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JP6467850B2 - Method for manufacturing honeycomb core material - Google Patents

Method for manufacturing honeycomb core material Download PDF

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JP6467850B2
JP6467850B2 JP2014207851A JP2014207851A JP6467850B2 JP 6467850 B2 JP6467850 B2 JP 6467850B2 JP 2014207851 A JP2014207851 A JP 2014207851A JP 2014207851 A JP2014207851 A JP 2014207851A JP 6467850 B2 JP6467850 B2 JP 6467850B2
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face plate
thermoplastic resin
resin film
pressing member
face
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JP2016074191A (en
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丹娜 銭
丹娜 銭
昌次 伊藤
昌次 伊藤
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Mitsubishi Chemical Corp
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Description

本発明は、屋根材や内装材等の建築材料、看板等の装飾材料など、各種用途に用いることができるハニカム構造材の構成材料として有用なハニカムコア材の製造方法に関する。   The present invention relates to a method for manufacturing a honeycomb core material useful as a constituent material of a honeycomb structure material that can be used for various applications such as building materials such as roofing materials and interior materials, and decorative materials such as signboards.

三角形、四角形、六角形などの各種開口形状を呈する無数のセル(小部屋)の集合体であるハニカムコア材は、例えば、2枚の板(スキン層)で挟んでハニカムサンドイッチ構造とすることで、軽量かつ高強度と言った優れた特性を発揮する。そのため、ハニカムコア材は、建築業、自動車産業、航空宇宙産業など各種産業に用いる構成資材として注目されている材料である。   A honeycomb core material, which is an aggregate of countless cells (small chambers) having various opening shapes such as a triangle, a quadrangle, and a hexagon, has a honeycomb sandwich structure sandwiched between two plates (skin layers), for example. It exhibits excellent properties such as light weight and high strength. Therefore, the honeycomb core material has been attracting attention as a constituent material used in various industries such as the construction industry, the automobile industry, and the aerospace industry.

このようなハニカムコア材の製造方法としては、従来、樹脂ペレットからシートを形成し、2枚のシートを重ねて適宜間隔を置いてシート間を接着しておき、2枚のシートをそれぞれ両側に引っ張ることで、多数のセルが配列したシート体を成形し、これを液体接着材で接着してハニカムコア材とする引っ張り成形法や、波型ロールを通してシートを波型に成形し、これを上下重ねて多数のセルが配列したシート体を成形して、これを液体接着材で接着してハニカムコア材とするコルゲート法などが知られていた。   As a manufacturing method of such a honeycomb core material, conventionally, a sheet is formed from resin pellets, two sheets are stacked, and the sheets are bonded to each other at an appropriate interval, and the two sheets are respectively attached to both sides. By pulling, a sheet body in which a large number of cells are arranged is formed, and this is bonded with a liquid adhesive to form a honeycomb core material. There has been known a corrugation method in which a sheet body in which a large number of cells are arranged is formed, and this is bonded with a liquid adhesive material to form a honeycomb core material.

特殊な製法としては、例えば特許文献1において、ハニカムコアの空隙部に軟質樹脂発泡体を充填した後、該軟質樹脂発泡体に二液硬化型樹脂の液体を含浸させた後、前記ハニカムコアを面材間に配置して型に重合載置し、加圧して面材とハニカムコアを圧着する方法が開示されている。   As a special manufacturing method, for example, in Patent Document 1, after filling a void of the honeycomb core with a soft resin foam, the soft resin foam is impregnated with a liquid of a two-part curable resin, and then the honeycomb core is There is disclosed a method in which a face material and a honeycomb core are pressure-bonded by placing them between face materials, placing them on a mold and pressurizing them.

さらにまた、特許文献2において、ハニカムコアのバッチ式作製方法に関し、六角バーを有するかご形ローラーを、固定台上の多数の主六角バーと関連して作動させるようにし、前進するかご形バーと固定台バーとの間における高温の熱可塑性ウェブへの圧縮作用により波型ウェブを形成する。こうして作られた波型ウェブを、台の主バー上に第1の波型ウェブを置き、これに続いて副バーをウェブの上方の結節点に置くことによりハニカム構造に組み立てる。次いで、第2の波型シートを、その接続点を第1のウェブの腹部に隣接するように置き、副バーの別の層を頂部に置くようにする。この手順を希望のハニカム厚さに達するまで繰り返す。このとき、組立体を、カール板とブラテンとの間に置いて加熱して最終のハニカム製品を作製する方法が開示されている。   Furthermore, in Patent Document 2, regarding a batch-type manufacturing method of a honeycomb core, a cage roller having a hexagonal bar is operated in association with a number of main hexagonal bars on a fixed base, A corrugated web is formed by the compression action of the hot thermoplastic web between the fixed base bars. The corrugated web thus made is assembled into a honeycomb structure by placing the first corrugated web on the main bar of the platform, followed by placing the secondary bar at the knot above the web. The second corrugated sheet is then placed so that its connection point is adjacent to the abdomen of the first web and another layer of secondary bars is placed on top. This procedure is repeated until the desired honeycomb thickness is reached. At this time, a method is disclosed in which the assembly is placed between a curl plate and a platen and heated to produce a final honeycomb product.

特開昭62−249732号公報Japanese Patent Laid-Open No. 62-249732 米国特許第3356555号公報U.S. Pat. No. 3,356,555

従来のように、樹脂ペレット原料若しくは樹脂シートからハニカムコア材を連続製造する方法は、製造ラインが長くなり、製造設備が大型化するため、ハニカムコア材の製造コストを低下させることが難しいという課題を抱えていた。そればかりか、接着剤の塗布工程や、液体樹脂に含浸する工程などを経る必要があるため、生産効率が低くなってしまうという課題も抱えていた。   The conventional method of continuously manufacturing honeycomb core material from resin pellet raw material or resin sheet is a problem that it is difficult to reduce the manufacturing cost of the honeycomb core material because the manufacturing line becomes long and the manufacturing equipment becomes large Was holding. In addition, since it is necessary to go through an adhesive application process, a liquid resin impregnation process, and the like, there is also a problem that production efficiency is lowered.

そこで本発明は、樹脂ペレットや樹脂シートからハニカムコア材を連続製造するのではなく、市販されている中間材料を原料として使用することで、製造コストを低下させつつ、生産効率を高めることができる、新たなハニカムコア材の製造方法を提案せんとするものである。   Therefore, the present invention does not continuously manufacture the honeycomb core material from resin pellets or resin sheets, but can use a commercially available intermediate material as a raw material, thereby improving the production efficiency while reducing the manufacturing cost. Therefore, a new method for manufacturing a honeycomb core material is proposed.

本発明は、2枚の面板の間に、一方向に長尺な壁部が該一方向と直交する方向に適宜間隔をおいて配設され、当該2枚の面板の間に複数の長尺なセルを備えた中空体を、前記一方向に適宜間隔をおいて切断して、多数のセルが並んだ構成を備えた複数のセル列中空体に分断する分断工程と、前記分断工程で得られたセル列中空体同士を、互いの面板部が向かい合うように並べると共に、前記面板部間に熱可塑性樹脂フィルムを介在させて、該熱可塑性樹脂フィルムを加熱して前記面板部間を接着するセル列中空体接着工程と、を備えたハニカムコア材の製造方法を提案する。   In the present invention, a wall portion that is long in one direction is disposed between two face plates at appropriate intervals in a direction perpendicular to the one direction, and a plurality of long pieces are provided between the two face plates. A hollow body provided with a simple cell is cut at an appropriate interval in the one direction so as to be divided into a plurality of cell row hollow bodies having a structure in which a large number of cells are arranged, and obtained in the dividing step. The formed cell row hollow bodies are arranged so that the face plate portions face each other, and a thermoplastic resin film is interposed between the face plate portions, and the thermoplastic resin film is heated to bond the face plate portions. A method for manufacturing a honeycomb core material comprising a cell row hollow body bonding step is proposed.

本発明が提案するハニカムコア材の製造方法によれば、市販されている中空体を原料として利用することができるから、樹脂ペレットや樹脂シートからハニカムコア材を連続製造する場合に比べて、製造ラインが長くなることも、製造設備が大型化することもなく、簡単な設備で連続生産できるため、ハニカムコア材の製造コストを低下させることができる。
また、熱可塑性樹脂フィルムを使用して材料を接着するため、液体接着剤を使用する必要がない。その結果、作業ハンドリング性、作業環境を大幅に改良することができる。
According to the method for manufacturing a honeycomb core material proposed by the present invention, since a commercially available hollow body can be used as a raw material, it is manufactured in comparison with a case where a honeycomb core material is continuously manufactured from resin pellets or resin sheets. The production line of the honeycomb core material can be reduced because the production line can be continuously produced with simple equipment without increasing the line length and the production equipment.
Moreover, since a material is bonded using a thermoplastic resin film, it is not necessary to use a liquid adhesive. As a result, work handling and work environment can be greatly improved.

中空体の一例を示した斜視図である。It is the perspective view which showed an example of the hollow body. 前記中空体を、複数のセル列中空体に分断した状態の一例を示した斜視図である。It is the perspective view which showed an example of the state which divided | segmented the said hollow body into the several cell row | line | column hollow body. (A)は、2つの前記セル列中空体の間に熱可塑性樹脂フィルムを介在させて状態の一例を示した斜視図であり、(B)は、セル列中空体の間に熱可塑性樹脂フィルムを介在させて接着してセル列結合中空体とした状態の一例を示した上面図である。(A) is the perspective view which showed an example of the state which interposed the thermoplastic resin film between two said cell row | line hollow bodies, (B) is a thermoplastic resin film between cell row | line hollow bodies It is the top view which showed an example of the state which made the cell row | line coupling | bonding hollow body bonded by interposing. (A)は、2つの前記セル列結合中空体の間に熱可塑性樹脂フィルムを介在させて状態の一例を示した斜視図であり、(B)は、セル列結合中空体の間に熱可塑性樹脂フィルムを介在させて接着した状態の一例を示した上面図である。(A) is the perspective view which showed an example of the state which interposed the thermoplastic resin film between two said cell row coupling | bonding hollow bodies, (B) is thermoplasticity between cell row coupling | bonding hollow bodies It is the top view which showed an example of the state which adhered and interposed the resin film. ハニカムコア材の一例を示した斜視図である。It is the perspective view which showed an example of the honeycomb core material. 中空体の一例を示した正面図である。It is the front view which showed an example of the hollow body. (A)は、2つの前記セル列中空体の間に熱可塑性樹脂フィルムを介在させて、押圧部材で押圧している状態の一例を示した斜視図であり、(B)は、その状態の上面図である。(A) is a perspective view showing an example of a state in which a thermoplastic resin film is interposed between two hollow cell bodies and pressed by a pressing member, and (B) is a state of that state. It is a top view. 押圧部材の一例を示した斜視図である。It is the perspective view which showed an example of the press member.

次に、本発明の一例に係る実施形態の一例(「本実施形態」と称する)について説明する。但し、本発明が次に説明する実施形態例に限定されるものではない。   Next, an example of an embodiment (referred to as “this embodiment”) according to an example of the present invention will be described. However, the present invention is not limited to the embodiment described below.

<ハニカムコア材製造方法>
本実施形態は、2枚の面板2,2の間に、一方向に長尺な壁部4,4・・が該一方向と直交する方向に適宜間隔をおいて配設され、当該2枚の面板2,2の間に複数の長尺セル5,5・・を備えた中空体1(図1参照)を、図2に示すように、前記一方向に適宜間隔をおいて切断して、多数のセル5A,5A・・が並んだ構成を備えた複数のセル列中空体1A、1A・・に分断し(分断工程)、
次に、図3(A)(B)に示すように、前記分断工程で得られたセル列中空体1A、1A同士を、互いの面板部2A、2Aが向かい合うように並べると共に、前記面板部2A、2A間に熱可塑性樹脂フィルム6を介在させて、該熱可塑性樹脂フィルム6を加熱して前記面板部2A、2A間を接着してセル列結合中空体1Bを形成し(セル列中空体接着工程)、
次に、前記セル列中空体接着工程で接着して得られたセル列結合中空体1B、1B同士を、前記セル列中空体接着工程と同様に熱可塑性樹脂フィルム6を用いて接着してセル列結合中空体1Cを形成し、さらに次に、前記工程で接着して得られたセル列結合中空体1C、1C同士を、前記セル列中空体接着工程と同様に熱可塑性樹脂フィルム6を用いて接着し、必要に応じてセル列結合中空体の接着工程を繰り返してハニカムコア材10を製造することができる(ハニカムコア材形成工程)。
<Honeycomb core material manufacturing method>
In the present embodiment, between the two face plates 2 and 2, wall portions 4, 4... Elongated in one direction are disposed at an appropriate interval in a direction orthogonal to the one direction, and the two sheets A hollow body 1 (see FIG. 1) having a plurality of long cells 5, 5,... Between the face plates 2, 2 is cut at an appropriate interval in the one direction as shown in FIG. , Dividing into a plurality of cell row hollow bodies 1A, 1A... Having a configuration in which a large number of cells 5A, 5A.
Next, as shown in FIGS. 3A and 3B, the cell array hollow bodies 1A and 1A obtained in the dividing step are arranged so that the face plate portions 2A and 2A face each other, and the face plate portion A thermoplastic resin film 6 is interposed between 2A and 2A, and the thermoplastic resin film 6 is heated to bond the face plate portions 2A and 2A to form a cell array coupled hollow body 1B (cell array hollow body). Bonding process),
Next, the cell row bonded hollow bodies 1B and 1B obtained by bonding in the cell row hollow body bonding step are bonded to each other using the thermoplastic resin film 6 in the same manner as in the cell row hollow body bonding step. Using the thermoplastic resin film 6 in the same manner as in the cell row hollow body bonding step, the cell row bonded hollow bodies 1C and 1C obtained by forming the row connection hollow body 1C and then bonding the cells in the above step are used. The honeycomb core material 10 can be manufactured by repeating the bonding process of the cell row bonded hollow bodies as necessary (honeycomb core material forming process).

なお、本発明では、3個以上のセル列中空体1A、1A・・を、隣の面板部2A、2Aが向かい合うように並べると共に、各面板部2A、2A間に熱可塑性樹脂フィルム6を介在させて、一度に3個以上のセル列中空体1A、1A・・を接着することも可能であり、そのようにしてハニカムコア材10を製造することも可能である。   In the present invention, three or more cell row hollow bodies 1A, 1A,... Are arranged so that the adjacent face plate portions 2A, 2A face each other, and a thermoplastic resin film 6 is interposed between each face plate portion 2A, 2A. Thus, three or more cell row hollow bodies 1A, 1A,... Can be bonded at a time, and the honeycomb core material 10 can be manufactured in this way.

<ハニカムコア材>
本実施形態で製造するハニカムコア材10は、同一方向に開口してなるセルの列が複数並設されてなる構成を備えた部材である。
セルは、ハニカムコア材の厚み方向に貫通した空間を備え、厚み方向両端面を開口し、周囲を壁部で囲われてなる構成を備えた部屋である。
<Honeycomb core material>
The honeycomb core material 10 manufactured in the present embodiment is a member having a configuration in which a plurality of rows of cells opened in the same direction are arranged in parallel.
The cell is a room having a structure including a space penetrating in the thickness direction of the honeycomb core material, opening both end surfaces in the thickness direction and being surrounded by a wall portion.

ハニカムコア材10の材質としては、例えば紙、樹脂、金属及び繊維、並びにこれらの複合材料などを挙げることができる。但し、これらに限定するものではない。
中でも、熱可塑性樹脂フィルムで接着し易いという観点から、ハニカムコア材10の材質としては、紙或いは樹脂、その中でも、熱可塑性樹脂からなるものが特に好ましい。
ハニカムコア材10の寸法は、用途によって適宜調整するのが好ましい。例えば、厚み(高さ)が1mm〜100mm、壁部の厚みが0.2mm〜30mm、セル空間のピッチが2mm〜40mmのものを形成することができる。
Examples of the material of the honeycomb core material 10 include paper, resin, metal and fiber, and composite materials thereof. However, it is not limited to these.
Among these, from the viewpoint of easy adhesion with a thermoplastic resin film, the material of the honeycomb core material 10 is particularly preferably paper or resin, and among them, the one made of thermoplastic resin is particularly preferable.
The dimensions of the honeycomb core material 10 are preferably adjusted as appropriate according to the application. For example, a material having a thickness (height) of 1 mm to 100 mm, a wall thickness of 0.2 mm to 30 mm, and a cell space pitch of 2 mm to 40 mm can be formed.

ハニカムコア材10は、建材、装飾材、自動車部品など、各種用途に用いることができるハニカム構造材の構成材料として有用である。ハニカムコア材10は、特に透明なプラスチックから形成することができるため、建材や装飾材などの用途に特に有用である。   The honeycomb core material 10 is useful as a constituent material of a honeycomb structure material that can be used for various applications such as building materials, decoration materials, and automobile parts. Since the honeycomb core material 10 can be formed from a transparent plastic, it is particularly useful for applications such as building materials and decorative materials.

<中空体>
本実施形態で原料とする中空体1は、熱可塑性樹脂からなる面板2,2の間に、一方向に長尺な壁部4,4・・が該一方向と直交する方向に適宜間隔をおいて配設され、当該面板2,2の間に複数の長尺なセル5、5・・を備えたものであればよい。
<Hollow body>
In the hollow body 1 used as a raw material in the present embodiment, the wall portions 4, 4 which are long in one direction are appropriately spaced in a direction perpendicular to the one direction between the face plates 2 and 2 made of thermoplastic resin. And a plurality of long cells 5, 5... Are provided between the face plates 2 and 2.

本実施形態では、このような中空体1を原料材として使用することによって、ハニカムコア材10を効率よく、安価に製造することができる。
中空体1は、自ら製造しても、購入してもよい。
中空体1の開口サイズや厚さを適宜選択することにより、ハニカムコア材10の力学特性を適宜設計することができる。
In this embodiment, the honeycomb core material 10 can be manufactured efficiently and inexpensively by using such a hollow body 1 as a raw material.
The hollow body 1 may be manufactured by itself or purchased.
By appropriately selecting the opening size and thickness of the hollow body 1, the mechanical characteristics of the honeycomb core material 10 can be designed as appropriate.

中空体1の面板2,2の材質は、例えば紙、樹脂、金属及び繊維、並びにこれらの複合材料などを挙げることができる。中でも、熱可塑性樹脂フィルムで接着し易いという観点から、紙或いは樹脂、その中でも、熱可塑性樹脂からなるものが特に好ましい。例えば、ポリエチレン、ポリプロピレン、ポリスチレン、ポリカーボネート、ポリエチレンテレフタレート(PET)などの熱可塑性樹脂を挙げることができる。その中でも、透明性の観点から、例えばポリエチレンテレフタレート(PET)、ポリカーボネートなどが特に好ましい。
他方、中空体1において、面板2,2の間に設けられた壁部4の材質は、上記面板2,2と同じ材質でもよいし、異なる材質でもよい。
Examples of the material of the face plates 2 and 2 of the hollow body 1 include paper, resin, metal and fiber, and composite materials thereof. Among these, from the viewpoint of easy adhesion with a thermoplastic resin film, paper or resin, and among them, those made of thermoplastic resin are particularly preferable. Examples thereof include thermoplastic resins such as polyethylene, polypropylene, polystyrene, polycarbonate, and polyethylene terephthalate (PET). Among these, polyethylene terephthalate (PET), polycarbonate and the like are particularly preferable from the viewpoint of transparency.
On the other hand, the material of the wall 4 provided between the face plates 2 and 2 in the hollow body 1 may be the same as or different from the face plates 2 and 2.

上記長尺セル5の開口形状は、三角形、四角形(長方形、正方形、台形状など)、六角形、八角形などの形状でもよいし、また、図6に示すような、四角形内を複数に区画してなる複雑な形状であってもよい。   The opening shape of the long cell 5 may be a triangle, a quadrangle (rectangle, square, trapezoid, etc.), a hexagon, an octagon, or the like. Further, as shown in FIG. It may be a complicated shape.

中空体1は、図6に示すように、面板2を3段以上備えた中空体1であってもよい。すなわち、3枚或いはそれ以上の枚数の面板2,2.・・の間において、隣り合う各2枚の面板2,2の間に複数の壁部4、4・・が配設された構成のものであってもよい。   As shown in FIG. 6, the hollow body 1 may be a hollow body 1 having three or more face plates 2. That is, three or more face plates 2,2. .. May be configured such that a plurality of wall portions 4, 4... Are disposed between two adjacent face plates 2, 2.

<分断工程>
分断工程では、図2に示すように、前記中空体1を、長尺なセルの長さ方向に適宜間隔をおいて切断して、多数のセルが列として並んだ構成を備えた複数のセル列中空体1A,1A・・に分断すればよい。
この際、図6に示すように、面板2を3段以上備えた中空体1の場合には、セル列が2列並んだセル列中空体1A,1A・・に分断することができる。
<Division process>
In the dividing step, as shown in FIG. 2, the hollow body 1 is cut at an appropriate interval in the length direction of the long cells, and a plurality of cells having a configuration in which a large number of cells are arranged in a row. What is necessary is just to divide into row | line | column hollow body 1A, 1A ....
At this time, as shown in FIG. 6, in the case of the hollow body 1 having three or more face plates 2, it can be divided into cell row hollow bodies 1A, 1A,.

中空体1を切断する間隔がハニカムコア材10の厚さとなるから、ハニカムコア材10の用途等に応じて、切断する間隔を変更することにより、最終的に形成するハニカムコア材10の厚さを適宜変更することができる。   Since the interval at which the hollow body 1 is cut becomes the thickness of the honeycomb core material 10, the thickness of the honeycomb core material 10 to be finally formed is changed by changing the interval to be cut according to the use of the honeycomb core material 10 or the like. Can be changed as appropriate.

中空体1を切断する方法としては、例えばハンドカット法、ワイヤーカット法、NCカット法、レーザーカット法などを挙げることができる。   Examples of a method for cutting the hollow body 1 include a hand cut method, a wire cut method, an NC cut method, and a laser cut method.

<セル列中空体接着工程>
セル列中空体接着工程では、図3に示すように、前記分断工程で分断されたセル列中空体1A,1A同士を、互いの面板部2A,2Aが向かい合うように並べて、前記面板部2A,2A間に熱可塑性樹脂フィルム6を介在させ、該熱可塑性樹脂フィルム6を加熱して前記面板部間2A,2Aを接着して、セル列中空体1A,1Aを接合してセル列結合中空体1Bを形成する。
<Cell row hollow body adhesion process>
In the cell row hollow body bonding step, as shown in FIG. 3, the cell row hollow bodies 1A, 1A divided in the dividing step are arranged so that the face plate portions 2A, 2A face each other, and the face plate portion 2A, The thermoplastic resin film 6 is interposed between 2A, the thermoplastic resin film 6 is heated to bond the face plate portions 2A and 2A, and the cell array hollow bodies 1A and 1A are joined to each other to connect the cell array coupled hollow bodies. 1B is formed.

前記分断工程で得られたセル列中空体1A,1A同士を、互いの面板部が向かい合うように並べるには、各セル列中空体1Aの面板部2A,2Aが立設してセル5A,5A・・が上下に開口するように、各セル列中空体1Aの向きを90度変えて、隣接するセル列中空体1A,1A同士の面板部2A,2Aが向かい合うように並べるようにすればよい。   In order to arrange the cell row hollow bodies 1A, 1A obtained in the dividing step so that the face plate portions face each other, the face plate portions 2A, 2A of the cell row hollow bodies 1A are erected and the cells 5A, 5A .., So that each cell row hollow body 1A is changed by 90 degrees such that the face plate portions 2A and 2A of the adjacent cell row hollow bodies 1A and 1A face each other. .

次に、隣接するセル列中空体1A,1Aの互いの面板部2A,2A間に、熱可塑性樹脂フィルム6を挿入して介在させる。   Next, the thermoplastic resin film 6 is inserted and interposed between the face plate portions 2A and 2A of the adjacent cell row hollow bodies 1A and 1A.

(熱可塑性樹脂フィルム)
熱可塑性樹脂フィルム6は、加熱によって溶融するものであって、ガラス転移温度(Tg)が少なくとも中空体1の面板部2,2のガラス転移温度(Tg)よりも低く、かつ面板部2,2を構成する材料との相溶性が良い樹脂からなるフィルムであればよい。例えばグリコール変性ポリエステル(PETG)などの非晶性ポリエステルや、ポリメチルメタクリレートなどのポリ(メタ)アクリル酸アルキルエステルなどの樹脂を用いたフィルムを、好ましい例として挙げることができる。
熱可塑性樹脂フィルム6は、強度の点から、フィラーや繊維を含むものであってもよい。
(Thermoplastic resin film)
The thermoplastic resin film 6 is melted by heating, and has a glass transition temperature (Tg) lower than at least the glass transition temperature (Tg) of the face plate portions 2 and 2 of the hollow body 1 and the face plate portions 2 and 2. Any film may be used as long as it is made of a resin having good compatibility with the material constituting the material. For example, a film using a non-crystalline polyester such as glycol-modified polyester (PETG) or a resin such as poly (meth) acrylic acid alkyl ester such as polymethyl methacrylate can be cited as a preferred example.
The thermoplastic resin film 6 may contain a filler or a fiber from the viewpoint of strength.

熱可塑性樹脂フィルム6のガラス転移温度は、中空体の面板部のガラス転移温度よりも低いことが好ましい。中でも、熱可塑性樹脂フィルム6のガラス転移温度は、中空体1の面板部2,2のガラス転移温度よりも10℃以上低いことが好ましく、中でも15℃以上、その中でも20℃以上低いことがより一層好ましい。
かかる観点から、熱可塑性樹脂フィルム6のガラス転移温度(Tg)は30℃〜130℃であるのが好ましく、中でも40℃以上或いは110℃以下、その中でも50℃以上或いは90℃以下であるのが好ましい。
It is preferable that the glass transition temperature of the thermoplastic resin film 6 is lower than the glass transition temperature of the face plate portion of the hollow body. Especially, it is preferable that the glass transition temperature of the thermoplastic resin film 6 is 10 degreeC or more lower than the glass transition temperature of the faceplate parts 2 and 2 of the hollow body 1, and it is 15 degrees C or more especially, and it is more preferable that it is 20 degrees C or more especially low Even more preferred.
From such a viewpoint, the glass transition temperature (Tg) of the thermoplastic resin film 6 is preferably 30 ° C. to 130 ° C., more preferably 40 ° C. or more and 110 ° C. or less, particularly 50 ° C. or more or 90 ° C. or less. preferable.

また、熱可塑性樹脂フィルム6は、中空体1の少なくとも面板部2と相溶する材質のものが好ましい。
このような観点から、例えば、中空体1の面板部2がポリカーボネートであれば、熱可塑性樹脂フィルム6の材質は、ポリメチルメタクリレートなどのポリ(メタ)アクリル酸アルキルエステルや、α−オレフィンと(メタ)アクリル酸アルキルエステルの共重合体、グリコール変性ポリエステル(PETG)などの非晶性ポリエステル、ポリウレタン、ポリ塩化ビニル、アクリロニトリル−ブタジエン−スチレン共重合体などが好ましい。
また、中空体1の面板部2がポリエチレンテレフタレートなどの結晶性ポリエステルであれば、熱可塑性樹脂フィルム6の材質はグリコール変性ポリエステル(PETG)などの非晶性ポリエステルや、ポリエステル系の熱可塑性エラストマーなどが好ましい。
また、中空体1の面板部2がポリメチルメタクリレートの場合には、熱可塑性樹脂フィルム6の材質はポリ塩化ビニルや、グリコール変性ポリエステル(PETG)などの非晶性ポリエステルが好ましい。
The thermoplastic resin film 6 is preferably made of a material compatible with at least the face plate portion 2 of the hollow body 1.
From such a viewpoint, for example, if the face plate portion 2 of the hollow body 1 is polycarbonate, the material of the thermoplastic resin film 6 is poly (meth) acrylic acid alkyl ester such as polymethyl methacrylate, α-olefin and ( A copolymer of an alkyl methacrylate (meth), an amorphous polyester such as glycol-modified polyester (PETG), polyurethane, polyvinyl chloride, an acrylonitrile-butadiene-styrene copolymer, and the like are preferable.
If the face plate portion 2 of the hollow body 1 is a crystalline polyester such as polyethylene terephthalate, the thermoplastic resin film 6 is made of an amorphous polyester such as glycol-modified polyester (PETG), a polyester-based thermoplastic elastomer, or the like. Is preferred.
Moreover, when the face plate part 2 of the hollow body 1 is polymethylmethacrylate, the material of the thermoplastic resin film 6 is preferably an amorphous polyester such as polyvinyl chloride or glycol-modified polyester (PETG).

熱可塑性樹脂フィルム6の短手幅及び長手幅は、セル列中空体1Aの面板部2A、2A間に介在させた際にフィルム6が面板部2A、2A間からはみ出さないように、当該面板部2Aの高さ又は長さと同程度か、或いは、それより短いのが好ましい。但し、長くてもよい。
熱可塑性樹脂フィルム6の厚さは、接着性、ハンドリング性、経済性などを考慮すると、20μm〜150μm、中でも30μm以上或いは100μm以下、その中でも40μm以上或いは80μm以下であるのが好ましい。
The short width and the long width of the thermoplastic resin film 6 are such that the film 6 does not protrude between the face plate portions 2A and 2A when interposed between the face plate portions 2A and 2A of the cell array hollow body 1A. The height or length of the portion 2A is preferably the same as or shorter than that. However, it may be long.
The thickness of the thermoplastic resin film 6 is preferably 20 μm to 150 μm, more preferably 30 μm or more or 100 μm or less, and particularly preferably 40 μm or more or 80 μm or less in consideration of adhesiveness, handling properties, economy, and the like.

隣接するセル列中空体1A,1Aの互いの面板部2A,2A間に、熱可塑性樹脂フィルム6を介在させたら、前記面板部2A、2Aで熱可塑性樹脂フィルム6を押圧するのが好ましい。
この際、セル列中空体1A,1Aの面板部2A,2A間に熱可塑性樹脂フィルム6を介在させて、前記面板部2A,2A間で熱可塑性樹脂フィルム6を押圧する方法としては、例えば、図7(A)(B)に示すように、セル列中空体1A,1Aの面板部2A,2A間に熱可塑性樹脂フィルム6を介在させて、各面板部2の外側面、すなわちフィルム6とは反対側の面に押圧部材7を当接し、該押圧部材7によって各面板部2Aを内側、すなわちフィルム側に押圧するようにすればよい。
When the thermoplastic resin film 6 is interposed between the face plate portions 2A and 2A of the adjacent cell row hollow bodies 1A and 1A, it is preferable to press the thermoplastic resin film 6 with the face plate portions 2A and 2A.
At this time, as a method of interposing the thermoplastic resin film 6 between the face plate portions 2A, 2A of the cell array hollow bodies 1A, 1A and pressing the thermoplastic resin film 6 between the face plate portions 2A, 2A, for example, As shown in FIGS. 7A and 7B, the thermoplastic resin film 6 is interposed between the face plate portions 2A and 2A of the cell row hollow bodies 1A and 1A, and the outer surface of each face plate portion 2, that is, the film 6 and The pressing member 7 may be brought into contact with the opposite surface, and the pressing plate 7 may press each face plate portion 2A toward the inside, that is, the film side.

押圧部材7Aの形態は任意である。例えば、図7(A)(B)に示すように、セル5A内に挿入することができて、セル5Aの内側から面板部2Aを押圧できる部分を備えたものであればよく、その形態は任意である。
例えば、図8に示すように、櫛状を呈する、すなわち水平軸部から複数の棒状押圧部が垂下されてなる形状の押圧部材7Aの棒状押圧部をセル5A内に挿入して各面板部2Aの外側面を押圧するようにすればよい。
The form of the pressing member 7A is arbitrary. For example, as shown in FIGS. 7 (A) and 7 (B), it is only necessary to have a portion that can be inserted into the cell 5A and that can press the face plate portion 2A from the inside of the cell 5A. Is optional.
For example, as shown in FIG. 8, each face plate portion 2A is inserted into a cell 5A by inserting a rod-like pressing portion of a pressing member 7A having a comb shape, that is, a shape in which a plurality of rod-like pressing portions are suspended from a horizontal shaft portion. What is necessary is just to make it press the outer surface of.

(加熱手段)
熱可塑性樹脂フィルム6を加熱する手段としては、例えば、セル列中空体1A、1A同士を、互いの面板部2A、2Aが向かい合うように並べて、前記面板部2A、2A間に熱可塑性樹脂フィルム6を介在させた状態のまま、加熱炉内に入れて、該熱可塑性樹脂フィルム6を加熱するようにしてもよいし、また、セル列中空体1A、1A同士を、互いの面板部2A、2Aが向かい合うように並べて、前記面板部2A、2A間に熱可塑性樹脂フィルム6を介在させて、2枚の面板部2A、2Aの該フィルム6とは接していない面にそれぞれ押圧部材7を当接し、該押圧部材7によって面板部2を両側から該フィルム側に押圧すると共に、該押圧部材7の伝熱によって該熱可塑性樹脂フィルム6を加熱するようにしてもよい。
(Heating means)
As a means for heating the thermoplastic resin film 6, for example, the cell array hollow bodies 1A and 1A are arranged so that the face plate portions 2A and 2A face each other, and the thermoplastic resin film 6 is interposed between the face plate portions 2A and 2A. The thermoplastic resin film 6 may be heated in a heating furnace with the intervening state interposed therebetween, and the cell array hollow bodies 1A, 1A may be connected to each other with the face plate portions 2A, 2A. Are arranged so that they face each other, and a thermoplastic resin film 6 is interposed between the face plate portions 2A and 2A, and the pressing members 7 are brought into contact with the surfaces of the two face plate portions 2A and 2A that are not in contact with the film 6, respectively. The pressing member 7 may press the face plate portion 2 from both sides to the film side, and the thermoplastic resin film 6 may be heated by heat transfer from the pressing member 7.

この際、熱可塑性樹脂フィルム6の加熱温度は、熱可塑性樹脂フィルム6のガラス転移温度よりも高温であればよく、中でも、熱可塑性樹脂フィルム6のガラス転移温度より15℃以上高温であるのが好ましく、30℃以上高温であるのが更に好ましい。また、セル列中空体1Aのガラス転移温度よりも低温とするのが好ましい。   Under the present circumstances, the heating temperature of the thermoplastic resin film 6 should just be higher than the glass transition temperature of the thermoplastic resin film 6, and above all, it is 15 degreeC or more higher than the glass transition temperature of the thermoplastic resin film 6. Preferably, the temperature is higher than 30 ° C. In addition, the temperature is preferably lower than the glass transition temperature of the cell row hollow body 1A.

<ハニカムコア材形成工程>
本工程では、前記セル列中空体接着工程で接合して得られたセル列結合中空体1B、1B同士を、前記セル列中空体接着工程と同様に熱可塑性樹脂フィルム6を用いて接着して結合して、セル列結合中空体1Cを形成する。
次に、前記工程で接着して得られたセル列結合中空体1C、1C同士を、フタタ旅前記セル列中空体接着工程と同様に熱可塑性樹脂フィルム6を用いて接着し、必要に応じてこのような接着工程を繰り返してハニカムコア材10を形成すればよい。
<Honeycomb core material forming process>
In this step, the cell row bonded hollow bodies 1B and 1B obtained by joining in the cell row hollow body bonding step are bonded using the thermoplastic resin film 6 in the same manner as in the cell row hollow body bonding step. Bonding to form a cell array coupled hollow body 1C.
Next, the cell array bonded hollow bodies 1C, 1C obtained by bonding in the above process are bonded using the thermoplastic resin film 6 in the same manner as the cell array hollow body bonding process, and if necessary, What is necessary is just to form the honeycomb core material 10 by repeating such an adhesion process.

前記セル列結合中空体同士の接着を適宜繰り返すことで、所望の大きさのハニカムコア材を製造することができる。
なお、3個以上のセル列中空体1A、1A・・を、隣の面板部2A、2Aが向かい合うように並べると共に、各面板部2A、2A間に熱可塑性樹脂フィルム6を介在させて、一度に3個以上のセル列中空体1A、1A・・を接着して、所望の大きさのハニカムコア材10を製造することもできる。
A honeycomb core material having a desired size can be manufactured by appropriately repeating the bonding of the cell row-bonded hollow bodies.
The three or more cell row hollow bodies 1A, 1A,... Are arranged so that the adjacent face plate portions 2A, 2A face each other, and the thermoplastic resin film 6 is interposed between the face plate portions 2A, 2A. The honeycomb core material 10 having a desired size can be manufactured by bonding three or more cell row hollow bodies 1A, 1A,.

<ハニカムコア材の用途>
このように作製したハニカムコア材10は、そのまま各種用途に用いることもできるし、又、上下にスキン層を貼り合せることで、ハニカムサンドイッチ構造体を作製することができ、この状態で各種用途に用いることもできる。
<Use of honeycomb core material>
The honeycomb core material 10 manufactured in this way can be used for various applications as it is, or a honeycomb sandwich structure can be manufactured by laminating skin layers on the upper and lower sides. It can also be used.

<語句の説明>
本明細書において「X〜Y」(X,Yは任意の数字)と表現する場合、特にことわらない限り「X以上Y以下」の意と共に、「好ましくはXより大きい」或いは「好ましくはYより小さい」の意も包含する。
また、「X以上」(Xは任意の数字)或いは「Y以下」(Yは任意の数字)と表現した場合、「Xより大きいことが好ましい」或いは「Y未満であることが好ましい」旨の意図も包含する。
<Explanation of words>
In the present specification, when expressed as “X to Y” (X and Y are arbitrary numbers), unless otherwise specified, “X is preferably greater than X” or “preferably Y”. It also includes the meaning of “smaller”.
In addition, when expressed as “X or more” (X is an arbitrary number) or “Y or less” (Y is an arbitrary number), it is “preferably greater than X” or “preferably less than Y”. Includes intentions.

また、一般的に「シート」とは、JISにおける定義上、薄く、一般にその厚さが長さと幅のわりには小さく平らな製品をいい、一般的に「フィルム」とは、長さ及び幅に比べて厚さが極めて小さく、最大厚さが任意に限定されている薄い平らな製品で、通常、ロールの形で供給されるものをいう(日本工業規格JISK6900)。例えば厚さに関して言えば、狭義では100μm以上のものをシートと称し、100μm未満のものをフィルムと称すことがある。しかし、シートとフィルムの境界は定かでなく、本発明において文言上両者を区別する必要がないので、本発明においては、「フィルム」と称する場合でも「シート」を含むものとし、「シート」と称する場合でも「フィルム」を含むものとする。   In general, “sheet” is a thin product as defined by JIS and generally has a thickness that is small and flat instead of length and width. In general, “film” refers to length and width. A thin flat product having an extremely small thickness and an arbitrarily limited maximum thickness, usually supplied in the form of a roll (Japanese Industrial Standard JISK6900). For example, in terms of thickness, in the narrow sense, a film having a thickness of 100 μm or more is sometimes referred to as a sheet, and a film having a thickness of less than 100 μm is sometimes referred to as a film. However, since the boundary between the sheet and the film is not clear and it is not necessary to distinguish the two in terms of the present invention, in the present invention, even when the term “film” is used, the term “sheet” is included and the term “sheet” is used. In some cases, “film” is included.

次に、本発明の実施例について説明する。   Next, examples of the present invention will be described.

<実施例1>
ポリカーボネート(Tg153℃)からなる厚さ0.6mmの2枚の面板間(8.8mm)に、ポリカーボネートからなる厚さ0.5mmの長尺な壁部が該一方向と直交する方向に9.5mm間隔をおいて配設され、当該2枚の面板間に複数の長尺セルを備えた中空体1(厚さ10.0mm、幅1000mm、長さ2000mm)を用意した。
この中空体Aを、図2に示すように、8mm間隔をおいて自動型ハンドカット機を用いて切断し、多数のセル5Aが並んだ構成を備えた複数のセル列中空体に分断した。
次に、図3(A)(B)に示すように、前記分断工程で得られたセル列中空体1Aの向きを90度変えて、互いの面板部2A、2Aが向かい合うように並べると共に、前記面板部2A、2A間に、ポリメチルメタクリレート(Tg89℃)からなる厚さ50μm、幅8mm、長さ1000mmの熱可塑性樹脂フィルム6を介在させて、図8に示すように、クリップ型の押圧部材7Aを使用して、クリップの棒状部を面板部2の外側面に当接し、機械的に押圧部材7によって各面板部2Aを内側に押圧して前記面板部2A、2A間に熱可塑性樹脂フィルム6を挟止させた。この状態で、炉内温度128℃に調整した加熱炉に入れて、熱可塑性樹脂フィルム6を加熱して溶融させて前記面板部2A、2A間を接着して、セル列結合中空体1Bを作製した。
次に、同様に作製した2つのセル列結合中空体1B間に、上記同様に熱可塑性樹脂フィルム6を挟止させて、加熱炉に入れて熱可塑性樹脂フィルム6を加熱して前記面板部2A、2A間を接着して、セル列結合中空体1Cを作製した。そして、これを繰り返してハニカムコア材10を製造した。
<Example 1>
Between two face plates (8.8 mm) made of polycarbonate (Tg 153 ° C.) having a thickness of 0.6 mm, a long wall portion made of polycarbonate having a thickness of 0.5 mm is placed in a direction perpendicular to the one direction. A hollow body 1 (thickness 10.0 mm, width 1000 mm, length 2000 mm) provided with a plurality of long cells between the two face plates was prepared with an interval of 5 mm.
As shown in FIG. 2, this hollow body A was cut using an automatic hand-cutting machine at an interval of 8 mm, and divided into a plurality of cell row hollow bodies having a configuration in which a large number of cells 5A were arranged.
Next, as shown in FIGS. 3 (A) and 3 (B), the direction of the cell row hollow bodies 1A obtained in the dividing step is changed by 90 degrees, and the face plate portions 2A and 2A are arranged to face each other. As shown in FIG. 8, a clip-type press is interposed between the face plate portions 2A and 2A with a thermoplastic resin film 6 made of polymethyl methacrylate (Tg 89 ° C.) having a thickness of 50 μm, a width of 8 mm, and a length of 1000 mm. Using the member 7A, the bar-shaped portion of the clip is brought into contact with the outer surface of the face plate portion 2, and each face plate portion 2A is mechanically pressed by the pressing member 7 so that the thermoplastic resin is interposed between the face plate portions 2A and 2A. The film 6 was clamped. In this state, it is placed in a heating furnace adjusted to a furnace temperature of 128 ° C., the thermoplastic resin film 6 is heated and melted, and the face plate portions 2A and 2A are bonded to produce a cell array coupled hollow body 1B. did.
Next, the thermoplastic resin film 6 is sandwiched between the two cell array coupling hollow bodies 1B produced in the same manner as described above, and the thermoplastic resin film 6 is heated in the heating furnace to heat the face plate portion 2A. 2A was adhered to produce a cell array coupled hollow body 1C. And this was repeated and the honeycomb core material 10 was manufactured.

<実施例2>
ポリカーボネート(Tg153℃)からなる厚さ0.7mmの2枚の面板間(23.6mm)に、ポリカーボネートからなる厚さ0.5mmの長尺な壁部が該一方向と直交する方向に24.5mm間隔をおいて配設され、当該2枚の面板間に複数の長尺セルを備えた中空体1(厚さ25mm、幅500mm、長さ1000mm)を用意した。
この中空体Aを、図2に示すように、28mm間隔をおいて自動型ハンドカット機を用いて切断し、多数のセル5Aが並んだ構成を備えた複数のセル列中空体に分断した。
ポリウレタン(Tg50℃)からなる厚さ70μm、幅28mm、長さ500mmの熱可塑性樹脂フィルム6を用い、炉内温度を100℃に調整した以外は、その後の工程は実施例1と同様にして、ハニカムコア材10を製造した。
<Example 2>
Between the two face plates (23.6 mm) made of polycarbonate (Tg 153 ° C.) having a thickness of 0.7 mm, a long wall part made of polycarbonate having a thickness of 0.5 mm is placed in a direction perpendicular to the one direction. A hollow body 1 (thickness 25 mm, width 500 mm, length 1000 mm) provided with a plurality of long cells between the two face plates was prepared with an interval of 5 mm.
As shown in FIG. 2, this hollow body A was cut using an automatic hand-cutting machine at intervals of 28 mm, and divided into a plurality of cell row hollow bodies having a configuration in which a large number of cells 5A were arranged.
Using the thermoplastic resin film 6 made of polyurethane (Tg 50 ° C.) with a thickness of 70 μm, a width of 28 mm, and a length of 500 mm, the subsequent steps were the same as in Example 1 except that the furnace temperature was adjusted to 100 ° C. A honeycomb core material 10 was manufactured.

1 中空体
1A セル列中空体
2 面板
2A 面板部
4 壁部
5 長尺セル
5A セル
6 熱可塑性樹脂フィルム
10 ハニカムコア材
DESCRIPTION OF SYMBOLS 1 Hollow body 1A Cell row | line | column hollow body 2 Face plate 2A Face plate part 4 Wall part 5 Long cell 5A Cell 6 Thermoplastic resin film 10 Honeycomb core material

Claims (4)

2枚の面板の間に、一方向に長尺な壁部が該一方向と直交する方向に適宜間隔をおいて配設され、当該2枚の面板の間に複数の長尺なセルを備えた中空体を、前記一方向に適宜間隔をおいて切断して、多数のセルが並んだ構成を備えた複数のセル列中空体に分断する分断工程と、
前記分断工程で得られたセル列中空体同士を、互いの面板部が向かい合うように並べると共に、前記面板部間に熱可塑性樹脂フィルムを介在させて、セル内に押圧部材を挿入して、面板部の外側面に該押圧部材を当接し、該押圧部材によって面板部を熱可塑性樹脂フィルム側に押圧し、該熱可塑性樹脂フィルムを加熱して前記面板部間を接着するセル列中空体接着工程と、を備えたハニカムコア材の製造方法。
A wall portion that is long in one direction is disposed between the two face plates at an appropriate interval in a direction perpendicular to the one direction, and a plurality of long cells are provided between the two face plates. The hollow body is cut at an appropriate interval in the one direction, and divided into a plurality of cell row hollow bodies having a configuration in which a large number of cells are arranged; and
The cell array hollow bodies obtained in the dividing step are arranged so that the face plate portions face each other, a thermoplastic resin film is interposed between the face plate portions, a pressing member is inserted into the cell, and the face plate the pressing member contacts the outer surface of the part, a face plate portion pressed onto the thermoplastic resin film side by the pressing member, the thermoplastic resin film cell column heated to bond between the surface plate portion hollow adhesin And a method for manufacturing a honeycomb core material.
前記分断工程で得られたセル列中空体同士を、互いの面板部が向かい合うように並べると共に、前記面板部間に熱可塑性樹脂フィルムを介在させて、セル内に押圧部材を挿入して、面板部の外側面に該押圧部材を当接し、該押圧部材によって面板部を熱可塑性樹脂フィルム側に押圧した状態で加熱炉内に入れて、該熱可塑性樹脂フィルムを加熱して前記面板部間を接着することを特徴とする、請求項1に記載のハニカムコア材の製造方法。 The cell array hollow bodies obtained in the dividing step are arranged so that the face plate portions face each other, a thermoplastic resin film is interposed between the face plate portions, a pressing member is inserted into the cell, and the face plate part of the pressing member abuts against the outer surface of the face plate portion by the pressing member placed in a heating furnace in a state of pressing to the thermoplastic resin film side, between said face plate portion by heating the thermoplastic resin film The method for manufacturing a honeycomb core material according to claim 1, wherein: 前記セル列中空体接着工程では、前記分断工程で得られたセル列中空体同士を、互いの面板部が向かい合うように並べると共に、前記面板部間に熱可塑性樹脂フィルムを介在させて、セル内に押圧部材を挿入して、面板部の外側面に該押圧部材を当接し、該押圧部材によって面板部を熱可塑性樹脂フィルム側に押圧し、該押圧部材の伝熱によって該熱可塑性樹脂フィルムを加熱して前記面板部間を接着することを特徴とする、請求項1に記載のハニカムコア材の製造方法。 In the cell row hollow body bonding step, the cell row hollow bodies obtained in the dividing step are arranged so that the face plate portions face each other, and a thermoplastic resin film is interposed between the face plate portions, by inserting a pressing member, the pressing member on the outer surface of the face plate section abuts the face plate pressed onto the thermoplastic resin film side by the pressing member, the thermoplastic resin film by heat transfer pressing member The method for manufacturing a honeycomb core material according to claim 1, wherein the face plate portions are bonded together by heating. 前記押圧部材は、水平軸部から複数の棒状押圧部が垂下してなる形状を有するものである、請求項1〜3の何れかに記載のハニカムコア材の製造方法。
The method for manufacturing a honeycomb core material according to any one of claims 1 to 3, wherein the pressing member has a shape in which a plurality of rod-shaped pressing portions are suspended from a horizontal shaft portion.
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