JP2004149968A

JP2004149968A - Method for producing three-dimensional fiber structure and apparatus for arranging fiber bundle in circumferential direction of laminated fiber group

Info

Publication number: JP2004149968A
Application number: JP2002317302A
Authority: JP
Inventors: Junji Takeuchi; 純治竹内
Original assignee: Toyota Industries Corp
Current assignee: Toyota Industries Corp
Priority date: 2002-10-31
Filing date: 2002-10-31
Publication date: 2004-05-27

Abstract

<P>PROBLEM TO BE SOLVED: To prevent a fiber bundle from meandering by reducing difference between the thickness of a laminated fiber group in a finished state of arrangement of the fiber bundle constituting the laminated fiber group of a three-dimensional fiber structure in a shape of a cylinder with a bottom, and a thickness after binding each fiber bundle layer by a yarn in the thickness direction. <P>SOLUTION: The apparatus 16 for arranging the fiber bundle in the circumferential direction has a holding device 17, a first pressing structure 18, a second pressing structure 19 and a fiber bundle-feeding part 20. The holding device 17 holds a frame body 11 having restriction members 15a installed at a prescribed pitch along a position corresponding to the periphery of an opening part of the three-dimensional fiber structure so as to be rotatably driven. The first pressing mechanism 18 has a pressing member 23 for pressing a position of the fiber bundle layer arranged on the frame body 11 held by the holding device 17, and corresponding to the bottom part of the three-dimensional fiber structure. The second pressing mechanism 19 has a pressing body 26 moving while pressing a position corresponding to a side wall of the fiber bundle layer arranged on the frame body 11. The fiber bundle-feeding part 20 feeds the fiber bundle to be arranged at the position corresponding to the side wall of the three-dimensional fiber structure. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は複数の繊維束層を積層して形成された少なくとも２軸配向となる積層繊維群を、前記繊維束層と直交する方向に配列される厚さ方向糸で結合した、底部と側壁とから成る有底筒状の三次元繊維構造体の製造方法及び積層繊維群の周方向繊維束配列装置に関する。
【０００２】
【従来の技術】
繊維強化複合材は軽量の構造材料として広く使用されている。繊維強化複合材のうち、三次元織物（三次元繊維構造体）を強化材として使用したものは強度が非常に高く、航空機等の構造材等に使用が考えられ、一部使用されている。前記三次元繊維構造体の製法として、糸（繊維束）が折り返し状に配列された複数の糸層を積層して少なくとも２軸配向となる積層糸群（積層繊維群）を形成し、その積層糸群を各糸層と直交する方向に配列される厚さ方向糸で結合する製造方法がある（例えば、特許文献１及び特許文献２参照。）。
【０００３】
前記特許文献１には、複数の板状部が湾曲部を介して連続する形状、例えばＬ字状、Ｕ字状、コ字状等の異形断面の三次元織物及びその製造方法が開示されている。そして、積層糸群が配列された後、積層糸群を厚さ方向の両側からプレッシャーバーで圧縮して厚さを調整した状態で、積層糸群を構成する各糸層を厚さ方向糸で結合することが開示されている。また、前記プレッシャーバーによる圧縮操作は配列糸の完了後ではなく、糸の配列段階の途中で小刻みに行う方が好ましいと記載されている。
【０００４】
また、特許文献２には、三次元繊維構造体として本願明細書の図９（ａ），（ｂ）に示す四角箱体、円形箱体のような、底部Ｆｂと側壁Ｆｓとから成る有底筒状の三次元繊維構造体Ｆも繊維束を積層配列して形成された積層糸群の各糸層を厚さ方向糸で結合することにより製造できる旨が記載されている。
【０００５】
【特許文献１】
特開平５−５９６３４号公報（段落番号［００１２］〜［００１９］、図１〜図５）
【特許文献２】
特開平９−１３７３３６号公報（段落番号［００３６］〜［００３７］，［００７１］、図１９）
【０００６】
【発明が解決しようとする課題】
前記の積層糸群を作成した後、厚さ方向糸で各糸層を結合して三次元繊維構造体を製造する方法では、単純に糸（繊維束）を積層した状態では、積層糸群の厚さは製造すべき三次元繊維構造体の厚さの２倍程度の厚さとなる。そして、厚さ方向糸の挿入時に厚さ方向糸に張力をかけることで、積層糸群の各糸層を締め込み、積層糸群を所定の厚さまで薄くして結合するようにしている。
【０００７】
三次元繊維構造体がＬ字状やコ字状の場合は、積層糸群を厚さ方向糸で締め付ける際に、糸の弛みは三次元繊維構造体の端部へと移動するため支障はない。しかし、有底筒状形状（例えば、四角箱状）の場合は、図１０に示すように、積層糸群Ｆｃのコーナー部に弛みＬが集中して、繊維が蛇行する部分が生じる。繊維の蛇行部が存在する状態で樹脂を含浸させて複合材を製造した場合は、複合材の物性が低下する。特許文献２には有底筒状の三次元繊維構造体も製造できる旨記載されているが、前記弛みに伴う繊維の蛇行を解消する方法に付いては何ら開示されていない。
【０００８】
本発明の第１の目的は、積層繊維群を構成する繊維束の配列が完了した状態での積層繊維群の厚さと、厚さ方向糸により各繊維束層を結合した後の厚さとの差を小さくでき、繊維束の蛇行を抑制することができる有底筒状の三次元繊維構造体の製造方法を提供することにある。また、第２の目的は前記有底筒状の三次元繊維構造体を製造する際に好適な積層繊維群の周方向繊維束配列装置を提供することにある。
【０００９】
【課題を解決するための手段】
前記第１の目的を達成するため請求項１に記載の発明は、複数の繊維束層を積層して形成された少なくとも２軸配向となる積層繊維群を、前記繊維束層と直交する方向に配列される厚さ方向糸で結合した、底部と側壁とから成る有底筒状の三次元繊維構造体の製造方法である。前記積層繊維群の形成の際に、三次元繊維構造体の外形形状に対応し、かつ少なくとも前記三次元繊維構造体の開口部周縁に対応する位置に沿って規制部材が所定ピッチで設けられた枠体を使用して繊維束の配列を行う。前記繊維束層として前記開口部周縁に設けられた規制部材で折り返して三次元繊維構造体の前記側壁から前記底部に跨るように配列される第１の繊維束層と、前記側壁の周方向に配列される第２の繊維束層とを複数層ずつ形成する。前記第２の繊維束層を形成する際には、三次元繊維構造体の底部を構成するそれまでに積層された繊維束層を押圧部材により押圧して繊維束の弛みを前記側壁側に移動させる。そして、その移動された弛みを三次元繊維構造体の開口部側へ移動させるように当該第２の繊維束層を形成する周方向繊維束を底部側から前記開口部側に向かって順に配列させて前記積層繊維群を形成する。
【００１０】
この発明では、三次元繊維構造体の外形形状に対応し、かつ少なくとも前記三次元繊維構造体の開口部周縁に対応する位置に沿って規制部材が所定ピッチで設けられた枠体を使用して、積層繊維群を構成する繊維束の配列が行われる。第１の繊維束層を形成する繊維束は、前記開口部周縁に設けられた規制部材で折り返して三次元繊維構造体の側壁から底部に跨るように配列される。第２の繊維束層を形成する周方向繊維束は、側壁の周方向に配列される。第２の繊維束層を形成する繊維束を配列する際には、三次元繊維構造体の底部を構成するそれまでに積層された第１の繊維束層が押圧部材により押圧されて、繊維束の弛みが、底部の周縁である前記側壁側に移動される。そして、側壁側に移動された弛みを三次元繊維構造体の開口部側へ移動させるように、当該第２の繊維束層を形成する周方向繊維束が底部側から開口側へと順に配列される。その結果、第１の繊維束層を形成する繊維束の弛みが除去される。以下、同様に第２の繊維束層を形成する際に、それまでに積層された第１の繊維束層の繊維束の弛みが除去されるように、周方向繊維束の配列が行われる。その結果、積層繊維群を構成する繊維束の配列が完了した状態での積層繊維群の厚さと、厚さ方向糸により各繊維束層を結合した後の厚さとの差を小さくでき、繊維束の蛇行を抑制することができる。
【００１１】
請求項２に記載の発明は、請求項１に記載の発明において、前記第１の繊維束層は繊維束が前記周方向繊維束と直交する方向に配列された層と、繊維束が前記周方向繊維束と傾斜するように配列された層とを備えている。前記枠体は前記三次元繊維構造体の開口部周縁と、底部周縁とに前記規制部材が設けられている。
【００１２】
この発明では、底部及び側壁を構成する積層繊維群が面内４軸配列となる。各繊維束層を構成する繊維束は、開口部周縁に設けられた規制部材に巻き掛けられて折り返すように配列されるとともに、底部周縁に設けられた規制部材で配列位置が規制されるため、周方向繊維束と傾斜するように配列される際も、所定の位置に良好に配列される。
【００１３】
請求項３に記載の発明は、請求項１又は請求項２に記載の発明において、前記第２の繊維束層を形成する周方向繊維束を配列する際、周方向繊維束の配列前に前記側壁と対応する位置に配列された第１の繊維束層を押圧体で押圧しつつ該押圧体を第１の繊維束層を構成する繊維束の配列方向に沿って移動させる。この発明では、押圧体が第１の繊維束層を構成する繊維束の配列方向に沿って移動されるため、繊維束の弛みを開口部側に効率良く移動させることができる。
【００１４】
第２の目的を達成するため請求項４に記載の発明は、複数の繊維束層を積層して形成された少なくとも２軸配向となる積層繊維群を、前記繊維束層と直交する方向に配列される厚さ方向糸で結合した、底部と側壁とから成る有底筒状の三次元繊維構造体を形成するための積層繊維群の周方向繊維束配列装置である。周方向繊維束配列装置は、保持装置と、第１の押圧機構と、第２の押圧機構と、繊維束供給部とを備えている。保持装置は、前記三次元繊維構造体の外形形状に対応し、かつ少なくとも前記三次元繊維構造体の開口部周縁に対応する位置に沿って規制部材が所定ピッチで設けられた枠体を保持するとともに駆動手段により回転駆動可能となっている。第１の押圧機構は、前記保持装置に保持された枠体上に配列された繊維束層の前記三次元繊維構造体の底部に対応する箇所を押圧する押圧位置と、前記押圧位置から退避した待機位置とに配置される押圧部材を備えている。第２の押圧機構は、前記保持装置に保持された枠体上に配列された繊維束層の前記三次元繊維構造体の側壁に対応する箇所を押圧しつつ移動する作用位置と、前記作用位置から退避した待機位置とに配置される押圧体を備えている。繊維束供給部は、前記枠体上の前記三次元繊維構造体の側壁に対応する位置に配列される繊維束を供給する。
【００１５】
この発明の周方向繊維束配列装置では、規制部材が所定ピッチで設けられた枠体が保持装置に保持される。枠体上の三次元繊維構造体の底部に対応する箇所に配列された繊維束層は、第１の押圧機構の押圧部材により押圧され、繊維束の弛みが底部周縁である前記側壁側に移動される。前記側壁側に移動された弛みは、第２の押圧機構の押圧体により押圧されて開口側へ移動される。また、繊維束供給部から供給される繊維束は、前記保持装置が回転駆動されることにより、前記枠体上の前記三次元繊維構造体の側壁に対応する位置に周方向に延びるように配列される。従って、この周方向繊維束配列装置を使用することにより、底部と側壁とから成る有底筒状の三次元繊維構造体を形成する積層繊維群の周方向繊維束の配列を、周方向繊維束と交差するように配列された繊維束の弛みを開口側に移動させる（逃がす）ように円滑に行うことができる。
【００１６】
【発明の実施の形態】
（第１の実施の形態）
以下、本発明を有底四角筒状（四角箱状）の三次元繊維構造体を製造する場合に具体化した第１の実施の形態を図１〜図７及び図９（ａ）に従って説明する。
【００１７】
先ず三次元繊維構造体の製造に使用する枠体の構成を説明する。図２は枠体の模式斜視図である。この枠体は三次元繊維構造体の形状に対応した積層繊維群の形成と、形成された積層繊維群への厚さ方向糸の挿入時における積層繊維群の保持とに使用される。
【００１８】
図２に示すように、枠体１１は、互いに平行に配置された長方形状の一組の枠部１２，１３を複数本（この実施の形態では６本）の連結部１４で連結して直方体形状に形成されている。即ち、枠体１１は、有底四角筒状の三次元繊維構造体の外形形状に対応して形成されている。この実施の形態では図２における、下側の枠部１２が三次元繊維構造体の開口部周縁に対応し、上側の枠部１３が三次元繊維構造体の底部周縁に対応する。枠部１２には多数の規制部材１５ａが所定ピッチで取り外し可能に設けられ、枠部１３には多数の規制部材１５ｂが所定ピッチで取り外し可能に設けられている。規制部材１５ａ，１５ｂは、例えばピンで形成されている。
【００１９】
枠部１２に設けられた規制部材１５ａは、枠部１２を含む平面とほぼ平行又は枠部１３と反対側へ多少傾斜する状態（図２では多少下降傾斜する状態）で外側に突出するように設けられている。枠部１３に設けられた規制部材１５ｂは、枠部１２を含む平面と、枠部１３の一辺、当該一辺と対向する枠部１２の一辺及び両辺を連結する連結部１４を含む平面に対してほぼ４５°の角度を成して外側に突出するように設けられている。
【００２０】
枠部１２に設けられた規制部材１５ａは、三次元繊維構造体の底部及び側壁に跨るように配列される繊維束の折り返し位置と、配列位置とを規制する役割を果たす。枠部１３に設けられた規制部材１５ｂは、三次元繊維構造体の底部及び側壁に跨るように配列される繊維束の配列位置を規制する役割を果たす。
【００２１】
次に前記枠体１１上に有底筒状の三次元繊維構造体を形成するための積層繊維群の周方向繊維束を配列する周方向繊維束配列装置について説明する。図１に示すように、周方向繊維束配列装置１６は保持装置１７と、第１の押圧機構１８と、第２の押圧機構１９と、繊維束供給部２０とを備えている。
【００２２】
保持装置１７は、枠体１１を保持する回転テーブル２１と、駆動手段としてのモータ２２とを備えている。回転テーブル２１は、枠体１１の底面、即ち図１における枠部１２の下面を支承する部分２１ａと、枠体１１の内側に挿入されて枠体１１の内面に当接する部分２１ｂとを備えている。モータ２２は回転テーブル２１を回転させる。即ち、回転テーブル２１は、枠体１１を保持した状態で駆動手段により回転駆動可能となっている。
【００２３】
第１の押圧機構１８は、保持装置１７に保持された枠体１１上に配列された繊維束層の三次元繊維構造体の底部に対応する箇所を押圧する押圧位置と、前記押圧位置から退避した待機位置（図１に示す位置）とに配置される押圧部材２３を備えている。この実施の形態では、第１の押圧機構１８は回転テーブル２１の上方に配設されている。押圧部材２３はエアシリンダ２４のピストンロッド２４ａに固定され、エアシリンダ２４の作動によって前記押圧位置と待機位置とに配置されるようになっている。
【００２４】
押圧部材２３は、枠部１３に設けられた規制部材１５ｂで囲まれる範囲をほぼ覆う大きさの長方形状の金属製の支持板２３ａと、支持板２３ａの片面（図１では下面）に固着された押圧部２３ｂとから構成されている。押圧部２３ｂは発泡樹脂製で、支持板２３ａに対向する面と反対側の面（押圧面）が押圧位置に配置されて支持板２３ａから押圧力を受けた場合に、前記押圧面が中央部から外側へ向かって拡がるように変形可能に形成されている。例えば、図１に示すように、押圧部２３ｂの押圧面側に多数の切り込み２５が形成されている。
【００２５】
第２の押圧機構１９は、保持装置１７に保持された枠体１１上に配列された繊維束層の三次元繊維構造体の側壁に対応する箇所を押圧しつつ移動する作用位置と、前記作用位置から退避した待機位置とに配置される押圧体２６を備えている。図１，３に示すように、押圧体２６は水平に配設されたエアシリンダ２７のピストンロッド２７ａにスライド機構２８を介して取り付けられ、エアシリンダ２７の作動によって前記作用位置と待機位置とに配置されるようになっている。
【００２６】
図１，３に示すように、スライド機構２８は、ピストンロッド２７ａに固定された基板２９に対して相対回動可能かつ図示しないボルトで所定位置に固定された支持部材３０と、支持部材３０に摺動可能に連結支持されたスライド部材３１とを備えている。支持部材３０は円柱の一端を斜めに（この実施の形態では軸線と４５度の角度を成すように）切断した形状に形成され、先端面には図４（ｂ），（ｃ）に示すように、中心を通り直線状に延びるガイド溝３０ａが形成されている。また、支持部材３０には、軸心と直交する状態で一端がガイド溝３０ａと対応する位置に開口し、他端が周面に開口する孔３０ｂが形成されている。
【００２７】
スライド部材３１も円柱の一端を斜めに（この実施の形態では軸線と４５度の角度を成すように）切断した形状に形成され、図４（ａ）に示すように、支持部材３０の先端面と対向する端面にガイド溝３０ａに係合可能な凸条３１ａが形成されている。また、スライド部材３１には、軸心と直交する状態で一端が凸条３１ａの中央と対応する位置に開口し、他端が周面に開口するねじ孔３１ｂが形成されている。ねじ孔３１ｂには図１，３に示すように、支持部材３０の孔３０ｂを貫通したボルト３２の先端部が螺合されている。ボルト３２の頭部と支持部材３０の周面との間にはコイルばね３３が介装され、スライド部材３１に重力以外の力が作用しない状態では、コイルばね３３によりボルト３２を介してスライド部材３１が図１，３に示す所定の位置に保持されるようになっている。孔３０ｂはボルト３２の移動を許容するように形成されている。
【００２８】
押圧体２６は、スライド部材３１に固定された支持板２６ａと、支持板２６ａの片面に固着された押圧部２６ｂとから構成されている。押圧部２６ｂは図１，３における上下方向の長さ、即ち高さが、枠体１１の高さより若干小さく形成され、幅（図１，３の紙面と垂直方向の長さ）が枠体１１の長さと同じに形成されている。押圧部２６ｂは発泡樹脂製で、支持板２６ａに対向する面と反対側の面（押圧面）が作用位置に配置されて支持板２６ａから押圧力を受けた場合に、押圧面が繊維束を傷つけずに押圧するように形成されている。
【００２９】
繊維束供給部２０は、第２の押圧機構１９と対向する位置に配設され、枠体１１上の三次元繊維構造体の側壁に対応する位置に配列される繊維束Ｒを供給するようになっている。繊維束供給部２０は、繊維束供給ヘッド３４、張力付与部３５及び把持ローラ３６を備えた支持プレート３７が、支柱３８に沿って上下方向に往復移動可能に設けられている。支持プレート３７は繊維束供給ヘッド３４の移動範囲が、枠体１１の高さの範囲となるように図示しないアクチュエータにより駆動されるようになっている。繊維束供給ヘッド３４は図示しないボビンから繰り出されるとともに張力付与部３５を経て供給される繊維束Ｒを扁平な状態で送り出すように先端が扁平に形成された筒状体で構成されている。
【００３０】
張力付与部３５は、把持ローラ３６と繊維束供給ヘッド３４との間に設けられ、繊維束Ｒの供給方向に直交するように配設された３本一組のローラ３９ａ，３９ｂ，３９ｃを備えている。把持ローラ３６は繊維束Ｒを把持する把持位置と、繊維束Ｒの移動を許容する開放位置とに移動されるようになっている。ローラ３９ｂは図示しないアクチュエータにより昇降可能に構成され、繊維束Ｒが把持ローラ３６に把持された状態で、ローラ３９ｂがローラ３９ａ，３９ｃ間に位置する繊維束Ｒと係合して張力を付与するようになっている。
【００３１】
次に前記のように構成された枠体１１及び周方向繊維束配列装置１６を使用して、枠体１１上に繊維束Ｒを折り返し状に配列して、図９（ａ）に示すような底部Ｆｂと側壁Ｆｓとから成る有底筒状の三次元繊維構造体Ｆを構成する積層繊維群を形成する際の作用を説明する。
【００３２】
図５（ａ）は、枠体１１上に、枠体１１の開口部周縁に設けられた規制部材で折り返して三次元繊維構造体の側壁から底部に跨るように、かつ繊維束Ｒが周方向繊維束と直交する方向に配列された第１の繊維束層４０ａの配列状態を示す模式図である。図５（ｂ）は、枠体１１上に、枠体１１の開口部周縁に設けられた規制部材で折り返して三次元繊維構造体の側壁から底部に跨るように、かつ繊維束Ｒが周方向繊維束と傾斜するように配列された第１の繊維束層４０ｂの配列状態を示す模式図である。なお、図５（ａ），（ｂ）では規制部材１５ａ，１５ｂの図示を省略しており、分かりやすくするため繊維束Ｒの間隔を広くとって示している。図６（ａ）〜（ｆ）は、周方向繊維束の配列作用を示す模式平面図である。なお、図示の都合上、図６（ａ）〜（ｆ）では枠体１１に対する第２の押圧機構１９と繊維束供給部２０との関係が、図１の場合と異なる状態で示している。
【００３３】
先ず図１に示すように、保持装置１７の回転テーブル２１に、枠体１１をその枠部１３を上にした状態で保持する。次に繊維束供給ヘッド３４が枠部１３と対応する状態となる位置に支持プレート３７を配置する。次にボビンから繰り出した繊維束Ｒを、把持ローラ３６及び張力付与部３５を経て繊維束供給ヘッド３４に挿通して、繊維束Ｒの端部を繊維束供給ヘッド３４の先端から引き出す。そして、繊維束Ｒの先端を枠体１１の所定位置、例えば枠部１２に固定する。繊維束Ｒの固定は、例えば図示しない接着テープを使用して行う。この繊維束Ｒは、三次元繊維構造体の側壁の周方向に配列される第２の繊維束層を構成するものとなる。
【００３４】
また、三次元繊維構造体の側壁から底部に跨るように配列される第１の繊維束層４０ａ，４０ｂを構成する繊維束Ｒを別の図示しないボビンから繰り出し、その端部を枠体１１の所定位置、例えば枠部１３に固定する。繊維束Ｒの固定は、例えば図示しない接着テープを使用して行う。以上で積層繊維群を構成する準備が終了する。なお、繊維束Ｒは炭素繊維の無撚りのマルチフィラメントからなり、マルチフィラメントはフィラメント数が３０００〜２４０００本程度である。
【００３５】
次にその状態で先ず第１の繊維束層４０ａの配列が開始される。第１の繊維束層の配列は手作業あるいは多軸ロボットのアームに繊維束供給ヘッドを装備した装置による作業により行われる。繊維束Ｒを開口部周縁、即ち枠部１２に設けられた規制部材１５ａで折り返して三次元繊維構造体の側壁から底部に跨るように、かつ枠体１１の周方向に配列される周方向繊維束と直交する方向に配列された図５（ａ）に示す第１の繊維束層４０ａが形成される。次に、繊維束Ｒが周方向繊維束と傾斜するように配列された図５（ｂ）に示す第１の繊維束層４０ｂが形成される。これらの繊維束層４０ａ，４０ｂを形成する際、繊維束Ｒは枠体１１の枠部１２に設けられた規制部材１５ａと、枠部１３に設けられた規制部材１５ｂとによって位置が規制されて配列される。
【００３６】
第１の繊維束層４０ａ，４０ｂの一方が形成される毎に第１の押圧機構１８が駆動され、押圧部材２３が待機位置から押圧位置に移動される。そして、図７（ａ），（ｂ）に示すように、枠体１１上の三次元繊維構造体の底部に対応する箇所に配列された繊維束層は、押圧部材２３により押圧され、繊維束Ｒの弛みが底部周縁である側壁側（枠部１３側）に移動される。図７（ａ）は第１の繊維束層４０ａが配列された状態で押圧部材２３が押圧位置に配置された状態を示し、図７（ｂ）はその後、第２の繊維束層４１が形成された状態を示している。
【００３７】
次に第２の押圧機構１９が駆動され、図６（ａ）に示すように、押圧体２６が待機位置から作用位置に移動される。押圧体２６は、押圧部２６ｂが第１の繊維束層４０ａ，４０ｂと係合するまでは直進し、その後、スライド機構２８の作用により、開口部側へ移動される。移動方向は予め支持部材３０の取り付け状態によって決まり、周方向繊維束を配列する前の第１の繊維束層４０ａ，４０ｂの繊維束Ｒの配列方向に移動される。即ち、繊維束Ｒの配列が図５（ａ）に示す第１の繊維束層４０ａであれば、押圧体２６は下方へ移動され、繊維束Ｒの配列が図５（ｂ）に示す第１の繊維束層４０ｂの場合であれば、斜め４５度傾いた方向へ押圧体２６は移動される。
【００３８】
次に図６（ｂ）に示すように押圧体２６が待機位置に移動された後、図６（ｃ），（ｄ）に示すように、把持ローラ３６による繊維束Ｒの把持及び張力付与部３５のローラ３９ａ〜３９ｃとの係合が解除された状態で、回転テーブル２１が９０度回転されて周方向繊維束としての繊維束Ｒが配列される。次に図６（ｅ）に示すように、再び押圧体２６が作用位置に移動され、押圧部２６ｂによる配列面の加圧と、第１の繊維束層４０ａ，４０ｂの弛みの移動が行われる。その後、図６（ｆ）に示すように、把持ローラ３６が把持位置に移動されるとともに、ローラ３９ｂが張力付与位置に移動され、配列中の繊維束Ｒの弛みが除去される。
【００３９】
以下、同様にして、押圧体２６の待機位置への移動、繊維束Ｒの把持が解除された状態における回転テーブル２１の９０度の回転、押圧体２６の作用位置への移動、張力付与部３５による繊維束Ｒへの張力の付与が繰り返される。そして、回転テーブル２１が一回転した時点で、周方向繊維束としての繊維束Ｒの最初の１周分の配列が完了する。次に支持プレート３７が下降されて繊維束供給ヘッド３４が１ピッチ分ずれた位置へ移動され、その状態で再び前記と同様にして繊維束Ｒの配列が行われる。そして、繊維束Ｒが三次元繊維構造体の底部側から順に配列されることにより、第１の繊維束層４０ａ，４０ｂの弛みが除去される。
【００４０】
図７（ｂ）に示すように、１層分の第２の繊維束層４１の形成が完了すると、押圧部材２３及び押圧体２６が待機位置に移動された後、再び第１の繊維束層４０ａ，４０ｂの形成が行われる。そして、枠体１１上に第１の繊維束層４０ａ，４０ｂ及び第２の繊維束層４１が所定の順序で所定数積層されて積層繊維群が形成される。
【００４１】
積層繊維群が形成された後、枠体１１は積層繊維群とともに回転テーブル２１から取り外され、厚さ方向糸挿入装置にセットされる。そして、厚さ方向糸挿入装置により第１の繊維束層４０ａ，４０ｂ及び第２の繊維束層４１と直交するように厚さ方向糸が積層繊維群に挿入され、積層繊維群が結合されて、図９（ａ）に示すような有底四角筒状（箱状）の三次元繊維構造体Ｆの製造が完了する。積層繊維群が形成された状態の厚みと、厚さ方向糸が挿入されて三次元繊維構造体Ｆとなった状態の厚みとの差が７％以下となった。
【００４２】
なお、枠体１１上に配列された繊維束Ｒを分かり易くするため、隣接する繊維束Ｒが隙間を有するように図示しているが、実際は隣接する繊維束Ｒの間に隙間は殆ど無い状態に配列される。また、規制部材１５ａ，１５ｂは、その間隔が実際は繊維束Ｒの太さと同程度となるように設けられる。
【００４３】
この実施の形態では次の効果を有する。
（１）底部と側壁とから成る有底筒状の三次元繊維構造体を構成する積層繊維群の形成の際に、側壁から底部に跨るように配列される第１の繊維束層４０ａ，４０ｂと、側壁の周方向に配列される第２の繊維束層４１とを複数層ずつ形成する。第２の繊維束層４１を形成する際には、三次元繊維構造体の底部を構成するそれまでに積層された繊維束層を押圧部材２３により押圧して繊維束の弛みを側壁側に移動させる。そして、その移動された弛みを三次元繊維構造体の開口部側へ移動させるように第２の繊維束層４１を形成する周方向繊維束を底部側から前記開口部側に向かって順に配列させて積層繊維群を形成する。従って、第２の繊維束層４１を形成する際に、第１の繊維束層４０ａ，４０ｂの繊維束の弛みが確実に除去され、積層繊維群を構成する繊維束の配列が完了した状態での積層繊維群の厚さと、厚さ方向糸により各繊維束層を結合した後の厚さとの差を小さくでき、繊維束の蛇行を抑制することができる。その結果、前記積層繊維群に厚さ方向糸を挿入して製造した三次元繊維構造体を強化材とした複合材の物性が向上する。
【００４４】
（２）第１の繊維束層４０ａ，４０ｂは繊維束が周方向繊維束と直交する方向に配列された層と、繊維束が周方向繊維束と傾斜するように配列された層とを備えているため、底部及び側壁を構成する積層繊維群が面内４軸配列となり、面内２軸配列に比較して物性が向上する。
【００４５】
（３）枠体１１は三次元繊維構造体の開口部周縁に対応する箇所即ち枠部１２と、底部周縁に対応する箇所即ち枠部１３とに規制部材１５ａ，１５ｂが設けられている。そして、積層繊維群の第１の繊維束層４０ａ，４０ｂを構成する繊維束は、枠部１２に設けられた規制部材１５ａに巻き掛けられて折り返すように配列されるとともに、枠部１３に設けられた規制部材１５ｂで配列位置が規制される。従って、周方向繊維束と傾斜するように配列される際も、所定の位置に良好に配列される。
【００４６】
（４）第２の繊維束層４１を形成する周方向繊維束を配列する際、周方向繊維束の配列前に側壁と対応する位置に配列された第１の繊維束層４０ａ，４０ｂを押圧体２６で押圧しつつ該押圧体２６を第１の繊維束層を構成する繊維束Ｒの配列方向に沿って移動させる。従って、押圧体２６が第１の繊維束層４０ａ，４０ｂを構成する繊維束Ｒの配列方向に沿って移動されるため、繊維束Ｒの弛みを開口部側に効率良く移動させることができる。
【００４７】
（５）周方向繊維束配列装置１６は、枠体１１を保持してモータ２２により回転駆動可能な保持装置１７と、第１の繊維束層４０ａ，４０ｂの三次元繊維構造体の底部に対応する箇所を押圧する押圧位置と、待機位置とに配置される押圧部材２３を備えた第１の押圧機構１８とを備えている。また、保持装置１７に保持された枠体１１上に配列された繊維束層の三次元繊維構造体の側壁に対応する箇所を押圧しつつ移動する作用位置と、作用位置から退避した待機位置とに配置される押圧体２６を備えた第２の押圧機構１９を備えている。枠体１１上の三次元繊維構造体の側壁に対応する位置に配列される繊維束を供給する繊維束供給部２０とを備えている。従って、この周方向繊維束配列装置１６を使用することにより、底部と側壁とから成る有底筒状の三次元繊維構造体を形成する積層繊維群の周方向繊維束の配列を、周方向繊維束と交差するように配列された繊維束の弛みを開口側に移動させる（逃がす）ように円滑に行うことができる。
【００４８】
（６）三次元繊維構造体の底部に対応する箇所を押圧する押圧部材２３は、第１の繊維束層に押圧されると中央から周縁に向かって拡がる作用をなす押圧部２６ｂを備えている。従って、第１の繊維束層４０ａ，４０ｂを形成するために配列された繊維束Ｒの弛みを円滑に周縁部に移動させることができる。
【００４９】
（７）第２の押圧機構１９の押圧体２６がスライド機構２８を介してピストンロッド２７ａに支持され、ピストンロッド２７ａの突出作動により押圧部２６ｂが第１の繊維束層４０ａ，４０ｂに押圧された状態で繊維束の弛みを前記開口側へ移動させる方向へスライドされる。従って、押圧体２６を待機位置と作用位置との間で移動させるアクチュエータのみで、押圧体２６のスライド動作も行わせることができスライド用のアクチュエータを別に設ける必要がない。
【００５０】
（８）枠体１１上に積層繊維群が形成され、積層繊維群に厚さ方向糸を挿入する際も同じ枠体１１に積層繊維群を保持した状態で行うことができ、三次元繊維構造体の製造が完了するまで枠体１１を代える必要がない。
【００５１】
なお、実施の形態は前記に限定されるものではなく、例えば、次のように具体化してもよい。
○ 回転テーブル２１に枠体１１を保持し、周方向繊維束としての繊維束Ｒの配列を回転テーブル２１を回転駆動することで行う構成に代えて、枠体１１を所定位置に固定保持し、繊維束供給ヘッド３４側を移動させる構成としてもよい。例えば、図８に示すように、枠体１１を保持するテーブルは所定位置に固定配置され、繊維束供給部２０が枠体１１の周囲を所定方向に回転して、枠体１１の側面に周方向繊維束としての繊維束Ｒを配列する構成とする。この構成では支持プレート３７及び支柱３８（いずれも図示せず）がテーブルの周囲に沿って移動可能に構成される。また、第２の押圧機構１９が枠体１１の各側面と対向する位置にそれぞれ設けられている。そして、周方向繊維束の繊維束Ｒの配列は、押圧体２６の作用位置への移動、押圧体２６の待機位置への移動、繊維束供給ヘッド３４等の移動による繊維束Ｒの配列、繊維束Ｒへの張力付与の各動作が順次行われて、枠体１１の一つの側面への繊維束Ｒの配列が完了する。以下、同様の動作が４回繰り返されて、繊維束供給ヘッド３４等が一回転した時点で、周方向繊維束としての繊維束Ｒの最初の１周分の配列が完了する。そして、繊維束供給ヘッド３４の位置を１ピッチずらした状態で、前記と同様に周方向繊維束の繊維束Ｒの配列が行われる。
【００５２】
〇三次元繊維構造体の底部を構成するそれまでに積層された第１の繊維束層４０ａ，４０ｂの繊維束の弛みを側壁側に移動させる構成は、押圧部材２３の押圧部２３ｂを発泡樹脂製としてその押圧面側に多数の切り込み２５を形成した構成に限らない。例えば、底部より面積の小さな押圧部２３ｂを設け、押圧部２３ｂを押圧位置に配置した状態で、中央から周縁側に向かって渦を描くように移動させる構成としてもよい。この場合も第１の繊維束層４０ａ，４０ｂの繊維束Ｒの弛みが円滑に除去される。
【００５３】
〇第１の繊維束層４０ａ，４０ｂを繊維束が周方向繊維束と直交する方向に配列された層と、繊維束が前記周方向繊維束と傾斜するように配列された層との何れか一方のみとし、積層繊維群を面内２軸配列としてもよい。第１の繊維束層を繊維束が周方向繊維束と直交する方向に配列された層のみで構成する場合、枠体１１は枠部１２にのみ規制部材１５ａを設けた構成としてもよい。この場合、枠体１１の構造が簡単になる。
【００５４】
〇張力付与用のローラ３９ａ〜３９ｃを繊維束供給ヘッド３４と、把持ローラ３６との間に配置する構成に代えて、ローラ３９ａ〜３９ｃを枠体１１に最も近い位置に配設し、ローラ３９ａ〜３９ｃと把持ローラ３６との間に繊維束供給ヘッド３４を配置する構成としてもよい。
【００５５】
〇第２の押圧機構１９として、押圧体２６が１個のアクチュエータの作動により、作用位置に配置された際に自動的にアクチュエータの往復移動方向と直交する方向に移動可能なスライド機構２８を設けずに、２個のアクチュエータを備えた構成としてもよい。例えば、ピストンロッド２７ａの先端に支持プレートを固定し、支持プレートにピストンロッド２７ａと直交する方向に押圧体２６を移動させるアクチュエータを設ける。
【００５６】
〇周方向繊維束としての繊維束Ｒを配列する前に第２の押圧機構１９の押圧部２６ｂを作用位置でスライドさせる構成において、スライド方向は必ずしも、その前に配列された第１の繊維束層４０ａ，４０ｂを構成する繊維束Ｒの配列方向と一致させなくてもよい。しかし、一致させる方が、弛みを円滑に移動させ易い。
【００５７】
〇積層繊維群の構成は、周方向繊維束で形成される第２の繊維束層４１と、第１の繊維束層４０ａ，４０ｂとを交互に配列した構成に限らない。例えば、底部において繊維束Ｒが互いに直交し、かつ側壁において周方向繊維束と直交する第１の繊維束層４０ａと、側壁において周方向繊維束と斜めに交差する第１の繊維束層４０ｂとが少なくとも１層ずつ配列された後、第２の繊維束層４１を形成してもよい。
【００５８】
〇アクチュエータはエアシリンダに限らず、リニアアクチュエータを使用してもよい。
○ 規制部材１５ａ，１５ｂとしてピンに代えてパイプを使用したり、ピンやパイプのように棒状の物に限らず、板状のものを使用してもよい。但し板状のものを使用する場合は、底部において繊維束Ｒが互いに直交し、かつ側壁において周方向繊維束と斜めに交差する第１の繊維束層４０ｂを設けない構成の積層繊維群を形成する際に使用される枠体１１となる。第１の繊維束層４０ｂを形成する場合は、規制部材１５ａ，１５ｂとしてピン又はパイプが使用される。
【００５９】
○ 繊維束供給ヘッド３４は１本の繊維束Ｒを供給、配列する構成に限らず、複数本の繊維束Ｒを同時に配列する構成としてもよい。この場合、１本の繊維束Ｒを順次配列する場合に比較して、繊維束Ｒの配列時間を大幅に短縮することができる。
【００６０】
○ 張力付与部３５は繊維束Ｒを把持した状態で、３個一組のローラ３９ａ〜３９ｃで繊維束Ｒに張力を付与する構成に限らず、例えば、繊維束Ｒに巻き戻し方向の力を付与する構成としてもよい。
【００６１】
○ 繊維束Ｒとして炭素繊維に限らず、複合材の用途に応じてボロン繊維、炭化ケイ素繊維等の無機繊維を使用したり、ポリアラミド繊維、超高分子量ポリエチレン繊維などの高強度・高弾性率の有機繊維の無撚りマルチフィラメントを使用してもよい。
【００６２】
前記実施の形態から把握される発明（技術的思想）について以下に記載する。（１）請求項１に記載の発明において、前記押圧部材は発泡樹脂製で第１の繊維束層と対向する面に、押圧部材が第１の繊維束層に押圧されると中央から周縁に向かって拡がる作用をなす複数の切れ込みが形成されている。
【００６３】
（２）請求項４に記載の発明において、前記第２の押圧機構は、前記押圧体が前記側壁に対応する箇所を押圧する位置に配置された状態で、前記押圧体を自動的に繊維束の弛みを前記開口部周縁側に移動させる方向に移動される。
【００６４】
【発明の効果】
以上、詳述したように、請求項１〜請求項３に記載の発明によれば、積層繊維群を構成する繊維束の配列が完了した状態での積層繊維群の厚さと、厚さ方向糸により各繊維束層を結合した後の厚さとの差を小さくでき、繊維束の蛇行を抑制することができる。また、請求項４に記載の発明によれば、前記有底筒状の三次元繊維構造体を製造する際に好適な積層繊維群の周方向繊維束の配列を行うことができる。
【図面の簡単な説明】
【図１】周方向繊維束配列装置の模式正面図。
【図２】枠体の模式斜視図。
【図３】第２の押圧機構の模式側面図。
【図４】（ａ）はスライド部材の模式斜視図、（ｂ）は支持部材及びスライド部材の関係を示す模式分解図、（ｃ）は支持部材の模式斜視図。
【図５】（ａ）は第１の繊維束層の繊維束配列状態を示す模式斜視図、（ｂ）は同じく別の第１の繊維束層の繊維束配列状態を示す模式斜視図。
【図６】（ａ）〜（ｆ）は作用を説明する模式平面図。
【図７】（ａ）は押圧部材が作用位置に配置された状態を示す模式斜視図、（ｂ）は周方向繊維束が配列された状態を示す模式斜視図。
【図８】別の実施の形態の模式平面図。
【図９】（ａ），（ｂ）は有底筒状の三次元繊維構造体の模式斜視図。
【図１０】従来の厚さ方向糸挿入終了時の繊維束の状態を示す模式斜視図。
【符号の説明】
Ｆ…三次元繊維構造体、Ｆｂ…底部、Ｆｓ…側壁、Ｒ…繊維束、１１…枠体、１５ａ，１５ｂ…規制部材、１６…周方向繊維束配列装置、１７…保持装置、１８…第１の押圧機構、１９…第２の押圧機構、２０…繊維束供給部、２３…押圧部材、２６…押圧体、４０ａ，４０ｂ…第１の繊維束層、４１…第２の繊維束層。[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention combines a laminated fiber group having at least biaxial orientation formed by laminating a plurality of fiber bundle layers, with a thickness direction thread arranged in a direction orthogonal to the fiber bundle layer, a bottom portion and a side wall. And a device for arranging circumferential fiber bundles of a laminated fiber group.
[0002]
[Prior art]
Fiber reinforced composites are widely used as lightweight structural materials. Among fiber-reinforced composite materials, those using a three-dimensional woven fabric (three-dimensional fiber structure) as a reinforcing material have extremely high strength, and are considered to be used for structural materials of aircraft and the like, and are partially used. As a method of manufacturing the three-dimensional fiber structure, a plurality of yarn layers in which yarns (fiber bundles) are arranged in a folded shape are laminated to form a laminated yarn group (laminated fiber group) having at least biaxial orientation. Are bonded by a thickness direction yarn arranged in a direction orthogonal to each yarn layer (for example, see Patent Documents 1 and 2).
[0003]
Patent Literature 1 discloses a three-dimensional woven fabric having a shape in which a plurality of plate-shaped portions are continuous via a curved portion, for example, an L-shaped, U-shaped, or U-shaped, and a method for manufacturing the same. I have. Then, after the laminated yarn group is arranged, the respective yarn layers constituting the laminated yarn group are joined with the thickness direction yarns in a state where the laminated yarn group is compressed from both sides in the thickness direction with a pressure bar to adjust the thickness. Is disclosed. Further, it is described that the compression operation by the pressure bar is preferably performed in small increments during the yarn arrangement stage, not after completion of the arrangement yarns.
[0004]
In addition, Patent Document 2 discloses a three-dimensional fiber structure having a bottom having a bottom Fb and a side wall Fs, such as a rectangular box or a circular box shown in FIGS. 9A and 9B of the present specification. It is described that a cylindrical three-dimensional fiber structure F can also be manufactured by combining the yarn layers of a laminated yarn group formed by laminating and arranging fiber bundles with a thickness direction yarn.
[0005]
[Patent Document 1]
JP-A-5-59634 (paragraph numbers [0012] to [0019], FIGS. 1 to 5)
[Patent Document 2]
JP-A-9-137336 (paragraph numbers [0036] to [0037], [0071], FIG. 19)
[0006]
[Problems to be solved by the invention]
In the method of manufacturing the three-dimensional fiber structure by combining the respective yarn layers with the thickness direction yarns after creating the above-described laminated yarn group, the thickness of the laminated yarn group is determined in a state where the yarns (fiber bundles) are simply laminated. Is about twice the thickness of the three-dimensional fiber structure to be manufactured. Then, by applying a tension to the thickness direction yarn when the thickness direction yarn is inserted, each yarn layer of the layered yarn group is tightened, and the layered yarn group is thinned to a predetermined thickness and joined.
[0007]
When the three-dimensional fiber structure has an L-shape or a U-shape, when the laminated yarn group is fastened with the thickness direction yarn, the slack of the yarn moves to the end of the three-dimensional fiber structure, so that there is no problem. However, in the case of a bottomed cylindrical shape (for example, a square box shape), as shown in FIG. 10, the slack L is concentrated at the corners of the laminated yarn group Fc, and a portion where the fibers meander is generated. When the composite material is manufactured by impregnating the resin with the meandering portion of the fiber, the physical properties of the composite material deteriorate. Patent Document 2 describes that a cylindrical bottomed three-dimensional fiber structure can also be produced, but does not disclose any method for eliminating the meandering of the fiber due to the loosening.
[0008]
A first object of the present invention is to provide a difference between the thickness of a laminated fiber group in a state where the arrangement of the fiber bundles constituting the laminated fiber group is completed, and the thickness after the respective fiber bundle layers are combined by the thickness direction yarn. It is an object of the present invention to provide a method of manufacturing a bottomed cylindrical three-dimensional fiber structure which can reduce the meandering of the fiber bundle and suppress the meandering of the fiber bundle. It is a second object of the present invention to provide an apparatus for arranging circumferential fiber bundles of a group of laminated fibers which is suitable for producing the bottomed cylindrical three-dimensional fiber structure.
[0009]
[Means for Solving the Problems]
In order to achieve the first object, the invention according to claim 1, wherein a group of laminated fibers having at least biaxial orientation formed by laminating a plurality of fiber bundle layers is arranged in a direction orthogonal to the fiber bundle layers. This is a method for producing a bottomed cylindrical three-dimensional fiber structure composed of a bottom portion and a side wall, which are connected by arranged thickness direction yarns. At the time of forming the laminated fiber group, regulating members were provided at a predetermined pitch corresponding to the outer shape of the three-dimensional fiber structure, and at least along a position corresponding to the periphery of the opening of the three-dimensional fiber structure. The fiber bundle is arranged using the frame. A first fiber bundle layer arranged so as to be folded from the side wall of the three-dimensional fiber structure so as to extend from the side wall of the three-dimensional fiber structure to the bottom as the fiber bundle layer by a regulating member provided on the periphery of the opening; The second fiber bundle layer to be arranged is formed in a plurality of layers. When forming the second fiber bundle layer, the fiber bundle layer that has been laminated so far, which constitutes the bottom of the three-dimensional fiber structure, is pressed by a pressing member to move the slack of the fiber bundle to the side wall side. Let it. Then, circumferential fiber bundles forming the second fiber bundle layer are sequentially arranged from the bottom side to the opening side so as to move the moved slack to the opening side of the three-dimensional fiber structure. To form the laminated fiber group.
[0010]
In the present invention, a frame is used in which the regulating members are provided at a predetermined pitch along a position corresponding to the outer shape of the three-dimensional fiber structure and at least along the periphery of the opening of the three-dimensional fiber structure. The arrangement of the fiber bundles constituting the laminated fiber group is performed. The fiber bundles forming the first fiber bundle layer are arranged so as to be folded by a regulating member provided on the periphery of the opening and to extend from the side wall to the bottom of the three-dimensional fiber structure. The circumferential fiber bundles forming the second fiber bundle layer are arranged in the circumferential direction of the side wall. When arranging the fiber bundles that form the second fiber bundle layer, the first fiber bundle layer that has been laminated so far that constitutes the bottom of the three-dimensional fiber structure is pressed by the pressing member, Is moved toward the side wall, which is the periphery of the bottom. Then, circumferential fiber bundles forming the second fiber bundle layer are arranged in order from the bottom side to the opening side so as to move the slack moved to the side wall side to the opening side of the three-dimensional fiber structure. You. As a result, the slack of the fiber bundle forming the first fiber bundle layer is removed. Hereinafter, when the second fiber bundle layer is similarly formed, the circumferential fiber bundles are arranged so that the slack of the fiber bundles of the first fiber bundle layer that has been laminated so far is removed. As a result, it is possible to reduce the difference between the thickness of the laminated fiber group in a state where the arrangement of the fiber bundles constituting the laminated fiber group is completed and the thickness after the respective fiber bundle layers are joined by the thickness direction yarn, Meandering can be suppressed.
[0011]
According to a second aspect of the present invention, in the first aspect of the present invention, the first fiber bundle layer includes a layer in which fiber bundles are arranged in a direction orthogonal to the circumferential direction fiber bundle, and a fiber bundle in the first fiber bundle layer. Directional fiber bundles and layers arranged to be inclined. In the frame, the regulating member is provided on the periphery of the opening of the three-dimensional fiber structure and on the periphery of the bottom.
[0012]
According to the present invention, the laminated fiber group forming the bottom and the side wall has an in-plane four-axis arrangement. The fiber bundles constituting each fiber bundle layer are arranged so as to be wrapped around the restricting member provided on the periphery of the opening and folded back, and the arrangement position is regulated by the restricting member provided on the bottom periphery, Even when the fiber bundles are arranged to be inclined with the circumferential fiber bundle, they are well arranged at predetermined positions.
[0013]
According to a third aspect of the invention, in the first or second aspect of the invention, when arranging the circumferential fiber bundles forming the second fiber bundle layer, the circumferential fiber bundles are arranged before the circumferential fiber bundles are arranged. While pressing the first fiber bundle layer arranged at the position corresponding to the side wall with the pressing body, the pressing body is moved along the arrangement direction of the fiber bundles constituting the first fiber bundle layer. In the present invention, since the pressing body is moved along the arrangement direction of the fiber bundles constituting the first fiber bundle layer, the slack of the fiber bundle can be efficiently moved to the opening side.
[0014]
In order to achieve the second object, the invention according to claim 4 arranges at least biaxially oriented laminated fiber groups formed by laminating a plurality of fiber bundle layers in a direction orthogonal to the fiber bundle layers. This is a circumferential fiber bundle arrangement device for a laminated fiber group for forming a bottomed cylindrical three-dimensional fiber structure composed of a bottom portion and a side wall, which is connected by a thickness direction yarn. The circumferential direction fiber bundle arranging device includes a holding device, a first pressing mechanism, a second pressing mechanism, and a fiber bundle supply unit. The holding device holds the frame body corresponding to the outer shape of the three-dimensional fiber structure and having the regulating members provided at a predetermined pitch at least along a position corresponding to the periphery of the opening of the three-dimensional fiber structure. At the same time, it can be rotationally driven by the driving means. The first pressing mechanism presses a portion corresponding to the bottom of the three-dimensional fiber structure of the fiber bundle layer arranged on the frame held by the holding device, and retracts from the pressing position. A pressing member is provided at the standby position. A second pressing mechanism configured to move an operation position of the fiber bundle layer arranged on the frame held by the holding device while pressing a portion corresponding to a side wall of the three-dimensional fiber structure; And a pressing member disposed at a standby position retracted from the vehicle. The fiber bundle supply unit supplies a fiber bundle arranged at a position corresponding to a side wall of the three-dimensional fiber structure on the frame.
[0015]
In the circumferential direction fiber bundle arranging device of the present invention, the frame provided with the regulating members at a predetermined pitch is held by the holding device. The fiber bundle layer arranged at a position corresponding to the bottom of the three-dimensional fiber structure on the frame is pressed by the pressing member of the first pressing mechanism, and the slack of the fiber bundle moves to the side wall, which is the bottom peripheral edge. Is done. The slack moved to the side wall side is pressed by the pressing body of the second pressing mechanism and moved to the opening side. The fiber bundle supplied from the fiber bundle supply unit is arranged so as to extend in the circumferential direction at a position corresponding to a side wall of the three-dimensional fiber structure on the frame by rotating the holding device. Is done. Therefore, by using this circumferential fiber bundle arranging apparatus, the circumferential fiber bundles of the laminated fiber group forming the bottomed cylindrical three-dimensional fiber structure including the bottom and the side wall are arranged. The slack of the fiber bundles arranged so as to intersect with each other can be smoothly moved (released) to the opening side.
[0016]
BEST MODE FOR CARRYING OUT THE INVENTION
(First Embodiment)
Hereinafter, a first embodiment in which the present invention is embodied in the case of manufacturing a three-dimensional fiber structure having a bottomed square cylindrical shape (square box shape) will be described with reference to FIGS. 1 to 7 and FIG. .
[0017]
First, the configuration of a frame used for manufacturing a three-dimensional fiber structure will be described. FIG. 2 is a schematic perspective view of the frame. This frame is used for forming a laminated fiber group corresponding to the shape of the three-dimensional fiber structure, and for holding the laminated fiber group when inserting the thickness direction yarn into the formed laminated fiber group.
[0018]
As shown in FIG. 2, the frame body 11 is formed by connecting a pair of rectangular frame parts 12 and 13 arranged in parallel with each other by a plurality of (six in this embodiment) connecting parts 14. It is formed in a shape. That is, the frame body 11 is formed so as to correspond to the outer shape of the three-dimensional fiber structure having the shape of a bottomed square tube. In this embodiment, the lower frame portion 12 in FIG. 2 corresponds to the periphery of the opening of the three-dimensional fiber structure, and the upper frame portion 13 corresponds to the bottom periphery of the three-dimensional fiber structure. A large number of regulating members 15a are detachably provided at a predetermined pitch in the frame portion 12, and a large number of regulating members 15b are detachably provided at a predetermined pitch in the frame portion 13. The regulating members 15a and 15b are formed, for example, by pins.
[0019]
The restricting member 15a provided on the frame portion 12 projects outward in a state substantially parallel to the plane including the frame portion 12 or slightly inclined to the opposite side to the frame portion 13 (a state slightly inclined downward in FIG. 2). Is provided. The restricting member 15b provided on the frame portion 13 is positioned between a plane including the frame portion 12 and a plane including the one side of the frame portion 13, one side of the frame portion 12 facing the one side, and a connecting portion 14 connecting both sides. It is provided so as to project outward at an angle of approximately 45 °.
[0020]
The regulating member 15a provided on the frame portion 12 has a role of regulating the folding position and the arrangement position of the fiber bundle arranged so as to straddle the bottom and the side wall of the three-dimensional fiber structure. The regulating member 15b provided on the frame 13 has a role of regulating the arrangement position of the fiber bundle arranged so as to straddle the bottom and the side wall of the three-dimensional fiber structure.
[0021]
Next, a description will be given of a circumferential fiber bundle arranging device for arranging circumferential fiber bundles of a laminated fiber group for forming a bottomed cylindrical three-dimensional fiber structure on the frame 11. As shown in FIG. 1, the circumferential direction fiber bundle arranging device 16 includes a holding device 17, a first pressing mechanism 18, a second pressing mechanism 19, and a fiber bundle supply unit 20.
[0022]
The holding device 17 includes a rotary table 21 for holding the frame 11 and a motor 22 as driving means. The turntable 21 includes a bottom portion 21a that supports the bottom surface of the frame 11, that is, a lower surface of the frame portion 12 in FIG. 1, and a portion 21b that is inserted inside the frame 11 and abuts on the inner surface of the frame 11. I have. The motor 22 rotates the turntable 21. That is, the rotary table 21 is rotatable by the driving unit while holding the frame 11.
[0023]
The first pressing mechanism 18 presses a portion corresponding to the bottom of the three-dimensional fiber structure of the fiber bundle layer arranged on the frame 11 held by the holding device 17, and retracts from the pressing position. And a pressing member 23 disposed at the standby position (the position shown in FIG. 1). In this embodiment, the first pressing mechanism 18 is disposed above the turntable 21. The pressing member 23 is fixed to the piston rod 24a of the air cylinder 24, and is arranged at the pressing position and the standby position by the operation of the air cylinder 24.
[0024]
The pressing member 23 is fixed to a rectangular metal supporting plate 23a having a size substantially covering the area surrounded by the regulating member 15b provided on the frame portion 13, and to one surface (the lower surface in FIG. 1) of the supporting plate 23a. And a pressing portion 23b. The pressing portion 23b is made of a foamed resin. When the surface (pressing surface) opposite to the surface facing the support plate 23a is disposed at the pressing position and receives a pressing force from the support plate 23a, the pressing surface moves to the central portion. It is formed so as to be deformable so as to expand from the outside. For example, as shown in FIG. 1, a number of cuts 25 are formed on the pressing surface side of the pressing portion 23b.
[0025]
The second pressing mechanism 19 is configured to move while pressing a portion corresponding to the side wall of the three-dimensional fiber structure of the fiber bundle layer arranged on the frame 11 held by the holding device 17, The pressing body 26 is provided at the standby position retracted from the position. As shown in FIGS. 1 and 3, the pressing body 26 is attached to a piston rod 27 a of an air cylinder 27 disposed horizontally via a slide mechanism 28, and is brought into the working position and the standby position by the operation of the air cylinder 27. It is to be arranged.
[0026]
As shown in FIGS. 1 and 3, the slide mechanism 28 includes a support member 30 rotatable relative to a substrate 29 fixed to the piston rod 27a and fixed at a predetermined position with a bolt (not shown). And a slide member 31 slidably connected and supported. The support member 30 is formed in a shape obtained by cutting one end of a cylinder obliquely (to form an angle of 45 degrees with the axis in this embodiment), and has a tip end surface as shown in FIGS. 4B and 4C. A guide groove 30a extending straight through the center is formed. The support member 30 is formed with a hole 30b whose one end is opened at a position corresponding to the guide groove 30a and the other end is opened on the peripheral surface in a state orthogonal to the axis.
[0027]
The slide member 31 is also formed in a shape in which one end of the cylinder is cut obliquely (to form an angle of 45 degrees with the axis in this embodiment), and as shown in FIG. A protruding ridge 31a that can be engaged with the guide groove 30a is formed on the end face opposite to. The slide member 31 is formed with a screw hole 31b whose one end is opened at a position corresponding to the center of the ridge 31a and the other end is opened on the peripheral surface in a state perpendicular to the axis. As shown in FIGS. 1 and 3, the tip of a bolt 32 penetrating through the hole 30 b of the support member 30 is screwed into the screw hole 31 b. A coil spring 33 is interposed between the head of the bolt 32 and the peripheral surface of the support member 30, and when no force other than gravity acts on the slide member 31, the coil spring 33 causes the slide member via the bolt 32. 31 is held at a predetermined position shown in FIGS. The hole 30b is formed to allow the bolt 32 to move.
[0028]
The pressing body 26 includes a support plate 26a fixed to the slide member 31 and a pressing portion 26b fixed to one surface of the support plate 26a. The pressing portion 26b has a length in the vertical direction in FIGS. 1 and 3, that is, a height slightly smaller than the height of the frame 11, and a width (length in a direction perpendicular to the paper surface of FIGS. 1 and 3) of the frame 11. It is formed to be the same as the length. The pressing portion 26b is made of a foamed resin, and the surface (pressing surface) opposite to the surface facing the support plate 26a is disposed at the operation position, and when receiving a pressing force from the support plate 26a, the pressing surface transfers the fiber bundle. It is formed so as to be pressed without damaging it.
[0029]
The fiber bundle supply unit 20 is disposed at a position facing the second pressing mechanism 19 and supplies the fiber bundle R arranged at a position corresponding to the side wall of the three-dimensional fiber structure on the frame 11. Has become. In the fiber bundle supply section 20, a support plate 37 including a fiber bundle supply head 34, a tension applying section 35, and a gripping roller 36 is provided so as to be able to reciprocate up and down along a column 38. The support plate 37 is driven by an actuator (not shown) so that the moving range of the fiber bundle supply head 34 is within the range of the height of the frame 11. The fiber bundle supply head 34 is formed of a tubular body whose tip is formed flat so that the fiber bundle R which is fed out from a bobbin (not shown) and supplied through the tension applying section 35 is fed out in a flat state.
[0030]
The tension applying unit 35 is provided between the gripping roller 36 and the fiber bundle supply head 34, and includes a set of three rollers 39a, 39b, and 39c disposed so as to be orthogonal to the supply direction of the fiber bundle R. ing. The gripping roller 36 is moved between a gripping position where the fiber bundle R is gripped and an open position where the fiber bundle R is allowed to move. The roller 39b is configured to be able to move up and down by an actuator (not shown). When the fiber bundle R is gripped by the gripping roller 36, the roller 39b engages with the fiber bundle R located between the rollers 39a and 39c to apply tension. It has become.
[0031]
Next, the fiber bundles R are arranged in a folded shape on the frame body 11 using the frame body 11 and the circumferential fiber bundle arrangement device 16 configured as described above, and as shown in FIG. An operation of forming a laminated fiber group constituting the bottomed cylindrical three-dimensional fiber structure F including the bottom portion Fb and the side wall Fs will be described.
[0032]
FIG. 5A shows a state in which the fiber bundle R is folded over the frame 11 by a regulating member provided on the periphery of the opening of the frame 11 so as to extend from the side wall to the bottom of the three-dimensional fiber structure, and the fiber bundle R is arranged in the circumferential direction. It is a schematic diagram which shows the arrangement state of the 1st fiber bundle layer 40a arranged in the direction orthogonal to a fiber bundle. FIG. 5B shows a state in which the fiber bundle R is folded over the frame 11 by a regulating member provided at the periphery of the opening of the frame 11 so as to extend from the side wall to the bottom of the three-dimensional fiber structure, and the fiber bundle R extends in the circumferential direction. It is a schematic diagram which shows the arrangement state of the 1st fiber bundle layer 40b arranged so that it may incline with the fiber bundle. In FIGS. 5A and 5B, the illustration of the regulating members 15a and 15b is omitted, and the spacing between the fiber bundles R is shown wide for easy understanding. FIGS. 6A to 6F are schematic plan views showing the arrangement of circumferential fiber bundles. 6A to 6F, the relationship between the second pressing mechanism 19 for the frame 11 and the fiber bundle supply unit 20 is shown in a state different from that in FIG.
[0033]
First, as shown in FIG. 1, the frame 11 is held on the turntable 21 of the holding device 17 with the frame 13 thereof facing upward. Next, the support plate 37 is disposed at a position where the fiber bundle supply head 34 is in a state corresponding to the frame portion 13. Next, the fiber bundle R drawn out from the bobbin is inserted into the fiber bundle supply head 34 via the gripping roller 36 and the tension applying unit 35, and the end of the fiber bundle R is pulled out from the tip of the fiber bundle supply head 34. Then, the tip of the fiber bundle R is fixed to a predetermined position of the frame body 11, for example, the frame portion 12. The fiber bundle R is fixed using, for example, an adhesive tape (not shown). This fiber bundle R constitutes a second fiber bundle layer arranged in the circumferential direction of the side wall of the three-dimensional fiber structure.
[0034]
Further, the fiber bundles R constituting the first fiber bundle layers 40a and 40b arranged so as to extend from the side walls to the bottom of the three-dimensional fiber structure are fed out from another bobbin (not shown), and the ends of the fiber bundles R are formed on the frame 11. It is fixed to a predetermined position, for example, the frame portion 13. The fiber bundle R is fixed using, for example, an adhesive tape (not shown). Preparation for forming the laminated fiber group is thus completed. The fiber bundle R is made of non-twisted multifilaments of carbon fibers, and the number of the multifilaments is about 3,000 to 24,000.
[0035]
Next, in this state, first, the arrangement of the first fiber bundle layers 40a is started. Arrangement of the first fiber bundle layer is performed manually or by a device equipped with a fiber bundle supply head on an arm of a multi-axis robot. Circumferential fibers arranged so that the fiber bundle R is folded back at the periphery of the opening, that is, the regulating member 15a provided in the frame portion 12, and extends from the side wall to the bottom of the three-dimensional fiber structure, and is arranged in the circumferential direction of the frame body 11. A first fiber bundle layer 40a shown in FIG. 5 (a) arranged in a direction orthogonal to the bundle is formed. Next, a first fiber bundle layer 40b shown in FIG. 5B in which the fiber bundles R are arranged so as to be inclined with respect to the circumferential fiber bundles is formed. When forming these fiber bundle layers 40a and 40b, the position of the fiber bundle R is regulated by the regulating member 15a provided on the frame 12 of the frame 11 and the regulating member 15b provided on the frame 13. Are arranged.
[0036]
Each time one of the first fiber bundle layers 40a and 40b is formed, the first pressing mechanism 18 is driven, and the pressing member 23 is moved from the standby position to the pressing position. Then, as shown in FIGS. 7A and 7B, the fiber bundle layer arranged at a position corresponding to the bottom of the three-dimensional fiber structure on the frame 11 is pressed by the pressing member 23, The slack of R is moved to the side wall side (frame 13 side) that is the bottom peripheral edge. FIG. 7A shows a state where the pressing member 23 is arranged at the pressing position in a state where the first fiber bundle layers 40a are arranged, and FIG. 7B shows a state where the second fiber bundle layer 41 is formed thereafter. FIG.
[0037]
Next, the second pressing mechanism 19 is driven, and the pressing body 26 is moved from the standby position to the operating position as shown in FIG. The pressing body 26 moves straight until the pressing portion 26b engages with the first fiber bundle layers 40a, 40b, and is thereafter moved toward the opening by the action of the slide mechanism 28. The moving direction is determined in advance by the attachment state of the support member 30, and is moved in the arrangement direction of the fiber bundles R of the first fiber bundle layers 40a and 40b before the arrangement of the circumferential fiber bundles. That is, if the arrangement of the fiber bundles R is the first fiber bundle layer 40a shown in FIG. 5A, the pressing body 26 is moved downward, and the arrangement of the fiber bundles R is the first arrangement shown in FIG. In the case of the fiber bundle layer 40b, the pressing body 26 is moved in a direction inclined at an angle of 45 degrees.
[0038]
Next, after the pressing body 26 is moved to the standby position as shown in FIG. 6B, as shown in FIGS. 6C and 6D, the gripping roller 36 grips the fiber bundle R and applies the tension. In a state where the engagement of the rollers 35 with the rollers 39a to 39c is released, the turntable 21 is rotated by 90 degrees, and the fiber bundles R as the circumferential fiber bundles are arranged. Next, as shown in FIG. 6E, the pressing body 26 is moved to the operation position again, and the pressing of the arrangement surface by the pressing portion 26b and the movement of the slack of the first fiber bundle layers 40a and 40b are performed. . Thereafter, as shown in FIG. 6F, the gripping roller 36 is moved to the gripping position, and the roller 39b is moved to the tension applying position, so that the slack of the fiber bundles R in the arrangement is removed.
[0039]
Hereinafter, similarly, the movement of the pressing body 26 to the standby position, the rotation of the turntable 21 by 90 degrees in a state where the grasp of the fiber bundle R is released, the movement of the pressing body 26 to the operation position, and the tension applying unit 35 Is repeated. Then, when the turntable 21 makes one rotation, the arrangement of the first round of the fiber bundle R as the circumferential direction fiber bundle is completed. Next, the support plate 37 is lowered to move the fiber bundle supply head 34 to a position shifted by one pitch, and in this state, the fiber bundles R are arranged again in the same manner as described above. Then, by arranging the fiber bundles R in order from the bottom side of the three-dimensional fiber structure, the slack of the first fiber bundle layers 40a and 40b is removed.
[0040]
As shown in FIG. 7B, when the formation of one layer of the second fiber bundle layer 41 is completed, the pressing member 23 and the pressing body 26 are moved to the standby position, and then the first fiber bundle layer 41 is again moved to the standby position. The formation of 40a and 40b is performed. Then, a predetermined number of the first fiber bundle layers 40a, 40b and the second fiber bundle layer 41 are laminated on the frame body 11 in a predetermined order to form a laminated fiber group.
[0041]
After the laminated fiber group is formed, the frame 11 is removed from the rotary table 21 together with the laminated fiber group, and set in the thickness direction thread insertion device. Then, the thickness direction yarn is inserted into the laminated fiber group by the thickness direction yarn insertion device so as to be orthogonal to the first fiber bundle layers 40a and 40b and the second fiber bundle layer 41, and the laminated fiber group is joined. Then, the manufacture of the three-dimensional fiber structure F having the shape of a bottomed square tube (box) as shown in FIG. 9A is completed. The difference between the thickness in the state where the laminated fiber group was formed and the thickness in the state where the thickness direction yarn was inserted to form the three-dimensional fiber structure F was 7% or less.
[0042]
In addition, in order to make the fiber bundles R arranged on the frame body 11 easy to understand, the adjacent fiber bundles R are illustrated as having a gap, but in reality, there is almost no gap between the adjacent fiber bundles R. It is arranged in. In addition, the regulating members 15a and 15b are provided so that the distance between them is substantially the same as the thickness of the fiber bundle R.
[0043]
This embodiment has the following effects.
(1) The first fiber bundle layers 40a and 40b arranged so as to extend from the side wall to the bottom when forming the laminated fiber group constituting the bottomed cylindrical three-dimensional fiber structure including the bottom and the side wall. And a plurality of second fiber bundle layers 41 arranged in the circumferential direction of the side wall. When the second fiber bundle layer 41 is formed, the fiber bundle layer that has been laminated so far, which constitutes the bottom of the three-dimensional fiber structure, is pressed by the pressing member 23 to move the slack of the fiber bundle to the side wall side. Let it. Then, circumferential fiber bundles forming the second fiber bundle layer 41 are arranged in order from the bottom side to the opening side so as to move the moved slack to the opening side of the three-dimensional fiber structure. To form a laminated fiber group. Therefore, when forming the second fiber bundle layer 41, the slack of the fiber bundles of the first fiber bundle layers 40a and 40b is surely removed, and the arrangement of the fiber bundles constituting the laminated fiber group is completed. Can be reduced, and the meandering of the fiber bundle can be suppressed. As a result, the physical properties of the composite material using the three-dimensional fiber structure manufactured by inserting the thickness direction yarn into the laminated fiber group as a reinforcing material are improved.
[0044]
(2) The first fiber bundle layers 40a and 40b include a layer in which the fiber bundles are arranged in a direction orthogonal to the circumferential fiber bundles, and a layer in which the fiber bundles are arranged to be inclined with the circumferential fiber bundles. Therefore, the laminated fiber group constituting the bottom and the side wall has an in-plane four-axis arrangement, and the physical properties are improved as compared with the in-plane biaxial arrangement.
[0045]
(3) The frame body 11 is provided with regulating members 15a and 15b at locations corresponding to the periphery of the opening of the three-dimensional fiber structure, ie, the frame portion 12, and at locations corresponding to the periphery of the bottom portion, ie, the frame portion 13. The fiber bundles constituting the first fiber bundle layers 40a and 40b of the laminated fiber group are arranged so as to be wound around the regulating member 15a provided on the frame portion 12 and folded, and provided on the frame portion 13. The arrangement position is regulated by the regulated member 15b. Therefore, even when the fiber bundles are arranged so as to be inclined with respect to the circumferential fiber bundles, they are well arranged at predetermined positions.
[0046]
(4) When arranging the circumferential fiber bundles forming the second fiber bundle layer 41, the first fiber bundle layers 40a and 40b arranged at positions corresponding to the side walls before the circumferential fiber bundles are arranged are pressed. The pressing body 26 is moved along the arrangement direction of the fiber bundles R constituting the first fiber bundle layer while being pressed by the body 26. Therefore, since the pressing body 26 is moved along the arrangement direction of the fiber bundles R constituting the first fiber bundle layers 40a and 40b, the slack of the fiber bundles R can be efficiently moved to the opening side.
[0047]
(5) The circumferential fiber bundle arranging device 16 corresponds to the holding device 17 that holds the frame 11 and can be driven to rotate by the motor 22 and the bottom of the three-dimensional fiber structure of the first fiber bundle layers 40a and 40b. And a first pressing mechanism 18 having a pressing member 23 disposed at a pressing position for pressing a position to be pressed and a standby position. Further, an operation position where the fiber bundle layer arranged on the frame body 11 held on the holding device 17 moves while pressing a position corresponding to the side wall of the three-dimensional fiber structure, and a standby position retracted from the operation position. Is provided with a second pressing mechanism 19 having a pressing body 26 disposed at the second position. A fiber bundle supply unit 20 for supplying a fiber bundle arranged at a position corresponding to the side wall of the three-dimensional fiber structure on the frame 11. Therefore, by using the circumferential fiber bundle arranging device 16, the circumferential fiber bundles of the laminated fiber group forming the bottomed cylindrical three-dimensional fiber structure including the bottom and the side wall can be arranged in the circumferential fiber bundle. The slack of the fiber bundle arranged so as to intersect with the bundle can be smoothly moved to the opening side (released).
[0048]
(6) The pressing member 23 that presses a portion corresponding to the bottom of the three-dimensional fiber structure includes a pressing portion 26b that has an operation of expanding from the center to the periphery when pressed by the first fiber bundle layer. . Therefore, the slack of the fiber bundles R arranged to form the first fiber bundle layers 40a and 40b can be smoothly moved to the periphery.
[0049]
(7) The pressing body 26 of the second pressing mechanism 19 is supported by the piston rod 27a via the slide mechanism 28, and the pressing portion 26b is pressed by the first fiber bundle layers 40a, 40b by the projecting operation of the piston rod 27a. In this state, the fiber bundle is slid in a direction to move the slack of the fiber bundle to the opening side. Therefore, only the actuator that moves the pressing body 26 between the standby position and the operation position can perform the sliding operation of the pressing body 26, and there is no need to provide a separate actuator for sliding.
[0050]
(8) The laminated fiber group is formed on the frame 11, and the thickness direction yarn can be inserted into the laminated fiber group while the laminated fiber group is held in the same frame 11, and the three-dimensional fiber structure can be obtained. It is not necessary to replace the frame 11 until the manufacture of the body is completed.
[0051]
The embodiment is not limited to the above, and may be embodied as follows, for example.
○ Instead of a configuration in which the frame 11 is held on the rotating table 21 and the arrangement of the fiber bundles R as circumferential fiber bundles is performed by rotating the rotating table 21, the frame 11 is fixedly held at a predetermined position, The fiber bundle supply head 34 may be moved. For example, as shown in FIG. 8, the table holding the frame 11 is fixedly disposed at a predetermined position, and the fiber bundle supply unit 20 rotates around the frame 11 in a predetermined direction, and Fiber bundles R as directional fiber bundles are arranged. In this configuration, the support plate 37 and the support columns 38 (both not shown) are configured to be movable along the periphery of the table. The second pressing mechanism 19 is provided at a position facing each side surface of the frame 11. The arrangement of the fiber bundles R of the circumferential fiber bundles is determined by the movement of the pressing body 26 to the operation position, the movement of the pressing body 26 to the standby position, the arrangement of the fiber bundles R by the movement of the fiber bundle supply head 34, and the like. Each operation of applying the tension to the bundle R is sequentially performed, and the arrangement of the fiber bundle R on one side surface of the frame 11 is completed. Hereinafter, the same operation is repeated four times, and when the fiber bundle supply head 34 or the like makes one rotation, the arrangement of the fiber bundle R as the circumferential fiber bundle for the first round is completed. Then, with the position of the fiber bundle supply head 34 shifted by one pitch, the arrangement of the fiber bundles R of the circumferential fiber bundles is performed in the same manner as described above.
[0052]
構成 The configuration in which the slack of the fiber bundles of the first fiber bundle layers 40a and 40b that have been laminated so far and constitutes the bottom of the three-dimensional fiber structure is moved to the side wall side is such that the pressing portion 23b of the pressing member 23 is The present invention is not limited to the configuration in which a large number of cuts 25 are formed on the pressing surface side. For example, a configuration is possible in which a pressing portion 23b having a smaller area than the bottom portion is provided, and the pressing portion 23b is moved to draw a vortex from the center toward the peripheral edge in a state where the pressing portion 23b is arranged at the pressing position. Also in this case, the slack of the fiber bundle R of the first fiber bundle layers 40a and 40b is smoothly removed.
[0053]
を The first fiber bundle layers 40a and 40b may be formed of one of a layer in which the fiber bundles are arranged in a direction perpendicular to the circumferential fiber bundles and a layer in which the fiber bundles are arranged to be inclined with respect to the circumferential fiber bundles. Only one, and the laminated fiber group may be in an in-plane biaxial arrangement. In the case where the first fiber bundle layer is formed only of layers in which the fiber bundles are arranged in a direction orthogonal to the circumferential direction fiber bundles, the frame 11 may have a configuration in which the regulating member 15 a is provided only on the frame 12. In this case, the structure of the frame 11 is simplified.
[0054]
代え Instead of the configuration in which the tension applying rollers 39a to 39c are disposed between the fiber bundle supply head 34 and the gripping roller 36, the rollers 39a to 39c are disposed at the position closest to the frame 11, and the rollers 39a to 39c are disposed. The fiber bundle supply head 34 may be arranged between the holding roller 36 and the holding roller 36.
[0055]
スライド As the second pressing mechanism 19, a slide mechanism 28 that can automatically move in a direction orthogonal to the reciprocating direction of the actuator when the pressing body 26 is disposed at the operation position by the operation of one actuator is provided. Instead, a configuration including two actuators may be employed. For example, an actuator that fixes a support plate to the tip of the piston rod 27a and moves the pressing body 26 in a direction orthogonal to the piston rod 27a is provided on the support plate.
[0056]
構成 In the configuration in which the pressing portion 26b of the second pressing mechanism 19 is slid at the operation position before the fiber bundle R as the circumferential fiber bundle is arranged, the sliding direction is not necessarily the first fiber bundle arranged in front thereof. It is not necessary to match the arrangement direction of the fiber bundles R constituting the layers 40a and 40b. However, it is easier to move the slack smoothly if they are matched.
[0057]
構成 The configuration of the laminated fiber group is not limited to the configuration in which the second fiber bundle layers 41 formed of circumferential fiber bundles and the first fiber bundle layers 40a and 40b are alternately arranged. For example, a first fiber bundle layer 40a in which the fiber bundles R are orthogonal to each other at the bottom and orthogonal to the circumferential fiber bundle at the side wall, and a first fiber bundle layer 40b obliquely intersecting the circumferential fiber bundle at the side wall. After the at least one layer is arranged, the second fiber bundle layer 41 may be formed.
[0058]
は The actuator is not limited to an air cylinder, and a linear actuator may be used.
A pipe may be used instead of the pin as the regulating member 15a, 15b, or a plate-like thing is not limited to a rod-like thing like a pin or a pipe. However, when a plate-shaped fiber bundle is used, a laminated fiber group having a configuration in which the first fiber bundle layer 40b in which the fiber bundles R are orthogonal to each other at the bottom and obliquely intersect with the circumferential fiber bundle at the side wall is formed. It becomes the frame 11 used when performing. When forming the first fiber bundle layer 40b, pins or pipes are used as the regulating members 15a and 15b.
[0059]
The fiber bundle supply head 34 is not limited to a configuration in which one fiber bundle R is supplied and arranged, but may be a structure in which a plurality of fiber bundles R are simultaneously arranged. In this case, the arrangement time of the fiber bundles R can be significantly reduced as compared with the case where one fiber bundle R is sequentially arranged.
[0060]
The tension applying section 35 is not limited to the configuration in which the tension is applied to the fiber bundle R by the set of three rollers 39a to 39c in a state where the fiber bundle R is gripped. It is good also as a structure provided.
[0061]
○ As the fiber bundle R, not only carbon fiber but also inorganic fiber such as boron fiber, silicon carbide fiber or the like, or polyaramide fiber, ultra-high molecular weight polyethylene fiber, etc. Non-twisted multifilaments of organic fibers may be used.
[0062]
The invention (technical idea) grasped from the embodiment will be described below. (1) In the invention as set forth in claim 1, the pressing member is made of a foamed resin and is formed on a surface facing the first fiber bundle layer, and from the center to the periphery when the pressing member is pressed by the first fiber bundle layer. A plurality of notches are formed which have the effect of spreading out.
[0063]
(2) In the invention according to claim 4, the second pressing mechanism automatically moves the pressing body to a fiber bundle in a state where the pressing body is disposed at a position where the pressing body presses a portion corresponding to the side wall. Is moved in a direction to move the slack to the periphery of the opening.
[0064]
【The invention's effect】
As described in detail above, according to the first to third aspects of the present invention, the thickness of the laminated fiber group in the state where the arrangement of the fiber bundles constituting the laminated fiber group is completed, and the thickness direction yarn Thereby, the difference from the thickness after bonding the respective fiber bundle layers can be reduced, and meandering of the fiber bundle can be suppressed. According to the fourth aspect of the invention, it is possible to arrange the circumferential fiber bundles of the laminated fiber group suitable for manufacturing the bottomed cylindrical three-dimensional fiber structure.
[Brief description of the drawings]
FIG. 1 is a schematic front view of a circumferential fiber bundle arrangement device.
FIG. 2 is a schematic perspective view of a frame.
FIG. 3 is a schematic side view of a second pressing mechanism.
4A is a schematic perspective view of a slide member, FIG. 4B is a schematic exploded view showing a relationship between the support member and the slide member, and FIG. 4C is a schematic perspective view of the support member.
FIG. 5A is a schematic perspective view showing a fiber bundle arrangement state of a first fiber bundle layer, and FIG. 5B is a schematic perspective view showing a fiber bundle arrangement state of another first fiber bundle layer.
FIGS. 6A to 6F are schematic plan views illustrating the operation.
FIG. 7A is a schematic perspective view showing a state in which a pressing member is arranged at an operation position, and FIG. 7B is a schematic perspective view showing a state in which circumferential fiber bundles are arranged.
FIG. 8 is a schematic plan view of another embodiment.
FIGS. 9A and 9B are schematic perspective views of a bottomed cylindrical three-dimensional fiber structure.
FIG. 10 is a schematic perspective view showing a state of a fiber bundle at the end of insertion of a conventional thickness direction yarn.
[Explanation of symbols]
F: three-dimensional fiber structure, Fb: bottom, Fs: side wall, R: fiber bundle, 11: frame, 15a, 15b: regulating member, 16: circumferential fiber bundle arrangement device, 17: holding device, 18: first 1 pressing mechanism, 19: second pressing mechanism, 20: fiber bundle supply unit, 23: pressing member, 26: pressing body, 40a, 40b: first fiber bundle layer, 41: second fiber bundle layer.

Claims

At least a biaxially-oriented laminated fiber group formed by laminating a plurality of fiber bundle layers is formed of a bottom portion and a side wall, which are connected by a thickness direction thread arranged in a direction perpendicular to the fiber bundle layer. A method for producing a bottom cylindrical three-dimensional fiber structure,
At the time of forming the laminated fiber group, regulating members were provided at a predetermined pitch corresponding to the outer shape of the three-dimensional fiber structure, and at least along a position corresponding to the periphery of the opening of the three-dimensional fiber structure. The fiber bundle is arranged using a frame, and the fiber bundle layer is folded by a regulating member provided on the periphery of the opening as the fiber bundle layer and is arranged so as to extend from the side wall of the three-dimensional fiber structure to the bottom. One fiber bundle layer and a second fiber bundle layer arranged in the circumferential direction of the side wall are formed in a plurality of layers, and when the second fiber bundle layer is formed, the three-dimensional fiber structure The fiber bundle layer that has been laminated so far that constitutes the bottom is pressed by the pressing member to move the slack of the fiber bundle to the side wall side, and the moved slack is moved to the opening side of the three-dimensional fiber structure. So that the circumferential fiber bundles forming the second fiber bundle layer Method for producing a three-dimensional fiber structure forming the laminated fiber group by arranging in order from a side toward the opening side.

The first fiber bundle layer includes a layer in which fiber bundles are arranged in a direction orthogonal to the circumferential fiber bundles, and a layer in which fiber bundles are arranged so as to be inclined with respect to the circumferential fiber bundles. The method for manufacturing a three-dimensional fiber structure according to claim 1, wherein the regulating member is provided at a position corresponding to an opening edge and a bottom edge of the three-dimensional fiber structure.

When arranging the circumferential fiber bundles forming the second fiber bundle layer, the first fiber bundle layer arranged at a position corresponding to the side wall before the circumferential fiber bundles are arranged is pressed by a pressing body. The method for manufacturing a three-dimensional fiber structure according to claim 1 or 2, wherein the pressing body is moved along a direction in which the fiber bundles constituting the first fiber bundle layer are arranged.

At least a biaxially-oriented laminated fiber group formed by laminating a plurality of fiber bundle layers is formed of a bottom portion and a side wall, which are connected by a thickness direction thread arranged in a direction perpendicular to the fiber bundle layer. A circumferential fiber bundle array device of a laminated fiber group for forming a bottom cylindrical three-dimensional fiber structure,
It is possible to hold a frame in which the regulating member is provided at a predetermined pitch along a position corresponding to the outer shape of the three-dimensional fiber structure and at least along a periphery of an opening of the three-dimensional fiber structure, and is driven. A holding device rotatable by means,
The fiber bundle layer arranged on the frame held by the holding device is disposed at a pressing position for pressing a portion corresponding to a bottom of the three-dimensional fiber structure, and a standby position retracted from the pressing position. A first pressing mechanism including a pressing member;
An operation position in which the fiber bundle layer arranged on the frame held by the holding device moves while pressing a portion corresponding to a side wall of the three-dimensional fiber structure, and a standby position retracted from the operation position. A second pressing mechanism having a pressing body to be arranged;
A fiber bundle supply unit for supplying a fiber bundle arranged at a position corresponding to a side wall of the three-dimensional fiber structure on the frame body.