CN105992791B - 纤维强化复合材料 - Google Patents

纤维强化复合材料 Download PDF

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CN105992791B
CN105992791B CN201480063976.1A CN201480063976A CN105992791B CN 105992791 B CN105992791 B CN 105992791B CN 201480063976 A CN201480063976 A CN 201480063976A CN 105992791 B CN105992791 B CN 105992791B
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神谷隆太
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Toyota Industries Corp
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Abstract

本发明提供一种纤维强化复合材料。该纤维强化复合材料具有包含被层叠的多个斜交织物层的织物基材。斜交织物层分别将多个第一强化纤维束和相对于上述第一强化纤维束斜交的多个第二强化纤维束进行织造而构成。多个斜交织物层以在层叠方向上相邻的2个斜交织物层中的一方斜交织物层的第一和第二强化纤维束中的任一方的取向方向与另一方斜交织物层的第一和第二强化纤维束中的任一方的取向方向相同的方式被层叠。在层叠方向上相邻的斜交织物层之间，配置由多个纤维束构成的单取向层。单取向层以单取向层的纤维束的取向方向与在相邻的斜交织物层相互具有相同的取向方向的强化纤维束的取向方向相同的方式被配置。

Description

纤维强化复合材料
技术领域
本发明涉及具有包含被层叠的多个斜交织物层的织物基材的纤维强化复合材料，即各斜交织物层是将相互平行排列的多个第一强化纤维束和相对于第一强化纤维束斜交且相互平行排列的多个第二强化纤维束进行织造而构成的纤维强化复合材料。
背景技术
作为轻型且高强度的材料使用纤维强化复合材料。纤维强化复合材料具有多个强化纤维束层，该强化纤维束层通过排列多个纤维束而形成，该纤维束由多个纤维捆扎而成。通过使基体树脂(Matrix resin)浸渍于包含被层叠的多个强化纤维束层的强化纤维基材，形成纤维强化复合材料。作为强化纤维基材，例如，专利文献1和专利文献2中公开了层叠多个织物层而成的织物基材，该织物层以平纹、斜纹、缎纹等将多个经纱(第一强化纤维束)和多个纬纱(第二强化纤维束)进行织造而构成。
专利文献1的织物基材例如通过将由具有0度的取向方向的经纱和具有90度的取向方向的纬纱构成的织物层与由具有+45度的取向方向的经纱和具有-45度的取向方向的纬纱构成的织物层交互层叠多个而形成。因为能够以这样简单的制造方法来使织物基材具有准各向同性，所以专利文献1的织物基材具有优异的制造成本和生产率。
另外，专利文献2的织物基材通过将经纱和纬纱以45度的狭角换言之135度的广角交叉的织物层(斜交织物层)相互错开45度重叠而形成。
专利文献1:日本特开平1-225538号公报
专利文献2:日本实开平7-43501号公报
在专利文献1的织物基材中，在织物层的层叠方向上相邻的织物层中的一方织物层的经纱和纬纱的取向方向与另一方织物层的经纱和纬纱的取向方向不同。因此，在织物层的层叠方向上相邻的织物层间的邻角较大，有可能在该相邻的织物层彼此之间产生内部应力，出现层间剥离的问题。
根据专利文献2的织物基材，与专利文献1的织物基材相比，能够缩小相邻的斜交织物层之间的邻角。但是，如果不充分地对齐相邻的斜交织物层的纹理，纱的重叠面积会缩小，其结果是，有可能会在相邻的斜交织物层彼此之间产生层间剥离的问题。
发明内容
本发明的目的在于提供一种能够抑制在斜交织物层的层叠方向上相邻的斜交织物层彼此之间产生层间剥离的纤维强化复合材料。
解决上述课题的纤维强化复合材料具有包含被层叠的多个斜交织物层的织物基材。上述多个斜交织物层分别将相互平行排列的多个第一强化纤维束和相对于上述第一强化纤维束斜交且相互平行排列的多个第二强化纤维束进行织造而构成。上述多个斜交织物层以在上述斜交织物层的层叠方向上相邻的2个上述斜交织物层中的一方斜交织物层的上述第一和第二强化纤维束中的任一方的取向方向与另一方斜交织物层的上述第一和第二强化纤维束中任一方的取向方向相同的方式被层叠。在上述斜交织物层的层叠方向上相邻的上述斜交织物层之间，配置由相互平行排列的多个纤维束构成的单取向层。上述单取向层以上述单取向层的上述纤维束的取向方向与相邻的上述斜交织物层中相互具有相同取向方向的强化纤维束的取向方向相同的方式，被配置于相邻的上述斜交织物层之间。
附图说明
图1是示出实施方式的纤维强化复合材料的剖视图。
图2是示意性地示出图1的织物基材的一部分的俯视图。
具体实施方式
下面，根据图1和图2对一实施方式所涉及的纤维强化复合材料10进行说明。
如图1所示，纤维强化复合材料10通过在织物基材11浸渍基体树脂12并使两者11、12复合化而形成。在本实施方式中，作为基体树脂12使用环氧树脂。
如图2所示，织物基材11具有第一斜交织物层21，该第一斜交织物层21以平纹将以90度的取向角度相互平行排列的多根作为第一强化纤维束的经纱21a和相对于经纱21a斜交的以-45度的取向角度相互平行排列的多根作为第二强化纤维束的纬纱21b进行织造而构成。另外，织物基材11具有第二斜交织物层22，该第二斜交织物层22以平纹将以-45度的取向角度相互平行排列的多根作为第一强化纤维束的经纱22a和相对于经纱22a斜交的以0度的取向角度相互平行排列的多根作为第二强化纤维束的纬纱22b进行织造而构成。
并且，织物基材11具有第三斜交织物层23，该第三斜交织物层23以平纹将以+45度的取向角度相互平行排列的多根作为第一强化纤维束的经纱23a和相对于经纱23a斜交的以0度的取向角度相互平行排列的多根作为第二强化纤维束的纬纱23b进行织造而构成。另外，织物基材11具有第四斜交织物层24，该第四斜交织物层24以平纹将以90度的取向角度相互平行排列的多根作为第一强化纤维束的经纱24a和相对于经纱24a斜交的以+45度的取向角度相互平行排列的多根作为第二强化纤维束的纬纱24b进行织造而构成。
因此，在第一～第四斜交织物层21、22、23、24的各层，纬纱21b、22b、23b、24b的取向方向相对于经纱21a、22a、23a、24a的取向方向成45度的角度。此外，“取向方向”的意思是纤维或者纤维束延伸的方向。织物基材11通过将第一～第四斜交织物层21、22、23、24以该顺序层叠而构成为具有准各向同性。经纱21a、22a、23a、24a和纬纱21b、22b、23b、24b分别为捆扎多根纤维(碳纤维)而成的纤维束。
第二斜交织物层22相对于第一斜交织物层21，以第二斜交织物层22的经纱22a的取向方向与第一斜交织物层21的纬纱21b的取向方向相同的方式被层叠。第三斜交织物层23相对于第二斜交织物层22，以第三斜交织物层23的纬纱23b的取向方向与第二斜交织物层22的纬纱22b的取向方向相同的方式被层叠。第四斜交织物层24相对于第三斜交织物层23，以第四斜交织物层24的纬纱24b的取向方向与第三斜交织物层23的经纱23a的取向方向相同的方式被层叠。
在第一斜交织物层21和第二斜交织物层22之间，双层配置有第一单取向层31，该第一单取向层31由以-45度的取向角度相互平行排列的多个纤维束31a构成。因此，各第一单取向层31以纤维束31a的取向方向与第一斜交织物层21的纬纱21b的取向方向和第二斜交织物层22的经纱22a的取向方向相同的方式被配置于第一和第二斜交织物层21、22之间。
在第二斜交织物层22和第三斜交织物层23之间，双层配置有第二单取向层32，该第二单取向层32由以0度的取向角度相互平行排列的多个纤维束32a构成。因此，各第二单取向层32以纤维束32a的取向方向与第二斜交织物层22的纬纱22b的取向方向和第三斜交织物层23的纬纱23b的取向方向相同的方式被配置于第二和第三斜交织物层22、23之间。
在第三斜交织物层23和第四斜交织物层24之间，双层配置有第三单取向层33，该第三单取向层33由以+45度的取向方向相互平行排列的多个纤维束33a构成。因此，各第三单取向层33以纤维束33a的取向方向与第三斜交织物层23的经纱23a的取向方向和第四斜交织物层24的纬纱24b的取向方向相同的方式被配置于第三和第四斜交织物层23、24之间。
在第一～第四斜交织物层21、22、23、24的层叠方向上，在第一斜交织物层21的与第一单取向层31相反的一侧，配置有第四单取向层34，该第四单取向层34由以90度的取向角度相互平行排列的多个纤维束34a构成。因此，第四单取向层34以纤维束34a的取向方向与第一斜交织物层21的经纱21a的取向方向相同的方式被配置。
在第一～第四斜交织物层21、22、23、24的层叠方向上，在第四斜交织物层24的与第三单取向层33相反的一侧，配置有第五单取向层35，该第五单取向层35由以90度的取向角度相互平行排列的多个纤维束35a构成的。因此，第五单取向层35以纤维束35a的取向方向与第四斜交织物层24的经纱24a的取向方向相同的方式被配置。各纤维束31a、32a、33a、34a、35a由多根纤维(碳纤维)捆扎而成。
接下来，对本实施方式的作用进行说明。
在第一～第四斜交织物层21、22、23、24的层叠方向上相邻的第一斜交织物层21和第二斜交织物层22间隔双层的第一单取向层31而被层叠。第一斜交织物层21的纬纱21b与被配置于其上的第一单取向层31的纤维束31a相重叠，在其相重叠的部位不形成供基体树脂12进入的间隙。另外，第二斜交织物层22的经纱22a与被配置于其下的第一单取向层31的纤维束31a相重叠，因此在其相重叠的部位不形成供基体树脂12进入的间隙。其结果是，抑制在第一～第四斜交织物层21、22、23、24的层叠方向上相邻的第一斜交织物层21和第二斜交织物层22之间出现层间剥离。
相同地，在第一～第四斜交织物层21、22、23、24的层叠方向上相邻的第二斜交织物层22和第三斜交织物层23间隔双层的第二单取向层32而被层叠。另外，在第一～第四斜交织物层21、22、23、24的层叠方向上相邻的第三斜交织物层23和第四斜交织物层24间隔双层的第三单取向层33而被层叠。其结果是，抑制在第二斜交织物层22和第三斜交织物层23之间以及第三斜交织物层23和第四斜交织物层24之间产生层间剥离。
并且，第一斜交织物层21的经纱21a与被配置于其下的第四单取向层34的纤维束34a相重叠，因此在其相重叠的部位不形成供基体树脂12进入的间隙。相同地，第四斜交织物层24的经纱24a与被配置于其上的第五单取向层35的纤维束35a相重叠，因此在其相重叠的部位不形成供基体树脂12进入的间隙。
在上述实施方式下，能够获得以下效果。
(1)第一～第四斜交织物层21～24以在其层叠方向上相邻的2个斜交织物层中的一方斜交织物层的经纱21a～24a和纬纱21b～24b中的任一方的取向方向与另一方斜交织物层的经纱21a～24a和纬纱21b～24b中的任一方的取向方向相同的方式被层叠。在层叠方向上相邻的斜交织物层之间，分别配置有由相互平行排列的多个纤维束31a～33a构成的第一～第三单取向层31～33。第一～第三单取向层31～33分别以纤维束31a～33a的取向方向与相邻的斜交织物层中具有相同取向方向的强化纤维束(21a～24a、21b～24b)的取向方向成为相同方向的方式，被配置于相邻的斜交织物层之间。由此，即使相邻的斜交织物层的纹理不对齐，也能在层叠方向上相邻的斜交织物层彼此之间，确保用于抑制层间剥离的充分的纱线重叠面积。其结果是，能够抑制在层叠方向上相邻的斜交织物层彼此之间产生层间剥离。
(2)在第一～第四斜交织物层21～24的各层，纬纱21b～24b的取向方向相对于经纱21a～24a的取向方向成45度的角度。即，第一～第四斜交织物层21～24不是相互不同种类的织物，而是相同种类的织物。而且，是将一种第一～第四斜交织物层21～24以在层叠方向上相邻的斜交织物层彼此错开45度的状态层叠。以这样的简单层叠方法，既能使织物基材11具有准各向同性，也能在层叠方向上相邻的斜交织物层之间使强化纤维束(21a～24a、21b～24b)的取向方向相同。
(3)单取向层31～33在相邻的斜交织物层之间被双层配置。由此能够更加提高织物基材11的准各向同性。
(4)在第一～第四斜交织物层21～24的层叠方向上，在第一斜交织物层21的与第一单取向层31相反的一侧，配置有第四单取向层34。另外，在第一～第四斜交织物层21～24的层叠方向上，在第四斜交织物层24的与第三单取向层33相反的一侧，配置有第五单取向层35。由此，与使第一斜交织物层21和第四斜交织物层24作为织物基材11的上下表面露出到外部的情况相比，会减少织物基材11的上下表面的凹凸，因此能够减少在织物基材11的上下表面所形成的树脂存积。
此外，还可以如下变更上述实施方式。
○可以删除第四单取向层34和第五单取向层35。
○可以在相邻的斜交织物层之间分别仅配置1层第一～第三单取向层31～33。
○在实施方式中，是以平纹织造构成第一～第四斜交织物层21～24，但织造方法也可以是斜纹和缎纹。
○作为基体树脂12，还可以使用环氧树脂以外的热固化性树脂。
○作为基体树脂12还可以使用热固化性树脂以外的树脂。
○还可通过厚度方向纱将第一～第四斜交织物层21～24和第一～第五单取向层31～35在层叠方向上相结合。
○形成经纱21a～24a、纬纱21b～24b或纤维束31a～35a的纤维并不局限于碳纤维。例如，也可以是玻璃纤维、陶瓷纤维等无机纤维，或者芳族聚酰胺纤维、聚亚苯基苯并二唑纤维、多芳基化合物纤维、超高分子量聚乙烯纤维等高强度的有机纤维。
○在第一～第四斜交织物层21～24的各层，纬纱21b～24b的取向方向相对于经纱21a～24a的取向方向例如可以成60度的角度。总而言之，只要纬纱21b～24b的取向方向相对于经纱21a～24a的取向方向斜交即可。

Claims (3)

1.一种纤维强化复合材料，具有包含被层叠的多个斜交织物层的织物基材，其中，
上述多个斜交织物层分别将相互平行排列的多个第一强化纤维束和相对于上述第一强化纤维束斜交且相互平行排列的多个第二强化纤维束进行织造而构成，
上述多个斜交织物层以在上述斜交织物层的层叠方向上相邻的2个上述斜交织物层中的一方斜交织物层的上述第一和第二强化纤维束中的任一方的取向方向与另一方斜交织物层的上述第一和第二强化纤维束中的任一方的取向方向相同的方式被层叠，
在上述斜交织物层的层叠方向上相邻的上述斜交织物层之间，配置由相互平行排列的多个纤维束构成的单取向层，
上述单取向层以上述单取向层的上述纤维束的取向方向与相邻的上述斜交织物层中相互具有相同取向方向的强化纤维束的取向方向相同的方式，被配置于相邻的上述斜交织物层之间。
2.根据权利要求1所述的纤维强化复合材料，其中，
在全部斜交织物层的各层中，上述第二强化纤维束的取向方向相对于上述第一强化纤维束的取向方向成45度的角度。
3.根据权利要求1或者2所述的纤维强化复合材料，其中，
上述单取向层被双层配置于相邻的上述斜交织物层之间。
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