CN116348263A - Net-shaped fiber reinforced composite material, net-shaped knitted structure, net-shaped fiber reinforced composite material molding material, and net-shaped fiber reinforced composite molded article - Google Patents
Net-shaped fiber reinforced composite material, net-shaped knitted structure, net-shaped fiber reinforced composite material molding material, and net-shaped fiber reinforced composite molded article Download PDFInfo
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- CN116348263A CN116348263A CN202180066779.5A CN202180066779A CN116348263A CN 116348263 A CN116348263 A CN 116348263A CN 202180066779 A CN202180066779 A CN 202180066779A CN 116348263 A CN116348263 A CN 116348263A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
- B29B11/14—Making preforms characterised by structure or composition
- B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
- B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
- B29B15/10—Coating or impregnating independently of the moulding or shaping step
- B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/10—Open-work fabrics
- D04B21/12—Open-work fabrics characterised by thread material
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Abstract
The invention provides a net-shaped fiber reinforced composite, a net-shaped knitting structure, a net-shaped fiber reinforced composite molding material and a net-shaped fiber reinforced composite molding body, wherein the net-shaped fiber reinforced composite molding body is composed of a knitted fabric base material capable of tolerating deep drawing during molding, has better elasticity and drapability than the prior materials, has better moldability into a curved surface shape and air permeability, prevents stuffiness, has light weight, high strength, and has large rigidity and excellent impact resistance. A mesh-type fiber-reinforced composite having a mesh-type knitted structure formed of 3 kinds of strands of a plurality of rows of knitting stitches (20) formed by endless continuity of chain knitting yarns (2) in the longitudinal direction, a plurality of rows of transversely inserted yarns (3 or more rows of longitudinally inserted knitting stitches turned back in the transverse direction on each of the rows of loops, and longitudinally inserted yarns (4) inserted with chain knitting yarns in the opposite direction of the transversely inserted yarns in the direction of 1 row of transversely inserted yarns on each of the rows of loops, the mesh-type fiber-reinforced composite being formed by impregnating and curing only the knitting stitches and the longitudinally and transversely inserted yarns with a resin, the knitting yarns being (a) organic fibers such as polyester, nylon, vinylon, or (b) high-strength fibers such as aramid long fibers, PBO long fibers, ultra-high molecular weight polyethylene fibers, high-strength polyester long fibers, or (c) inorganic fibers such as glass long fibers, basalt fibers, longitudinally inserted fibers, or (b) inorganic fibers such as polyester, nylon, ultra-high-molecular weight polyester long fibers, or the like.
Description
Technical Field
The present invention relates to a net-like fiber-reinforced composite material, which is a composite material of a thermosetting or thermoplastic resin and reinforcing fibers, and which has a high aperture ratio, a light weight, a high strength and a high impact resistance because of being net-like, and is therefore suitable as an inner and outer decorative member for a filter, a cover, a reinforcing member, particularly a protector for a helmet or the like, a prosthesis (prosthetic foot, prosthetic hand). The present invention also relates to a mesh knitted structure for a mesh fiber reinforced composite material, a mesh fiber reinforced composite material molding material, and a mesh fiber reinforced composite molded article obtained by molding a mesh fiber reinforced composite material.
Background
Conventionally, most of the net-like materials are made of resin or metal, but there is a problem that the resin is lightweight but has insufficient strength, and the metal is strong but has heavy weight.
This problem is particularly significant in a body-worn attachment for protecting the body, and in recent years, the use of a fiber-reinforced plastic member has also been observed. For example, a lined cap has been proposed and commercially available, in which a police, a station person, a police, or the like can wear the lined cap as a cap to protect the head from accidental dropping, or from external impacts, or the like, and in which a general person represented by children or the elderly can wear the lined cap as a sports cap or the like to protect the head.
As described in fig. 7 (a) and (b) attached to the present invention, patent document 1 describes a cap 100 with a protective lining, wherein the cap 100 includes a cap body (crown) 102 and a flange 103, which are made of cloth, and a protective lining 110 is provided inside the cap body 102. As shown in the figure, the protective liner 110 is composed of a liner main body 111, a buffer member 112 disposed inside the liner main body 111, and a cover piece 113 disposed so as to cover the liner main body 111 and the buffer member 112, wherein the liner main body 111 is formed in a bowl shape bent into a substantially spherical shape so as to be fitted to the inside of the cap main body 102 and so as to be able to be fitted to the head of a person when worn by the person, and is formed in a basic structure of a liner made of a fiber reinforced resin material (FRP) having a bent shape similar to the shape of the top region of the cap main body 102.
The cap 100 with a protective lining described in patent document 1 is lightweight, has good air permeability, is excellent in impact resistance, and is excellent in mountability.
However, in the cap with protective lining 100 described in patent document 1, the lining body 111 constituting the basic structure of the lining is made of a fiber reinforced resin material (FRP) obtained by impregnating a matrix resin, which is a thermosetting resin or a thermoplastic resin, with reinforcing fibers, which are unidirectional or woven, and curing the matrix resin. Therefore, it is found that the fabric is lightweight and has high strength, but may feel stuffy when worn for a long period of time, and further improvement in air permeability is desired. As described above, the liner body 111 is formed into a bowl shape that is bent into a substantially spherical shape so as to be able to match the human head, and is formed of a fiber reinforced resin material (FRP) cured by impregnating a resin into a reinforcing fiber sheet that is unidirectional or woven, but the reinforcing fiber sheet that is unidirectional or woven before resin impregnation has problems in terms of stretchability and drapability, and further improvement in terms of formability (formability) is desired.
The present inventors focused on the excellent stretchability and drapability of the sheet-like carbon fiber knitted fabric described in patent document 2, and found that, when a net-like reinforcing fiber composite material produced by impregnating a predetermined amount of resin in a sheet-like carbon fiber knitted fabric while maintaining a predetermined aperture ratio of the sheet-like carbon fiber knitted fabric and curing the resin is used as a material for constructing a basic structure of interior parts (interiors) of caps, various guards, prostheses (prosthetic feet, prosthetic hands) and the like, or exterior parts (frames) and the like, excellent breathability can be provided, stuffiness can be prevented, and lightweight and high strength can be achieved.
Accordingly, the present inventors have proposed a net-like fiber reinforced composite material 10A having voids G as described in patent document 3, as shown in fig. 8 (a) and (b) attached to the present application,
(a) The net-shaped fiber reinforced composite 10A has a net-shaped knitting structure 1A, the net-shaped knitting structure 1A has a gap G formed by a plurality of longitudinal knitting stitches 20 and an insertion yarn 3, the plurality of longitudinal knitting stitches 20 are produced by knitting chain stitches 2A while forming chain stitches 2A continuously in the longitudinal direction in a loop shape, the insertion yarn 3 is inserted in the transverse direction relative to the longitudinal knitting stitches 20 and binds the knitting stitches 20 adjacent to each other,
(b) The net-shaped fiber reinforced composite 10A is cured and shaped to have a curved shape by impregnating the resin R only in the stitch pattern 20 (chain stitch yarn 2) and the insert yarn 3 in the net-shaped knitting structure 1A,
(c) The yarns of at least a part of the chain knitting yarn 2 and the insertion yarn 3 are carbon fiber bundles composed of carbon fibers,
(d) The mesh knitting structure 1A has an opening ratio of 20 to 60%.
The mesh-knitted structure 1A used for the mesh-fiber reinforced composite material 10A described in patent document 3 has the following advantages because the reinforcing fibers used are not straight but knitted: the stretch and drapability are excellent, and the stretch and drapability are excellent in formability (formability) to a curved shape, and the air permeability is excellent because the stretch and drapability are excellent in the gaps G, and stuffiness can be prevented. The light weight and the sufficient strength can form the basic structure of interior parts (inner liners) such as caps, various protectors, prostheses (prosthetic feet, prosthetic hands), or exterior parts (frames).
Prior art literature
Patent literature
Patent document 1: japanese patent application registration No. 3187008
Patent document 2: japanese patent No. 4822528
Patent document 3: japanese patent No. 6362454
Disclosure of Invention
Problems to be solved by the invention
The mesh-knitted structure 1A used for the mesh-fiber reinforced composite 10A described in patent document 3 is excellent in stretchability and drapability, and is excellent in shape forming into a curved surface. However, it is found that even when carbon fiber bundles made of carbon fibers are used as yarns of at least a part of the chain stitch yarn 2 and the insertion yarn 3, the net-shaped fiber-reinforced composite 10A obtained by impregnating the resin and curing the same is easily broken from the resin by an external force, and for example, in the case of a cap for head protection such as a helmet, when stress (impact) is applied by a falling object or the like, deflection (deformation) is easily generated in the portion to which the stress is applied, and there is a problem that mechanical strength such as tensile strength and bending elasticity is also lowered.
Further, the knitted fabric is generally a blank or a base material which is easily deformed, i.e., has high drapability and is suitable for the production of a deep drawn product. However, the product has such characteristics that mechanical properties such as tensile strength, elasticity, and bending elasticity are low. The reason for this is that,
(1) When stress is applied, the base material itself is a knitted fabric, and thus is easily deformed. In addition, in the case of the optical fiber,
(2) The breaking strength of the stitches constituting the knitted fabric is derived from the knot strength of the fibers, which is lower than the usual tensile strength. (for example, the knot strength of carbon fiber is zero, so that it is not appropriate as a fiber to be used in a coil.)
Therefore, when stress (impact) is applied to the surface of the molded article, the portion to which the stress is applied is deflected or deformed. When the deflection or deformation amount is large, the stress is transmitted to the lower portion of the molded article, and the stitches of the knitted fabric composed of the fibers having low knot strength are broken with deformation of the knitted fabric or the molded article, so that the molded article is broken.
Accordingly, the present inventors have attempted to solve the above problems by providing a knitted fabric or a base material which can withstand deep drawing during molding.
That is, an object of the present invention is to provide a net-shaped fiber-reinforced composite material, a net-shaped knitted structure, a net-shaped fiber-reinforced composite material molding material, and a net-shaped fiber-reinforced composite molded article, which are composed of a knitted fabric base material that can withstand deep drawing during molding, are excellent in stretchability and drapability as compared with a usual material, are excellent in moldability into a curved shape and air permeability, are prevented from stuffiness, are lightweight and high in strength, are large in rigidity, and are excellent in impact resistance.
Means for solving the problems
The above-described problems and objects are achieved by the following (1) to (4) of the present invention, which are a net-shaped fiber-reinforced composite material, a net-shaped knitted structure, a net-shaped fiber-reinforced composite molding material, and a net-shaped fiber-reinforced composite molded article.
(1) The knot strength of the fibers constituting the coil is improved.
(2) High denier fibers are used.
(3) The type of fiber used is determined.
(4) A knitting structure excellent in impact resistance was determined.
In summary, according to the first invention, there is provided a net-like fiber reinforced composite having a net-like knitting structure formed of 3 kinds of yarns of a plurality of rows of knitting stitches forming chain stitches by endless continuity of chain knitting yarn in a longitudinal direction, a plurality of rows of transverse insertion yarns turned back in a transverse direction by 3 or more rows in each of the coil rows to be inserted into the longitudinal knitting stitch, and a longitudinal insertion yarn inserted in a direction of 1 row in each of the coil rows in an opposite direction to the transverse insertion yarn,
the mesh fiber reinforced composite is formed by impregnating and curing only the knitting structure, the longitudinal insertion yarn, and the lateral insertion yarn in the mesh knitting structure with a resin,
the chain knitting yarn is
(a) Organic fibers such as polyester, nylon, vinylon, or the like
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, or
(c) Inorganic fibers such as long glass fibers and basalt fibers,
the longitudinal inserting yarn and the transverse inserting yarn are
(a) Inorganic fibers such as long glass fibers and basalt fibers, or
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, and the like.
According to a second aspect of the present invention, there is provided a mesh fiber reinforced composite having a mesh knitting structure formed of 3 yarns of a plurality of rows of knitting stitches forming chain stitches by endless continuity of chain knitting yarn in a longitudinal direction, a plurality of rows of transverse insertion yarns turned back by 3 or more rows in a transverse direction in each of the coil rows to be inserted into the longitudinal knitting stitch, and a longitudinal insertion yarn inserted into the chain knitting yarn in a direction of a plurality of rows in a 1-row turn in an opposite direction to the transverse insertion yarn,
The mesh fiber reinforced composite is formed by shaping the mesh knitting structure into a predetermined shape, then impregnating and curing only the knitting structure, the longitudinal insertion yarn, and the lateral insertion yarn in the mesh knitting structure,
the chain knitting yarn is
(a) Organic fibers such as polyester, nylon, vinylon, or the like
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, or
(c) Inorganic fibers such as long glass fibers and basalt fibers,
the longitudinal inserting yarn and the transverse inserting yarn are
(a) Inorganic fibers such as long glass fibers and basalt fibers, or
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, and the like.
According to one embodiment of the first and second aspects of the present invention, the resin impregnated in the mesh-like knitted structure is a thermosetting resin such as a room temperature curable or thermosetting epoxy resin, a vinyl ester resin, an MMA resin, an acrylic resin, an unsaturated polyester resin, or a phenolic resin; or thermoplastic resins such as thermoplastic epoxy resins, phenoxy resins, polycarbonate resins, polyester resins, polyurethane resins, polyamide resins, polyetherimide resins, polyetheretherketone resins, or polyphenylene sulfide resins.
According to a third aspect of the present invention, there is provided a mesh fiber reinforced composite having a mesh knitting structure formed of 3 yarns of a plurality of rows of knitting stitches forming chain stitches by endless continuity of chain knitting yarn in a longitudinal direction, a plurality of rows of transverse insertion yarns turned back by 3 or more rows in a transverse direction in each of the coil rows to be inserted into the longitudinal knitting stitch, and a longitudinal insertion yarn inserted into the chain knitting yarn in a direction of a plurality of rows in a 1-row turn in an opposite direction to the transverse insertion yarn,
the mesh fiber reinforced composite is formed by impregnating only the knitting structure, the longitudinal insertion yarn, and the lateral insertion yarn in the mesh knitting structure with a resin, curing the resin, and shaping the resin into a predetermined shape,
the chain knitting yarn is
(a) Organic fibers such as polyester, nylon, vinylon, or the like
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, or
(c) Inorganic fibers such as long glass fibers and basalt fibers,
The longitudinal inserting yarn and the transverse inserting yarn are
(a) Inorganic fibers such as long glass fibers and basalt fibers, or
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, and the like.
According to one embodiment of the third invention, the resin impregnated in the mesh-like knitted structure is a thermoplastic resin such as a thermoplastic epoxy resin, a phenoxy resin, a polycarbonate resin, a polyester resin, a polyurethane resin, a polyamide resin, a polyetherimide resin, a polyetheretherketone resin, or a polyphenylene sulfide resin.
According to one embodiment of the present invention, the fibers used in the chain knitting yarn are 40tex or more in terms of single yarn or doubled yarn, and the fibers used in the longitudinal insertion yarn and the lateral insertion yarn are 80tex or more in terms of single yarn or doubled yarn.
According to one embodiment of the present invention, the mesh-knitted structure has an aperture ratio of 20 to 60%.
Further, according to a fourth aspect of the present invention, there is provided a mesh-like knitting structure formed of 3 kinds of yarns, a plurality of rows of knitting stitches formed by endless continuity of chain knitting yarns in a longitudinal direction, a plurality of rows of lateral insertion yarns for turning back and inserting the longitudinal knitting stitches in 3 or more rows in a lateral direction, and a longitudinal insertion yarn for inserting the chain knitting yarns in a direction of a plurality of rows in which 1 row is turned back in a direction opposite to the lateral insertion yarn.
Further, according to a fifth aspect of the present invention, there is provided a net-shaped fiber-reinforced composite material having a net-shaped knitting structure formed of 3 yarns of a plurality of rows of knitting stitches formed by endless continuity in a longitudinal direction of chain knitting yarns, a plurality of rows of laterally inserted yarns turned back in the transverse direction by 3 or more rows in each of the coil rows to be inserted into the longitudinal knitting stitches, and longitudinally inserted yarns inserted in the opposite direction to the laterally inserted yarns in a direction of 1 row in each of the coil rows to be turned back in the longitudinal direction,
the mesh fiber reinforced composite molding material is obtained by impregnating resin only in the knitting structure, the longitudinal insertion yarn, and the lateral insertion yarn in the mesh knitting structure,
the chain knitting yarn is
(a) Organic fibers such as polyester, nylon, vinylon, or the like
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, or
(c) Inorganic fibers such as long glass fibers and basalt fibers,
The longitudinal inserting yarn and the transverse inserting yarn are
(a) Inorganic fibers such as long glass fibers and basalt fibers, or
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, and the like.
Further, according to a sixth aspect of the present invention, there is provided a net-shaped fiber-reinforced composite molded article obtained by molding the net-shaped fiber-reinforced composite molding material.
ADVANTAGEOUS EFFECTS OF INVENTION
The net-shaped fiber reinforced composite material of the present invention is composed of a knitted fabric base material which can withstand deep drawing during molding, and is excellent in stretchability and drapability and moldability into a curved shape. Further, the air permeability is excellent, stuffiness can be prevented, the weight is light, the strength is sufficient, the rigidity is high, and the impact resistance is improved. Therefore, the present invention is suitable as a filter, a cover, and a reinforcing member, and particularly, as a member constituting a basic structure of an interior material (lining) such as a protector, a prosthesis (prosthetic foot, prosthetic hand), or an exterior material (frame). The mesh fiber-reinforced composite of the present invention is suitably produced from the mesh knitted structure and the mesh fiber-reinforced composite molding material of the present invention, and a mesh fiber-reinforced composite molded article of a desired shape can be suitably produced by molding the mesh fiber-reinforced composite molding material.
Drawings
Fig. 1 is a partial knitting structure diagram showing one embodiment of the mesh knitting structure of the present invention.
Fig. 2 is an enlarged schematic view of the mesh-type knitted fabric shown in fig. 1.
Fig. 3 is a partial knitting structure diagram showing another embodiment of the mesh knitting structure of the invention.
Fig. 4 is a schematic view showing a conventional mesh knitting structure according to a comparative example of the present invention.
Fig. 5 (a) to (e) are diagrams illustrating an embodiment of a method for forming a mesh-type fiber reinforced composite according to the present invention.
Fig. 6 (a) and (b) are diagrams illustrating another embodiment of the method for forming a mesh-type fiber reinforced composite according to the present invention.
Fig. 7 (a), (b) are diagrams showing one embodiment of a hat in which the mesh-fiber reinforced composite of the present invention can be applied as a lining member.
Fig. 8 (a) is a partial knitting structure diagram showing an example of the mesh knitting structure described in japanese patent No. 6362454, and fig. 8 (b) is a schematic cross-sectional view for explaining a resin-impregnated state with respect to the mesh knitting structure.
Detailed Description
Hereinafter, the mesh fiber-reinforced composite, the mesh knitted structure, the mesh fiber-reinforced composite molding material, and the mesh fiber-reinforced composite molded article according to the present invention will be described in more detail with reference to the accompanying drawings.
In this specification, "curing" includes not only curing of the thermosetting resin to form a 3-dimensional network structure but also curing of the thermoplastic resin from a flowing state.
Example 1
An embodiment of the mesh-fiber reinforced composite of the present invention is described with reference to fig. 1. Fig. 1 is a partially enlarged knitting structure diagram for explaining a mesh knitting structure, that is, a mesh fiber sheet 1, of a sheet-like reinforcing fiber knitted fabric, particularly a sheet-like reinforcing fiber longitudinal knitted fabric, constructed according to the present invention.
The mesh-like fiber reinforced composite material (FRP) of the present invention is a mesh-like fiber reinforced composite material (FRP) which has a mesh-like knitted structure formed in a sheet-like shape, and which is obtained by impregnating the mesh-like knitted structure 1 with a resin while maintaining the mesh (void) G formed in the mesh-like knitted structure 1. That is, the net-shaped fiber reinforced composite material of the present invention is a net-shaped fiber reinforced composite material (FRP) obtained by impregnating each of the constituent yarns of the net-shaped knitted structure 1 shown in fig. 1 with a resin and curing the resin.
As described above, when stress (impact) is applied to the surface of the molded article formed of the net-shaped fiber reinforced composite, the portion to which the stress is applied is deflected or deformed. When the deflection or deformation amount is large, the stress is transmitted to the lower portion of the molded article. Further, in general, when a stress is applied to FRP using a knitted fabric base material such as circular knitting, flat knitting, or longitudinal knitting, stitches constituting a knitted fabric having low stitch strength are broken. To eliminate this problem, consider
(1) The knot strength of the fibers constituting the coil is improved.
(2) High denier fibers are used.
(3) The type of fiber used is determined.
(4) And a knitting structure excellent in impact resistance.
The present invention solves the above problems and provides a knitted fabric substrate which can withstand deep drawing during molding.
In general, the breaking of the knitted fabric by the impact from above is initially started by the yarn being unraveled due to the breakage of the chain knitting yarn. In order to prevent breakage of the chain stitch yarn, the following is important:
(1) The strength of the chain knitting yarn is improved. That is, the cutting resistance is improved by taking the material and thickness into consideration.
(2) The other yarns are also subjected to the load carried by the chain knitting yarns. That is, the load is received by crossing the yarns by reversing the longitudinal main yarns to the transverse main yarns.
(3) By providing the main yarn on both sides of the chain knitting yarn, the warp yarn direction eccentricity is reduced.
(4) The difference in yarn amounts of the longitudinal and transverse main yarns is reduced, and the difference in deformation amount due to the difference in direction is suppressed.
(5) By turning the longitudinal main yarn to at least 3 rows (needles) so that the chain knitting yarn breaks without breaking the stitch, even if the chain knitting yarn breaks at one location, 1 of the longitudinal main yarn does not unravel, and therefore the load can be borne by the lateral main yarn. However, since the longitudinal interval of the remaining stitch becomes wider due to breakage of the chain knitting yarn, the yarn amount is also reduced, and thus the strength is remarkably lowered.
(6) The physical property values of the chain knitting yarn and the main yarn are made to approach.
Accordingly, as shown in fig. 1, the mesh-like knitting structure 1 of the present invention is a mesh-like sheet formed of 3 kinds of yarns, that is, a plurality of rows of knitting stitches 20, a plurality of rows of laterally inserted yarns 3, and longitudinally inserted yarns 4, the plurality of rows of knitting stitches 20 being endless in the longitudinal direction by the chain knitting yarns 2 to form stitches 2A, the plurality of rows of laterally inserted yarns 3 being turned back in the longitudinal direction by 3 or more rows, for example, 3 to 6 rows, on each of the rows of stitches, and the longitudinally inserted yarns 4 being inserted in the longitudinal direction by 1 row of turned back of the chain knitting yarns 2 on each of the rows of stitches in the opposite direction of the laterally inserted yarns 3. The mesh knitting structure may be a mesh or a belt.
After the mesh knitting structure 1 is shaped into a predetermined shape or before the mesh knitting structure 1 is shaped into a predetermined shape, only the chain knitting yarn 2, the lateral insertion yarn 3, and the longitudinal insertion yarn 4 in the mesh knitting structure 1 are impregnated with a resin. That is, the mesh-like knitted fabric 1 is shaped into a predetermined shape, and then the resin is impregnated into only the chain knitting yarn 2, the lateral insertion yarn 3, and the longitudinal insertion yarn 4 forming the mesh-like knitted fabric 1 to be cured, thereby forming a mesh-like fiber-reinforced composite of a predetermined shape, or the mesh-like knitted fabric 1 is first impregnated with the resin into only the chain knitting yarn 2, the lateral insertion yarn 3, and the longitudinal insertion yarn 4 to be cured, and then the mesh-like knitted fabric is heated to be formed into a mesh-like fiber-reinforced composite of a predetermined shape, which will be described later in detail. The mesh-like knitted structure 1 having the above-described structure is excellent in drapability, can be deep drawn and shaped, and can be formed with a very simple molding operation.
Since a typical longitudinal knitted fabric base material is formed of a loop of a yarn which is a chain knitting yarn 2 and an insert yarn which turns back to the chain knitting yarn 2 across 2 or more columns, the tensile strength in the strongest tensile direction which is characteristic of a fiber cannot be used, and therefore yarn breakage is liable to occur, and the knitting structure 20 is broken, and it is difficult to develop rigidity. The main reason for the breakage of the stitch structure 20 is that the loops of the chain knitting yarn 2 break and the lateral and longitudinal insertion yarns 3 and 4 cannot be bundled. The mesh-like knitted fabric 1 of the present invention is rigid by filling the characteristics of the usual longitudinal knitted fabric with a material and a knitting structure.
Since a usual longitudinal knitted fabric base material is formed of stitches in which yarns are chain knitting yarns 2 and lateral and longitudinal insert yarns 3, 4 turned to the chain knitting yarns 2 in 2 or more rows, the base material is rich in stretchability with respect to all directions and excellent in formability. The mesh-like knitted fabric 1 of the present invention hardly expands in the longitudinal direction, but contracts in the longitudinal direction and expands in the transverse direction. Although the formability is inferior to that of a usual wale knitted fabric base material, it can be formed into a hemispherical shape without any problem.
Next, the mesh knitting structure 1 constituting the mesh fiber-reinforced composite material of the present invention will be further described.
(mesh knitting Structure)
Referring to fig. 1, a mesh knitting structure 1 constituting the mesh fiber-reinforced composite of the present invention includes chain knitting yarns 2 forming knitting stitches 20, lateral insertion yarns 3 inserted in the knitting stitches 20 in the lateral direction and longitudinal insertion yarns 4 inserted in the chain knitting yarns 2 in the opposite direction to the lateral insertion yarns 3 as described above.
In the mesh-like knitting structure 1 of the present invention, the chain knitting yarn 2 is
(a) Organic fibers such as polyester, nylon, vinylon, or the like
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, or
(c) Inorganic fibers such as long glass fibers and basalt fibers,
the transverse insertion yarn 3 and the longitudinal insertion yarn 4 are
(a) Inorganic fibers such as long glass fibers and basalt fibers, or
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, and the like.
As described above, the chain stitch yarn 2 used in the present invention is preferably selected from organic fibers such as polyester, nylon, vinylon, etc., or high-strength fibers such as aramid long fibers, PBO long fibers, ultra-high molecular weight polyethylene fibers, high-strength polyarylate long fibers, etc., or inorganic fibers such as glass long fibers, basalt fibers, etc., as single yarns or doubled yarns, depending on the purpose of use of the net-shaped fiber-reinforced composite. When the number of the net-shaped fiber reinforced composite material is too small, the impact resistance of the net-shaped fiber reinforced composite material is reduced, and therefore, it is preferably 40tex or more, which is selected according to the purpose of use of the net-shaped fiber reinforced composite material.
The transverse insert yarn 3 used in the present invention is preferably selected from high-strength fibers such as aramid long fibers, PBO long fibers, ultra-high molecular weight polyethylene fibers, and high-strength polyarylate long fibers as single yarns or doubled yarns, in addition to inorganic fibers such as glass long fibers and basalt fibers, as the use fibers, depending on the purpose of use of the net-shaped fiber-reinforced composite. In addition, when the number of the used net-shaped fiber reinforced composite material becomes too small, the strength is not exhibited, and therefore, the net-shaped fiber reinforced composite material is set to at least 80tex, preferably 100tex or more, and is preferably selected according to the purpose of use.
The longitudinal inserted yarn 4 used in the present invention is preferably a single yarn or a doubled yarn of high strength fibers such as aramid long fibers, PBO long fibers, ultra-high molecular weight polyethylene fibers, and high strength polyarylate long fibers, as well as inorganic fibers such as glass long fibers and basalt fibers, depending on the purpose of use of the net-like fiber-reinforced composite material. In addition, when the number of the used net-shaped fiber reinforced composite material becomes too small, the strength is not exhibited, and therefore, the net-shaped fiber reinforced composite material is set to at least 80tex, preferably 100tex or more, and is preferably selected according to the purpose of use.
The mesh-like fiber reinforced composite of the present invention is a mesh-like fiber reinforced composite formed by impregnating only the knitting structure 20 (chain knitting yarn 2) and the longitudinal and lateral insertion yarns 4 and 3 of the mesh-like knitting structure shown in fig. 1 with a resin, curing the resin, and shaping the resin into a curved shape.
In order to further improve the impact resistance of the FRP by the net-like fiber-reinforced composite material of the present invention, it is preferable to use a resin having a large elongation at break so as to increase the impact absorption energy at the resin portion. In the case of the thermoplastic resin, a thermoplastic epoxy resin, a phenoxy resin, a polycarbonate resin, a polyester resin, a polyurethane resin, a polyamide resin, a polyetherimide resin, a polyetheretherketone resin, a polyphenylene sulfide resin, or the like is used, and in the case of the thermosetting resin, a normal-temperature curing type or thermosetting type epoxy resin, a vinyl ester resin, an MMA resin, an acrylic resin, an unsaturated polyester resin, a phenolic resin, or the like is used, and a high-elongation at break resin having an elongation at break of 4% or more is preferable.
The thermoplastic epoxy resin is a linear polymer exhibiting thermoplasticity, which is produced by chain extension of a 2-functional epoxy compound and a 2-functional phenolic compound by addition polymerization accompanied by ring opening of an epoxy ring, and can be obtained by, for example, setting a ratio of a bisphenol a type epoxy resin to bisphenol a to a functional group to 1:1 and carrying out in-situ polymerization in the presence of a phosphorus-based polymerization catalyst.
The mesh-like knitted fabric 1 of the present invention hardly expands in the longitudinal direction, but contracts in the longitudinal direction and expands in the transverse direction. Although the formability is inferior to that of a usual wale knitted fabric base material, it can be formed into a hemispherical shape without any problem.
A typical longitudinal knitted fabric base material is formed of stitches of chain knitting yarn 2 and transverse insert yarn 3 turned to chain knitting yarn 2 in 2 or more rows. Since the lateral insertion yarn 3 is folded back and bound to the chain knitting yarn 2, the load applied to the lateral insertion yarn 3 is necessarily transmitted to the chain knitting yarn 2. The chain stitch yarn 2 is weak in strength and is broken first because of its characteristic of forming stitches and because of its numerous small counts in consideration of workability of knitting.
In contrast, in the mesh-like knitting structure 1 of the present invention, for example, polyester long fibers are used in the chain knitting yarn 2, and the amount of the used fibers is increased than usual to increase the cross-sectional area, thereby improving the cross-sectional performance and increasing the strength of the chain knitting yarn 2. Further, by bundling the vertical insertion yarns 4 so as to be aligned along the chain knitting yarns 2 by reversing the horizontal insertion yarns 3, the horizontal insertion yarns 3 intersect the vertical insertion yarns 4 at the stitch portions, and the vertical insertion yarns 4 are allowed to bear the load borne by the chain knitting yarns 2, thereby reducing the load borne by the chain knitting yarns 2. The crosswise yarns 3 turn back over 3 columns to the chain knitting yarns 2, so that the chain knitting yarns 2 receiving the load are 4 columns, and the load borne by 1 column of the chain knitting yarns 2 is reduced. The insertion yarn 3 is not limited to the insertion of the chain knitting yarn 2 across 3 columns, and for example, the insertion of the chain knitting yarn 2 may be turned back across 4 columns or more. As is clear from the shape of fig. 1, even if the chain stitch yarn 2 breaks 1 column and the stitch 20 is broken, the transverse insertion yarn 3 bundles the chain stitch yarn 2 across 3 columns or more, and therefore, large-scale breakage of the stitch 20 is not caused.
As understood from the above, in fig. 2, the load most acting on the chain stitch yarn 2 is the catching load at the portion where the force P3 generated by the lateral insertion yarn 3 to be elongated in the lateral direction and the force P4 to be elongated in the longitudinal direction intersect each other due to the deformation of the mesh stitch structure 1 when the impact is applied. Therefore, the chain knitting yarn 2 is difficult to cut by dispersing the load received by the chain knitting yarn 2 while improving the cross-sectional performance, and the mesh knitting structure 1 is a structure having a high impact load resistance.
Specific example 1
In one embodiment of the present invention, the mesh-like knitted structure 1 is a mesh-like piece knitted fabric formed by using a chain knitting yarn 2 as a polyester fiber and using a long glass fiber as a lateral insertion yarn 3 and a longitudinal insertion yarn 4.
The mesh knitting structure 1 of this embodiment 1 will be described with reference to fig. 1, in this embodiment 1, in the knitting structure 20 of the mesh knitting structure 1, the chain knitting yarn 2 forms stitches in the longitudinal direction, and the lateral insertion yarn 3 and the longitudinal insertion yarn 4 are knitted into the stitches and bound. The knitting structure (so-called raschel structure) 20 shown in this embodiment may be a tricot structure other than the above-described knitting structure, or may be a structure in which the raschel structure and the tricot structure of this embodiment are combined. The stitch 20 in the mesh-type knitted fabric 1 is preferably selected according to the purpose of use of the mesh-type fiber reinforced composite.
In this embodiment 1, as the polyester fiber used as the chain knitting yarn 2 forming the knitting structure 20 in the mesh knitting structure 1, the polyester fiber 110tex is used.
As the long glass fibers used as the transverse insertion yarns 3 and the longitudinal insertion yarns 4, there are E glass, T glass, NE glass, and the like, depending on the characteristics of the glass, and in this specific example 1, E glass (general-purpose product) is used. The glass filaments are preferably selected according to the intended use of the reticulated fiber reinforced composite.
The long glass fiber filler may be any of various types and various counts such as glass fiber yarn, glass direct roving, and glass roving, depending on the production method, but is preferably selected according to the purpose of use and mesh size of the net-shaped fiber-reinforced composite. In addition, when the count of the long glass fiber filler used becomes too small, the strength is not originally provided, and therefore, as described above, it is preferably 100tex or more. In this embodiment 1, the glass long fibers used for the transverse insertion yarn 3 and the longitudinal insertion yarn 4 were long fibers of 420tex spun glass fiber yarn.
That is, in this embodiment 1, the mesh-like knitting structure 1 is a mesh-like sheet formed of 3 yarns of a plurality of rows of knitting stitches 20 formed by endless continuity in the longitudinal direction of the chain knitting yarn 2 using the polyester fiber 110tex, a plurality of rows of the transverse insertion yarn 3 using the glass long fiber 420tex, and a plurality of rows of the chain knitting yarn 2 turned back across 3 or more rows in the transverse direction to insert the transverse direction by the chain knitting yarn 2 turned back in the longitudinal direction of 1 row in the opposite direction of the transverse insertion yarn 3 on each of the coil rows, and a longitudinal insertion yarn 4 using the glass long fiber 420 tex. The mesh-like knitted structure 1 of this specific example 1 had a mass of 476g/m 2 。
The mesh knitting structure 1 of this specific example 1 can be produced using a Shan Lashe-liter knitting machine, and can be knitted using a tricot knitting machine, a crochet knitting machine, or the like. Such a method for producing a knitted fabric is known in the industry, and therefore a more detailed description thereof is omitted.
Specific example 2
According to another specific example 2 of the present invention, the mesh-like knitted fabric 1 is a mesh-like piece knitted fabric formed by using a chain knitting yarn 2 as an aramid filament and using a glass filament as a lateral insertion yarn 3 and a longitudinal insertion yarn 4.
In this specific example 2, the aramid long fiber used for the chain stitch yarn 2 was 88tex long fiber obtained by twisting a standard of para-aramid fiber.
The mesh-like knitting structure 1 of this embodiment 2 also has the same knitting structure as the mesh-like knitting structure 1 of embodiment 1 described with reference to fig. 1, and this embodiment 2 is different from embodiment 1 in that the chain knitting yarn 2 is changed to an aramid filament, particularly an aramid filament doubled yarn 88tex. By this modification, the strength of the chain knitting yarn increases, and the impact load resistance of the mesh knitting structure 1 of this specific example 2 increases. The mesh-like knitted structure 1 of this specific example 2 had a mass of 461g/m 2 。
The mesh knitting structure 1 of this specific example 2 can be produced using a Shan Lashe-liter knitting machine, and can be knitted using a tricot knitting machine, a crochet knitting machine, or the like. Such a method for producing a knitted fabric is known in the industry, and therefore a more detailed description thereof is omitted.
Specific example 3
Next, another specific example 3 of the present invention will be described with reference to fig. 3. The knitting structure 20 of the mesh-like knitting structure 1 used in this specific example 3 is not limited to the specific example described above. As shown in fig. 3, the loop shape of the chain stitch yarn 2 may be a tricot stitch.
In this specific example 3, the chain knitting yarn 2, the lateral and vertical insert yarns 3 and 4 forming the tricot structure for the mesh knitting structure 1 are set to be the same as those described in the above embodiments and specifically described in the above specific examples 1 and 2, etc., and are appropriately selected according to the purpose of use of the mesh fiber reinforced composite.
(aperture ratio)
In the present invention, the open area ratio of the mesh-fiber reinforced composite 10 produced using the mesh-knitted structure 1 is important, and as described in detail later, the open area ratio is 20 to 60%, preferably 20 to 50%, and more preferably 30 to 50%.
Further, according to the present invention, in the mesh-knitting structure 1, the resin is impregnated and cured only in the knitting structure 20 formed of the chain knitting yarn 2 and the longitudinal and lateral insertion yarns 4, 3 in the mesh-knitting structure 1, in other words, the void portion G of the mesh-knitting structure 1 is not filled with the resin, so that the aperture ratio of the mesh-fiber reinforced composite 10 is substantially the same as that of the mesh-knitting structure 1.
The aperture ratio generally means the aperture ratio of the holes in the plane used for, for example, screen-printed mesh fabric, punched metal, or the like, and similarly, in the present invention, the aperture ratio of the mesh-knitted structure 1 means the aperture ratio of the holes in the plane of the mesh-knitted structure 1. The mesh-knitting structure 1 was read by a 2-dimensional scanner, and the ratio of the portion having the fibers to the portion having no fibers was calculated. Actually, the aperture ratio was calculated by dividing the void portion and the fiber portion by the image software by reading with a 2-dimensional scanner. For example, such an aperture ratio can be efficiently obtained by using a 2-dimensional scanner (trade name "CanoScan 4400F") manufactured by Canon corporation.
The opening ratio (%) = { (area of void portion)/(area of fiber portion+area of void portion) } ×100
As described above, in the present invention, the opening ratio of the mesh-knitted structure 1 is set to 20 to 60%. When the aperture ratio is less than 20%, the rigidity is excellent, but the pores cannot be opened after molding, and the air permeability is poor and very heavy. When the opening ratio exceeds 60%, the air permeability is excellent and the weight is light, but the amount of reinforcing fibers as a whole is insufficient and the rigidity is insufficient. Preferably 20 to 50%, more preferably 30 to 50%.
In the present invention, the size of each opening (hole) is also important in the mesh-like knitted fabric 1, and the area of each opening is 1.5 to 80mm 2 Is important. The area of each opening is smaller than 1.5mm 2 In the case of forming, there is a possibility that the hole cannot be opened, and in addition, when the opening area exceeds 80mm 2 When the mesh after molding becomes excessively large, there is a possibility that the rigidity as the net-like fiber reinforced composite 10 may disappear.
(impregnating resin)
In the present invention, as described above, after the mesh-like knitted structure 1 is formed into a predetermined shape, or before the mesh-like knitted structure 1 is formed into a predetermined shape, only the knitting structure 20 and the longitudinal and lateral insertion yarns 4 and 3 in the mesh-like knitted structure 1 are impregnated with a resin and cured, thereby forming the mesh-like fiber reinforced composite 10. The content of the fibers in the net-shaped fiber reinforced composite member 10 is 30 to 70%, preferably 40 to 70% by weight of the fibers.
In the above examples and the like, examples of the thermoplastic resin include thermoplastic epoxy resins, phenoxy resins, polycarbonate resins, polyester resins, polyurethane resins, polyamide resins, polyetherimide resins, polyether ether ketone resins, polyphenylene sulfide resins and the like, and examples of the thermosetting resin include epoxy resins, vinyl ester resins, MMA resins, acrylic resins, unsaturated polyester resins, phenolic resins and the like which are cured at normal temperature, preferably thermoplastic resins, more preferably thermoplastic resins having an elongation at break of 4% or more, even more preferably thermoplastic resins having an elongation at break of 10% or more, and most preferably thermoplastic resins having an elongation at break of 50% or more.
(method of Forming)
Next, a method of forming the net-shaped fiber reinforced composite 10 of the present invention will be described.
The net-shaped fiber reinforced composite material 10 may be formed by the same method as the conventionally known fiber reinforced composite material, such as press forming, sheet winding forming, tape winding forming, and manual bending forming.
Fig. 5 (a) to (c) show press forming methods as one embodiment of the forming method. According to this press molding method, the mesh-like knitted structure 1 is matched with the convex-shaped punch 201, and the mesh-like knitted structure 1 is molded by following the punch 201 by pressing (fig. 5 (a)). In this case, the mesh-like knitted fabric 1 produced according to the present invention has excellent drapability and stretchability, and is excellent in formability, as described above, and is easy to work.
Next, in order to impregnate resin only in the knitting structure 20 composed of the chain knitting yarn 2 and the vertical and horizontal inserting yarns 4, 3 of the mesh knitting structure 1, the resin R is applied to the mesh knitting structure 1 using a brush (brush) or the like for impregnation ((b) of fig. 5). As the resin R, a thermosetting resin or a thermoplastic resin may be used. Thereafter, the concave die 202 is set in correspondence with the male die 201, and the resin R is cured by applying pressure and heat with a predetermined pressing force, thereby forming the mesh-like fiber reinforced composite 10 shaped into a predetermined shape (fig. 5 (c)). The net-shaped fiber reinforced composite 10 is taken out of the mold (fig. 5 (d)), and finished into a predetermined shape (fig. 5 (e)).
Fig. 6 (a) and (b) show vacuum forming methods as other examples of forming methods. According to this vacuum forming method, the mesh-like knitting structure 1 is formed by impregnating only the knitting structure 20 composed of the chain knitting yarn 2 and the longitudinal and lateral insertion yarns 4 and 3 with resin and curing the resin, thereby forming a flat plate-like mesh-like knitting structure 1a as an FRP material. As the resin, a thermosetting resin can be applied by setting the B-stage state as well, but a thermoplastic resin is preferably used. The resin impregnation into the mesh-like knitted structure may be applied or impregnated in advance, or may be performed immediately before molding.
The mesh-knitted structure 1 cured by pre-impregnating with the resin R by coating or impregnating is provided as a mesh-fiber-reinforced composite molding material 1a on a concave vacuum-type (female) mold 202, and is further covered with a resin film 60 ((a) of fig. 6). The female die 202 is evacuated, and the male die 201 is pressurized and heated from the resin film 60 side with a predetermined pressing force in accordance with the female die 202. As a result, the resin impregnated and solidified in the mesh-like knitted structure 1a softens (melts), and is molded in conformity with the die 202. The forming die is cooled to obtain a net-shaped fiber-reinforced composite material 10 shaped into a predetermined shape (fig. 6 (b)). Thereafter, as in the press molding method, as shown in fig. 5 (d) and (e), the net-shaped fiber-reinforced composite material 10 is removed from the mold and finished into a predetermined shape.
In this vacuum forming method, the mesh-like knitted structure 1 is excellent in drapability and stretchability when the resin is softened or melted, and is excellent in formability, and is formed by following a male die, thereby facilitating the work.
According to the vacuum forming method described above, since the mesh-like knitted structure 1, which is pre-coated or impregnated with a resin and cured, can be used as the material 1a for forming the mesh-like fiber reinforced composite material, the productivity is good, the holes of the mesh-like knitted structure 1 do not collapse during forming, and the sheet thickness does not become thin during forming, so that a composite material having a thick cross section is obtained, which has an advantage that high strength can be easily obtained.
(Experimental examples 1 and 2, comparative examples 1 and 2)
Next, in order to verify the effects of the mesh-fiber reinforced composite 10 and the mesh-knitting structure 1 of the present invention, the type of the chain knitting yarn 2, the lateral insertion yarn 3, and the longitudinal insertion yarn 4 of the mesh-knitting structure 1, etc. were changed to verify the impact strength of the mesh-fiber reinforced composite. Table 1 shows the details of the mesh knitted fabric 1 and the results of verifying the impact strength of the mesh reinforced composite.
In this experiment, a thermoplastic epoxy resin (trade name "XNR6850V" manufactured by Nagase ChemteX corporation) was impregnated as an impregnating resin into the mesh-type knitted structure 1, and then the solvent was dried in an oven at 120 ℃ for 10 minutes, followed by heating at 160 ℃ for 30 minutes using a mold, thereby producing a mesh-type fiber-reinforced composite. At this time, the content of the fibers in the composite was 65% by weight of the fibers.
For the verification of impact strength, a net-like fiber composite material formed into a flat plate shape by an universal tester "CEAST9310" made of Instron was used as a test body, and a punching impact strength test (drop mass: 1.59kg, drop height: 580mm, striker: 20mm hemispherical shape) was performed. In table 1, "Peak Force/mass" is the maximum load per unit mass, and the larger this value is, the more excellent the impact resistance can be judged as the structure.
Experimental example 1
The mesh-knitted fabric 1 used in experimental example 1 used the mesh-knitted fabric 1 produced in specific example 1 as a knitted fabric base material. Referring to FIG. 1, the interval (SB) between the longitudinal columns was 4mm and the interval (SA) between the transverse columns was 5mm. The chain knitting yarn 2 is polyester fiber 110tex, the transverse inserting yarn 3 is glass long fiber doubling and twisting yarn 420tex, the longitudinal inserting yarn 4 is glass long fiber doubling and twisting yarn 420tex, and the mass of the net knitting structure 1 is 476g/m 2 The aperture ratio was 45%.
As a result of the punching impact strength test of the mesh-fiber composite material 10 produced using the mesh-knitting structure 1, the maximum impact load was 852N, and the knitting structure 20 after the test was broken.
Experimental example 2
The mesh-knitted fabric 1 used in experimental example 2 used the mesh-knitted fabric 1 produced in specific example 2 as a knitted fabric base material. As a shape, the interval (SB) of the longitudinal alignment was 4mm, and the interval (SA) of the transverse alignment was 5mm. The chain knitting yarn 2 is 88tex of aramid long fiber doubled and twisted yarn, the transverse inserting yarn 3 is 420tex of glass long fiber doubled and twisted yarn, the longitudinal inserting yarn 4 is 420tex of glass long fiber doubled and twisted yarn, and the net knitting structure 1 has the mass of 461g/m 2 The aperture ratio was 40%.
As a result of the punching impact strength test of the mesh-fiber composite material 10 produced using the mesh-knitting structure 1 of this experimental example, the maximum impact load was 1748N, and in addition, although the knitting structure 20 after the test was deformed, it was not broken, and it was confirmed that the strength of the chain knitting yarn 2 had a large influence on the impact load.
Comparative example 1
The knitted fabric base material used for the mesh-like knitted structure 1 used in comparative example 1 had the same knit structure 20 as in experimental examples 1 and 2, and had a shape in which the interval (SB) of longitudinal alignment was 4mm and the interval (SA) of transverse alignment was 5mm. The chain knitting yarn 2 was 88tex of aramid filament yarn twisted yarn, the transverse insertion yarn 3 was 400tex of carbon fiber bundle, the longitudinal insertion yarn 4 was 400tex of carbon fiber bundle, and the mesh knitting structure 1 had a mass of 488g/m 2 The aperture ratio was 29%.
As a result of the punching impact strength test of the mesh-fiber composite material 10 produced using the mesh-knitted structure 1 of the present comparative example 1, the maximum impact load was 1254N, and the knitted texture 20 after the test was broken.
The present comparative example was an example for comparing the impact load resistance of the long glass fiber filler with that of the long glass fiber filler by changing the long glass fiber filler of the horizontal and vertical inserted yarns 3 and 4 of the experimental example 2 to the long glass fiber filler, and the carbon fiber filler used in the present comparative example had a lower count than the long glass fiber filler by 20, but the specific gravity was 2.6 and the carbon fiber filler was 1.8 with respect to the long glass fiber filler, so that the maximum load resistance was only 72% although the inserted yarn volume was 1.37 times larger, and it could be confirmed that the impact load of the long carbon fiber filler was weaker than that of the long glass fiber filler.
Further, since the volume of the carbon fiber is larger than that of the glass fiber, the aperture ratio is also reduced, and as a result, ventilation is deteriorated.
Comparative example 2
Comparative example 2 is a mesh-fiber reinforced composite material using a mesh-knitted structure 1A shown in fig. 4, and is described in patent document 3 (japanese patent No. 6362454), and adopts the same structure as the mesh-knitted structure 1A described with reference to fig. 8 (a) and (b) attached to the present application. Comparative example 2 is a mesh fiber reinforced composite 10A obtained by impregnating the chain knitting yarn 2 and the lateral insertion yarn 3 with a resin and curing the resin in the mesh knitting structure 1A.
The mesh-like knitted structure 1A used in comparative example 2 uses the knitted structure of fig. 4, and the interval (SB) of the vertical alignment is 4mm and the interval (SA) of the horizontal alignment is 5mm. The chain knitting yarn 2 was 88tex of aramid filament yarn and the transverse inserting yarn 3 was 1145tex of glass filament yarn, and the mass of the net knitting structure 1A was 674g/m 2 The aperture ratio was 38%.
As a result of the punching impact strength test of the mesh-fiber reinforced composite 10A produced using the mesh-knitted structure 1A of comparative example 2, the maximum impact load was 441N, and the knitted texture 20 after the test was broken.
In comparative example 2, the chain knitting yarn 2 and the lateral insertion yarn 3 were used to reinforce the knitting structure 20 having good stretchability, and thus it was confirmed that the knitting structure 20 of the mesh-like fiber-reinforced composite shown in example 2 was effective against the impact load because the impact load resistance was 53% of that of example 1, although the strength of the chain knitting yarn 2 was high and the fiber amount of the lateral insertion yarn 3 was large, as compared with example 1.
The mesh-like fiber composite of the present invention is particularly suitable as an inner and outer member of a protective member for helmets and the like, and a prosthetic (leg prosthesis, hand prosthesis), but the use thereof is not limited thereto. For example, the present invention is applicable to various applications, including applications to medical materials such as plaster for fixing an affected area, clothing or tools such as shoes and hats for sports and leisure, reinforcing or protecting members such as filters and housing members and piping and hoses, reinforcing members for structural bodies, and structural members or finishing members for aircraft or rockets, satellites, automobiles, motorcycles, railroad trains, bicycles, houses, optical devices, home appliances, portable electronic devices, etc. which are required to be molded and processed into complex curved surfaces while maintaining high rigidity.
TABLE 1
Description of the reference numerals
1. Net-shaped knitting structure
1a Net-shaped fiber reinforced composite material for molding
2. Chain knitting yarn
2A chain coil
3. Cross insert yarn
4. Longitudinally inserted yarn
10. Net-shaped fiber reinforced composite
20. Knitting structure
Claims (10)
1. A mesh fiber reinforced composite having a mesh knitting structure formed of 3 kinds of yarns of a plurality of rows of knitting stitches forming chain stitches in a loop-like manner by chain knitting yarns, a plurality of rows of transverse insertion yarns forming chain stitches in a longitudinal direction, the plurality of rows of transverse insertion yarns being turned back by 3 or more rows in a transverse direction in each of the coil rows to be inserted into the longitudinal knitting stitches, and a longitudinal insertion yarn being inserted into the chain knitting yarns in a direction of a plurality of rows in a 1-row turn in each of the coil rows in an opposite direction to the transverse insertion yarns,
the mesh fiber reinforced composite is formed by impregnating and curing only the knitting structure, the longitudinal insertion yarn, and the lateral insertion yarn in the mesh knitting structure with a resin,
the chain knitting yarn is
(a) Organic fibers such as polyester, nylon, vinylon, or the like
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, or
(c) Inorganic fibers such as long glass fibers and basalt fibers,
the longitudinal inserting yarn and the transverse inserting yarn are
(a) Inorganic fibers such as long glass fibers and basalt fibers, or
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, and the like.
2. A mesh fiber reinforced composite having a mesh knitting structure formed of 3 yarns of a plurality of rows of knitting stitches forming chain stitches by endless continuity of chain knitting yarn in a longitudinal direction, a plurality of rows of transverse insertion yarn turned back by 3 or more rows in a transverse direction into the longitudinal knitting stitch, and a longitudinal insertion yarn inserted in a direction of 1 row in a reverse direction of the transverse insertion yarn,
the mesh fiber reinforced composite is formed by shaping the mesh knitting structure into a predetermined shape, and then impregnating and curing only the knitting structure, the longitudinal insertion yarn, and the lateral insertion yarn in the mesh knitting structure,
The chain knitting yarn is
(a) Organic fibers such as polyester, nylon, vinylon, or the like
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, or
(c) Inorganic fibers such as long glass fibers and basalt fibers,
the longitudinal inserting yarn and the transverse inserting yarn are
(a) Inorganic fibers such as long glass fibers and basalt fibers, or
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, and the like.
3. The reticulated fiber reinforced composite of claim 1 or 2, wherein,
the resin to be impregnated into the mesh-like knitted structure is a thermosetting resin such as a room temperature curable or thermosetting epoxy resin, vinyl ester resin, MMA resin, acrylic resin, unsaturated polyester resin, or phenolic resin, or a thermoplastic resin such as a thermoplastic epoxy resin, phenoxy resin, polycarbonate resin, polyester resin, polyurethane resin, polyamide resin, polyetherimide resin, polyether ether ketone resin, or polyphenylene sulfide resin.
4. A mesh fiber reinforced composite having a mesh knitting structure formed of 3 yarns of a plurality of rows of knitting stitches forming chain stitches by endless continuity of chain knitting yarn in a longitudinal direction, a plurality of rows of transverse insertion yarn turned back by 3 or more rows in a transverse direction into the longitudinal knitting stitch, and a longitudinal insertion yarn inserted in a direction of 1 row in a reverse direction of the transverse insertion yarn,
The mesh fiber reinforced composite is formed by impregnating only the knitting structure, the longitudinal insertion yarn, and the lateral insertion yarn in the mesh knitting structure with a resin, curing the resin, and shaping the resin into a predetermined shape,
the chain knitting yarn is
(a) Organic fibers such as polyester, nylon, vinylon, or the like
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, or
(c) Inorganic fibers such as long glass fibers and basalt fibers,
the longitudinal inserting yarn and the transverse inserting yarn are
(a) Inorganic fibers such as long glass fibers and basalt fibers, or
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, and the like.
5. The reticulated fiber reinforced composite of claim 4, wherein,
the resin to be impregnated into the mesh-like knitted structure is a thermoplastic resin such as a thermoplastic epoxy resin, a phenoxy resin, a polycarbonate resin, a polyester resin, a polyurethane resin, a polyamide resin, a polyetherimide resin, a polyetheretherketone resin, or a polyphenylene sulfide resin.
6. The reticulated fiber reinforced composite of any one of claim 1 to 5, wherein,
the fibers used in the chain knitting yarn are 40tex or more in terms of single yarn or double twisting, and the fibers used in the longitudinal insertion yarn and the transverse insertion yarn are 80tex or more in terms of single yarn or double twisting.
7. The reticulated fiber reinforced composite of any one of claim 1 to 6, wherein,
the mesh knitting structure has an opening ratio of 20 to 60%.
8. A mesh knitting structure comprising 3 yarns, a plurality of rows of knitting stitches, a plurality of rows of laterally inserted yarns, and a longitudinally inserted yarn, wherein the plurality of rows of knitting stitches are endless and continuous in the longitudinal direction by chain knitting yarns, the plurality of rows of laterally inserted yarns are folded back in 3 or more rows on each of the rows of stitches in the transverse direction and are inserted into the longitudinal knitting stitches, and the longitudinally inserted yarn is inserted into the chain knitting yarns in a direction of a plurality of rows of 1 row on each of the rows of stitches in the opposite direction to the laterally inserted yarn.
9. A material for forming a net-like fiber-reinforced composite, comprising a net-like knitting structure formed of 3 kinds of yarns, i.e., a plurality of rows of knitting stitches forming chain stitches by endless continuity of chain knitting yarns in a longitudinal direction, a plurality of rows of weft insertion yarns turned around in the longitudinal direction by 3 or more rows of turns in a transverse direction on each of the weft rows, and a longitudinal insertion yarn inserted into the chain knitting yarns in a direction of 1 row of turns on each of the weft rows in an opposite direction to the weft insertion yarns,
The mesh fiber reinforced composite molding material is characterized in that only the knitting structure, the longitudinal insertion yarn and the transverse insertion yarn in the mesh knitting structure are impregnated with resin,
the chain knitting yarn is
(a) Organic fibers such as polyester, nylon, vinylon, or the like
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, or
(c) Inorganic fibers such as long glass fibers and basalt fibers,
the longitudinal inserting yarn and the transverse inserting yarn are
(a) Inorganic fibers such as long glass fibers and basalt fibers, or
(b) High strength fibers such as aramid long fibers, PBO long fibers, ultra high molecular weight polyethylene fibers, high strength polyarylate long fibers, and the like.
10. A net-shaped fiber reinforced composite molded article characterized in that,
the reticulated fiber-reinforced composite molded article obtained by molding the reticulated fiber-reinforced composite molding material according to claim 9.
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| JP2020-166605 | 2020-09-30 | ||
| JP2020166605 | 2020-09-30 | ||
| PCT/JP2021/036025 WO2022071455A1 (en) | 2020-09-30 | 2021-09-29 | Mesh-like fiber-reinforced composite material, mesh-like knitted structure, material for forming mesh-like fiber-reinforced composite material, and mesh-like fiber-reinforced composite material shaped body |
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| CN116348263A true CN116348263A (en) | 2023-06-27 |
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| JP (1) | JPWO2022071455A1 (en) |
| CN (1) | CN116348263A (en) |
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|---|---|---|---|---|
| CN114771052B (en) * | 2022-04-25 | 2022-10-04 | 叶金蕊 | Mixed-woven fiber cloth for high-voltage-resistant composite material and preparation method thereof |
| CN115569234B (en) * | 2022-10-25 | 2023-06-06 | 北京连续玄武岩纤维科技有限公司 | Basalt fiber pipe sleeve for prosthetic socket and preparation method thereof |
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|---|---|---|---|---|
| US5265445A (en) * | 1992-09-01 | 1993-11-30 | Shytles Douglas M | Breathable elastic fabric and method of making same |
| JP2592165Y2 (en) * | 1993-02-08 | 1999-03-17 | 株式会社ダスキン | Mop for rental |
| JP2011241505A (en) * | 2010-05-18 | 2011-12-01 | Shindo Co Ltd | Reinforcement fiber sheet material |
| JP6362454B2 (en) * | 2014-07-07 | 2018-07-25 | 新日鉄住金マテリアルズ株式会社 | Mesh fiber reinforced composite |
| JP6593767B2 (en) * | 2015-03-17 | 2019-10-23 | 株式会社Ｓｈｉｎｄｏ | High-strength warp knitted mesh sheet |
| JP2017218688A (en) * | 2016-06-07 | 2017-12-14 | 三菱重工業株式会社 | Reinforcing base material for composite material part, composite material part, and method for producing the same |
-
2021
- 2021-09-29 TW TW110136327A patent/TW202223190A/en unknown
- 2021-09-29 CN CN202180066779.5A patent/CN116348263A/en active Pending
- 2021-09-29 JP JP2022554075A patent/JPWO2022071455A1/ja active Pending
- 2021-09-29 WO PCT/JP2021/036025 patent/WO2022071455A1/en active Application Filing
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| Publication number | Publication date |
|---|---|
| TW202223190A (en) | 2022-06-16 |
| JPWO2022071455A1 (en) | 2022-04-07 |
| WO2022071455A1 (en) | 2022-04-07 |
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