JP2015086491A - Three-dimensional fiber structure and method for producing three-dimensional fiber structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a three-dimensional fiber structure which can be produced by a simple process and can facilitate continuous production even when the three-dimensional fiber structure is large in size.SOLUTION: A three-dimensional fiber structure 10 includes: a body 11 formed so as to have a U-shaped cross section by a base plate part 11a and two side plate parts 11b extending from both ends of the base plate part 11a in parallel to a direction orthogonal to the base plate part 11a; and a rib 12 formed in a state of being orthogonal to the base plate part 11a and the two side plate parts 11b so as to be integrated with the body 11. The body 11 is formed by multilayer weaving such that warp yarns x1 extend in a direction in which the line of intersection of the base plate part 11a and each side plate part 11b extends, and such that weft yarns y are orthogonal to the warp yarns x1. The rib 12 is formed of warp yarns x2 extending straight between the two side plate parts 11b and the weft yarns y extending straight in a state of being orthogonal to the warp yarns x2.

Description

  The present invention relates to a three-dimensional fiber structure and a method for manufacturing the three-dimensional fiber structure, and more specifically, a main body having a U-shaped cross section (C shape), and the main body integrated with the three surfaces of the main body. The present invention relates to a three-dimensional fiber structure including a rib formed on the surface and a method for manufacturing the three-dimensional fiber structure.

  Fiber reinforced composites are widely used as lightweight structural materials. There is a three-dimensional fabric (three-dimensional fiber structure) as a reinforcing base material for composite materials. A composite material using this three-dimensional woven fabric as a reinforcing base and a resin as a matrix is used as a structural member for aircraft, automobiles, ships, or general industrial equipment.

  In order to increase the strength, the structural member has a cross-sectional shape that is not rectangular, but is formed in a cross-sectional shape such as an I shape, a T shape, or a C shape (U shape). Among these, when the cross-sectional shape is U-shaped, as shown in FIG. 13, a beam-shaped main structure 61 having a U-shaped cross-section, and a web portion 61a and a flange of the beam-shaped main structure 61 are provided. An auxiliary member (rib) 62 joined to the portion 61b has been proposed. (See Patent Document 1). The auxiliary member 62 is formed separately from the beam-shaped main structure 61 and then joined to the beam-shaped main structure 61. The auxiliary member 62 is a box-type drive formed by laminating a plurality of box-shaped carbon fiber woven materials and stitching them in the thickness direction using carbon fiber yarns so that they do not deviate from each other. It is formed by cutting the reform at the center.

Japanese Patent Laid-Open No. 9-1681

  In the configuration of Patent Document 1, the beam structure is manufactured by separately manufacturing the beam-shaped main structure 61 and the auxiliary member 62 having a U-shaped cross-section, and then joining them together. This complicates the manufacturing process. In particular, the auxiliary member 62 is a box shape formed by laminating a plurality of box-shaped carbon fiber woven materials and joining them so as not to shift each other by stitching in the thickness direction using carbon fiber yarns. Since this dry preform is formed by cutting at the center, it takes time to manufacture.

  The present invention has been made in view of the above problems, and the object thereof is a three-dimensional fiber that has a simple manufacturing process and can facilitate continuous production even if the three-dimensional fiber structure is large. It is providing the manufacturing method of a structure and a three-dimensional fiber structure.

  A three-dimensional fiber structure that solves the above problems is a main body formed in a U-shaped cross section with a substrate portion and two side plate portions that extend in parallel in a direction orthogonal to the substrate portion from both ends of the substrate portion, It is a three-dimensional fiber structure provided with a rib formed integrally with the main body in a state orthogonal to the substrate portion and the two side plate portions. The main body is composed of a multi-layered weave in which warps extend in the direction in which the line of intersection of the base plate portion and the side plate portion extends, and the rib is either a warp yarn or a weft yarn that extends straight between the two side plate portions. One of these is composed of a weft or a warp that extends straight in a state orthogonal to either the warp or the weft.

  According to this configuration, since the three-dimensional fiber structure having ribs integrally formed in a state orthogonal to the U-shaped main body is composed of warp and weft, the three-dimensional U-shaped three-dimensional When the fiber structure is manufactured, it can be manufactured by changing the arrangement state of the warp and the weft in the portion corresponding to the rib. Therefore, the manufacturing process of the three-dimensional fiber structure is simple, and continuous production can be facilitated even if the three-dimensional fiber structure is large.

  Also, which of the warp and weft constituting the ribs is arranged in a state of extending straight between the two side plate portions of the main body is determined when the three-dimensional fiber structure is manufactured. It depends on how the warp for constituting the main body is stretched between the warp beam and the warp support member.

  It is preferable that the ribs are provided at both ends of the main body, and the main body and the rib form a box having the substrate portion as a bottom wall. The fiber reinforced resin manufactured using the three-dimensional fiber structure having this structure as a reinforced base material is, for example, a member (crash box) that absorbs collision energy at the time of automobile collision for the purpose of reducing the weight of automobile parts and ensuring collision safety performance. ).

  It is preferable that a plurality of the ribs are provided at an intermediate portion in the longitudinal direction of the main body. The fiber reinforced resin manufactured using the three-dimensional fiber structure having this configuration as a reinforcing base material can be used as, for example, a lightweight and high-strength structural member.

  A manufacturing method of a three-dimensional fiber structure that solves the above problems is a main body formed in a U-shaped cross section by a substrate portion and two side plate portions that extend in parallel to a direction orthogonal to the substrate portion from both ends of the substrate portion. And a rib formed integrally with the main body in a state orthogonal to the substrate portion and the two side plate portions. Then, a warp for forming the substrate portion and the two side plate portions is stretched in a state corresponding to a cross-sectional shape of the main body between a warp beam and a warp support member, and the rib is formed. A warp is stretched between the auxiliary warp beam and the warp support member, and the warp for forming the rib is in the state corresponding to the portion where the rib is not formed, and the substrate portion and the two side plate portions The distance is perpendicular to the entire weft layer constituting the rib to be formed by the warp forming the rib in the state corresponding to the position where the rib is formed. A plurality of wefts are inserted between adjacent warp layers that are opened so as to reciprocate only. Here, the “distance perpendicular to all the weft layers constituting the rib” is the distance between the side plate portions when the warp yarns are stretched so that the both side plate portions are in a horizontal state. In a state where the warp is stretched so that the portion extends in the vertical direction, the distance corresponds to the height of the both side plate portions.

  According to this configuration, at the start of manufacture, the warp for forming the substrate portion and the two side plate portions is stretched between the warp beam and the warp support member in a state corresponding to the cross-sectional shape of the main body. A warp for forming the rib is stretched between the auxiliary warp beam and the warp support member. And the warp for forming a rib is opened in the state which becomes the same opening amount as the warp for forming a board | substrate part and said two side-plate part in the state corresponding to the location which does not form a rib. In the state corresponding to the location where the rib is formed, the warp forming the rib is opened so as to move forward or backward by a distance orthogonal to the entire weft layer constituting the rib to be formed. As a result, in substantially the same manner as when producing a three-dimensional fiber structure having a U-shaped cross section, a main body having a U-shaped cross section, and a rib formed integrally with the main body in a state orthogonal to the three surfaces of the main body, Can be manufactured. Therefore, the manufacturing process of the three-dimensional fiber structure is simple, and continuous production can be facilitated even if the three-dimensional fiber structure is large.

  It is preferable to open warps for forming the ribs so that a plurality of the ribs are provided at predetermined intervals. According to this configuration, it is possible to efficiently produce a three-dimensional fiber structure as a reinforcing base material of a fiber-reinforced composite material suitable as a structural material (beam) having a U-shaped cross section and having ribs at predetermined intervals.

  A plurality of locations where two ribs are formed in the state where the ribs are close to each other, a warp for forming the ribs is opened so as to be provided at intervals corresponding to the box to be formed, and a tertiary as an intermediate After the original fiber structure is manufactured by the method for manufacturing a three-dimensional fiber structure, the intermediate body is cut at a place where two of the ribs are close to each other to form a bottomed box-shaped three-dimensional fiber It is preferable to manufacture the structure. According to this structure, a bottomed box-shaped three-dimensional fiber structure can be produced efficiently.

  According to the present invention, the production process is simple, and continuous production can be facilitated even if the three-dimensional fiber structure is large.

(A) is a schematic perspective view of the three-dimensional fiber structure of one embodiment, (b) is a schematic partial end view of the side plate portion and the rib cut along a plane parallel to the substrate portion, and (c) is the rib of the main body and the rib. Is a schematic end view cut along a plane parallel to the surface and including the weft. The general | schematic partial end elevation which cut | disconnected the board | substrate part in the plane parallel to a board | substrate part and containing a warp. (A) is a schematic partial sectional view in which the side plate portion and the rib are cut in a plane parallel to the substrate portion and shifted by one pitch of the warp arrangement interval with respect to the cut surface in FIG. 1 (b), and (b) is the substrate portion. And the schematic sectional drawing which cut | disconnected the side-plate part in the plane parallel to a rib and containing a weft. The schematic side view which shows the weaving state of a three-dimensional fiber structure. The schematic plan view which shows the weaving state of a three-dimensional fiber structure. The schematic perspective view which shows the tension state of the warp at the time of the start of weaving of a three-dimensional fiber structure. The schematic side view which shows the weaving state of the part of the rib of a three-dimensional fiber structure. The schematic side view which shows the weaving state of the part of the rib of a three-dimensional fiber structure. The schematic perspective view of the three-dimensional fiber structure of another embodiment. The schematic partial perspective view in the middle of manufacture of the three-dimensional fiber structure of FIG. The schematic perspective view which shows the tension state of the warp at the time of the start of weaving of another embodiment. (A) is a schematic perspective view of the three-dimensional fiber structure of another embodiment, (b) is a schematic partial end view obtained by cutting the base plate portion and the rib in a plane parallel to the side plate portion and including the warp. The schematic perspective view which shows a prior art.

(First embodiment)
A first embodiment of the present invention will be described below with reference to FIGS.
As shown in FIG. 1A, the three-dimensional fiber structure 10 includes a main body 11 having a U-shaped cross section and a rib 12 formed integrally with the main body 11. The main body 11 is formed in a U-shaped cross section by a substrate portion 11a and two side plate portions 11b extending in parallel to a direction orthogonal to the substrate portion 11a from both ends of the substrate portion 11a. In this embodiment, the side plate part 11b is formed so as to protrude horizontally from both ends in the vertical direction of the substrate part 11a. The rib 12 is formed integrally with the main body 11 in a state of being orthogonal to the substrate portion 11a and the two side plate portions 11b. A plurality of ribs 12 are provided at predetermined intervals. In FIG. 1A, the three-dimensional fiber structure 10 having two ribs 12 is illustrated, but the length of the main body 11, the number of ribs 12, and the interval between the ribs 12 are set according to the purpose. .

  As shown in FIGS. 1 (b), (c), FIG. 2, FIG. 3 (a), (b), the main body 11 has a warp x1 extending in the direction in which the line of intersection between the substrate portion 11a and the side plate portion 11b extends. It extends in the longitudinal direction of the three-dimensional fiber structure 10, and is composed of a multi-layered weave arranged so that the wefts y are orthogonal to the substrate portion 11a and extend in parallel with the side plate portion 11b.

  More specifically, as shown in FIGS. 1C and 3B, the wefts y constituting the substrate portion 11a and the side plate portion 11b are parallel to the side plate portion 11b and orthogonal to the substrate portion 11a. Arranged in layers. Further, as shown in FIGS. 1B, 2 and 3A, the warps x1 constituting the substrate portion 11a and the side plate portion 11b are adjacent to each other in the vertical direction constituting the substrate portion 11a and the side plate portion 11b. The layers are arranged in a wavy pattern alternately engaged with the wefts y of each layer.

  As shown in FIG. 1 (c), the rib 12 does not have the warp x1 extending in the longitudinal direction of the three-dimensional fiber structure 10, and as shown in FIGS. 1 (b) and 3 (a), the rib 12 is composed of a warp yarn x2 extending straight between the two side plate portions 11b and a weft yarn y extending straight in a state orthogonal to the warp yarn x2. Each warp x2 is continuous with the warp x1 constituting the side plate portion 11b. Further, as shown in FIGS. 1, 2, and 3, the weft y is folded back at the end in the width direction of the three-dimensional fiber structure 10 even when it is inserted in an independent state for each layer. Alternatively, it may be inserted in a state of being continuous with the weft y of the adjacent layer.

  For the warps x1, x2 and the weft y, for example, inorganic fibers such as carbon fiber, glass fiber, ceramic fiber, or high strength such as aramid fiber, poly-p-phenylenebenzobisoxazole fiber, ultrahigh molecular weight polyethylene fiber, A high elastic modulus organic fiber or the like is used and is appropriately selected according to the required performance. For example, when the required performance of rigidity and strength is high, carbon fiber is preferable.

  Next, the manufacturing method of the three-dimensional fiber structure 10 comprised as mentioned above is demonstrated. As shown in FIG. 4, the weaving apparatus used for manufacturing the three-dimensional fiber structure 10 includes a warp beam 20 for supplying a warp x1, and a warp support member 21 for fixing one end of the warp x1 supplied from the warp beam 20. A woven front frame 22 is disposed between the warp beam 20 and the warp support member 21.

  As shown in FIGS. 4 and 5, the substrate portion heald frame 23 as a main body heald frame that opens a warp yarn x <b> 1 for forming the substrate portion 11 a between the warp beam 20 and the woven front frame 22. And a side plate portion heald frame 24 as a main body heald frame for opening a warp x1 for forming the side plate portion 11b. In FIG. 4, the side plate portion heald frame 24 is not shown, and the side plate portion heald frame 24 is illustrated only in FIG. 5. The board frame heald frame 23 and the side plate frame heald frame 24 are configured to be independently driven. As shown in FIG. 5, each board-portion heald frame 23 and each side plate-portion heald frame 24 are each formed in a width corresponding to the arrangement width of the warp yarns x1 to be driven.

  The substrate frame heald frame 23 is provided with 2 (n-1) pieces when the number of layers of the warp yarns x1 constituting the substrate portion 11a is n, and every other pair of warp yarns x1 constituting one layer. The warp x1 and the other set of warp x1 are driven by the adjacent substrate frame heald frames 23, respectively.

  The number of side plate portion heald frames 24 for opening the warp yarns x1 forming the upper side plate portion 11b is 2 (n-1), where n is the number of layers of the warp yarns x1 forming the side plate portions 11b. Thus, every other pair of warps x1 of the warps x1 constituting one layer and the other set of warps x1 are driven by the adjacent side plate portion heald frames 24, respectively. Of the warps x1 forming the lower side plate portion 11b, the warp x1 constituting the uppermost layer is constituted by a part of the warp x2 supplied from the auxiliary warp beam 25, and the opening is made by the rib heald frame 27. Is called. Of the warp yarns x1 constituting the lower side plate portion 11b, the warp yarn x1 constituting the lower layer than the uppermost layer is supplied from the warp beam 20. Therefore, the number of the side plate portion heald frames 24 for opening the warp yarns x1 constituting the lower side plate portion 11b is 2 (n-2), where n is the number of the warp yarns x1 forming the side plate portion 11b. Is provided.

  4 and 5, for the convenience of illustration, the number of layers of the warp x1 is smaller than the number of layers of the warp x1 in the case of the three-dimensional fiber structure 10 described above, and the substrate frame heald frame 23 and the number of side plate portion heald frames 24 are also smaller than necessary. If the number of warp x1 constituting the substrate portion 11a and the side plate portion 11b shown in FIGS. 1 to 3 is supported, the number of the side plate portion heald frames 24 is half that of the substrate portion heald frames 23. Although shown below, FIG. 5 shows the same number for convenience.

  The weaving apparatus includes an auxiliary warp beam 25 that supplies a warp x2 for forming the rib 12. The auxiliary warp beam 25 is disposed at a position above the substrate frame heald frame 23 and the side plate frame 24, and one end of the warp x2 supplied from the auxiliary warp beam 25 is supported by a warp through a guide bar 26. It is fixed to the member 21. Between the side plate portion heald frame 24 and the warp supporting member 21, a rib heald frame 27 for opening the warp x2 is provided. A pair of rib heald frames 27 are provided, each having a width corresponding to the arrangement width of the warp x2 to be driven. The warp x2 is used not only to constitute the rib 12, but also to constitute the uppermost layer of the warp layer constituting the lower side plate portion 11b. Therefore, the rib heald frame 27 and the side plate portion heald frame 24 so as to enable the weft insertion of the fourth layer of the weft y of the lower side plate portion 11b in a state where the portions other than the ribs 12 are woven. They are driven synchronously.

  As shown in FIGS. 4 and 5, a collar 28 is disposed between the pre-woven frame 22 and the rib heald frame 27. Further, the board frame heald frame 23, the side plate frame frame 24, and the rib frame frame 27 are driven by an opening device such as a dobby device, for example, but the warp yarns x1 and x2 may be opened by a jacquard device. .

Next, a method for manufacturing the three-dimensional fiber structure 10 using the weaving apparatus will be described.
First, the warp x1 for forming the substrate portion 11a and the two side plate portions 11b is stretched so as to have a U-shaped cross section as shown in FIG. The warp x1 is stretched through a substrate-side heald frame 23 and a side-plate-side heald frame 24 provided between the warp support member 21 and the warp beam 20. Further, the warp x2 constituting part of the rib 12 and the side plate portion 11b is stretched between the warp support member 21 and the auxiliary warp beam 25. In addition to constituting the rib 12, the warp x2 constitutes the uppermost warp layer x1 of the warp layer forming the lower side plate portion 11b. Therefore, the warp x2 is the warp x1 layer forming the lower side plate portion 11b. The warp support member 21 and the auxiliary warp beam 25 are stretched between the warp support member 21 and the auxiliary warp beam 25. The warp x1 and the warp x2 are stretched in a state of passing through the eyes of a heald (not shown) supported by the corresponding heald frame 23 for the substrate portion, the heald frame 24 for the side plate portion, and the heald frame 27 for the ribs, respectively. .

Weaving is started from a state in which the warp x1 and the warp x2 are stretched at the weaving start position.
The weft y is inserted into the warp opening using a single shuttle (not shown). Further, the substrate frame heald frame 23 that performs the opening operation of the warp yarns x1 constituting each layer of the substrate portion 11a and the side plate portion 11b so that the shuttle moves back and forth at the same height position so that the weft insertion is performed by the shuttle. The side plate portion heald frame 24 is sequentially driven so that the warp opening positions of the respective layers are the same. Further, the warp x2 constituting the rib 12 is woven so as to function as the warp x1 of the lower side plate portion 11b at a place other than the rib 12, so that the rib heald frame 27 is formed of a material other than the rib 12. In a state in which the place is woven, it is driven in synchronism with the side plate portion heald frame 24 so as to enable the weft insertion of the fourth layer of weft yarn y from below the lower side plate portion 11b.

The weaving of the three-dimensional fiber structure 10 is performed such that the wefts y are sequentially inserted from the upper side to the lower side of the main body 11.
First, the substrate frame heald frame 23 and the side plate frame heddle 24 are driven to form warp openings by warps x1 at positions where weft insertion by the shuttle is possible, and the warps x1 constituting each layer are inserted. The weft y is inserted into the warp opening formed by sequentially moving the heald frame 23 for the substrate portion and the heald frame 24 for the side plate portion so as to be arranged at positions that pass the same side every other weft y. Is done. When the shuttle moves forward in the warp opening, the board-side heald frame 23 and the side plate-side heald frame 24 are driven so that the warp opening of the next layer is formed at the return position of the shuttle. The shuttle will return. Thereafter, the wefts y are inserted by the shuttle in the same manner.

  The rib heald frame 27 stands by without performing the opening operation until the weft insertion is completed to the layer above the lowermost layer of the upper side plate portion 11b and the layer of the corresponding substrate portion 11a. Then, prior to the next weft insertion, one rib heald frame 27 is moved to the opening position. This opening position is not a position where the wefts y for one layer for forming the substrate part 11a and the side plate part 11b can be inserted, but the wefts y for all layers inserted between the two side plate parts 11b can be inserted. It becomes a position.

  In this state, the substrate portion heald frame 23 is driven, and the wefts y that generate the substrate portions 11a corresponding to the ribs 12 and the ribs 12 are arranged. The rib heald frame 27 is stopped at the open position from the next weft insertion until the weft insertion for forming the uppermost layer of the lower side plate portion 11b is performed, and only the substrate heald frame 23 is gradually moved closer to the upper layer. In order from the warp opening, the warp opening is driven so that the weft insertion of the shuttle is possible, and the weft insertion is performed in the opening of the warp x1 by the shuttle.

  Since the weft y inserted into the warp opening forming the substrate portion 11a also forms the rib 12, the rib heald frame 27 is started to be inserted to form the uppermost layer of the lower rib 12. Until then, the driving of the side plate portion heald frame 24 is stopped. 7 and 8, at the location of the rib 12, the warp x2 constituting the rib 12 is between the wefts y constituting the layers adjacent in the vertical direction as x1 constituting the side plate portion 11b. Rather than being arranged in a wavy manner so as to straddle, they are arranged so as to extend straight in a state orthogonal to the wefts y arranged between the upper and lower two side plate portions 11b. Therefore, in the rib heald frame 27, at the portion where the rib 12 is to be formed, the wefts y for all layers constituting the substrate portion 11a corresponding to the warp x2 between the both side plate portions 11b are transferred from the substrate portion 11a to the rib 12. Forward or backward movement by a distance orthogonal to the wefts y of all layers of the corresponding side plate portion 11b between the position where the opening state becomes very large and the position where the opening is closed so that the insertion can be performed in a continuously extending state. To be moved.

  When the insertion of the weft yarn y into the position where the rib 12 and the substrate portion 11a are formed at the position corresponding to the rib 12 is finished, the rib heald frame 27 arranged at the open position is arranged at the closed position. When the lower side plate portion 11b is formed, the rib heald frame 27 has the warp yarn x2 in the same manner as the substrate portion heald frame 23 and the side plate portion heald frame 24 perform the opening operation of the warp yarn x1. It is driven in a range that is arranged in a wave shape so as to straddle between the wefts y constituting the adjacent layers in the vertical direction. When the weft insertion of the lower side plate portion 11b and the corresponding substrate portion 11a is completed and the weft insertion for one layer in the longitudinal direction of the three-dimensional fiber structure 10 is completed, the warp support member 21 is one pitch. The same operation as described above is repeated.

  When the weaving of the main body 11 and the weaving of the main body 11 and the ribs 12 are repeated a predetermined number of times, and the three-dimensional fiber structure 10 having a preset length is woven, the weft y connected to the three-dimensional fiber structure 10 The warp x1 and the warp x2 are cut, and the three-dimensional fiber structure 10 is taken out. And the three-dimensional fiber structure 10 is cut | disconnected to required length, and the three-dimensional fiber structure 10 as a product is obtained. The three-dimensional fiber structure 10 is used as, for example, a reinforced base material of fiber reinforced resin, and the manufactured fiber reinforced resin is used as a structural member having a light weight and high strength.

According to this embodiment, the following effects can be obtained.
(1) The three-dimensional fiber structure 10 has a main body 11 formed in a U-shaped cross section by a substrate portion 11a and two side plate portions 11b extending in parallel to a direction orthogonal to the substrate portion 11a from both ends of the substrate portion 11a. And ribs 12 formed integrally with the main body 11 in a state orthogonal to the substrate portion 11a and the two side plate portions 11b. The main body 11 is composed of a multi-layer weave in which the warp x1 extends in the direction in which the line of intersection of the base plate portion 11a and the side plate portion 11b extends, and the weft y is formed of a multilayer weave orthogonal to the warp yarn x1, and the rib 12 is between the two side plate portions 11b. The warp x2 extends straight and the weft y extends straight in a state orthogonal to the warp x2. According to this configuration, the three-dimensional fiber structure 10 having the ribs 12 integrally formed in a state orthogonal to the body 11 having a U-shaped cross section is composed of warps x1, x2 and wefts y. When the three-dimensional fiber structure 10 having a U-shaped cross section is manufactured, it can be manufactured by changing the arrangement state of the warp and the weft in the portion corresponding to the rib 12. Therefore, the manufacturing process of the three-dimensional fiber structure 10 is simple, and continuous production can be facilitated even if the three-dimensional fiber structure 10 is large.

  (2) A plurality of ribs 12 are provided in the middle part of the main body 11 in the longitudinal direction. Therefore, the fiber reinforced resin manufactured using the three-dimensional fiber structure 10 having this configuration as a reinforcing base material can be used as, for example, a lightweight and high-strength structural member.

  (3) The manufacturing method of the three-dimensional fiber structure 10 includes a substrate portion as a main body heald frame configured to be able to independently drive the warp x1 for forming the substrate portion 11a and the two side plate portions 11b. In a state of being inserted through the heald frame 23 for the side plate and the heald frame 24 for the side plate portion, it is stretched between the warp beam 20 and the warp support member 21 in a state corresponding to the cross-sectional shape of the main body 11. Further, the warp x2 for forming the rib 12 formed integrally with the main body 11 in a state of being orthogonal to the main body 11, the substrate portion 11a and the two side plate portions 11b, the auxiliary warp beam 25, the warp support member 21, and the like It is stretched while being inserted through the rib heald frame 27. Then, the rib heald frame 27 is driven in a state corresponding to a position where the rib 12 is not formed, and the rib 12 is driven in a state corresponding to the position where the rib 12 is formed. The warp x2 to be formed is driven so as to move forward or backward by a distance orthogonal to the entire weft layer constituting the rib 12 to be formed. As a result, unlike the prior art, in the same manner as the case of manufacturing a three-dimensional fiber structure having a U-shaped cross section, the main body 11 having a U-shaped cross section and the three surfaces of the main body 11 are orthogonal to each other. And the rib 12 formed integrally with the three-dimensional fiber structure 10 can be manufactured. Therefore, the manufacturing process of the three-dimensional fiber structure 10 is simple, and continuous production becomes easy even if the three-dimensional fiber structure 10 is large.

(Second Embodiment)
Next, a second embodiment will be described with reference to FIGS. This embodiment is greatly different from the above embodiment in that the three-dimensional fiber structure 30 is formed in a bottomed box shape. The same parts as those in the first embodiment are denoted by the same reference numerals and detailed description thereof is omitted.

  As shown in FIG. 9, the three-dimensional fiber structure 30 is formed in a bottomed box shape, and ribs 12 are formed on both ends of the body 11 having a U-shaped cross section. More specifically, the main body 11 includes a substrate portion 11a and two side plate portions 11b, and ribs 12 are formed in a state orthogonal to the end portions of the substrate portion 11a and the side plate portions 11b. The substrate portion 11a is a bottom wall and side plates. The part 11b and the rib 12 form opposite side walls. In FIG. 9, the three-dimensional fiber structure 30 is illustrated in a state in which one side plate portion 11 b is on the lower side and the substrate portion 11 a serving as a bottom wall is arranged in a vertically extending state.

  As shown in FIG. 10, the bottomed box-shaped three-dimensional fiber structure 30 is provided with a plurality of locations where the ribs 12 are close to each other at intervals corresponding to the boxes to be formed. It is formed by cutting a long three-dimensional fiber structure 10 as an intermediate body formed at a predetermined position. In FIG. 10, for easy understanding, the interval between the two ribs 12 formed close to each other is illustrated widely. However, actually, the cutting blade that cuts the three-dimensional fiber structure 10 does not damage the ribs 12. It is sufficient that there is an interval at which the main body 11 can be cut.

  Manufacturing of the three-dimensional fiber structure 10 shown in FIG. 10 is performed basically in the same manner as in the first embodiment, but the ribs 12 are not close to each other but formed at regular intervals. The difference is that two places are formed so as to be provided at intervals corresponding to the boxes to be formed.

According to this embodiment, in addition to the effect described in (1) of the first embodiment, the following effect can be obtained.
(4) The three-dimensional fiber structure 30 is a main body 11 formed in a U-shaped cross section by a substrate portion 11a and two side plate portions 11b extending in parallel to a direction orthogonal to the substrate portion 11a from both ends of the substrate portion 11a. And ribs 12 provided at both ends of the main body 11. The main body 11 and the rib 12 form a box whose bottom wall is the substrate portion 11a. The fiber reinforced resin manufactured using the three-dimensional fiber structure 30 having this configuration as a reinforced base material is a member that absorbs collision energy at the time of automobile collision (crash, for example, for the purpose of reducing the weight of automobile parts and ensuring collision safety performance). Box).

  (5) The three-dimensional fiber structure 30 can be manufactured by cutting the long three-dimensional fiber structure 10 in which the box-shaped portions are continuously formed at short intervals. Therefore, the bottomed box-shaped three-dimensional fiber structure 30 can be produced efficiently.

(Third embodiment)
Next, a third embodiment will be described with reference to FIGS. In the manufacture of the three-dimensional fiber structure 10 of this embodiment, when the warp x1 for forming the main body 11 is stretched between the warp beam 20 and the warp support member 21, as shown in FIG. The group 29 is channel-shaped, that is, U-shaped in cross section, and the portion that becomes the substrate portion 11a is located on the lower side, and the portion that becomes the side plate portion 11b is extended so as to protrude upward with respect to the location that becomes the substrate portion 11a. .

  As shown in FIG. 12 (b), the warp x2 constituting the rib 12 is not part of the side plate part 11b in addition to the rib 12, but part of the substrate part 11a, unlike the two embodiments. Configure. Specifically, the uppermost layer warp x1 is sandwiched between both side plate portions 11b of the substrate portion 11a. The warps x2 forming the ribs 12 are not arranged in a state of extending straight in the direction orthogonal to the side plate portions 11b between the side plate portions 11b, but parallel to the side plate portions 11b and the substrate portions 11a. They are arranged so as to extend straight in the vertical direction and to be folded back at the upper ends of the ribs 12.

  Moreover, the point from which the weft y is inserted in a warp opening in the state orthogonal to the side-plate part 11b differs from both embodiment. When the weft y is inserted using a shuttle, the shuttle does not reciprocate for each side plate portion 11b to insert the both side plate portions 11b, but from the outer surface of one side plate portion 11b to the side plate. After penetrating through the portion 11b, the other side plate portion 11b is penetrated from the inner side surface, then folded back and penetrated through the other side plate portion 11b from the outer side, and then the one side plate portion 11b is penetrated from the inner side surface. And the same operation | movement is repeated again from the outer surface of one side plate part 11b. Therefore, the manufactured three-dimensional fiber structure 10 is in a state in which a large number of unnecessary wefts y are arranged between both side plate portions 11b where the ribs 12 are not formed. Unnecessary wefts y are removed after weaving.

  As shown in FIG. 12A, the three-dimensional fiber structure 10 of this embodiment is basically the same in appearance as the three-dimensional fiber structure 10 of the first embodiment, but constitutes the rib 12. The warp yarns x2 are arranged so as to extend in the vertical direction with respect to the substrate portion 11a and in parallel with the side plate portion 11b except for the folded portion. The wefts y constituting the ribs 12 are arranged so as to extend in parallel to the substrate part 11a and to extend in the vertical direction with respect to the side plate part 11b.

  Also in this embodiment, the three-dimensional fiber structure 10 is formed in a U-shaped cross section by the substrate portion 11a and the two side plate portions 11b extending in parallel to the direction orthogonal to the substrate portion 11a from both ends of the substrate portion 11a. And a rib 12 formed integrally with the main body 11 so as to be orthogonal to the substrate portion 11a and the two side plate portions 11b. The main body 11 is composed of a multi-layer weave in which the warp x1 extends in the direction in which the line of intersection of the base plate portion 11a and the side plate portion 11b extends, and the weft y is formed of a multi-layer weave orthogonal to the warp yarn x1. And the weft yarn y extending straight and the warp yarn x2 extending straight in a state orthogonal to the weft yarn y. Also in this configuration, the three-dimensional fiber structure 10 having the ribs 12 integrally formed in a state orthogonal to the U-shaped main body 11 is composed of the warps x1 and x2 and the wefts y. When the U-shaped three-dimensional fiber structure 10 is manufactured, it can be manufactured by changing the arrangement state of the warp and the weft in the portion corresponding to the rib 12. Therefore, the manufacturing process of the three-dimensional fiber structure 10 is simple, and continuous production becomes easy even if the three-dimensional fiber structure 10 is large.

The embodiment is not limited to the above, and may be embodied as follows, for example.
○ Insertion of the weft y is not limited to the method using the shuttle, it can be inserted using a rapier like a rapier loom, or it can be inserted using fluid jet like an air jet loom or a water jet loom. Also good. However, it is preferable to insert in a folded shape using a shuttle.

  ○ Instead of changing the opening amount of each warp layer formed by the warp x1 without changing the insertion position of the weft y inserted into the warp opening, the insertion position of the weft y is changed to the position of the warp opening. You may make it change according to it.

The insertion of the wefts y may be performed in parallel to the plurality of warp openings, instead of inserting the wefts y in order to the different warp openings.
The following technical idea (invention) can be understood from the embodiment.

  (1) A fiber-reinforced composite material comprising the three-dimensional fiber structure according to any one of claims 1 to 3 as a reinforcing fiber substrate.

  x1, x2 ... warp, y ... weft, 10, 30 ... three-dimensional fiber structure, 11 ... main body, 11a ... substrate part, 11b ... side plate part, 12 ... rib, 20 ... warp beam, 21 ... warp support member, 23 ... Helder frame for substrate part as a heald frame for main body, 24 ... Held frame for side plate part as a heald frame for main body, 25 ... Beam for auxiliary warp, 27 ... Held frame for ribs.

Claims (6)

A main body formed in a U-shaped cross section by a substrate portion and two side plate portions extending in parallel to a direction orthogonal to the substrate portion from both ends of the substrate portion, and a state orthogonal to the substrate portion and the two side plate portions A three-dimensional fiber structure comprising a rib formed integrally with the main body,
The main body is composed of a multi-layer weave in which warps extend in the direction in which the line of intersection between the substrate portion and the side plate portion extends,
The rib is composed of any one of a warp and a weft that extends straight between the two side plate portions, and a weft or a warp that extends straight in a state orthogonal to either the warp or the weft. Characteristic three-dimensional fiber structure.   The three-dimensional fiber structure according to claim 1, wherein the rib is provided at both ends of the main body, and the main body and the rib form a box having the base portion as a bottom wall.   The three-dimensional fiber structure according to claim 1, wherein a plurality of the ribs are provided in an intermediate portion in the longitudinal direction of the main body. A main body formed in a U-shaped cross section by a substrate portion and two side plate portions extending in parallel to a direction orthogonal to the substrate portion from both ends of the substrate portion, and orthogonal to the substrate portion and the two side plate portions A manufacturing method of a three-dimensional fiber structure comprising a rib formed integrally with the main body in a state,
A warp for forming the substrate portion and the two side plate portions is stretched in a state corresponding to the cross-sectional shape of the main body between a warp beam and a warp support member,
The warp for forming the rib is stretched between the auxiliary warp beam and the warp support member,
The warp for forming the rib is opened in a state corresponding to the position where the rib is not formed, in the same opening amount as the warp for forming the substrate portion and the two side plate portions, and the rib is In the state corresponding to the place to be formed, the warp forming the rib is opened so as to reciprocate by a distance orthogonal to the entire weft layer constituting the rib to be formed, and a plurality of wefts are inserted between adjacent warp layers. A method for producing a three-dimensional fiber structure.   The manufacturing method of the three-dimensional fiber structure of Claim 4 which opens the warp for forming the said rib so that multiple said ribs may be provided at predetermined intervals.   A plurality of locations where two ribs are formed in the state where the ribs are close to each other, a warp for forming the ribs is opened so as to be provided at intervals corresponding to the box to be formed, and a tertiary as an intermediate After the original fiber structure is manufactured by the method for manufacturing a three-dimensional fiber structure according to claim 4, the intermediate body is cut at two places where the ribs are close to each other to form a bottomed box shape A method for producing a three-dimensional fiber structure for producing a three-dimensional fiber structure.