JP2007039867A - Method for producing multi-axial base material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a multi-axial base material, capable of crosswise laminating warp sheets at a low cost, by controlling a yarn thread width of the warp or the weft comprising many yarn threads and conducting insertion and lamination of the sheets, without forming gaps between reinforcing fiber yarn threads. <P>SOLUTION: This method for producing the multi-axial base material comprises arranging many of the yarn threads in a sheet-like state, so as to form a layer, laminating at least two or more of layers thus formed, in such a state that the yarn threads cross one another, and structuring a laminated material by integrating the layers, wherein the base material is produced through processes (A) to (D) as follows: (A) a warp unwinding process for sidewards unwinding the fiber yarn threads from bobbins in a group at a constant speed, (B) a warp drawing-out process for paralleling two or more of the unwound yarn threads of the warp, while opening the yarn threads up to a yarn thread width larger than a width of the fiber yarn threads on the bobbin, (C) a warp sheet forming process for forming the layer of the yarn sheet, while controlling the yarn thread width of the drawn-out warp to be substantially identical, and (D) a warp sheet laminating process for crosswise laminating layers of the formed warp sheets, while substantially bringing the layers into contact with the laminated material through a laminating roller. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for producing a multiaxial substrate that is suitably used as a reinforcing fiber fabric for a fiber-reinforced composite material.

  Composite materials using reinforcing fibers such as carbon fibers are used in various applications such as aircraft, ships and sports / leisure because of their excellent mechanical properties and light weight reduction effect. In these composite materials, in order to obtain a more homogeneous structure, the sheet-like material composed of reinforcing fiber yarns is usually cross-laminated by shifting in a direction such as 0 °, ± α °, 90 °, for example. Used. However, when a normal bi-directional woven fabric is used as the sheet-like material, the fiber arrangement direction is arranged only in two directions of 0 ° (warp direction) and 90 ° (weft direction). For directions such as 45 °, the woven fabric must be cut and used in the direction of 45 °, and there is a problem that material loss increases and lamination takes time.

  In response to the above problems, a multiaxial stitch base material has been proposed in which reinforcing fiber yarns are arranged in parallel in the longitudinal direction, width direction and oblique direction of the sheet-like material, and these laminates are stitched and integrated. Yes. In such a multi-axis stitch base material, since a multi-directional laminated structure can be obtained with a single material, the cut loss of the material and the laminating work can be reduced.

In the production of such a multi-axis stitch base material, a plurality of reinforcing fiber yarns are drawn from the creel and are inserted and laminated as a layer of warp sheets (0 ° direction, longitudinal direction of the base material) to obtain a laminate. Go through the process. In particular, when forming a layer with a low basis weight of 50 to 150 g / m ² of reinforcing fibers per layer, the fiber yarns unwound from the bobbin are aligned so that the yarn width does not narrow. It is important to make a warp yarn sheet and insert and stack. That is, when the fiber yarn width is narrowed, there is a problem that only a non-uniform material having a large gap between the fiber yarns can be obtained. The gap in the reinforcing fiber substrate forms an impregnated resin-rich portion when it is molded into a composite material, and becomes a starting point of fracture when stress concentration occurs. In addition, this portion is recessed due to curing shrinkage, causing a problem that the surface unevenness becomes large.

  In order to solve this problem, the yarn is prepared by laterally unwinding and pre-drawing (opening) the tow and inserting a sheet in the 0 ° direction (see Patent Document 1), or by vertically unwinding the tow. There has been proposed a method (see Patent Document 2 and Patent Document 3) in which the sheet is spread, formed into a sheet, wound up, and the sheet is inserted and stacked in the vertical direction or other lateral directions. However, in the methods proposed in Patent Documents 1, 2, and 3, only the process of opening the tow is performed, and the process of regulating the width of each tow is not performed thereafter. In such a method, there is a problem that it is impossible to uniformly control each tow having variation in spreadability to a desired yarn width, and the position of each tow is accurately determined. Therefore, there is a problem in that the basis weight and thickness variation in the sheet increase.

  Further, Patent Document 1 does not teach any method or means for disposing a warp yarn (0 ° direction) sheet in an intermediate portion other than the outermost layer, and mirror-symmetric lamination. In Patent Documents 2 and 3, there is a description that the warp yarn (0 ° direction) sheet is arranged in a position other than the outermost layer. However, not only a specific method and a means thereof are taught, but the tow is formed into a sheet once. Since it is inserted and laminated after being wound and partially warped, there is a problem that an extra step is increased. In other words, nothing is taught about a method of inserting and laminating a warp yarn sheet directly from the tow and its means.

In addition, there is a proposal that 8 layers of reinforcing fiber yarns are laminated with mirror symmetry (see Patent Document 4). However, in this proposal, the 0 ° -direction sheet is inserted only in the outermost layer, and there is no proposal to insert the 0 ° -direction sheet in the intermediate portion of the other laminates. It doesn't teach me how or how to do it. If the warp yarn (0 ° direction) sheet cannot be arranged in the middle part of the laminate, there is a problem that the mirror configuration is extremely limited and the design freedom is significantly impaired when mirror-symmetric lamination is assumed. It was. That is, in order to maximize the mechanical properties of the composite material, it is important to stack a plurality of warp sheet layers, but there is a problem that the configuration cannot be adopted.
By controlling the yarn width of the warp yarns of multiple yarns, insert a layer of warp yarn sheets (especially inserted other than the outermost layer of the base material) and laminate without forming a gap (gap) between the reinforcing fibers, An inexpensive method for producing a multiaxial substrate that can be cross-laminated (particularly mirror-symmetrical lamination) has not been found, and a technology that can solve this problem has been eagerly desired.
JP-T-2004-521197 Special table 2001-516406 gazette International Patent Publication WO98 / 10128 Pamphlet International Patent Publication WO01 / 63033 Pamphlet

  The object of the present invention is to solve the above-mentioned problems, that is, to control the fiber yarn width of the warp sheet of the multi-yarn and to form a layer of the warp sheet without forming a gap (gap) between the fiber yarns. It is an object of the present invention to provide an inexpensive method for producing a multiaxial base material that can be inserted into a layer other than the outermost layer of the base material, particularly preferably cross-laminated, particularly preferably mirror-symmetrically laminated.

The present invention employs the following means in order to solve such problems. That is, in the method for producing a multiaxial substrate of the present invention, a large number of fiber yarns are arranged in parallel in a sheet to form a layer, and at least two layers of the layers intersect with the fiber yarn. In a method for producing a multiaxial base material in which a laminated body is formed by laminating the laminated body, a layer of warp yarn sheets constituting the multiaxial base material is formed and the layers are cross-laminated. And a process for producing a multiaxial substrate characterized by passing through the following steps (A), (B), (C) and (D).
(A) A warp unwinding step of laterally unwinding the fiber yarn from the bobbin group at a substantially constant speed;
(B) A warp drawing step of drawing a plurality of unraveled warp yarns while opening them to a yarn width larger than the fiber yarn width on the bobbin,
(C) a warp sheet forming step of forming a layer of warp sheets that are aligned while regulating the width of each drawn warp thread substantially the same,
(D) A warp sheet laminating step in which the formed warp sheet layers are cross-laminated while being substantially in contact with the laminated body via a laminating roller.

According to a preferred embodiment of the method for producing a multiaxial substrate of the present invention, when forming a weft sheet layer constituting the multiaxial substrate and cross-laminating the layers, the following (H), (I) , (J) and (K).
(H) a weft unwinding step in which a fiber yarn is unrolled from a bobbin group at a substantially constant speed;
(I) a weft drawing step of drawing a plurality of unraveled weft yarns while opening them to a yarn width larger than the fiber yarn width on the bobbin,
(J) a weft sheet forming step in which a weft sheet layer is formed by aligning the widths of the drawn weft threads to be substantially the same while forming a weft sheet layer;
(K) A weft sheet laminating step in which layers of the formed weft sheet are cross-laminated.

Moreover, according to the preferable aspect of the manufacturing method of the multiaxial base material of this invention, following (E) warp sheet | seat lamination process or the weft sheet lamination | stacking process of (K), or the following (E ), (F) and (G).
(E) a transporting step of transporting each layer that is cross-stacked or each layer that is cross-stacked by a transport unit having a width that is at least half of the total width of each layer, to a location where they are integrated;
(F) an integration step of integrating the cross-layered layers by an integration means,
(G) A winding step of winding the integrated multiaxial base material around a core having a diameter of 75 to 400 mm.

  The method for producing a multiaxial substrate of the present invention also includes the following preferred embodiments.

  [1] In the transporting step (E), the warp yarn sheet arranged in the outermost layer among the cross-laminated layers is divided into a plurality of warp yarns constituting the warp yarn sheet, and the arrangement positions thereof are determined. Determine, align them, form a warp yarn sheet again, and pass through a group of rollers.

  [2] The warp sheet forming step (C) and the warp sheet stacking step (D) are continuously performed, and the step of temporarily winding the warp sheet between both steps is not included.

  [3] In the warp unwinding step of (A), the floor on which the integration means for integrating the laminated body is arranged is different from the floor on which the creel for pulling out the plurality of warps is arranged. .

  [4] In the warp unwinding step of (A), when the creel for pulling out a plurality of warps and the transport means for transporting the laminated body are viewed from the plane, the respective centers are arranged substantially on the same line. thing.

  [5] In the warp drawing process of (B), a plurality of warps are passed through a roller group composed of a plurality of rollers in an atmosphere having a temperature in the range of 50 to 250 ° C. and / or a temperature of 50 to Passing through a roller group composed of a plurality of rollers including at least a heated roller in a range of 250 ° C. to open the fiber.

  [6] The roller group is composed of a combination of a swinging roller that swings in the axial direction and a non-swinging roller that does not swing.

  [7] The means for regulating the warp yarn width in the warp sheet forming step (C) or the means for determining the warp yarn arrangement position in the conveying step (E) is a guide for regulating the warp yarns to a predetermined dimension. There is.

  [8] The restriction of the warp yarn width in the warp sheet forming step of (C) is arranged immediately before all the rollers to be contacted at a contact angle of 90 ° or more.

  [9] The guide is a grooved roller provided with a groove having a predetermined dimension, a flange, or a combination thereof.

  [10] The regulation of the warp yarn width in the warp sheet forming step (C) is performed by alternately passing adjacent wefts through at least two rollers.

  [11] A feed roller that feeds out the warp yarn sheet in the warp yarn sheet laminating step of (D), at least, a feed roller composed of a drive roller and a nip roller, and a free rotating roller disposed between the feed roller and the creel And the warp yarn contact angle of at least one of the free rotating rollers is less than 90 °.

  [12] The number of layers is 5 to 12 and each layer is cross-laminated to a mirror surface to form a laminate.

  [13] Fiber yarns are arranged in an angle (0 °) parallel to the longitudinal direction of the multiaxial substrate in a layer other than the outermost layer of the laminate.

  [14] The integration means in the integration step of (F) is integrated with stitch yarns.

  [15] In the stitching means integrated with the stitch yarn, the stitch comb has a cover of a planar body over the entire width of the multiaxial substrate.

  [16] The integration means in the integration step of (F) is integrated with the resin material disposed between the layers and on the surface of the laminate.

  According to the present invention, warp yarns or wefts of multiple yarns composed of fiber yarns are aligned without twisting, and the warp yarns are arranged in parallel while defining the yarn width of the fiber yarns, into a sheet, Since it can be directly inserted and laminated, even if the fiber yarn weight per layer is low, no gap (gap) is formed between the fiber yarns. A multiaxial substrate can be obtained. When such a multiaxial substrate is used, a composite material excellent in surface quality, mechanical properties, durability and quality stability can be obtained at low cost.

In the method for producing a multiaxial substrate of the present invention, a large number of fiber yarns are arranged in parallel in a sheet to form a layer, and at least two or more of the layers are laminated so that the fiber yarns intersect. In the method for producing a multiaxial base material in which the laminated body is formed and the laminated body is integrated, when a layer of the warp yarn sheet constituting the multiaxial base material is formed and the layer is inserted and cross-laminated In addition, the following steps (A), (B), (C) and (D) are performed.
(A) A warp unwinding step of laterally unwinding the fiber yarn from the bobbin group at a substantially constant speed;
(B) A warp drawing step of drawing a plurality of unraveled warp yarns while opening them to a yarn width larger than the fiber yarn width on the bobbin,
(C) a warp sheet forming step of forming a layer of warp sheets that are aligned while regulating the width of each drawn warp thread substantially the same,
(D) A warp sheet laminating step in which the formed warp sheet layers are cross-laminated while being substantially in contact with the laminated body via a laminating roller.

In the method for producing a multiaxial base material of the present invention, when forming a layer of a weft sheet constituting the multiaxial base material and cross-laminating the layers, the following (H), (I), (J) and The step (K) can be performed.
(H) a weft unwinding step in which a fiber yarn is unrolled from a bobbin group at a substantially constant speed;
(I) a weft drawing step of drawing a plurality of unraveled weft yarns while opening them to a yarn width larger than the fiber yarn width on the bobbin,
(J) a weft sheet forming step in which a weft sheet layer is formed by aligning the widths of the drawn weft threads to be substantially the same while forming a weft sheet layer;
(K) A weft sheet laminating step in which layers of the formed weft sheet are cross-laminated.

In the method for producing a multiaxial substrate of the present invention, the following (E), (F) and (G) are performed simultaneously with or after the warp sheet laminating step (D) or the weft sheet laminating step (K). ).
(E) Conveying step of conveying each layer to be cross-laminated or each cross-laminated layer to a portion where the layers are integrated with stitch yarns by a conveying means having a width of half or more of the total width of each layer,
(F) an integration step of integrating the cross-layered layers by an integration means,
(G) A winding step of winding the integrated multiaxial base material around a core having a diameter of 75 to 400 mm.

Next, the manufacturing method of the multiaxial base material of this invention is demonstrated based on drawing. FIG. 1 is a schematic sectional side view showing an example of a manufacturing process and an apparatus for manufacturing the multiaxial substrate of the present invention, and FIG. 2 is a schematic plan view showing an example of an apparatus for manufacturing the multiaxial substrate of the present invention. FIG.
In FIG. 1, a multiaxial substrate sa according to the present invention includes a warp sheet s1 in which fiber yarns (warp yarn group 0) for reinforcing in the warp direction (longitudinal direction of the substrate, 0 ° direction) are arranged in parallel. At least two or more layers containing s3 or s5 are cross-laminated to form a laminate, and are conveyed by the conveying means bc and integrated by the integrating means st.
The integrated multiaxial base material sa may be wound up as a scroll-like object pt by the winding means wd. The warp yarn sheets s3 and s5 are inserted and stacked by the warp sheet insertion means wa1 or the like. In addition to the warp yarn sheet, weft yarn sheets s2, s4 and the like are laminated on the multiaxial base material, and the weft yarn sheet is inserted and laminated by weft yarn sheet insertion means we1, we2, and the like.

  Hereinafter, (A) the warp unwinding step, (B) the warp drawing step, (C) the warp sheet forming step, (D) the warp sheet laminating step, and the weft sheet in the formation, insertion and lamination of the warp sheet in the present invention (H) Weft Unwinding Process, (I) Weft Pulling Process, (J) Weft Sheet Forming Process, (K) Weft Sheet Laminating Process, and Laminate Integration Process and Multiaxial Base Each process of (E) conveyance process, (F) integration process, and (G) winding process in the winding of the material will be described in detail with reference to the drawings.

(A) Warp Unwinding Step In this step, the fiber yarns arranged on the warp creel cl are unrolled at a substantially constant speed from the wound bobbin bb group. The substantially constant speed refers to a speed within a range of ± 10% of the set unwinding speed when the fiber yarn is unwound from the bobbin bb group.

As the delivery means for laterally unraveling and unwinding the fiber yarns arranged in the warp creel cl and sending out the warp yarn group 0, details will be described later. For example, drive rollers d0 and d1 driven at a constant speed are used. , D2 to unwind the fiber yarn from the bobbin group bb. The driving roller d2 may be used in combination with the nip roller n1 in order to further stabilize the speed of the fiber yarn to be unwound, or a dancer roller (not shown) in order to suppress loosening of the warp yarn group 0. You may use combining tension adjustment means, such as.
Although not shown, the fiber yarn can be unrolled at a substantially constant speed by means of rotating the shaft of the bobbin holder holding the bobbin bb group at a constant speed by a drive motor. However, this means is particularly suitable when the number of bobbins is small because the number of drive motors required increases as the number of bobbins increases.
In the horizontal unwinding of the fiber yarn of the warp group 0 in this step, it is preferable to unravel the warp yarn group 0 which is a fiber yarn while bringing the contact roller ct1 into contact with the bobbin bb group. With the contact roller ct1, it is possible to ensure that no twist enters the fiber yarn during unwinding. In particular, in the case of a flat fiber yarn, false twist is likely to be mixed. However, by using the contact roller ct1, it is possible to suppress the false twist from being mixed into the fiber yarn to a minimum. It is possible to prevent a gap (gap between yarns) from being formed inside.
Here, when the fiber yarn is unwound while the contact roller ct1 is in contact with the bobbin bb group, the variation in the yarn width and the mixing of false twist can be prevented more stably. In the present invention, since the fiber yarn is laterally unwound, a single twist is not added to the length of one bobbin that is generated when the fiber yarn is vertically unwound. Thereby, the yarn width of the warp yarn group 0 can be stably held. If the contact roller ct1 has a mechanism that can follow the bobbin bb even if its winding diameter changes due to its own weight or an elastic mechanism, the contact roller ct1 can be constantly pressed against the bobbin bb with the same linear pressure. It is possible to achieve even higher effects.
In this step, when manufacturing a multiaxial base material in which fiber yarns are arranged in the warp direction of the multiaxial base material in at least a layer other than the outermost layer of the laminated body, an integration means for integrating the laminated body It is preferable that the floor f1 on which st is arranged and the floor f2 on which at least one of the warp creel cl is arranged are different floors. Specifically, a floor configuration that minimizes the length of the yarn path through which the warp group 0 is guided to the warp sheet insertion means wa1, that is, a floor f2 that is higher than the floor f1 on which the integration means st is disposed. Preferably, at least one of the warp creel cl is placed on (or on a lower floor (not shown)). If these are arranged on the same floor, the warp yarn group 0 has to be guided to the warp sheet insertion means wa1 through a long yarn path, so that the possibility of fluctuations in the warp yarn width and false twisting increases. That is, by controlling the length of the yarn path to a minimum, it becomes possible to control the warp yarn width and to minimize false twisting.

  Further, in this step, as shown in FIG. 2, the centers of the warp clel for pulling out a plurality of warps cl and the transport means bc for transporting the laminate are arranged substantially on the same line. It is preferable. With such an arrangement, the length of the yarn path of the warp group 0 can be kept to a minimum, so that the warp yarn width control and false twisting can be kept to a minimum, and the effects of the present invention are reliably exhibited. can do. When the creel cl and the conveying means bc are arranged off the same line, the length of the yarn path is different between the bobbins bb arranged at both ends of the creel, and the warp yarns in which the fiber yarn lengths are evenly aligned. In some cases, a sheet cannot be obtained, and only a multiaxial substrate having poor mechanical properties can be obtained.

  On the above line. It is preferable that the respective centers when the integration unit st and the winding unit wd are viewed from the plane are arranged. By arranging in this way, the above-described effect can be further enhanced.

  In the weft unwinding step (H), the warp yarn in the warp unwinding step (A) may be replaced with the weft yarn. However, in the warp unwinding step (A), the bobbins bb necessary for constituting the full width of the multiaxial base material are arranged on the warp creel cl, but in the weft unwinding step (H) There is no need for the number of bobbins constituting the entire width of the substrate, and the number of bobbins necessary for constituting the weft sheet width at a level that does not impair productivity (for example, 5 to 50 cm width) may be prepared.

(B) Warp Thread Pulling Step In this step, the plurality of untwisted warp yarn groups 0 are aligned while being opened to a yarn width larger than the yarn width on the bobbin. By opening each of the warp yarn groups 0, a gap between the parallel yarns is not formed when forming the warp yarn sheet by aligning the multiple yarns, and a layer in which no gap is generated after the warp yarn insertion is formed. It can be done.

Examples of the opening means sp1 and sp2 that open the respective yarn widths of the warp yarn group 0 include those that allow the warp yarn group 0 to pass through the rollers r0, r1, and r2. With respect to such a roller group, if the roller r1 is a swinging roller that swings in the axial direction and the rollers r0 and r2 before and after the roller r1 are non-swinging rollers that do not swing, the roller r1 can be opened more widely. This can be said to be a preferred embodiment in the present invention. As the swing roller, a roller (ladder roller, engraving roller, similar roller, or the like) that can freely rotate and has a reduced contact area is preferably used. From such a viewpoint, it is preferable that the contact angle of the warp yarn group 0 to the swing roller is less than 90 °. On the other hand, the non-oscillating roller is preferably a normal circular roller that can freely rotate and does not reduce the contact area. Here, from the viewpoint of suppressing the occurrence of fluff on the fiber yarn, the surface of the roller group is preferably subjected to a satin finish or the like to reduce the coefficient of friction with the fiber yarn.
When the warp yarn group 0 is passed through the fiber opening means sp1, the adjacent warp yarns are alternately passed through different rollers r1 and r1 ′ to form the part warp yarn sheet 1 before being formed into a sheet. When the fibers are made, they can be opened to the maximum without interference. A lead 10 may be used to position the fiber yarn.

  In addition, the rollers r0, r1, r2 are heated to a temperature in the range of 50 to 250 ° C. and / or fiber yarns are placed in the rollers r0, r1, r2 in an atmosphere in such a temperature range. It is preferable to rub. By setting the temperature within this range, the sizing agent adhering to the fiber yarn can be softened, and even a fiber yarn having a narrow yarn width on the bobbin can be easily widened to form a warp yarn sheet. It is possible to eliminate the occurrence of a gap when doing so. In the above-described warp unwinding step, the same fiber opening effect can be obtained by heating the fiber yarn, which is the warp when unwinding from the bobbin bb, in the range of 50 to 250 ° C. If it is lower than 50 ° C., the effect of widening is low, and if it exceeds 250 ° C., the sizing agent may be deteriorated.

  In the weft drawing step (I), the warp yarns in the warp drawing step (B) may be replaced with weft yarns.

(C) Warp Thread Sheet Forming Step In this step, each fiber yarn opened to a yarn width larger than the yarn width on the bobbin in the warp drawing step of (B) is substantially the same in yarn width. The warp yarn sheet is formed while being regulated. In the warp drawing process of (B), the present invention once opens each warp yarn group 0 to a yarn width larger than the yarn width on the bobbin, and then regulates (narrows) the yarn width in this step. The main feature is that the warp yarn sheet is formed. That is, by combining the warp yarn drawing step (B) and the warp sheet forming step (C), the yarn width can be easily and accurately controlled stably, and the effects of the present invention can be achieved. You can play it. Restricting the yarn width to be substantially the same means that each fiber yarn is regulated within a range of ± 10% of the set yarn width.
As the restricting means for narrowing the width of each of the warp yarn groups 0, the yarn width can be accurately controlled by allowing the fiber yarn to pass through a restricting guide having a predetermined size. An example of such regulating means is one that allows the warp yarn group 0 to pass through the leads 11, 12, 13, and 14. Such leads l1, l2, 13, and 14 are preferably provided at a plurality of locations in order to accurately regulate the yarn width. In particular, when a plurality of leads are used, it is preferable to regulate the regulation width on the creel side (upstream side) to 100 to 150% of the regulation width on the winding side (downstream side). The regulation width is more preferably 103 to 130%, and still more preferably 105 to 110%. As in the above aspect, the yarn width can be regulated more accurately by regulating in stages.

  The positions where the leads 11, 12, 13, and 14 are arranged can be more accurately regulated at least immediately before the contact roller in the warp yarn stacking step (D) described later. More preferably, the leads l1, l2, 13, and 14 are arranged immediately before all the rollers such as the rollers d1 and d2 that are brought into contact at a contact angle of 90 ° or more. In particular, a roller to be contacted at a contact angle of 90 ° or more is less likely to slip between the warp yarn and the roller, so that if the roller contacts the roller at a position where it should be arranged, warping of the warp yarn is induced on the roller. It is easy to do, and a yarn length difference occurs between a plurality of warp yarns. Such a yarn length difference may cause local slack in the warp yarn sheet, making it difficult to obtain a high-quality multiaxial substrate. For the above reasons, it is a particularly preferable aspect to arrange the leads 11, 12, 13 and 14 immediately before all the rollers to be contacted.

There are no particular restrictions on the restricting means for allowing the fiber yarn to pass as long as it is a restricting guide having a predetermined dimension (for example, a lead). The yarn width of each fiber yarn can be controlled by adjusting the position and interval of the regulation guide, the thickness of the separator (wings), and the like. In this way, a warp yarn sheet with a regulated yarn width is guided to a warp yarn laminating step (D) described later, and a warp yarn sheet is inserted and laminated to obtain a desired multi-axis base material without forming a gap. Can do.
As a guide other than the lead (筬), a grooved (糸) guide roller having a groove (鍔) of a predetermined dimension, a comb (comb), a hole (circular) to regulate the yarn width , Rectangular), horizontal guides (tubular, plate-like), vertical guides (tubular, plate-like), and combinations thereof, etc. ) Since the guide roller can control the yarn width more accurately, it can be said to be a preferable embodiment in the present invention.

  FIG. 3 is a schematic sectional side view showing an example of the regulation guide roller used in the present invention. As shown in FIG. 3, when the restricting means alternately passes the warp fiber yarns adjacent to the two different grooved rollers r3 and r4 and the rollers have grooves, The yarn width is regulated by the groove width provided in the roller, and not only the occurrence of fluff of the fiber yarn can be suppressed to the minimum, but also the yarn width can be regulated more stably. The two warp yarn sheets 2 and 3 before being formed into sheets are combined with one warp yarn sheet s6 by the integrated rollers r5 and r6 and guided to the next warp yarn stacking step (D). Here, it is preferable that the groove width of the grooved rollers r3 and r4 is larger than the groove width of the integrated roller r5. The groove width is preferably 100 to 180%, more preferably 110 to 150%. When the groove width ratio is used in combination, the fiber yarn can be efficiently opened. In such an embodiment, it is preferable to perform the yarn width regulation by arranging a lead or the like immediately after the integrated roller r6. Such a lead can be more stably regulated to an accurate yarn width.

  FIG. 4 is a schematic sectional side view showing an example of another regulation guide roller used in the present invention. As shown in FIG. 4, when the restricting means allows at least two rollers r7 and r8 to alternately pass adjacent warp yarns alternately, it is not necessary to process grooves in the rollers, and the yarn width can be reduced at a low cost. Can be regulated. The warp yarn sheets 4 and 5 before being formed into two sheets are combined with one warp yarn sheet s7 by the integrated rollers r9 and r10 and guided to the next warp yarn stacking step (D). In such an embodiment, it is preferable to position the fiber yarn and regulate the yarn width by arranging a lead or the like immediately before the roller r7 and immediately after the roller r8. Such a lead can be more stably regulated to an accurate yarn width.

  In this step, it is preferable to form a warp yarn sheet having a width of 50 to 260 cm. The width of the warp yarn sheet is more preferably in the range of 100 to 160 cm. If the width of the warp yarn sheet is narrower than 50 cm, the width of the multilayer base material itself is also narrowed, so that the usable applications are limited. On the other hand, if the width of the warp sheet is wider than 260 cm, the apparatus becomes too large and the equipment becomes too expensive.

The yarn width of the fiber yarn in the warp yarn sheet is determined by the balance between the fineness of the fiber yarn and the fiber yarn weight per layer. Although details will be described later, the fiber yarn weight per layer is preferably in the range of 50 to 150 g / m ² . For example, when the fineness of the fiber yarn is 800 tex, when the fiber yarn weight per layer is 50 g / m ² , the warp yarn width is 16 mm and the fiber yarn weight is 150 g / m ^2. In this case, the warp yarn width is 5.3 mm. From this point of view, it can be said that the yarn width of the fiber yarn is preferably in the range of 5 to 16 mm (when the fineness of the fiber yarn is 800 tex). For the purposes of the present invention, the variation in the yarn width is a coefficient of variation (average standard deviation). (CV value divided by value) is preferably 10% or less.
In the weft sheet forming step (J), the warp yarn in the warp sheet forming step (C) may be replaced with the weft yarn, and the warp sheet may be replaced with the weft sheet. However, in the warp sheet forming process of (C), a warp sheet forming a layer extending over the entire width of the multiaxial substrate is formed, but in the weft sheet forming process of (J) a level that does not impair productivity (for example, 5 to 5). A weft sheet having a width of 50 cm) may be formed. If the weft sheets are sequentially arranged in parallel, a layer over the entire width of the multiaxial substrate can be formed.
(D) Warp Thread Sheet Lamination Step In this step, the formed warp sheet layers are cross-laminated while being substantially in contact with the laminate via the lamination roller ct2. However, when the warp sheet is the first layer of the laminated body, there is no laminated body to be brought into contact with, and therefore it is not possible to carry out lamination while contacting the laminated body via the lamination roller. Here, “substantially in contact with” means a part of the warp yarn sheet as a result of the warp yarn sheet being bent by its own weight or slight uneven tension in addition to the mode in which the entire warp yarn sheet is reliably in contact with the laminate. However, the aspect which is contacting the laminated body is included. More specifically, the lamination roller ct2 indicates a range of 10 mm or less from the laminated body. By cross-lamination while contacting the warp yarn sheets via the laminating roller ct2, gaps between the fiber yarns are not formed, and layers without gap generation can be stably inserted and laminated as they are. . Moreover, the effect which suppresses that the laminated | multiplyed warp sheet | seat floats up from a laminated body or an orientation angle shift | offset | expresses is also expressed.

  As the sending means for sending out the warp yarn, at least the driving roller d2 and the nip roller n1 (may be driven or may be depolarized depending on the driving roller) and / or the driving roller d1 not combined with the nip roller , D2 and a means for feeding out the warp yarn sheet. When the surfaces of the drive rollers d1 and d2 are coated with plastic and the contact angle with the warp yarn is 90 ° or more, no slip occurs between the drive roller and the warp yarn, so that the drive roller d1 and d2 is reliably and stable. Warp yarn sheet can be sent out.

When using a feeding roller, if there is a free rotating roller arranged on the creel side (upstream side) of the sending roller, the warp yarn contact angle in at least one of the free rotating rollers should be less than 90 °. Is preferred. In such an embodiment, not only can a layer without gap generation be stably inserted and laminated as it is, but also a section having a play that makes uniform the lengths of individual warps easily. And a uniform warp sheet can be fed out. The contact angle of the yarn refers to the central angle of the roll with respect to the arc in which the yarn is in contact with the roll, between the contact point at which the yarn contacts the roll and the contact point away from the roll.
It is preferable that the warp yarn sheet forming step (C) and the main step are continuously performed, and the step of winding the warp yarn sheet is not included between the steps. That is, it is preferable to draw out the warp yarns from the individual warp bobbins and draw them together to form a sheet, and insert the warp yarn sheets as they are in this step and stack them. If the warp process once winding the warp yarn sheet around the beam, not only may the extra process increase and the manufacturing cost may increase, but the warp process may not make the individual warp yarn length uniform. The warp yarn sheet tends to be non-uniform, and surface irregularities such as non-uniformity of the sheet surface may be generated in the obtained multiaxial base material, or the mechanical properties may be deteriorated.
In the weft sheet stacking step (K), the warp sheet in the warp sheet stacking step (D) may be replaced with a weft sheet. However, in the warp sheet laminating step (D) described above, cross-lamination is performed while contacting the laminated body via the laminating roller ct2, whereas in the weft sheet laminating step (K), while contacting the laminated body via the laminating roller, Cross lamination may be performed, or cross lamination may be performed without using a lamination roller. As a laminating method without using a laminating roller, there is a method in which a weft sheet is temporarily arranged above the laminated body and then parallelly moved downward and cross-laminated. Even if the weft sheet is narrower than the warp sheet, the problem of the present invention can be solved. Therefore, the gap between the fiber yarns is not formed by any method, and the layer without gap generation is stably cross-laminated. It can be done. When the weft sheet width is equal to or greater than the warp sheet width, cross-lamination via a laminating roller is preferable as in the warp sheet.
In the weft sheet stacking step (K), the inserted weft sheet is cut immediately before being transported in the transporting step (E) or at the same time as being transported, unlike the warp sheet stacking step (D). May be. By cutting each time a weft sheet is inserted, there is no need to fold back and insert the weft sheet. Therefore, the effect of the present invention that a gap between fiber yarns is not easily formed even with a low basis weight sheet is enhanced. Can play.
(E) Conveying step In this step, at least each of the cross-laminated layers including the warp yarn sheet obtained in the above step or each cross-laminated layer has a width that is at least half of the total width of each layer up to the point where they are integrated. Transport by transport means. As the conveying means, a belt conveyor is preferably used. A more preferable width of the conveying means is 90 to 110% of the entire width of the base material. When a conveying means having a width of half or more of the entire width of the base material is used, a phenomenon in which the laminated warp and weft sheets are bent by their own weight can be suppressed. By suppressing such bending (loosening of the fiber yarn), it is possible to obtain a multiaxial base material on which sheets with an accurate and uniform orientation angle are laminated.
Usually, in order to use a chopped fiber cut to a predetermined length, the belt conveyor as described above is used, but the present invention can also be used in the case of producing a multiaxial substrate that does not use chopped fiber. The present invention is characterized by finding that the problems of the present invention can be solved by conveying the laminate using the belt conveyor.
FIG. 5 is a schematic cross-sectional side view showing an example of a transport process used in the present invention.

In this step, the warp yarn sheet arranged in the outermost layer among the cross-layered layers is divided into a plurality of warp yarns constituting the warp yarn sheet, the respective arrangement positions are determined, and they are aligned and again. It is preferable to form a warp yarn sheet and pass a roller group (resuming fiber means sp3) composed of a plurality of rollers. By passing through this process, the gap formed during conveyance from the warp sheet forming process of (C) to the integration process of (F) described later can be eliminated, and the generation of the gap more reliably. It is possible to form a layer of warp yarn sheet without any.
A guide is preferably used as means for determining the arrangement position of each of the plurality of warps. As such a guide, those similar to the restricting means in the warp sheet forming step of (C) can be used, but it is preferable to use a perforated guide 15 due to space problems.
Further, as the resuming fiber means sp3, it is preferable to use one having the same configuration as the roller group in the warp drawing process of (B). In particular, in this step, since it is necessary to arrange and incorporate a roller group in the conveying means, it is preferable to configure as simple as possible. From this viewpoint, the roller group uses, for example, 2 to 7 rollers r11, r12, and r13 that are not heated and do not swing (preferably 3 to 5 fixed rollers), and at least one contact angle. Is preferably contacted within a range of 30 to 180 °. When contact is made within such a range, each of the warp yarns can be efficiently opened, and the gap can be reliably eliminated in the newly formed warp yarn sheet.
(F) Integration step In this step, the cross-layered layers are integrated by an integration means. As the integration means, it is preferable that stitch yarns forming a knitted structure hold the laminated body integrally. When such a stitch yarn is used, the laminated body can be held stably and surely, there is no fear that the arrangement angle of the fiber yarns is shifted, and the handleability is excellent. For such stitch yarn, a knitting structure suitable for the orientation angle of the fiber yarn can be appropriately selected in order to stably hold the laminate. For example, in the case of one guide bar, chain knitting, 1/1 tricot knitting, and combinations thereof can be mentioned. In the case of two guide bars, knitting structure such as combination of chain knitting and insertion yarn is applied. can do. Above all, when the combination of the chain stitch and the insertion yarn is used, the tightening of the fiber yarn by the stitch yarn can be relatively loosened, and the impregnation property of the resin used when molding the composite material can be highly expressed. . Further, the bending of the fiber yarn can be reduced, and particularly excellent mechanical properties such as compressive strength and tensile strength can be expressed. Such an effect is particularly highly manifested when the multiaxial substrate is a laminate of three or more layers or has a 0 ° layer.
When the laminated body is integrally held by the stitch yarn, it is preferable that the stitch comb sc has a planar cover fc over the entire width of the multiaxial base material. The stitch comb sc refers to what regulates the position in the normal direction of the laminated body that suppresses the floating of the laminated body when the stitch needles knitting the stitch yarn penetrate the laminated body. Usually, it is a collection of linear pins or plate-like combs arranged at equal intervals between the stitch needles. The planar cover fc covers the entire width of the multiaxial substrate at the point where the linear pin or plate-shaped comb and the layer arranged in the outermost layer start to contact each other. Point to. When the planar cover fc is provided, it is possible to suppress disturbing the arrangement position with the warp sheet layer or the weft sheet layer disposed in the outermost layer of the laminate. In other words, if the sheet-like cover fc is not provided, the linear pin or the plate-like comb is caught by the fiber yarn of the layer arranged in the outermost layer, disturbing the arrangement. A gap may be generated in the warp yarn sheet or the weft yarn sheet.

  Although it depends on the number of layers to be laminated, the supply amount of the stitch yarn is preferably 3,000 to 12,000 mm / rack (480 courses). More preferably, it is 4,000 to 10,000 mm. When the supply amount is less than 3000 mm, yarn breakage frequently occurs and the productivity may be lowered, and the impregnation property and mechanical properties of the resin may be lowered. On the other hand, if the supply amount exceeds 12000 mm, the stitch yarn may be too loose and the fiber yarn may be displaced, and the integrated layer may collapse.

In this step, it is preferable to integrate the laminate obtained in the above step by one stitch. For example, a base material integrated by stitching with a configuration of [0 ° / 90 °] and a base material stitched with a configuration of [90 ° / 0 °] are laminated in order, and then stitched again and integrated. It is preferable to integrate with a single stitch in a configuration of [0 ° / 90 ° / 90 ° / 0 °], not a base material that has been converted into a base material. Originally, by stitching, the fiber yarn is easily damaged by the stitch needle. Therefore, reducing the number of stitches as much as possible can minimize a decrease in mechanical properties of the obtained composite material. That is, the effect of the present invention can be exhibited to the maximum extent by integrating the multilayered laminate with one stitch.
The stitch yarn used in the present invention preferably has a fineness of 15% or less of the fineness of the fiber yarn, more preferably 5% or less, and still more preferably 1% or less. The smaller the fineness of the stitch yarn, the smaller the influence due to its presence. That is, it is possible to suppress the bending and meandering of the fiber yarn and to exhibit the mechanical characteristics that are inherently possessed. From such a viewpoint, the fineness of the stitch yarn is preferably in the range of 0.5 to 10 tex. The fineness of the stitch yarn is more preferably in the range of 0.5 to 5 tex, and still more preferably in the range of 1 to 3 tex. If the fineness of the stitch yarn is smaller than 0.5 tex, yarn breakage may occur frequently when stitching, whereas if it exceeds 10 tex, bending or meandering of the fiber yarn may be induced.
The stitch yarn to be used is not particularly limited, but when the stitch yarn is an inorganic fiber such as carbon fiber or glass fiber, the specific strength and the specific elastic modulus are excellent, and the problem due to shrinkage is small. From another point of view, stitch yarns are organic fibers such as polyamide, polyester, paraphenylene benzobisoxazole, aramid, polyphenylene sulfide, polyethylene, polyvinyl alcohol, polyarylate, etc. Furthermore, thread breakage can be suppressed. Among these, it is particularly preferable to use polyamide from the viewpoint that the fineness can be reduced and the mechanical properties of the composite material are expressed.
As an integration means, resin materials (for example, non-woven fabric, particles, cut fibers, arranged yarns, and combinations thereof) are arranged between the layers and the surface of the laminate, and the laminate is integrated with the resin material. Can also be held. The resin material may be integrated by dissolving a part or all of the resin material, or may be integrated by simply disposing a resin material that originally has adhesiveness. According to such an integration means, since the stitches are not stitched, there is no possibility of damaging the fiber yarn with the needle, and a composite material having higher mechanical properties can be obtained.
As the resin material, it is preferable to use a nonwoven fabric in order to efficiently and uniformly integrate a wide area. Moreover, in order to improve a moldability (drape property), it is preferable to use particle | grains and can use it properly according to the objective. Among these, the nonwoven fabric can be said to be the most preferable aspect because it can maximize the productivity of the multiaxial substrate. As a nonwoven fabric, the minimum amount which can be integrated should just be arrange | positioned and it is preferable that the fabric weight is 2-10 g / m < ² >. Further, when the melting point of the polymer used is 170 ° C. or lower, it can be dissolved and integrated at a relatively low temperature.
(G) Winding step The integrated multiaxial base material sa is wound up as a roll-like material pt of the multiaxial base material by the winding means wd via the nip roller n2. That is, in this step, the integrated multiaxial base material sa is wound around a core having a diameter of preferably 75 to 400 mm. The preferred diameter of a core such as a paper tube or an iron tube, for example, that winds up the multiaxial substrate used in the present invention is 150 to 320 mm. In a multiaxial base material laminated in multiple layers, if the core is less than 75 mm in diameter, a circumferential length difference occurs between the inner layer and the outer layer, and the multiaxial base material is loosened in the inner layer. In some cases, the fiber yarn may bend or wrinkle. On the other hand, if the core has a diameter exceeding 400 mm, it is advantageous in terms of the difference in circumferential length, but there may be inconveniences such as an increase in transportation cost because the scroll itself is bulky.

In the method for producing a multiaxial base material of the present invention, in particular, when more than 5 layers are laminated, the winding itself may be a problem. In such a case, it is good to cut | disconnect for every predetermined length, without winding up, and to manufacture a sheet-like multiaxial base material continuously.
As a winding means for winding the multi-axis base material, for example, a driving roller is arranged in contact with the surface of the multi-axis base material and the surface is driven by friction between the scroll and the roller, or the core itself is used. Direct drive to rotate is mentioned. In the case of surface driving, since it is easy for slack to occur particularly at the winding start portion (core portion of the winding), it is preferable to wind up the winding by direct driving of the core.

  The multiaxial base material obtained by the method for producing a multiaxial base material of the present invention preferably has 5 to 12 layers. Assuming mirror-symmetrical lamination, if the number of laminations is less than 5, there are cases where the lamination configuration is extremely restricted, and the degree of freedom in base material design and composite material design may be significantly impaired. On the other hand, when the number of laminated layers exceeds 12, the multiaxial base material becomes too thick, and it becomes difficult to handle the roll when the multiaxial base material is difficult to wind and transport, or when the formability is poor. . That is, the effect of the present invention can be exhibited to the maximum extent within the range of the number of layers.

  According to the method for producing a multiaxial substrate of the present invention, at least the layers other than the outermost layer of the laminate can be arranged with fiber yarns at an angle (0 °) parallel to the longitudinal direction of the multiaxial substrate, And the multiaxial base material in which the laminated body cross-laminates mirror-symmetrically can be manufactured easily. If the warp yarn sheet can only be laminated on the outermost layer, that is, if the 0 ° -direction sheet cannot be arranged in the middle part of the laminated body, then assuming a mirror-symmetric lamination, the lamination configuration is extremely limited, and the degree of freedom in design is reduced. It may be seriously damaged. That is, in order to maximize the mechanical properties of the composite material, it is important to stack a plurality of warp sheets, but the configuration may not be adopted. That is, in the multiaxial substrate produced by the method for producing a multiaxial substrate of the present invention, it is preferable that fiber yarns are arranged in the direction of 0 ° in at least a layer other than the outermost layer of the laminate, and The effect of the present invention can be exerted to the maximum extent only by mirror-symmetric lamination.

  According to the method for producing a multiaxial base material of the present invention, a multiaxial base material in which the stitch yarns that integrate the laminated body are integrated by one stitch can be easily produced. Originally, the fiber yarn is easily damaged by the stitch needle by stitching. Therefore, reducing the number of stitches as much as possible contributes to minimizing the deterioration of the mechanical properties of the resulting composite material. In other words, the effects of the present invention can be maximized by integrating them with a single stitch.

As an index of the quality stability of the multiaxial base material manufactured by the present invention, the frequency of the gap (gap) between the fiber yarns exceeding 2 mm in each laminated layer can be mentioned. The frequency of such gaps (value obtained by averaging the values for each layer in all layers) is preferably 0.5 pieces / m ² or less. When the frequency of the gap exceeds 0.5 pieces / m ² , pits (unfilled portions of the resin) are generated on the surface when the composite material is used, and the surface quality is inferior or a resin rich layer is formed. Depending on the application, it may be inferior in quality stability of mechanical properties (particularly environmental durability and compressive strength under wet heat environment). That is, the multiaxial base material manufactured by the present invention can exhibit the effects of the present invention to the maximum if the frequency of the gap is 0.5 pieces / m ² or less.

The frequency of gaps between fiber yarns exceeding 2 mm in the present invention (the number present per 1 m ² ) refers to a value obtained by averaging the values for each layer, measured as follows, in all layers. That is, the number of gaps exceeding 2 mm width existing on the outermost layer of the measurement sample is counted. Specifically, regarding the gap between the fiber yarn A and the fiber yarn B, if there is even one place exceeding 2 mm, the gap is counted as one. As the width of the gap, a gap measured with a caliper in the plane direction of the sample is used. The range to be measured is within an arbitrary 1 m width × 1 m length (1 m ² ) excluding 5 cm at the end of the sample. However, when the sample width is narrower than 1.1 m, the range is (width excluding 5 cm at the end of the sample) × (length determined so that the measurement range is 1 m ² ). Such measurement is repeated three times to obtain an average value, which is defined as the gap frequency of the layer. Next, the stitch yarn is unwound, the inner layer of the measurement sample is exposed, and each layer is counted in the same manner as described above. The frequency of the gap of each layer obtained by such measurement is averaged to obtain the frequency of the gap in the fiber substrate.

As the fiber yarn used in the present invention, those usable as fiber yarns for composite materials are preferably used. For example, carbon fiber, graphite fiber, glass fiber, aramid, paraphenylenebenzobisoxazole, polyvinyl Examples thereof include organic fibers such as alcohol, polyethylene, polyarylate, and polyimide. One or a combination of two or more of these can be used. Among these, carbon fibers are excellent in specific strength and specific elastic modulus and are preferably used.
The fiber yarn is preferably attached with 0.2 to 2.5% by weight of a sizing agent in order to improve handleability and resistance to needle abrasion during stitching. The fiber yarn to which the sizing agent within the above range is attached can efficiently suppress the generation of fuzz.

The fiber yarn can be used either untwisted or twisted, but is preferably substantially untwisted (less than 1 turn / m) from the viewpoint of mechanical properties such as tension and compression. The fineness of the fiber yarn is preferably 500 to 7,000 tex, more preferably 1,000 to 2,000 tex. When the fineness is too small, there is almost no problem that the fiber yarn is twisted, and the effect of the present invention may not be exhibited. Further, since the fiber yarn is expensive and a large number of fiber yarns having such fineness are used, the multiaxial substrate itself is also expensive. On the other hand, when the fineness is too large, for example, when obtaining a multi-axis base material having a low basis weight of 150 g / m ² / layer or less, the yarn width is likely to fluctuate with a slight force, and it is difficult to maintain a stable yarn width. There is.
The fiber yarn is particularly preferably a carbon fiber yarn having a yarn width of 5 to 30 mm and a yarn width / yarn thickness ratio of 30 to 100. By using such a flat carbon fiber yarn, a low basis weight multiaxial substrate can be easily obtained. When the yarn width is less than 5 mm or the yarn width / yarn thickness ratio is less than 30, there is almost no problem that the fiber yarn is twisted, and the effect of the present invention may not be exhibited. In addition, the fiber yarn may not be sufficiently opened, and it may be difficult to reduce the basis weight. On the other hand, if the yarn width exceeds 30 mm or the yarn width / yarn thickness ratio exceeds 100, the yarn width is likely to fluctuate and it may be difficult to maintain a stable yarn width.

The multiaxial base material obtained by the method for producing a multiaxial base material of the present invention preferably has a fiber yarn weight per layer of 50 to 150 g / m ² . The basis weight is more preferably in the range of 80 to 120 g / m ² . By applying the range of the basis weight to the case of obtaining a multiaxial base material using the fiber yarn having the fineness, the effect of the present invention is exhibited to the maximum extent. That is, if the basis weight of the fiber yarns in each layer exceeds 150 g / m ² , the significance of the present invention may be dilute. On the other hand, when the weight per unit area is less than 50 g / m ² , it is necessary to stack too many layers to obtain a desired strength in the composite material, which may result in poor productivity.

  The multiaxial base material can be made into a composite material by a molding method in which a matrix resin is impregnated to form a prepreg or semi-preg and then heated and solidified. More preferable molding methods in the present invention include injection molding methods such as high productivity RTM, RFI, RIM, vacuum pressure molding and the like. Among them, from the viewpoint of molding cost, RTM [for example, a molding method in which a resin is pressurized and injected into a cavity formed by a male mold and a female mold. Preferably, the cavity is decompressed and the resin is injected. ] And vacuum pressure molding [for example, the cavity formed by either one of the male mold or the female mold and a bag material such as a film (for example, nylon film, silicon rubber, etc.) is decompressed, and the pressure difference from the atmospheric pressure Molding method for resin injection. Preferably, a resin diffusion medium (media) is disposed in the preform in the cavity to promote resin impregnation, and the media is separated from the composite material after molding. ] Is preferably used.

  Hereinafter, the manufacturing method of the multiaxial base material of this invention is demonstrated in detail by an Example. The materials used in the examples are as follows.

・ Fiber yarn:
Tensile strength 4,900 MPa, tensile elastic modulus 235 GPa, number of filaments 12,000, total fineness 800 tex, thread width 6 mm on bobbin, thread thickness 0.16 mm, thread width / thread thickness ratio 38 (flat form), epoxy A flat untwisted carbon fiber yarn formed by adhering 0.5% by weight of a sizing agent mainly composed of a resin.

・ Stitch yarn:
Polyester fiber yarn with 36 filaments and total fineness of 5.6 tex.

Example 1
Seven layers are laminated mirror-symmetrically at an orientation angle [+ 45 ° / 0 ° / −45 ° / 90 ° / −45 ° / 0 ° / + 45 °], and the basis weight of each layer is 120 g / m ² / layer. Multiaxial substrate A (width 125 cm) was produced. Details will be described below.
(A) Warp unwinding step: 188 carbon fiber yarns arranged on the warp yarn creel were unrolled at a speed of 0.5 m / min. In the side unraveling, it was pulled out by a separately provided drive roller d2.
(B) Warp yarn drawing step: The carbon fiber yarns were aligned while being opened to a yarn width (9 mm) larger than the yarn width on the bobbin. As an opening means, a roller r1 that swings in the axial direction (which freely rotates and has a plurality of slits engraved on its surface parallel to the axial direction), non-oscillating rollers r0 and r2 that do not swing A means for passing adjacent carbon fiber yarns alternately through different rollers r1 and r1 ′ was used for the (free-textured circular free rotating roller). The rollers r1, r1 ′, r0, r2 and the like were arranged in an atmosphere in the range of 150 ° C.
(C) Warp yarn sheet forming step: A warp yarn sheet having a width of 125 cm was formed on the opened carbon fiber yarn while regulating the yarn width to be the same. As the restricting means, means for passing the carbon fiber yarn through the two leads 11 and 12 was used. At that time, the width between the wings of the creel side lead l1 was 105% of the winding side lead l2, and the winding side lead l2 was immediately before the contact roller ct2. The set yarn widths of the warp yarns were each 6.7 mm, and the average actual yarn width was 6.7 mm (variation coefficient CV value of 10% or less).
(D) Warp Thread Sheet Laminating Step: The warp yarn sheet was inserted while directly contacting the laminated body via the laminating roller ct2 (clearance distance to the laminated body = 1 mm) without winding the formed warp sheet once. As a warp yarn sheet feeding means, there is a feeding roller means composed of driving rollers d1 and d2 (contact angle with the warp yarn of 130 °) whose surfaces are coated with plastic and a nip roller n1 which rotates in a reverse direction depending on the driving roller d2. Using. In addition, the contact angle of the warp yarns of the free rotation rollers r0 and r2 arranged on the creel side with respect to the delivery roller was set to 80 ° at the maximum.
(H) Weft unwinding step: The carbon fiber yarns arranged in 18 weft creels were unwound at a substantially constant speed while being pulled out by a separately provided drive roller. Each bobbin was unwound while contacting with a contact roller having a mechanism capable of following the change in bobbin diameter by its own weight. In the weft sheet laminating process of (K), the weft tape is intermittently laminated, so that the dancer is inserted between the weft creel and the weft sheet inserting means so that the bobbin group can be taken off at a substantially constant speed. A roller was placed.
(I) Weft drawing step: The carbon fiber yarns were aligned while being opened to a yarn width (9 mm) larger than the yarn width on the bobbin. As the opening means, means for passing adjacent carbon fiber yarns alternately through different rollers was used. Each roller was placed in an atmosphere in the range of 200 ° C.
(J) Weft sheet forming step: A weft sheet having a width of 10 cm was formed on the opened carbon fiber yarn while regulating the yarn width to be the same. As the regulating means, means for passing the carbon fiber yarn through one lead was used. At that time, the lead was immediately before the weft sheet inserting means. The set yarn width of the weft yarn was 6.7 mm, and the actual yarn width was also 6.7 mm (variation coefficient CV value 10% or less).
(K) Weft sheet lamination step: The formed weft sheet was inserted by the weft sheet inserting means. As the weft sheet inserting means, two clamps, that is, a clamp that grips one of the weft sheets and places it above the laminate, and a clamp that grips the other of the weft sheets placed above the stack are used. The means for inserting both clamps as they were moved downward was used. The inserted weft sheet was cut at the same time as it started to be conveyed in the conveying step (E).
(E) Conveying step: The laminate was conveyed at a speed of 0.5 m / min by a belt conveyor having a width of 90% of the entire width of the substrate. The laminate was not bent by its own weight.
(F) Integration step: One-time stitching of the cross-layered seven-layer laminate so as to be 5 gauge (2.0 course / cm) and a loop distance of 3.8 mm (2.6 wal / cm) Integrated. The knitting structure was a combination of chain knitting and 2 × 1 wrap insertion yarn using two guide bars, and the supply amount of stitch yarn for chain knitting was 3,700 mm / rack (480 courses).
(G) Winding step: The integrated multiaxial base material was wound up by 3 m on a paper tube having a diameter of 300 mm by a surface-driven winding means.

The obtained multiaxial base material was able to be stably inserted and laminated with the warp sheet layer other than the outermost layer of the base material. In addition, almost no gap was observed in each layer, and the frequency of the gap between the fiber yarns exceeding 2 mm was 0.3 / m ² .

(Example 2)
Seven layers are laminated mirror-symmetrically at an orientation angle [0 ° / + 45 ° / −45 ° / 90 ° / −45 ° / + 45 ° / 0 °]
In the warp sheet forming step (C), means for passing the carbon fiber thread through the four leads l1, l2, l3, and l4 are used as the regulating means, and the width between the wings of the lead l1 on the creel side is 104% of take-up side lead l3, 106% of l4, 106% of l2, and most take-up side lead l2 was immediately before contact roller ct2,
(D) In the warp sheet laminating step, the driving rollers d1 and d2 (contact angle with the warp is 130 °) having a hard chrome plating surface as the warp sheet feeding means, and the nip roller n1 was not used.
In the conveying step (E), the warp yarn sheet is divided into a plurality of warp yarns constituting the warp yarn sheet arranged in the outermost layer, the respective arrangement positions are determined by the perforated guide l5, and they are aligned and re-warped. And re-passing means sp3 (contact angle 75 ° of three fixed rollers r11, r12, r13, r12),
In the integration step of (F), a stainless steel planar cover fc is attached to the stitch comb at the point where contact with the layer arranged in the outermost layer starts, and the winding step of (G) And using a paper tube with a diameter of 80 mm,
Except for this, a multiaxial substrate was obtained in the same manner as in Example 1. As a result of disassembling and observing the obtained multiaxial base material stitch yarn, variations in the length and width of each warp yarn were hardly observed. In addition, almost no gap was observed in each layer, and the frequency of gaps between fiber yarns exceeding 2 mm was 0.1 / m ² , which was superior to the multiaxial substrate obtained in Example 1. It was a substrate.

(Comparative Example 1)
(A) In the warp unwinding step, a point using 188 warps in advance,
(C) In the warp yarn sheet forming process, the yarn width was not regulated the same (there is no warp setting yarn width, the actual yarn width is 7 mm on average, but varies widely in the range of 4 to 9 mm Coefficient CV value was over 25%),
In the warp sheet laminating step of (D), a point where the warp sheet is inserted through a roller disposed at a position 20 mm away from the laminate, a driving roller having a metal surface as a warp sheet feeding means, and The point where the nip roller was not used, the contact angle of the warp yarn of the free rotation roller arranged on the creel side with respect to the delivery roller was 150 ° at the maximum,
In the weft unwinding process of (H), weft unwinding the weft thread intermittently without using contact rollers and dancer rollers,
In the weft drawing process of (I), the roller is placed in an atmosphere of 25 ° C.,
(J) In the weft sheet forming process, the yarn width was not regulated the same,
In the weft sheet stacking step of (K), the inserted weft sheet is inserted while being folded at the end of the multiaxial substrate without cutting.
(E) In the transporting process, the belt conveyor is not used and only the edge is gripped and transported,
In the winding process of (G), a point using a paper tube having a diameter of 80 mm,
Except for this, a multiaxial substrate was obtained in the same manner as in Example 1. As a result of disassembling and observing the stitch yarn of the obtained multiaxial base material, the yarn length and the yarn width of each warp yarn varied, and local bending was partially observed. In addition, weft misalignment was observed due to the phenomenon that the weft yarn was bent by its own weight in the conveying process. Further, gaps exceeding 2 mm were found in each layer, and the frequency of the gaps was 4 / m ² .

  According to the method for producing a multiaxial base material of the present invention, a gap is not formed even if the basis weight of the fiber yarn per layer is low, and a multiaxial base material having a high degree of freedom in a laminated structure is obtained. be able to. When such a multiaxial substrate is used, a composite material excellent in surface quality, mechanical properties, durability and quality stability can be obtained at a low cost. Therefore, structural members such as aircraft, automobiles and ships, exterior members and interiors It can be used for repairing / reinforcing structures such as members, concrete, and other sports equipment such as golf shafts and fishing rods.

It is a schematic sectional side view which shows an example of the manufacturing process and apparatus which manufacture the multiaxial base material of this invention. It is a schematic plan view which shows an example of the apparatus which manufactures the multiaxial base material of this invention. It is a schematic sectional side view which shows an example of the control guide roller used by this invention. It is a schematic sectional side view which shows an example of another regulation guide roller used by this invention. It is a schematic sectional side view which shows an example of the conveyance process used by this invention.

Explanation of symbols

0: Warp yarn groups 1, 2, 3, 4, 5: Partial warp yarn sheets 10, 11, 12, 13, 14 before sheeting: Lead 15: Perforated guide bb: Bobbin bc: Conveying means cl: Warp yarn creel ct1: Contact roller ct2: Laminated rollers d0, d1, d2: Driving roller f1, f2: Floor n1, n2: Nip roller pt: Multi-axis substrate roll r0, r1, r1 ′, r2, r7, r8: Roller r3, r4: grooved rollers r5, r6, r9, r10: integrated rollers r11, r12, r13: fixed rollers s1, s3, s5, s6, s7: warp sheet s2, s4: weft sheet sa: multiaxial substrate sp1, sp2: Opening means sp3: Reopening means st: Integration means sc: Stitch comb fc: Cover of sheet material wa1: Warp sheet insertion means wd: Winding means we1, we2 : Weft sheet insertion means

Claims (19)

A large number of fiber yarns are arranged in parallel in a sheet to form a layer, and at least two of the layers are laminated so that the fiber yarns intersect to form a laminate, and the laminate is integrated In the method for producing a multiaxial base material, the following (A), (B), (C) are used when forming a warp sheet layer constituting the multiaxial base material and cross-laminating the layers. ) And (D), and a method for producing a multiaxial substrate.
(A) A warp unwinding step of laterally unwinding the fiber yarn from the bobbin group at a substantially constant speed;
(B) A warp drawing step of drawing a plurality of unraveled warp yarns while opening them to a yarn width larger than the fiber yarn width on the bobbin,
(C) a warp sheet forming step of forming a layer of warp sheets that are aligned while regulating the width of each drawn warp thread substantially the same,
(D) A warp sheet laminating step in which the formed warp sheet layers are cross-laminated while being substantially in contact with the laminated body via a laminating roller. When forming a weft sheet layer constituting a multiaxial substrate and cross-laminating the layers, the following steps (H), (I), (J) and (K) are performed. The manufacturing method of the multiaxial base material of Claim 1.
(H) a weft unwinding step in which a fiber yarn is unrolled from a bobbin group at a substantially constant speed;
(I) a weft drawing step of drawing a plurality of unraveled weft yarns while opening them to a yarn width larger than the fiber yarn width on the bobbin,
(J) a weft sheet forming step in which a weft sheet layer is formed by aligning the widths of the drawn weft threads to be substantially the same while forming a weft sheet layer;
(K) A weft sheet laminating step in which layers of the formed weft sheet are cross-laminated. The following (E), (F) and (G) steps are allowed to pass simultaneously with or after the warp sheet laminating step (D) or the weft sheet laminating step (K). A method for producing a multiaxial substrate according to 1 or 2.
(E) a transporting step of transporting each layer that is cross-stacked or each layer that is cross-stacked by a transport unit having a width that is at least half of the total width of each layer, to a location where they are integrated;
(F) an integration step of integrating the cross-layered layers by an integration means,
(G) A winding step of winding the integrated multiaxial base material around a core having a diameter of 75 to 400 mm.   In the conveying step (E), the warp yarn sheet arranged in the outermost layer among the cross-laminated layers is divided into a plurality of warp yarns constituting the warp yarn sheet, and the arrangement positions thereof are determined. 4. The method for producing a multi-axis substrate according to claim 3, wherein the warp yarn sheet is formed again by aligning and passing through a roller group composed of a plurality of rollers.   The warp sheet forming step (C) and the warp sheet stacking step (D) are continuously performed, and the step of temporarily winding the warp sheet between the two steps is not included. The manufacturing method of the multiaxial base material in any one of.   In the warp unwinding step of (A), the floor on which the integration means for integrating the laminate is arranged and the floor on which creels for pulling out the plurality of warps are arranged are different floors. The manufacturing method of the multiaxial base material in any one of Claims 1-5.   In the warp unwinding step of (A), when the creel for pulling out a plurality of warps and the transport means for transporting the laminate are viewed from a plane, the respective centers are arranged substantially on the same line. The manufacturing method of the multiaxial base material in any one of Claims 1-6 to do.   In the warp drawing process of (B), a plurality of warps are passed through a roller group composed of a plurality of rollers in an atmosphere having a temperature in the range of 50 to 250 ° C and / or a temperature in the range of 50 to 250 ° C. The method for producing a multiaxial substrate according to any one of claims 1 to 7, wherein a fiber group comprising a plurality of rollers including at least a heated roller is passed and opened.   9. The multiaxial base according to claim 4, wherein the roller group is configured by a combination of a swinging roller swinging in the axial direction thereof and a non-swinging roller not swinging. A method of manufacturing the material.   (C) The means for regulating the width of the warp yarn in the warp sheet forming step or the means for determining the arrangement position of the warp yarns in the conveying step (E) is a guide for regulating the warp yarns to a predetermined dimension. The manufacturing method of the multiaxial base material in any one of Claims 1-9.   The multiaxial shaft according to any one of claims 1 to 10, wherein the restriction of the warp yarn width in the warp yarn sheet forming step (C) is arranged immediately before all the rollers to be contacted at a contact angle of 90 ° or more. A method for producing a substrate.   The method for producing a multi-axis substrate according to claim 10 or 11, wherein the guide is a grooved roller provided with a groove having a predetermined dimension, a flange, or a combination thereof.   The warp yarn width in the warp sheet forming step (C) is performed by alternately passing adjacent wefts alternately through at least two rollers. The manufacturing method of the multiaxial base material of description.   (D) The warp sheet feeding step in the warp sheet stacking step is composed of at least a feed roller composed of a drive roller and a nip roller, and a free rotating roller disposed between the feed roller and the creel. The method for producing a multiaxial substrate according to any one of claims 1 to 13, wherein a contact angle of the warp yarn in at least one of the free rotating rollers is less than 90 °.   The multiaxial base material according to any one of claims 1 to 14, wherein the number of layers is 5 to 12 and each layer is cross-laminated to a mirror surface to form a laminate. Manufacturing method.   The multiaxial base according to any one of claims 1 to 15, wherein fiber yarns are arranged at an angle (0 °) parallel to the longitudinal direction of the multiaxial base material in a layer other than the outermost layer. A method of manufacturing the material.   The method for producing a multiaxial substrate according to any one of claims 1 to 16, wherein the integration means in the integration step (F) is integrated by stitch yarns.   18. The method for producing a multiaxial substrate according to claim 17, wherein in the stitching means integrated by the stitch yarn, the stitch comb has a cover of a planar body over the entire width of the multiaxial substrate.   The integration means in the integration step of (F) is one that integrates with resin materials arranged between the layers and on the surface of the laminated body. Manufacturing method of shaft substrate.

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