JP2007001299A - Rod-shaped preform for filling gap, its manufacturing method, and manufacturing device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a rod-shaped preform capable of being applied to gaps having various cross sections and forms, and its manufacturing method and manufacturing device. <P>SOLUTION: The rod-shaped preform to be filled in a gap of the preform as a reinforcing material is constituted of a unidirectional fabric base material composed of a reinforced fiber. The end parts of the base material are folded to be the interior of the rod-shaped preform, and has a cross section having the end parts to be folded three times or more in a weft direction. Furthermore, the rod-shaped preform changes in the bending rigidity in the longitudinal direction. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a void-shaped rod-shaped preshaped object for filling a void portion having a longitudinal cross-sectional change or a rigidity change composed of a fibrous structure inserted as a reinforcing material in a joint portion of a preform, and a manufacturing method and a manufacturing apparatus therefor.

  A method of inserting a rod-shaped preshaped object in order to fill a void of a three-dimensional three-dimensional structure preform used in RTM (Resin Transfer Molding) molding is known. For example, a rod-shaped preshaped object obtained by passing a continuous reinforcing fiber bundle through a stabilizer tank diluted with acetone and water, and then clamping, heating, and cooling, and a manufacturing method thereof have been proposed (for example, patents). Reference 1).

  Further, a core material composed of a bundle of two or more continuous yarns that are focused, and a core material having a cross-sectional wedge shape covering from the outer peripheral surface side so as to be in close contact, and along the longitudinal direction of the core material, A rod-shaped preshaped object comprising a jacket member made of continuous yarn woven in a cylindrical shape around the core material, and a manufacturing method for the rod-shaped preshaped object in which the jacket member and the core material are integrated are proposed. (For example, refer to Patent Document 2).

  However, in these methods, all the unidirectional carbon fibers are continuously contained in the longitudinal direction in the longitudinal direction, so that the carbon fiber bundle cannot follow any voids with arbitrary cross-section changes or bends. Is used as it is from the core or bobbin, the carbon fiber bundles and the bundles have problems such as a small gap between them and poor resin impregnation.

Moreover, in order to solve the said subject, the rod-shaped preshaped object which has a cross-sectional change in a three-dimensional braid structure | tissue is proposed (for example, refer patent document 3). However, the fiber bundle constituting the three-dimensional braided structure is often composed of fibers with high elastic modulus such as carbon, glass, aramid, alumina, etc., and the fiber bundle is arranged at an angle with respect to the longitudinal direction. Because of its structure, it is not good at filling a cross section having a small radius of curvature or apex. Further, since the void area around the fiber bundle portion is large, the impregnation coefficient between the fiber bundle and the periphery is greatly different, and the resin is likely to wrap around, and there is a concern that voids may occur when used in resin injection molding. That is, it is difficult to fill a molded product having a cross-section change in the longitudinal direction with a cross section having a small curvature (three, square, wedge shape, star shape, etc.). Also, since the fibers are continuous in the full length direction, it is difficult to bend the braid itself at a steep angle.
US Pat. No. 5,650,229 Japanese Patent No. 3549271 Japanese Patent No. 3591347

  The subject of this invention is providing the rod-shaped preshaped object applicable to the space | gap part of various cross sections and shapes, its manufacturing method, and a manufacturing apparatus.

In order to solve the above problems, the present invention adopts the following configuration. That is,
(1) A rod-shaped preshaped object that is filled as a reinforcing material in a void portion of a preform, and the rod-shaped preshaped object is composed of a unidirectional woven fabric substrate composed of reinforcing fibers, It has a cross-sectional shape that is folded so that the end is inside the rod-shaped preshaped object and is folded three times or more in the weft direction, and the rod-shaped preshaped material has a bending rigidity in the longitudinal direction. A rod-shaped preshaped object for filling a void, characterized by being changed.
(2) The rod-shaped preshaped object for filling a void according to (1), wherein the rod-shaped preshaped material has a cross-sectional change in the longitudinal direction.
(3) The rod-shaped preshaped object for filling voids according to (1), wherein the rod-shaped preshaped material has a portion whose bending rigidity changes in the longitudinal direction.
(4) The unidirectional textile base material is characterized in that a particulate, fibrous, or film-like resin is partially disposed on at least one side. A rod-shaped preshaped object for filling the voids.
(5) The void-shaped rod-shaped preshaped object according to any one of (1) to (4), wherein the resin is a thermoplastic resin.
(6) A preform in which the void portion is filled with the rod-shaped preshaped object for filling the void portion according to any one of (1) to (5).
(7) The preform according to (6), wherein the cross section is for manufacturing I, T, J, L, or C type girders.
(8) A molded product obtained by impregnating and curing the preform according to any one of (6) and (7) above.
(9) A method for producing a rod-shaped preshaped object for filling voids, wherein the following three steps (A) to (C) are applied to a unidirectional fabric base material to obtain a predetermined cross-sectional shape.
(A) a folding step of folding three or more times so that the end portion of the unidirectional fabric base material is inside,
(B) Heating and pressurizing step for shaping the base material used in the folding step into a predetermined cross-sectional shape by heat and pressure,
(C) A cooling shape fixing step for cooling the rod-shaped preshaped object and fixing the shape.
(10) The method for producing a rod-shaped preshaped object for filling a void according to (9), wherein the unidirectional fabric base material is cut into a predetermined pattern in advance.
(11) An apparatus for producing a rod-shaped preshaped object for filling voids, comprising at least the following three means (a) to (c).
(A) folding means for folding three or more times so that the end of the unidirectional textile substrate is inside,
(B) heating and pressure shaping means for shaping the base material used for the folding means into a predetermined cross-sectional shape by heat and pressure;
(C) Cooling shape fixing means for cooling the rod-shaped preshaped object and fixing the shape.

  According to the present invention, it is possible to easily fill the gaps of various shapes of the preform and easily form without impregnation failure or resin richness, and to further improve the physical properties of the composite member manufactured by the preform. A shape can be obtained.

  The void-shaped rod-shaped preshaped object for filling the void portion of the present invention is a rod-shaped preshaped material that is filled in the void space of the preform as a reinforcing material. The preform is usually formed by combining and laminating sheet-like reinforcing fiber base materials, but when creating a preform with a cross-sectionally branched shape, the reinforcing fiber base material is in close contact with the corners at the branched portions. In most cases, there is a gap because it cannot bend completely. Filling such gaps and molding without impregnation failure or resin richness contributes to improving the physical properties of the composite member.

  The rod-shaped preshaped object for filling voids of the present invention is composed of a unidirectional woven fabric substrate made of reinforcing fibers, and is folded so that the end of the substrate is inside the rod-shaped preshaped material. And has a cross-sectional shape folded three or more times in the weft direction. By comprising the base material of the unidirectional woven fabric, it contributes to the most required longitudinal rigidity and can be highly filled by folding in the weft direction of the unidirectional woven fabric, which is advantageous for improving the rigidity. Furthermore, by having the cross section folded three times or more, as will be described later, the effect that the base material end does not come out and the impregnation property is improved is obtained.

  Moreover, the bending rigidity of the rod-shaped pre-shaped object for filling voids of the present invention changes in the longitudinal direction. By changing the bending rigidity in the longitudinal direction, it is possible to easily fill the gaps having various shapes. For example, by continuously changing the bending rigidity, it is easy to fit along the gap of the shape having a gentle bend, and if a part with a low rigidity is provided, it can be bent at that part, and the bent part It is possible to easily follow a gap having a gap.

  Further, when the bending stiffness is continuously changed, if the amount of reinforcing fibers is continuously reduced and the cross-sectional area is gradually reduced, the present invention can be applied to a gap in which the cross-sectional area changes in the longitudinal direction.

  This will be described below with reference to the drawings.

  FIG. 2A is a schematic view showing an example of a method for producing a void-shaped filling rod-shaped preshaped object of the present invention. In this schematic diagram, an example is given in which a void-shaped rod-shaped preshaped object for filling voids provided with a partially low-rigidity part is given. The rod-shaped preshaped object 18 of the present invention uses a unidirectional woven base material 11 that has been pre-patterned, and is folded at least three times so that the end enters the inside, a heating shaping process 14, and a cooling and fixing process. It is obtained by going through 15 and so on.

  The unidirectional fabric base 11 has a cross-sectional shape that is folded and folded three or more times in the weft direction so that the crease line is almost parallel to the fiber orientation direction (warp direction) that exhibits main strength and rigidity. is doing.

  The first purpose of folding and folding the substrate is to fold the substrate inward so that the end of the substrate does not come out of the outer layer. This is because the unidirectional fabric base end tends to cause fiber disturbance or single yarn breakage, and if it occurs, it is difficult to return to the original state. There is a concern of reducing the mechanical properties. In addition, a method of applying a resin material or a method of sewing may be applied in order to prevent fiber disturbance and single yarn breakage at the base end. As a resin to be applied in the case of applying a method of applying a resin material, the same resin as that used for molding, for example, an epoxy resin, a vinyl ester resin, an unsaturated polyester resin, etc., and as a fiber to be sewn Nylon, aramid fiber, boron fiber, glass fiber, etc. are mentioned, but it is not limited thereto, and the sewing method is not particularly limited, and both may be performed simultaneously. However, since these cause a long process, it is preferable to select them so as to satisfy physical properties and costs.

  The second purpose is to improve the impregnation property of the rod-shaped preshaped object. In general, when several sheets of reinforcing fiber woven materials are laminated, since the impregnation in the thickness direction is superior to the surface direction, the unidirectional woven fabric base material is folded as described above from a round spiral cross-sectional shape. This is because the number of sheets to be impregnated when reaching the center is smaller.

  Next, an example of a method of folding the substrate end portion into the interior three times will be described with reference to FIG. 5 which is a schematic cross-sectional view of the rod-shaped preshaped object of the present invention. First, the both ends 41 of the base material are folded so as to substantially coincide with the center line (the number of times of folding is twice), and then the base material is newly formed after the base material is folded as described above. Although there is a method of folding so that both ends are inside (folding frequency is 1), it is not limited to this as long as the ends are folded inside.

  The unidirectional textile base material used for the rod-shaped preshaped object is, for example, arranged on the sheet in parallel to each other in parallel to each other in the unidirectional woven fabric, which is stress-concentrated, and reinforced on both sides of this sheet surface The fibers are arranged in a sheet in parallel in one direction, and thin wefts that cross the reinforcing fibers are located on both sides of the sheet surface, and these wefts and the auxiliary yarns in the warp direction parallel to the reinforcing fibers form the woven structure. This is a so-called unidirectional non-crimp fabric in which reinforcing fibers are integrally held, and particles adhere to the surface of the unidirectional non-crimp fabric.

The case where warp reinforcing fibers and wefts are integrated with a non-crimp structure has been described as a unidirectional woven fabric forming a unidirectional woven base material. However, a plain structure, a twill structure, and a satin structure may be used. As a preferred form of the unidirectional woven fabric, the unidirectional woven fabric base material is carbon fiber in which the warp yarn is carbon fiber, the weft direction auxiliary yarn has a fineness of 6 to 70 dtex, and the density of the weft direction auxiliary yarn is 0.3. / Cm to less than 6.0 fibers / cm, and the basis weight of the carbon fiber is preferably 100 g / m ² or more. The basis weight is measured based on JIS K 7602.

  The reinforcing fiber used in the present invention is a multifilament, and the type thereof is not particularly limited. For example, glass fiber, alumina fiber, silicon carbide fiber, metal fiber, organic (polyaramid, polyphenylenebenzbisoxazole, liquid crystal polymer fiber, Polyvinyl alcohol, polyethylene, polyphenylene sulfide fiber, etc.) fiber or carbon fiber. In particular, carbon fibers are excellent in specific strength and specific elastic modulus and excellent in water absorption resistance, and are therefore preferably used as aircraft structural materials and automobile reinforcing fibers.

  In the present invention, as a unidirectional textile base material for producing a void-shaped filling rod-shaped preshaped article, a base material in which a particulate, fibrous or film-like resin is previously attached to at least one surface is used. preferable. Furthermore, it is preferable to be a rod-shaped preshaped object that is formed by folding and folding the substrate to which such a resin is attached and folding the end of the substrate into the rod-shaped preshaped object. Moreover, it is preferable that 50 to 90% of all the fibers of the rod-shaped preshaped object are oriented in the longitudinal direction.

  The resin used in the present invention preferably has a melting point or glass transition temperature in the range of 50 to 150 ° C. from the viewpoint of adhesion of the resin to the woven fiber and workability. As the component of the resin, those that improve the handleability of the textile substrate are preferable, and more preferably, the mechanical properties of the fiber-reinforced plastic obtained by using the same are improved. As the resin, various thermosetting resins and / or thermoplastic resins can be used.

  When the thermoplastic resin is used as the main component of the particles, for example, it is preferably at least one selected from polyamide, polysulfone, polyethersulfone, polyetherimide, polyphenylene ether, polyimide, polyamideimide, phenoxy, Of these, polyamide, polyetherimide, polyphenylene ether, and polyether sulfone are particularly preferable.

  The thermoplastic resin is the main component in the form of particles, fibers or films, and the blending amount is preferably 60 to 100% by weight. More preferably, it is 75-97 weight%, More preferably, it is 80-95 weight%. If the blending amount is less than 60% by weight, it may be difficult to obtain a fiber reinforced plastic excellent in impact resistance. Moreover, when a thermoplastic resin is a main component, the adhesiveness or bondability of particulate, fibrous, or film-like resin to a fabric may be inferior. In this case, it is preferable to add a small amount of a tackifier or a plasticizer to the resin. If a resin component containing a thermoplastic resin as a main component is used as a fixing agent, the resin does not deteriorate even if heating is repeated. Therefore, one of the preferable reasons is that heating shaping and re-shaping can be performed in multiple stages.

  Next, the steps necessary to produce the rod-shaped preshaped object will be described, but other steps may be included to improve the quality and yield.

1. Folding process (or means)
Prepare a base material with a cut pattern that takes into account the part of the base material that you want to deform and the part that you want to change the cross-section of. Try to be inside the shape. It is preferable to cut the cut pattern (being a fiber input amount) in consideration of the cross-sectional change and the portion to be bent, and when cutting into a stepped shape like the unidirectional fabric base 11 in FIG. 4B, When the ratio of the maximum cut width 27 and the maximum base material width 28 is smaller than 1/3, the outermost layer becomes a continuous fiber when folded so that the abrasion resistance is improved. preferable. In the case of a shape like the trapezoidal unidirectional woven fabric base 23 in FIG. 4A, the mold length 34 shown in FIG. 2A is L, the wide length 31 shown in FIG. 4A is B, and the narrow length 32 is. When C is C, it is preferable that these satisfy the following formula.
(BC) / L> 1/3
B: Long side C: Short side L: Mold length When folded so that the number of times of folding and the width 33 after folding are less than twice the maximum width of the die used in the next heating shaping step (or means) It is preferable because friction at the time of passing through the die can be reduced and local thread breakage is less likely to occur. The point of this manufacturing method is to control the following characteristics (such as resin type, shape, particle size, particle amount, particle Tg, substrate width, or core material of another member in the substrate). It is possible to produce rod-shaped preshaped products having various physical properties and impregnation properties. (How 3 examples (i) to (iii) are shown)
(I) As an example of reducing the rigidity in order to match the rigidity with other members, a rod-shaped preshaped article is manufactured using a unidirectional woven fabric base material and a small amount of resin material, and the rod-shaped When the preform using the preshaped object is RTM molded, if the rigidity of the rod-shaped preshaped object becomes too high from the surrounding area, in order to match the rigidity of the surrounding area, By reducing the amount of fiber input during production and increasing the resin material, the rigidity can be optimized without changing the cross-sectional shape.

  (ii) As another example, by introducing the core material as a core material into the rod-shaped preshaped object and covering the core material in the folding process, the area of the resin rich portion may be reduced and the overall rigidity may not be changed. it can.

  (iii) An example in which deterioration of impregnation due to the resin material (in the case where the resin flow path of the rod-shaped preshaped object is blocked by excessively increasing the resin amount) is improved is shown. Using two or more kinds of resins (one has a glass transition temperature (Tg) higher than the heating temperature, the other has a Tg lower than the heating temperature and a slightly different particle size), the resin flow path is formed on one side, and the shape is fixed on the other. By assigning the roles, the impregnation property can be improved without changing the rigidity (which is the fiber rule).

  As described above (i) to (iii), it is possible to easily control the impregnation property, the resin-rich area, and the rigidity by changing some of the properties, but these properties can be used in the production method of the present invention. Is not limited to these.

2. Heat shaping process (or means)
In this step (or means), the base material folded in the folding step (or means) 13 receives pressure, and a wedge-shaped die 19 (round shape, polygonal shape, cross-sectional shape combining curves and straight lines, or the like may be used. ) Is shaped into a rod-shaped preshaped object having a predetermined cross-sectional shape while being heated. As an example of the wedge-shaped die 19, there is a method of providing an enclosure of a square cross section 36 around a cross section 35 of a cylinder as shown in FIG. 2B. According to this method, it is possible to easily heat the hollow section 37 of the cylindrical section 35 through the heat medium.

  A method for forming a rod-shaped preshaped object having a different bending rigidity with respect to the longitudinal direction will be described. For example, there is a method in which a unidirectional woven fabric substrate is cut in a predetermined pattern in advance and then passed through a die having a constant cross-sectional shape. In addition, as a method of manufacturing a rod-shaped preshaped object having a cross-sectional change in the longitudinal direction, for example, using a taper-shaped die divided into several pieces in the longitudinal direction, the time from the start of passing the fiber and the fiber pass When the piece of the taper-shaped die is removed from the narrow side according to the distance, a rod-shaped preshaped object having a different cross-sectional shape in the longitudinal direction can be obtained.

3. Cooling process (or means)
In this step (or means), the rod-shaped preshaped object shaped into a predetermined cross-sectional shape and a predetermined reinforcing fiber volume ratio in the heating shaping step (or means) is cooled, and a particulate or fibrous resin or the like is cooled. This is a cooling step (or means) for fixing the shape with a material having a shape fixing function.

  The present invention only needs to include at least the three steps (or means) of the folding step (or means) 13, the heating shaping step (or means) 14, and the cooling step (or means) 15.

Further, the present production method can control the reinforcing fiber volume content from the basis weight of the fiber and the width of the unidirectional reinforcing fiber base material, and calculates the reinforcing fiber volume fraction Vpf constituting the rod-shaped preshaped object. As follows, the following equation is used.
Vpf = F × L / ρ / S × 100 (%)
F: Reinforcement fiber basis weight (g / cm ² )
L: Width of unidirectional substrate (cm) However, the direction orthogonal to the reinforcing fiber orientation direction is the width direction.
ρ: Reinforcing fiber weight (cm / cm ³ ) per 1 cm ^{3 of} unidirectional fabric base material
S: Spatial cross-sectional area (cm ² ) in the die having a final cross-sectional shape through which the unidirectional textile substrate can pass
The reinforcing fiber basis weight F and the width L of the unidirectional base material are based on JIS R 7602, and the weight of the reinforcing fiber per 1 cm ^{3 of the} unidirectional woven base material is based on JIS R 7603 in the case of carbon fiber. The density is based on JIS R 7603, and it is preferable to select and measure a solvent in consideration of wettability with fibers (when it is bad, it is easy to bite bubbles) and solubility of fibers.

  An example of a preform and a molded product in which the rod-shaped preshaped object is filled in the gap will be described with reference to FIG. 6 which is a schematic sectional view of the present invention. The rod-shaped preshaped object for filling a void portion of the present invention is preferably used for filling a void having a vertex portion. As an example of a preform having the void, the T-shaped preform 43, the I-shaped preform 44, J A cross section preform 45, a cross section preform 46, and a C section preform 50 are listed. In general, a preform having a bent cross-sectional shape such as an L-shaped cross-sectional preform 47 or a C-shaped cross-sectional preform 50 is often not bent at a right angle due to the high rigidity of the constituent fibers. In order to avoid stress concentration at the bent portion, the bent portion is often provided with R. The T-shaped preform 43, I-shaped preform 44, and J-shaped preform 45, which are examples of the present invention, are an L-shaped preform 47 or a C-shaped preform 50, a Z-shaped preform 51, and a rectangular parallelepiped. The cross-sectional preform 48 and the wedge-shaped cross-section preshaped object 49 are obtained by integrating the L-shaped cross-section preform 46 and the L-shaped cross-section preform 47 and the star-shaped cross-section preshaped object 52 as constituent members. The filling in the case of being independent as an individual like the C-shaped cross-section preform 50 is slightly different from the other, and is used to fill a gap formed when the base preform 53 and the C-shaped cross-sectional preform 50 are integrated. The wedge-shaped cross-section preshaped object 49 may be on the outermost surface or may be covered with a cover ply 54 of continuous fibers from above. As described above, various shapes can be considered as the preform of the present invention, and the point is that the gap has a gap to be filled and the gap is filled with a rod-shaped preshaped object. It can also be applied to various integrated uses such as filling between molded products or filling via an adhesive.

  A molded product obtained by impregnating and curing the preform with a resin is preferable because it fills the gap and is molded without impregnation failure or resin richness, and thus has high physical properties. As a preferable condition for obtaining such a molded article, it is preferable to use a resin having an initial viscosity of 1000 cP or less when the resin is injected at the injection temperature in order to sufficiently spread the resin to the preform. May be reduced pressure molding that can be expected to have a defoaming effect at the time of injection, that is, injection molding of the resin at a pressure below atmospheric pressure. Moreover, a wire etc. can also be mentioned as an example which uses a rod-shaped preshaped object directly at the end.

  Hereinafter, the present invention will be described more specifically based on embodiments shown in the drawings.

Example 1
The box produced in the corner portion 3 when the carbon fiber cloth 2 is laminated on the surface of the box-shaped core material 1 (inner dimensions: height: 100 mm × length: 200 mm × width: 200 mm) as shown in FIG. A rod-shaped preshaped object for filling the gap 4 between the shaped core material 1 and the carbon fiber cloth 2 is manufactured.

  In the rod-shaped preshaped article manufactured by the conventional method, all the unidirectional fibers are continuous in the longitudinal direction and it is difficult to deform at a predetermined position. In addition, since the fibers are oriented at a certain angle with respect to the longitudinal direction in a braided tissue that can be easily deformed, if the gap portion has a vertex, it will not be able to follow the vertex inevitably and become resin-rich. End up. Further, in terms of physical properties, the elastic modulus and strength are lowered because there are fewer fibers in the longitudinal direction than when unidirectional fibers are used.

  In the present invention, a rod-shaped preshaped object to be inserted into the gap between the core material and the carbon fiber cloth is manufactured by the following method in order to achieve both deformability and physical properties. First, as shown in FIG. 2A, a unidirectional woven fabric base material 3m coated with a resin material on one side is slit into a width of 80 mm, and a 100 mm position, a 300 mm position, a 500 mm position, and a 700 mm position in the longitudinal direction from both ends. A 10 mm × 2 mm piece was cut off to obtain a partially narrow unidirectional woven fabric base 11 having a part 60 mm wide. Then, the said partial narrow width unidirectional textile base material was made into the winding roll base material 12 in the roll of outer diameter 500mm, and was set to the drawing test apparatus. The pull-out test apparatus has a folding step (or means) 13, a heating shaping step (or means) 14, and a cooling and fixing step (or means) 15.

  In the pull-out test apparatus, first, the partially narrow unidirectional woven fabric base material 11 is folded three times along the wefts, both ends are inward, folded in half, and the folded unidirectional woven fabric base material is heated. A rod-shaped preshaped object 18 having a low-rigidity portion 16 and a high-rigidity portion 17 having a constant cross section after the resin material is cooled and fixed while passing through the cooling die after being compressed and shaped in the die. became. The cross-sectional shape of the die was a wedge-shaped shape 19 obtained by cutting out a fan-shaped cross section having a radius of 6 mm from a square having a side of 12 mm, and the rod-shaped preshaped object 18 was finished to have a substantially similar cross-section. Next, in order to insert the rod-shaped preshaped object into the box-shaped core material, the position in the longitudinal direction of the rod-shaped preshaped material 18 is cut to the same length as the inner peripheral length of the core material with scissors, Then, when the bent rod-shaped preshaped object 5 bent at an easily bent portion was used, the box-shaped core material was placed along the corner portion of the box-shaped core material without any gaps, and a box-shaped core material preform was obtained. . Thereafter, a carbon fiber woven base material was placed without covering the surface of the core material preform, and VaRTM molding was performed to obtain a sandwich panel A which was a molded product in which the core material was covered with the carbon fiber woven base material.

  In addition, a sandwich panel B manufactured without inserting a rod-shaped preshaped object by the same manufacturing method and a sandwich panel C inserted with a braid having the same fiber input amount as the rod-shaped preshaped material 18 are prepared for comparison. Then, cross-sectional observation and a tensile test (using a tensile test piece cut so that the rod-shaped preshaped object is in the longitudinal direction) were performed.

  As a result of observing the cross section, it was observed that in panel A, the resin rich was uniformly distributed as a whole. In panel B, a resin rich portion was observed at the apex portion of the sector cross section, and a large swell was observed in the fibers around the resin rich compared to the entire fiber swell. In panel C, voids and large resin richness were observed in the sector cross section. The tensile test results of the test pieces are as follows, and the results of panel A> panel B> panel C were obtained for both tensile modulus and strength.

Example 2
Next, an embodiment in the case of having a cross-sectional change in the longitudinal direction will be described with reference to FIG.

  In the second embodiment, the structural elements (for example, I, J, and T type cross sections) of the girder 21 having a gap portion having a cross-sectional change in the longitudinal direction, that is, the girder having the gap portion 22 having a tapered cross section in the longitudinal direction. The present invention relates to a rod-shaped preshaped object to be inserted into the gap portion of the material, a manufacturing method thereof, and a comparative evaluation result. The girders in Example 3 have a substantially right-angled isosceles triangular cross-section 26 as shown in FIG. 3 and have a total length of 1000 mm, a short side length of 6 mm on one end, and 5 mm on the other end, that is, a taper ratio of 1/1000. have. Since the manufacturing method is almost the same as that of the first embodiment, only different portions will be described. After preparing 1000 m of a unidirectional woven fabric substrate having an 80 mm width using the unidirectional woven fabric substrate similar to that in Example 1 described above, it was cut into a trapezoidal shape having a taper ratio of 1/50 using scissors. A directional fabric substrate 23 was obtained. Next, the trapezoidal unidirectional fabric base material 23 was set as a roll base material in the pull-out test apparatus and pulled out from a die to obtain a rod-shaped preshaped object 24 having a cross-sectional change. The die having a substantially right-angled isosceles triangle section has a split structure in the longitudinal direction and a taper shape. When one die is removed from the end for every 100 mm drawing (the total length of the die is shortened). The cross section could be changed by 1 mm. Next, after inserting the rod-shaped preshaped object into the gap portion 22 of the girder, a gap-filling girder covered with a cover 25 of four carbon fiber laminates from above was obtained. In addition, the gap filling girder traced the gap with the belly of the finger from the top of the cover 25, but it was not possible to find the irregularities that can be detected by palpation. Further, after molding in the same manner as described above, the cross-section of the portion where the rod-shaped preshaped object was inserted was observed, but resin-rich and voids could not be observed.

It is the schematic which shows an example of the preform using the rod-shaped preshaped object with a rigidity change in the longitudinal direction of this invention. It is an example of the method of manufacturing the rod-shaped preshaped object of this invention. It is the enlarged view which showed an example of the cross section of the heating shaping means of the direction orthogonal to the feed direction of the unidirectional textile base material in FIG. 2A. It is the schematic which shows an example of the preform using the rod-shaped preshaped object with a cross-sectional change in the longitudinal direction of this invention. It is the schematic which shows an example of the cut pattern of the unidirectional textile base material of this invention. It is the schematic which shows another example of the cut pattern of the unidirectional textile base material of this invention. It is sectional drawing which shows an example at the time of folding the unidirectional textile base material of this invention by 3 times. It is sectional drawing which shows the example of the preform of this invention, and a molded article.

Explanation of symbols

1: box-shaped core material 2: carbon fiber cloth 3: corner portion 4: gap 5: bent rod-shaped preshaped object 11: unidirectional fabric base material 12: roll base material 13: folding step (or means)
14: Heat shaping process (or means)
15: Cooling and fixing step (or means)
16: Low rigidity portion 17: High rigidity portion 18: Rod-shaped preshaped object 19: Wedge shape 21: Girder having a gap portion 22: Gap portion 23: Trapezoidal unidirectional fabric base material 24: Cross section change Rod-shaped preshaped object 25: Cover 26: Cross section of substantially right angle isosceles triangle 27: Maximum cut width 28: Maximum base material width 31: Wide width length 32: Narrow width length 33: Width after folding
34: Mold length 35: Cylindrical cross section 36: Square cross section 37: Hollow section 41: Both ends of base material 42: New end section 43: T-shaped cross section preform 44: I-shaped cross section preform 45: J-shaped cross section preform Reform 46: Cross section preform 47: L section preform 48: Rectangular section preform 49: Wedge section rod preform 50: C section preform 51: Z section preform 52: Star section preform 52 Preshaped object 53: Base preform 54: Cover ply

Claims (11)

It is a rod-shaped preshaped object that is filled as a reinforcing material in a void portion of a preform, and the rod-shaped preshaped object is composed of a unidirectional woven fabric substrate made of reinforcing fibers, and the end portion of the substrate is The rod-shaped preshaped object has a cross-sectional shape that is folded so as to be inside the rod-shaped preshaped object and is folded three times or more in the weft direction, and the bending rigidity of the rod-shaped preshaped object changes in the longitudinal direction. A rod-shaped preshaped object for filling voids. The rod-shaped preshaped object for filling voids according to claim 1, wherein the rod-shaped preshaped object has a cross-sectional change in the longitudinal direction. The said rod-shaped preshaped object is a rod-shaped preshaped object for void | hole filling of Claim 1 which has a part from which bending rigidity changes to a longitudinal direction. The said unidirectional textile base material is a bar-shaped rod filling rod according to any one of claims 1 to 3, wherein a particulate, fibrous, or film-like resin is partially disposed on at least one side. Preshaped object. The rod-shaped preshaped object for filling a void according to any one of claims 1 to 4, wherein the resin is a thermoplastic resin. The preform which filled the space | gap part with the rod-shaped preshaped object for space | gap filling in any one of Claims 1-5. The preform according to claim 6, wherein the preform is used for manufacturing I, T, J, L, or C type girders. A molded article obtained by impregnating and curing a resin in the preform according to claim 6. A method for producing a rod-shaped preshaped object for filling voids, wherein the following three steps (A) to (C) are applied to a unidirectional woven fabric substrate to obtain a predetermined cross-sectional shape.
(A) a folding step of folding three or more times so that the end portion of the unidirectional fabric base material is inside,
(B) Heating and pressurizing step for shaping the base material used in the folding step into a predetermined cross-sectional shape by heat and pressure,
(C) A cooling shape fixing step for cooling the rod-shaped preshaped object and fixing the shape. The manufacturing method of the rod-shaped preshaped object for gap | interval filling of Claim 9 using what was previously cut | disconnected by the predetermined pattern as said unidirectional textile base material. An apparatus for producing a rod-shaped preshaped object for filling a void, comprising at least the following three means (a) to (c).
(A) folding means for folding three or more times so that the end of the unidirectional textile substrate is inside,
(B) heating and pressure shaping means for shaping the base material used for the folding means into a predetermined cross-sectional shape by heat and pressure;
(C) Cooling shape fixing means for cooling the rod-shaped preshaped object and fixing the shape.

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