb structure 1A in which the foam does not overflow on both sides is manufactured. Thereafter, the honeycomb structure 1A is dried to remove moisture.

  The obtained honeycomb structure 1A has a structure in which the honeycomb cores 2a and 2b are filled with the foam 3 made of an inorganic composition, but the foam 3 does not overflow to the outside of the honeycomb cores 2a and 2b. For this reason, it is not necessary to cut off and remove the overflowing foam as in the prior art, and the manufacturing process can be simplified correspondingly. Although the honeycomb structure 1A may be used as it is, in this embodiment, as shown in FIG. 2 (f), the surface panels 4a and 4b are bonded to both surfaces by an adhesive. At this time, as described above, since the surfaces of the honeycomb cores 2a and 2b are not soiled, the surface panels 4a and 4b can be firmly bonded with an adhesive. Further, when applying the adhesive, since the surface of the foam 3 filled in the honeycomb space is in a position retracted from the surface of the honeycomb cores 2a and 2b, the adhesive is applied only to the surfaces of the honeycomb cores 2a and 2b using a roller coater. For this reason, it is possible to apply an adhesive to both surfaces of the honeycomb structure 1A at the same time and only on the surface of the honeycomb core using a roller coater, resulting in high productivity and excessive consumption of the adhesive. The surface panels 4a and 4b can be bonded without doing so. Although it does not specifically limit as surface panel 4a, 4b, A wooden board, a plywood, a metal plate, a resin board etc. can be mentioned. Thus, the honeycomb structure 1 shown in FIG. 1 is manufactured.

  Since the obtained honeycomb structure 1 has a structure in which the honeycomb cores 2a and 2b are filled with the foam 3 made of an inorganic composition, the honeycomb structure 1 has light weight, high strength, and excellent fire resistance and heat insulation properties. It is suitably used as various civil engineering and building materials such as wall materials, door materials, heat insulating materials, and sound insulation materials.

In the above-described method for manufacturing the honeycomb structure 1A, the foam 3 is foam-cured in order to fill the intermediate region excluding the lower end portion 5b of the first honeycomb core 2a and the upper end portion 5a of the second honeycomb core. The viscosity of the functional composition 7 and the size and opening ratio of the opening of the sheet-like support 6 are appropriately set. In addition, the thicknesses of the first and second honeycomb cores 2a and 2b are selected. It is also possible to use together. For example, when using a slurry having a high viscosity as the foam curable composition 7 or using a sheet-like support 6 that is difficult to transmit the foam curable composition 7, the foam curable composition 7 is on the lower side. since hardly enters the honeycomb core 2a, as shown in FIG. 3 (a), Oke thickness w ₂ of the upper side of the honeycomb core 2b is set larger than the thickness w ₁ of the lower side of the honeycomb core 2a In this way, the foam 3 can be filled in an intermediate region excluding the lower end portion 5a and the upper end portion 5b of the laminated honeycomb cores 2a and 2b. Conversely, when using a slurry having a low viscosity as the foam curable composition 7 or when using a sheet-like support 6 that is easily permeable to the foam curable composition 7, the foam curable composition 7 is provided at the lower stage. As shown in FIG. 3B, the thickness w ₁ of the lower honeycomb core 2a is set larger than the thickness w ₂ of the upper honeycomb core 2b. Thus, the foam 3 can be filled in the intermediate region excluding the lower end portion 5a and the upper end portion 5b of the laminated honeycomb cores 2a and 2b.

  Further, in the embodiment of the drawings, as the first honeycomb core 2a and the second honeycomb core 2b, those having the same cross-sectional shape are used and the openings of the upper and lower honeycomb cores are aligned and laminated, The present invention is not limited to this configuration, and as shown in FIG. 4, the first honeycomb core 2a and the second honeycomb core 2b may be stacked in a state where the openings are shifted. With this configuration, in the formed honeycomb structure 1B, the foam 3 filling the inside is not separated for each cell of the honeycomb core, but the whole is continuous, so that the strength of the honeycomb structure 1B is increased. The advantage that can be increased is obtained.

  The method for manufacturing the honeycomb structure described in FIG. 2 may be performed in a batch manner by placing the first honeycomb core 2a at a certain location, or the first honeycomb core 2a may be continuously carried by a conveyor or the like. Alternatively, it may be carried out continuously or intermittently.

(1) As the first honeycomb core 2a and the second honeycomb core 2b, those having the following specifications were prepared.
Material: Water-resistant paper Size: Width 95cm x Length 180cm x Thickness 25mm
Honeycomb space: shape hexagon
Space size 10mm
(2) A sheet-like support having the following specifications was prepared.
Sheet support: Nylon mesh
12x12 mesh (thickness about 0.3mm)
(3) A foam curable composition having the following composition was prepared and mixed with a hand mixer to obtain a slurry.
100 parts by weight of fly ash {composition SiO ₂ : Al ₂ O ₃ = 11: 5 (weight ratio), average particle size 10 μm}
Sodium silicate aqueous solution 50 parts by weight (composition SiO ₂ / Na ₂ O = 1.5, concentration 55%)
Hydrogen peroxide solution (concentration 10%) 18.8 parts by weight Zinc stearate 0.5 parts by weight Zirconium oxide (average particle diameter 30 μm) 10 parts by weight (4) Production of honeycomb structure As shown in FIG. The sheet-like support 6 is placed on the first honeycomb core 2a, and the foam curable composition (slurry obtained by mixing with a hand mixer) having the above composition is placed thereon so that the thickness t becomes 10 mm. The second honeycomb core 2b was immediately pushed in while being foamed and cured. Then, the honeycomb structure 1A shown in FIG. 2E was obtained by sufficiently foaming and curing. The obtained honeycomb structure 1A has a structure in which the first and second honeycomb cores 2a, 2b and the foam 3 are firmly integrated, and the foam 3 is about 5 mm from the surface of the honeycomb structure 1A. It was in a state of being retracted inside. In addition, the surface of the first and second honeycomb cores 2a and 2b was not contaminated with a foam curable composition. Surface panels of metal plates were bonded to both surfaces of the honeycomb structure 1A with an adhesive. Thereby, the honeycomb structure 1 shown in FIG. 1 was obtained.

  The honeycomb structure manufactured by the manufacturing method of the present invention has excellent fireproof properties, fire resistance, heat insulation properties, sound absorption properties, sound insulation properties, etc., so various types such as wall materials, door materials, heat insulation materials, sound insulation materials, etc. It can be used very effectively as a material for civil engineering and construction.

(A) is a schematic perspective view showing an example of the honeycomb structure produced by the method of the present invention, (b) is a schematic showing an enlarged schematic sectional view of the honeycomb structure, a portion of (c) the honeycomb structure Cross section (A), (b), (c), (d), (e), (f) is schematic sectional drawing which shows the manufacture procedure by the manufacturing method which concerns on embodiment of this invention. (A), (b) is schematic sectional drawing which shows the modification of a honeycomb structure Schematic sectional view showing still another modification of the honeycomb structure

Explanation of symbols

DESCRIPTION OF SYMBOLS 1, 1A, 1B Honeycomb structure 2a 1st honeycomb core 2b 2nd honeycomb core 3 Foam 4a, 4b Surface panel 6 Sheet-like support body 7 Foam curable composition

Claims (5)

  A step of laminating a sheet-like support having a large number of openings on one side of the first honeycomb core; and the sheet-like support in which the first honeycomb core is placed in a horizontal state with the sheet-like support facing up. The foam curable composition is made to have a uniform thickness and the thickness after foam curing does not exceed the total thickness of the first honeycomb core and the second honeycomb core described later. A step of applying to the foam curable composition, a step of inserting the second honeycomb core from above into the foam curable composition, with the opening end facing downward, and a step of foam curing the foam curable composition, The size of the opening of the sheet-like support and the viscosity of the foam-curable composition are partly transmitted through the sheet-like support when the foam-curable composition is foam-cured and the first honeycomb core. The foam after the foaming is finished is Method for manufacturing a honeycomb structure, characterized in that it determined to be the lower end portion and a state of being filled in the intermediate region excluding the upper end portion of the second honeycomb core a honeycomb core.   The honeycomb structure according to claim 1, wherein when the second honeycomb core is inserted into the foam curable composition, the second honeycomb core is inserted in a state in which an opening is shifted with respect to the first honeycomb core. Method.   The method for manufacturing a honeycomb structure according to claim 1 or 2, wherein the sheet-like support is formed of a plastic mesh.   The honeycomb structure according to any one of claims 1 to 3, further comprising a step of bonding a surface panel to outer surfaces of the laminated first and second honeycomb cores. Production method.   The method for manufacturing a honeycomb structure according to any one of claims 1 to 4, wherein the foam curable composition is a foam curable inorganic composition that foams and cures at room temperature.

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