JP2021059801A - Braid, braid structure using braid and resin molding provided with braid structure - Google Patents

Abstract

To provide a braid, a braid structure using a braid, and a resin molding provided with a braid structure.SOLUTION: A braid 1 is a braid using a reinforcing fiber bundle, and is formed by knitting a plurality of reinforcing fiber bundles. A reinforcing core made of a metal wire or the like may be arranged at the center of the braid in the radial direction. Furthermore, a braid structure using the braid is configured by joining respective ends of the plurality of braids, particularly by pin joining. It is preferable that in the braid structure the respective ends of the plurality of braids are joined by pin joining and that the braid structure has a truss structure. Further, a resin molding provided with the braid structure includes a structural portion in which the braid structure is embedded in a matrix resin, and other portions excluding the structural portion may be voids.SELECTED DRAWING: Figure 1

Description

The present invention relates to a braid, a braid structure using a braid, and a resin molded body including the braid structure. More specifically, the present invention relates to a braid in which a plurality of reinforcing fiber bundles are knitted, a braid structure in which the ends of the braids and the like are joined to each other, and a structure in which the braid structure is embedded in resin. The present invention relates to a resin molded body provided with a portion.

Resin molded products using fiber reinforced plastics are used in many product fields such as vehicles and buildings because they have high strength, high rigidity, light weight, and excellent durability. Further, as the reinforcing fiber, an inorganic fiber such as carbon fiber and glass fiber, and a resin fiber such as aramid fiber are used. Since the diameter of the single fibers of these reinforcing fibers is usually extremely small, practically, a large number of single fibers are bundled to form a filament, and a large number of filaments are bundled to form a tow. There is.

Further, there are known methods for producing a fiber winding body used as a fiber reinforced base material for a load energy absorber, a fiber reinforced resin material using the fiber winding body as a fiber reinforced base material, and a fiber winding body (for example). , Patent Document 1). In Patent Document 1, as a fiber-reinforced base material of a fiber-reinforced resin material, a fiber wound body manufactured by a filament winding (FW) method or a braiding (braid) is mentioned. Further, it is described that the fiber winding body is manufactured in a tubular shape or faithfully by winding a plurality of reinforcing fiber threads around the winding axis.

Furthermore, using reinforcing fibers as the core of the thermoplastic synthetic resin fibers, the synthetic resin fibers are arranged vertically, horizontally, and diagonally, and these are stacked one above the other to form a laminated sheet, and one or more of these are laminated. A multidirectional fiber-reinforced thermoplastic resin plate in which a reinforcing fiber is sufficiently impregnated with a molten resin by adhering the combined laminate to a heating plate and heating and pressurizing the laminated material is known (see, for example, Patent Document 2). ).

JP-A-2018-9265 Japanese Unexamined Patent Publication No. 2006-123417

In the fiber-reinforced resin material described in Patent Document 1, it is described that the mechanical properties (mechanical properties) are improved as compared with the matrix itself by combining the fiber-reinforced base material with a matrix such as resin. As the fiber reinforced base material, a fiber winding body manufactured by a filament winding (FW) method or a braiding (braid) method is mentioned. However, the fiber-reinforced base material is a fiber wound body, which is disadvantageous in terms of process and cost.

In addition, various resin molded products using fiber reinforced plastics made of inorganic fiber tow as a reinforcing fiber are provided, but when the reinforcing fiber is used as a woven fabric, the degree of freedom in the direction of the reinforcing fiber is low, and a specific product is provided. There is a problem that the resin molded product is reinforced only in the direction. Further, similarly to the multi-directional fiber reinforced thermoplastic resin plate described in Patent Document 2, if the toe is arranged in a required direction in which it is necessary to increase the strength in the resin molded product, it is reinforced only in a specific direction. The problem of being done may be solved.

However, when a plurality of tows are arranged in a predetermined direction, each toe is not restrained like a woven fabric, so that the toes may be decomposed into filaments or even single fibers. The problem arises. Further, the tow may be fixed with a binder or the like so that the toe does not decompose into filaments or even single fibers. However, in this case, it becomes difficult to change the shape such as the flexibility of the toe, and it becomes a circle. There is a problem that a curved shape such as an arc cannot be formed.

The present invention has been made in view of the above-mentioned conventional technique, and is a braid structure in which a plurality of reinforcing fiber bundles are knitted, a braid structure formed by joining the ends of each braid, and the like. It is an object of the present invention to provide a resin molded body having a structural portion in which a braided structure is embedded in a resin.

The present invention is as follows.
1. 1. A braid using a reinforced fiber bundle,
A braid characterized in that a plurality of the reinforcing fiber bundles are knitted.
2. A reinforcing core material is arranged at the center of the braid in the radial direction. The braid described in.
3. 3. The above 1. Or 2. It is a braid structure using the braid described in.
A braid structure characterized in that the ends of each of the plurality of braids are joined to each other.
4. The above 1. Or 2. It is a braid structure using the braid described in.
At least a part of the braids is branched in the length direction to form a branch cord, and the end of the braid is joined to the end of another braid or the end of the branch cord. A braided structure characterized by being composed of.
5. The above 1. Or 2. It is a braid structure using the braid described in.
At least a part of the braids is branched in the length direction to form a branch string, and at least a part of the braids is re-knitted to form a re-braid, and the end of the braid is formed. A braid structure characterized in that the portion is formed by being joined to the end of another braid or the end of the branch cord.
6. 3. The joint is a pin joint. To 5. The braided structure according to any one of the items.
7. 6. The joint is a pin joint and is formed in a truss structure. Braided structure described in.
8. 3. To 7. A resin molded product provided with the braid structure according to any one of the above items.
A resin molded body, wherein the braid structure includes a structural portion embedded in a matrix resin.
9. The other parts other than the structural part are voids. The resin molded product according to.
10. The above 9. The resin molded product according to.

In the braid of the present invention, a plurality of reinforcing fiber bundles are knitted, and it is possible to prevent the reinforcing fiber bundles from being separated into filaments and even single fibers during use. Further, for example, when the reinforcing fiber bundle is placed in the molding die and a resin or the like is poured into the molding die, the reinforcing fiber bundle is prevented from flowing in the molding die. Further, the braid has a high degree of freedom of deformation, and can easily correspond to a resin molded product having a curved shape such as an arc shape.
Further, when the reinforcing core material is arranged at the center of the braid in the radial direction, the braid itself can maintain a predetermined shape when the braid structure or the like is formed.

The braid structure of the present invention can be a structure having a predetermined shape composed of a plurality of braids by joining the ends of each of the plurality of braids.
In another braid structure of the present invention, a part of the braid is branched to form a branch cord, and the end of the braid is joined to the end of another braid or the end of the branch cord. It can be a structure having a complicated shape.
In yet another braid structure of the present invention, a part of the braid is branched to form a branch string, and some of the branch strings are re-knitted to form a re-braid, and the end of the braid is , It is joined to the end of another braid or the end of the branch string, and can be a structure having higher strength and easily maintaining the shape even if it has a complicated shape.
Further, when the joint is a pin joint, the braids and the like are not fixed to each other at the joint portion, so that the degree of freedom in setting the shape of the structure can be increased.
Further, in the case of having a truss structure, when a load is applied to the joint portion, stress is generated only in the length direction of each braid or the like, and deformation is suppressed as compared with when a bending moment is received.

Since the resin molded body of the present invention includes a structural portion in which the braided structure is embedded in the matrix resin, it can be a resin molded body having sufficient strength. Further, when a braid structure having a branch string is used, since the reinforcing fiber bundle is continuous at the branch portion, the strength and rigidity at the branch portion are improved, and the resin molded body as a whole has better strength. It can be a product having the above.
Further, when the other parts other than the structural part are voids, the weight can be reduced while maintaining sufficient strength.
Further, in the case of a vehicle seat, it is particularly advantageous from the viewpoint that weight reduction of the vehicle is an important issue.

It is a front view of an example of a six-knit braid. It is a schematic perspective view of the braid in which the reinforcing core material is arranged in the center part in the radial direction of the braid braid. It is explanatory drawing of the braid which became the branch string of two braids in the length direction by the braid of six braids. FIG. 3 is an explanatory diagram of a braid in which the branch cords of the braid as shown in FIG. 3 are re-knitted to form a re-braid. It is an example of a truss structure, and is a schematic front view of a flat truss (truss bridge). It is a schematic explanatory drawing of the three-dimensional truss composed of a plurality of triangular pyramids. It is a schematic perspective view of the resin molded body which is a sheet for a vehicle.

Hereinafter, the present invention will be described in detail with reference to the drawings.
The matters shown here are exemplary and are intended to illustrate embodiments of the present invention. It is described for the purpose of providing what seems to be the most effective and effortlessly understandable explanation of the principles and conceptual features of the present invention. In this respect, it is not intended to provide structural details of the invention beyond what is necessary for a fundamental understanding of the invention. The description combined with the drawings will clarify to those skilled in the art how some embodiments of the present invention will actually be embodied.

[1] Braid The braid of the present invention is a braid using a reinforcing fiber bundle, and is a braid in which a plurality of reinforcing fiber bundles are knitted (see the six-knit braid 1 in FIG. 1).
Reinforcing fibers such as inorganic fibers usually have an extremely small diameter of single fibers, so when used as a skeleton of a resin molded product or the like, a reinforcing fiber bundle in which a large number of single fibers are bundled, a so-called tow form. Used in.
The number of reinforcing fiber bundles constituting the braid is not particularly limited, and for example, a braid using 3 to 8 reinforcing fiber bundles, particularly 3 to 6 reinforcing fiber bundles, for example, braids such as braids and six braids. Can be.

As the reinforcing fiber, various inorganic fibers and organic fibers may be used as long as they do not soften or deform due to heating during molding when used for a skeleton of a resin molded body or the like. Examples of the inorganic fiber include carbon fiber, glass fiber, and ceramic fiber such as silica fiber, alumina fiber, and mulite fiber. Further, examples of the organic fiber include aramid fiber and the like. Among these reinforcing fibers, carbon fibers that are easy to knit when made into a braid, are lightweight, and can be made into a braid having excellent strength are preferable.

The braid is made by knitting a plurality of reinforcing fiber bundles, but may consist of only reinforcing fiber bundles, and other fiber bundles other than the reinforcing fiber bundles (non-reinforced fiber bundles, for example, polyolefin resin, polyamide resin, polyester resin, etc.) It may have a bundle of general-purpose thermoplastic resin fibers). However, when a non-reinforcing fiber bundle is provided, the non-reinforcing fiber bundle is preferably 10% by mass or less when the entire braid is 100% by mass.

The number of reinforcing fibers constituting one reinforcing fiber bundle is not particularly limited, but may be, for example, 3000 or more. Since the number of reinforcing fibers constituting the reinforcing fiber bundle is 3000 or more, it is possible to easily give a predetermined shape to a braided structure, a resin molded body, etc., and it is excellent. It can be a braided structure having strength or the like, a resin molded body, or the like. The number of reinforcing fibers constituting the reinforcing fiber bundle can be 3000 to 100,000, preferably 2000 to 10000, and more preferably 2000 to 70000 and 1000 to 50000. Further, in consideration of workability when forming the fiber bundle, the number may be 8000 to 30000, particularly 1000 to 25000.

The braid may have a form in which the reinforcing core material 2 (see FIG. 2) is arranged at the center in the radial direction. By disposing the reinforcing core material, the braid itself can maintain a predetermined shape of the braid structure when the braid structure is formed. Further, even in the case of a resin molded body provided with a braid structure, since the braid structure maintains a predetermined shape, the braid structure can be sufficiently and easily impregnated with the matrix resin, and the required structure can be impregnated. It can be a resin molded product of.

The reinforcing core material 2 can be arranged at the radial center of the braid by knitting a plurality of reinforcing fiber bundles a on the peripheral surface of the reinforcing core material 2. Further, the reinforcing core material 2 can be arranged by inserting it in the vicinity of the central portion of the braid formed by knitting a plurality of reinforcing fiber bundles. The reinforcing core material may be removed after forming a resin molded body having a braided structure. For example, when the resin molded body is a small member such as a headrest of a vehicle, the reinforcing core material may be removed. On the other hand, in the case of a large member such as the vehicle seat shown in FIG. 7, it is preferable to arrange the reinforcing core material as it is from the viewpoint of strength and the like.

The material of the reinforcing core material is not particularly limited as long as the braid can maintain a predetermined shape, and for example, a metal wire made of aluminum, stainless steel, etc. and having strength, rigidity, corrosion resistance, etc. can be used. .. In the form in which the reinforcing core material is arranged, the number of reinforcing fiber bundles is preferably large from the viewpoint of ease of knitting, and six braids are knitted rather than braids (6 on the peripheral surface of the reinforcing core material 2). It is preferable that the braid is such as (see FIG. 2) in which the reinforcing fiber bundle a of the book is woven. In addition, when a plurality of reinforcing fiber bundles are knitted into a braid and then a reinforcing core material is inserted and arranged at the center in the radial direction of the braid, even if it is a braid braid, it may be a braid. The reinforcing core material can be easily arranged.

[2] Braid structure (1) Braid structure of the present invention The braid structure of the present invention is configured by joining the ends of each of a plurality of braids. In this way, in the form in which the braids are not branched and the ends of all the braids are joined, the structure has a predetermined shape when it is a structure having high planar or three-dimensional symmetry. It is advantageous in terms of maintenance, strength, rigidity, and the like.

(2) Other Braid Structures of the Present Invention In other braid structures of the present invention, at least a part of the braids of the plurality of braids is branched in the length direction and is branched (for example, a six-knit braid). 1 is two braided branch cords 11 and 12), and the end of the braid is joined to the end of another braid or the end of the branch cord. Has been done.

The braid that branches in the length direction is at least a part of the plurality of braids, and the ratio of the branched braid to all braids is appropriately determined by the structure of the braid structure, structure maintenance, strength of the structure, rigidity, and the like. Can be set. Further, the end of the braid is joined to the end of another unbranched braid or the end of the branch by the structure of the braid structure to form a structure having a predetermined shape.

In the case of a form in which a branch string is formed like the other braid structure of the present invention, the number of reinforcing fiber bundles constituting the braid is not particularly limited, but may be 4 to 8 or the like, and four braids are used. In the braid of, two braided branch cords are formed, in the six-knitted braid, two braided branch cords are formed, and in the eight-knitted braid, two four-knitted branch cords are formed. This is formed. In this way, in the form in which the branch cord is formed, the even-numbered braid is branched into two branch cords each consisting of the same number of reinforcing fiber bundles. This is advantageous from the viewpoint of maintaining the planar or three-dimensional structure of the braided structure, and is also preferable from the viewpoint of the strength and rigidity of the structure.

In the form in which the branch cord is formed, as described above, the even-numbered braid is usually branched into two branch cords each consisting of the same number of reinforcing fiber bundles, but the present invention is not limited to this. For example, an even-numbered braid may be branched into two branch cords consisting of even-numbered braids or odd-numbered braided fiber bundles, and an odd-numbered braid may be split from an even-numbered and odd-numbered braided fiber bundle. It may be branched into two branch strings. When the braid is branched, it may be branched into three or more branch strings, but in such a form, the structure as a whole may not have a good balance of strength and the like, and it is practically branched. There are two branch strings to be made.

(3) Further Other Braid Structure of the Present Invention In the braid structure of the further other invention, at least a part of the braids of the plurality of braids is branched in the length direction to form a branch cord, and at least. Some branch strings are re-knitted and re-braided (for example, see FIG. 4 in which the branch string 11 of one braid 1 and the branch string 12 of another braid 1 are re-knitted to form re-braid 3). The end of the braid is joined to the end of another braid or the end of the branch cord.

The braid that branches in the length direction is at least a part of the plurality of braids, and the ratio of the branched braid to all braids is appropriately determined by the structure of the braid structure, structure maintenance, strength of the structure, rigidity, and the like. Can be set. Further, the branch string in which at least a part of the branch strings are re-knitted to become a re-braided string is at least a part of the plurality of branch strings, and the ratio of the re-knitted branch string to all the branch strings is the braided string. Depending on the structure of the structure, it can be appropriately set depending on the structure maintenance, the strength of the structure, the rigidity, and the like. Further, the end of the braid is joined to the end of another unbranched braid or the end of the branch due to the structure of the braid structure to form a structure.

Further, the form in which the branch string is formed and the action and effect produced by the branch string are the same as in the case of the above-mentioned (2) other braid structure of the present invention. Further, the re-braid is usually a re-braid in which an even braid is re-knitted with a branch cord branched into the same number of reinforcing fiber bundles, respectively, from the viewpoint of maintaining a planar or three-dimensional structure of the braid structure. In terms of strength, rigidity, etc. of the structure, it can be a useful braided structure. In the re-braid, the even-numbered braid is branched into two even-numbered braids, or the even-numbered and odd-numbered braids are branched, or the even-numbered braid is branched into even-numbered and odd-numbered braids. The branching string may be a re-knitted re-braided string, and the same effect is achieved.

In (1) the braid structure of the present invention, (2) another braid structure of the present invention, and (3) yet another braid structure of the present invention, the joint of each end of the braid and the branch cord is , Made by pin joining. If the ends are joined by pin joining in this way, at the joints of the ends of the braid and the branch cord, the ends are not fixed and can be rotated, and the shape of the structure. The degree of freedom of setting can be increased, and the deformation of the structure can be suppressed as compared with the case where a bending moment is received.

Further, (1) the braid structure of the present invention, (2) other braid structures of the present invention, and (3) further, the braid structure of the present invention has all the ends of the braid and the branch cord. It can be a structure formed by pin joining and formed in a truss structure. The truss structure is roughly classified into a flat truss and a three-dimensional truss. The braid structure of the present invention, (2) other braid structures of the present invention, and (3) the braid structure of the present invention are further classified. , Both can be flat trusses or three-dimensional trusses.

Examples of the flat truss include a truss bridge 10 as shown in FIG. The truss bridge 10 is configured such that the truss frame 10a is fixed to the substrate 10c bridged to the bridge girders 10b arranged at both end portions, and the upper plate 10d is fixed to the top of the truss frame 10a. (1) The braided structure of the present invention, (2) other braided structures of the present invention, and (3) the braided structure of the present invention are those used for a large structure such as the truss bridge 10. However, in the case of a braided structure having a flat truss structure, when a load is applied to the joint, stress is generated only in the length direction of each braid, etc., compared to when a bending moment is received. It has a useful effect of suppressing deformation.

Further, (1) the braided structure of the present invention, (2) another braided structure of the present invention, and (3) further, the braided structure of the present invention may be a three-dimensional truss. For example, it can be a three-dimensional truss composed of a plurality of triangular pyramids as shown in FIG. FIG. 6 is an explanatory view and does not have a three-dimensional effect, but is actually an aggregate of triangular pyramids whose four surfaces are formed by triangles, and a triangular pyramid having a predetermined shape is formed according to the required structure of the braided structure. When used in combination, when a load is applied to the joint, stress is generated only in the length direction of each braid, and deformation is suppressed compared to when a bending moment is applied, similar to a flat truss. The useful action effect of is played.

[3] Resin molded body The resin molded body of the present invention includes a structural portion in which a braid structure is embedded in a matrix resin. Further, it is preferable that the other parts other than the structural part are voids.

The matrix resin includes thermoplastic resins such as polyolefin resins, polyester resins, polyamide resins, and polyimide resins, epoxy resins, phenol resins, unsaturated polyester resins, melamine resins, thermosetting resins such as alkyd resins, and irradiation with ultraviolet rays. Examples thereof include a photocurable resin that reacts and cures. As the matrix resin, it is preferable to use a resin such as an epoxy resin that is cured by heat energy from the outside such as heat and light.

In the structural part, the braided structure is impregnated with a matrix resin, and after impregnation, the molten resin is solidified if it is a thermoplastic resin, and cured by heating or light irradiation if it is a thermosetting resin or a photocurable resin. The braided structure is formed by being embedded in the matrix resin. In this way, when the braid structure is impregnated with the matrix resin, it is preferable that the braid structure is sufficiently and evenly impregnated with the matrix resin. As a result, it is possible to obtain a resin molded product having excellent strength and the like and having little variation in strength and the like as a whole.

The braid structure is formed by using a braid in which a plurality of reinforcing fiber bundles are knitted, and the reinforcing fiber bundle is a reinforcing fiber bundle in which a large number of single fibers having an extremely small fiber diameter are bundled, so-called tow. It is used in the form described. Therefore, in order to sufficiently and evenly impregnate the braided structure with the matrix resin, it is preferable that the viscosity of the matrix resin at the time of impregnation is low. From this point of view, the thermosetting resin and the photocurable resin are preferable as the matrix resin.

The shape and dimensions of the resin molded body provided with the braid structure using the braid of the present invention are not particularly limited, and its use is not particularly limited. Applications of the resin molded body include, for example, interior materials for automobiles, railroad vehicles, ships and airplanes, specifically, headrests, seat backboards, seat frames, door trims, roof trims, instrument panels, pillar garnishes, packages. Examples include trays, dashboards, console boxes, armrests and sun visors.

Further, for example, applications such as interior materials such as buildings and furniture, exterior materials and structural materials can be mentioned. That is, it can be used as a door covering material, a door structural material, a desk, a chair, a shelf, a covering material for various furniture such as a chest of drawers, a structural material, and the like. Further, it can be used as a packaging body, an accommodating body such as a tray, a protective member, a partition member, or the like.

It should be noted that the above description is for the purpose of explanation only and is not construed as limiting the present invention. Although the present invention has been described with reference to typical embodiments, the language used in the description and illustration of the invention is understood to be descriptive and exemplary rather than restrictive. As described in detail here, modifications can be made within the scope of the appended claims without departing from the scope or spirit of the invention in that embodiment. Although specific structures, materials and embodiments have been referred to herein in detail of the invention, it is not intended to limit the invention to the disclosures herein, rather the invention is claimed in the accompanying claims. It shall cover all functionally equivalent structures, methods and uses within the scope.

The braid of the present invention, the braid structure using the braid, and the resin molded product provided with the braid structure can be used in various technical fields. Specifically, it can be suitably used in fields related to structures in various industries such as vehicles (automobiles and railroad vehicles), aircraft, ships, and construction.

1; Six-braided braid, 11, 12; Branch cord, 2; Reinforcing core material (metal wire), a; Reinforcing fiber bundle (toe), 3; Re-braided cord, 10; Truss bridge, 10a; Truss frame, 10b; bridge girder, 10c; substrate, 10d; top plate, 20; three-dimensional truss, 30; passenger car seat, 31; structural part, 32; void.

Claims (10)

A braid using a reinforced fiber bundle,
A braid characterized in that a plurality of the reinforcing fiber bundles are knitted. The braid according to claim 1, wherein a reinforcing core material is arranged at the center of the braid in the radial direction. A braid structure using the braid according to claim 1 or 2.
A braid structure characterized in that the ends of each of the plurality of braids are joined to each other. A braid structure using the braid according to claim 1 or 2.
At least a part of the braids is branched in the length direction to form a branch cord, and the end of the braid is joined to the end of another braid or the end of the branch cord. A braided structure characterized by being composed of. A braid structure using the braid according to claim 1 or 2.
At least a part of the braids is branched in the length direction to form a branch string, and at least a part of the braids is re-knitted to form a re-braid, and the end of the braid is formed. A braid structure characterized in that the portion is formed by being joined to the end of another braid or the end of the branch cord. The braided structure according to any one of claims 3 to 5, wherein the joint is a pin joint. The braided structure according to claim 6, wherein the joint is a pin joint and is formed in a truss structure. A resin molded product provided with the braid structure according to any one of claims 3 to 7.
A resin molded body, wherein the braid structure includes a structural portion embedded in a matrix resin. The resin molded product according to claim 8, wherein the other parts other than the structural part are voids. The resin molded product according to claim 9, which is a vehicle sheet.

Images