JP2022083927A - Sewing machine for producing preform and preform producing method - Google Patents

Abstract

To provide a sewing machine for producing preform, which can accelerate preform production and improve degree of freedom for design of the preform.SOLUTION: A sewing machine 1A has a plurality of bobbins 5 around which a fiber bundle 4 is wound, a fiber guide 7A that guides the fiber bundle fed out from the plurality of bobbins onto a base layer 3, and a sewing needle 8 that sews the fiber bundle guided by the fiber guide to the base layer. The fiber guide is provided so as to be switchable between a state A to arrange the fiber bundles fed out from the plurality of bobbins in parallel and guide them onto the base layer and a state B to vertically stack and guide at least two fiber bundles among the fiber bundles onto the base layer.SELECTED DRAWING: Figure 4

Description

The present invention relates to a sewing machine for manufacturing a preform and a method for manufacturing a preform, and more particularly to a sewing machine for manufacturing a preform and a method for manufacturing a preform using the sewing machine for manufacturing the preform.

Conventionally, a composite material (fiber reinforced plastic) called a fiber reinforced plastic is known. Generally, a fiber reinforced plastic is obtained by impregnating a fiber aggregate (preform) with a resin (matrix resin) as a matrix material and then curing or solidifying the fiber aggregate (preform). As the fiber aggregate, a woven fabric woven from a reinforced fiber bundle is often used (see, for example, Patent Document 1 and the like). However, when the woven fabric is used for the fiber aggregate, the fiber orientation is low, the woven fabric needs to be cut according to the shape of the final product, and the processing cost is high.

Therefore, as a technique for solving the above-mentioned problems, a TFP (Tailored Fiber Placement) technique for manufacturing a preform by sewing a fiber bundle to a base layer using an embroidery machine (sewing machine) has been proposed. As the embroidery machine 101, for example, as shown in FIG. 26, the bobbin 105 is provided with an embroidery head that freely rotates 360 degrees around the axis of the sewing needle 108, and the fiber bundle 104 is wound around the embroidery head. It is known that the fiber guide 107 for guiding the fiber bundle 104 unwound from the bobbin 105 onto the base layer 103 is mounted. With this TFP technique, the fiber orientation is excellent, the fiber bundle can be sewn according to the shape of the final product, and the processing cost can be suppressed. Furthermore, the structure can be made inexpensive because there are few operating parts of the embroidery machine.

Japanese Unexamined Patent Publication No. 2013-082229 JP-A-2007-301299A

However, the above-mentioned TFP technique has a problem that the production speed of the preform (that is, the embroidery speed) is slower than that of other construction methods such as weaving. Here, in the embroidery machine, since the supply amount of fibers depends on the thickness of the fiber bundle, the embroidery speed is limited when a relatively thin fiber bundle is used. On the other hand, if a relatively thick fiber bundle is used, the embroidery time can be shortened, but since the thick fiber bundle is thick, it does not meet the minimum thickness in topology optimization and cannot correspond to a portion to be sewn thinly. Further, in the curved portion where the fiber bundle is sewn in a curved shape (particularly, the curved portion having an extremely small radius of curvature), the fiber bundle gathers inside the curve and tends to be biased, so that it may not be possible to correspond to the curved portion.

It should be noted that Patent Document 2 is a technique for increasing the number of embroidery heads that can be used for high-mix low-volume production, and that a rotating body that rotates 360 degrees is driven by an individual motor to enable different embroidery in parallel at the same time. Is disclosed. However, in the technique of Patent Document 2, the embroidery head is large and it is not possible to embroider a single product at the same time with a plurality of embroidery heads. Therefore, even if the technique of Patent Document 3 is used, the TFP technique is not suitable for speeding up the production of large products.

The present invention has been made in view of the above situation, and an object of the present invention is to provide a sewing machine for manufacturing a preform, which can speed up the production of the preform and improve the degree of freedom in designing the preform. And.
Furthermore, another object of the present invention is to provide a method for producing a preform, which is suitable for obtaining the preform by using the sewing machine for producing the preform.

In order to solve the above problem, the invention according to claim 1 is for producing a preform which has a base layer and a fiber bundle sewn on the base layer and is a core material of a composite material. In a sewing machine, a plurality of bobbins around which the fiber bundle is wound, a fiber guide for guiding the fiber bundle unwound from the plurality of bobbins onto the base layer, and the fiber bundle guided by the fiber guide as the base layer. The fiber guide is provided with a sewing needle to be sewn to the base layer, and the fiber guide is provided with a state in which the fiber bundles unwound from a plurality of bobbins are arranged in parallel and guided onto the base layer, and at least two fiber bundles of the fiber bundles. It is a gist that it is provided so as to be switchable between a state in which the above-mentioned is vertically stacked and guided on the base layer.
The invention according to claim 2 is the invention according to claim 1, wherein the stitch pattern of the sewing thread is controlled by controlling the drop position of the sewing needle with respect to the base layer in response to the switching of the guide state of the fiber bundle by the fiber guide. The gist is to have a control unit to change.
The invention according to claim 3 is the invention according to claim 1 or 2, wherein the invention includes a feeding amount control mechanism for controlling the feeding amount of the fiber bundle unwound from the bobbin.
The invention according to claim 4 is the gist of the invention according to claim 3, wherein the feeding amount control mechanism is a brake that applies a braking force to the bobbin.
The invention according to claim 5 is the invention according to any one of claims 1 to 4, wherein the fiber bundle unwound from the bobbin is cut to stop the supply onto the base layer, and the invention is cut. The gist is to provide a fiber bundle supply mechanism for reinserting the fiber bundle onto the base layer.
In order to solve the above problem, the invention according to claim 1 is a method for manufacturing a preform having a base layer and a fiber bundle sewn on the base layer and serving as a core material of a composite material. The gist is to obtain the preform by using the sewing machine for manufacturing the preform according to any one of claims 1 to 5.

According to the sewing machine for manufacturing a preform of the present invention, a plurality of bobbins around which a fiber bundle is wound, a fiber guide that guides a fiber bundle unwound from the plurality of bobbins onto a base layer, and a fiber bundle guided by the fiber guide as a base layer. It is equipped with a sewing needle to be sewn. The fiber guide includes a state in which fiber bundles unwound from a plurality of bobbins are arranged in parallel and guided on the base layer, and a state in which at least two fiber bundles of the fiber bundles are vertically stacked and guided on the base layer. It is provided so that it can be switched to. As a result, since the fiber bundles unwound from the plurality of bobbins are sewn to the base layer at the same time, it is possible to speed up the sewing of the fiber bundles, that is, to speed up the production of the preform. Further, if necessary, the fiber bundles can be sewn by changing the thickness of the fiber bundles by arranging the fiber bundles in parallel by the fiber guide and supplying them onto the base layer, or by stacking them vertically and supplying them onto the base layer. Therefore, it is possible to deal with preforms having complicated shapes and improve the degree of freedom in designing preforms. Furthermore, when the type of fiber bundle is used properly for a plurality of bobbins, the degree of freedom in designing the preform can be further improved.
Further, when the control unit for controlling the drop position of the sewing needle with respect to the base layer to change the stitch pattern of the sewing thread according to the switching of the guide state of the fiber bundle by the fiber guide is provided, the fiber bundle by the fiber guide is provided. Fiber bundles can be sewn with a stitch pattern suitable for the guidance state.
Further, when the feeding amount control mechanism for controlling the feeding amount of the fiber bundles fed from the bobbin is provided, the feeding amount control mechanism is used when the fiber bundles supplied in parallel on the base layer are sewn in a curved shape. By controlling the feeding amount of the fiber bundle, it is possible to suppress the bias of the fiber bundle due to the difference in peripheral length and sew the fiber bundle.
Further, when the feeding amount control mechanism is a brake that applies a braking force to the bobbin, the feeding amount of the fiber bundle is prevented from being broken or the like, as compared with the form in which the braking force is applied to the fiber bundle. Can be controlled.
Further, when the fiber bundle supply mechanism is provided, when the fiber bundles supplied in parallel on the base layer are sewn in a curved shape, the fiber bundles are cut by the fiber bundle supply mechanism to stop the supply onto the base layer. This makes it possible to sew the fiber bundle while suppressing the bias of the fiber bundle due to the difference in peripheral length. Then, the fiber bundle cut by the fiber bundle supply mechanism can be reinserted onto the base layer at an appropriate timing such as at the end of curved sewing. As a result, it becomes possible to sew a wide complicated shape at a stretch, which contributes to a reduction in manufacturing time and materials.
According to the method for producing a preform of the present invention, it is a method for producing a preform having a base layer and a fiber bundle sewn on the base layer and serving as a core material of a composite material, and the above-mentioned preform production. Obtain a preform using a sewing machine. As a result, it is possible to speed up the production of the preform and improve the degree of freedom in designing the preform.

The present invention will be further described in the following detailed description with reference to the plurality of references mentioned with reference to non-limiting examples of typical embodiments according to the invention, although similar reference numerals are in the drawings. Similar parts are shown through several figures.
It is an overall view of the sewing machine for manufacturing a preform which concerns on Example 1. FIG. It is a block diagram for demonstrating the operation control of the said sewing machine. It is a perspective view of the main part of the sewing machine. It is a top view of the fiber guide which constitutes the sewing machine, (a) shows the state which guides a fiber bundle in parallel, and (b) shows the state which guides a fiber bundle by stacking. It is a front view of the fiber guide, (a) shows the state which guides a fiber bundle in parallel, and (b) shows the state which guides a fiber bundle by stacking. It is explanatory drawing for demonstrating the stitch pattern of the sewing thread by the sewing machine, (a) shows the stitch pattern in the fiber bundle guided in parallel, (b) shows the stitch pattern in the fiber bundle guided in layers. It is explanatory drawing for demonstrating the stitch pattern of the sewing thread which concerns on other forms, (a) shows the form which consists of the stitch which straddles one fiber bundle, and (b) is the stitch which straddles one fiber bundle. A morphology consisting of stitches straddling a plurality of fiber bundles is shown. It is explanatory drawing for demonstrating the action (sewing action of a straight line part) of the said sewing machine. 8 is a cross-sectional view of each part, FIG. 8A shows a cross-sectional view taken along the line aa, and FIG. 8B shows a cross-sectional view taken along the line bb. It is explanatory drawing for demonstrating the action (sewing action of a curve part) of the said sewing machine, (a) shows the state which the fiber bundle guided in parallel is sewn in a curve shape, and (b) is superposed and guided. The state where the fiber bundle is sewn in a curved shape is shown. 10 is a cross-sectional view of each part, FIG. 10A shows a cross-sectional view taken along the line aa, and FIG. 10B shows a cross-sectional view taken along the line bb. It is an appearance image processing figure of the preform obtained by using the said sewing machine. It is a perspective view of the main part of the sewing machine which concerns on Example 2. FIG. It is a perspective view of the fiber guide which constitutes the sewing machine, (a) shows the state which guides a fiber bundle in parallel, and (b) shows the state which guides a fiber bundle by stacking. It is a front view of the fiber guide, (a) shows the state which guides a fiber bundle in parallel, and (b) shows the state which guides a fiber bundle by stacking. It is a perspective view of the main part of the sewing machine which concerns on Example 3. FIG. It is a perspective view of the fiber guide which constitutes the sewing machine, (a) shows the state which guides a fiber bundle in parallel, and (b) shows the state which guides a fiber bundle by stacking. It is a vertical cross-sectional view of the fiber guide, (a) shows the state which guides a fiber bundle in parallel, and (b) shows the state which guides a fiber bundle by stacking. It is a perspective view of the main part of the sewing machine which concerns on Example 4. FIG. It is explanatory drawing for demonstrating the operation of the fiber bundle supply mechanism which comprises the said sewing machine, (a) shows the state which supplies the fiber bundle on the base layer, (b) cuts and holds the fiber bundle with a cutter. (C) indicates a state in which the fiber guide is flipped up backward, (d) indicates a state in which the holding of the fiber bundle by the cutter is released, and (e) indicates a state in which the fiber guide is swung down forward. The state where the fiber bundle is reinserted is shown. It is explanatory drawing for demonstrating the operation of the fiber bundle supply mechanism which comprises the said sewing machine, (a) shows the sewn state of a straight line part, (b) (c) show the sewn state of a curved part. It is explanatory drawing for demonstrating the operation of the fiber bundle supply mechanism which comprises the sewing machine which concerns on Example 5, (a) shows the state which supplies the fiber bundle on the base layer, and (b) is the fiber by the cutter. The state in which the bundle is cut and held is shown, (c) shows the state in which the holding of the fiber bundle by the cutter is released and the fiber bundle is grasped by the delivery part, and (d) shows the state in which the fiber bundle is reinserted by advancing the delivery part. A state is shown, and (e) shows a state in which the holding of the delivery part is released. It is a perspective view of the main part of the sewing machine which concerns on Example 6. FIG. It is explanatory drawing for demonstrating the guide | guide form of the fiber bundle by the fiber guide which concerns on other forms, (a)-(c) show the fiber bundle which was overlap-guided, and (d) is the fiber bundle which was guided in parallel. Is shown. It is explanatory drawing for demonstrating the bobbin and the brake which concerns on other forms. It is a perspective view of the main part of a conventional embroidery machine.

The matters shown here are for illustrative purposes and embodiments of the present invention, and are the most effective and effortless explanations for understanding the principles and conceptual features of the present invention. It is stated for the purpose of providing what seems to be. In this regard, it is not intended to show structural details of the invention beyond a certain degree necessary for a fundamental understanding of the invention, and some embodiments of the invention are provided by description in conjunction with the drawings. It is intended to clarify to those skilled in the art how it is actually realized.

<Sewing machine for preform manufacturing>
The sewing machine for manufacturing a preform according to the present embodiment has a base layer 3 and a fiber bundle 4 sewn on the base layer 3, and is a preform 2 as a core material of a composite material (see, for example, FIG. 12). 1A to 1F, for example, as shown in FIG. 1, a plurality of bobbins 5 around which a fiber bundle 4 is wound and a fiber bundle 4 unwound from the plurality of bobbins 5 are placed on a base layer 3. The fiber guides 7A to 7F for guiding and the sewing needle 8 for sewing the fiber bundle 4 guided by the fiber guides 7A to 7F to the base layer 3 are provided. Then, for example, as shown in FIGS. 4, 14 and 17, the fiber guides 7A to 7F have a state A in which the fiber bundles 4 unwound from the plurality of bobbins 5 are arranged in parallel and guided onto the base layer 3, and the fiber bundles. It is provided so as to be switchable between a state B in which at least two fiber bundles 4 of 4 are stacked one above the other and guided onto the base layer 3.

The structure, material, and the like of the bobbin 5 are not particularly limited as long as at least two or more bobbins 5 are provided. As shown in FIG. 25, the bobbins 5 may be arranged in a stepped manner at the top and bottom, but from the viewpoint of equalizing the feeding amount of the fiber bundle 4, the shaft ends of the adjacent bobbins 5 face each other. It is preferable that they are arranged side by side so as to (see, for example, FIG. 8). In this case, in order to suppress the rubbing between the fiber bundle 4 and the fiber guides 7A to 7F, it is preferable that the bobbins 5 are arranged so that their axes intersect on the same horizontal plane.

For example, the same type of fiber bundle 4 may be wound around the plurality of bobbins 5, but from the viewpoint of design freedom of the preform 2, at least two or more different types of fiber bundles 4 may be wound around the plurality of bobbins 5. It is preferable that it is rolled. Examples of the different types of fiber bundles 4 include fiber bundles 4 in which one or a combination of two or more of the number, material, fiber form, bundled form, etc. of the continuous fibers described later constituting the fiber bundle 4 is different. Be done.

As the sewing machine for manufacturing a preform according to the present embodiment, for example, as shown in FIG. 23, a bobbin around which a design fiber 58 distinguishable (identifiable) from the fiber bundle 4 is wound while being sewn on the base layer 3. A form including 59 can be mentioned. As a result, the design of the preform 2 can be dramatically improved.
The design fiber 58 is not particularly limited as long as it is a fiber that can be distinguished from the fiber bundle 4 by one type or a combination of two or more types such as color, surface shape, and thickness. Examples of the design fiber 58 include silk yarn, cotton yarn, yarn, blended yarn, blended yarn, knot yarn, spiral yarn, 杢 yarn, loop yarn, slab yarn, curl yarn and the like. Further, the design fiber 58 may be, for example, a fiber bundle (for example, a fiber bundle containing reinforcing fibers) as long as it can be distinguished from the fiber bundle 4.
The design fiber 58 unwound from the bobbin 59 is usually guided on the base layer 3 by the fiber guides 7A to 7F together with the fiber bundle 4.

The fiber guides 7A to 7F are not particularly limited in their guide form, structure and the like as long as the guide states (parallel guide and overlap guide) of the fiber bundle 4 can be switched.
As a parallel guide of the fiber bundles 4 by the fiber guides 7A to 7F, for example, as shown in FIG. 5A, the fiber bundles 4 are arranged in parallel so that the adjacent fiber bundles 4 are separated by a predetermined interval in the width direction. A form of guiding on the base layer 3 can be mentioned. Further, for example, as shown in FIG. 24D, there is a mode in which the fiber bundles 4 are arranged in parallel so that the adjacent fiber bundles 4 are in contact with each other without a gap in the width direction and guided onto the base layer 3.
The fiber guides 7A to 7F usually guide all the fiber bundles 4 unwound from the plurality of bobbins 5 on the base layer 3 by arranging them in parallel.

As the stacking guide of the fiber bundles 4 by the fiber guides 7A to 7F, for example, as shown in FIG. 5B, the fiber bundles 4 are moved up and down so that the centers of the fiber bundles 4 in the width direction substantially coincide with each other in the width direction. A form of superimposing and guiding onto the base layer 3 can be mentioned. Further, for example, as shown in FIGS. 24A and 24B, the fiber bundles 4 are vertically stacked and guided onto the base layer 3 so that the center of the fiber bundles 4 in the width direction is displaced in the width direction (that is,). A form in which the fiber bundle 4 is partially vertically overlapped and guided along the longitudinal direction) can be mentioned.
As the stacking guide of the fiber bundles 4 by the fiber guides 7A to 7F, for example, as shown in FIGS. 4 (b) and 5 (b), all the fiber bundles 4 unwound from the plurality of bobbins 5 are stacked vertically. A form of guiding on the base layer 3 can be mentioned. Further, for example, as shown in FIG. 24 (c), the other fiber bundles 4 are stacked one above the other without stacking at least one fiber bundle 4 among all the fiber bundles 4 unwound from the plurality of bobbins 5. A form of guiding on the base layer 3 can be mentioned.

As shown in FIGS. 4 and 5, for example, the fiber guide 7A has a plurality of outlets 32 for leading out the fiber bundle 4, and has a plurality of first positions C1 in which the plurality of outlets 32 do not overlap in the vertical direction. The outlet 32 of the above can be rotatably provided between the second position C2 and the second position C2 which overlaps in the vertical direction.
As a result, the guide state of the fiber bundle 4 can be smoothly and surely switched, and the switching mechanism 25 of the fiber guide 7A can be simplified.
The rotation angle of the fiber guide 7A between the first position C1 and the second position C2 is set to about 90 degrees in FIG. 5, but the rotation angle is not limited to this, and the fiber bundle 4 may be overlapped or guided in parallel. It is appropriately selected according to the form of.

As shown in FIGS. 14 and 15, for example, the fiber guide 7B includes a first fiber guide 41 for arranging the fiber bundles 4 in parallel and guiding them onto the base layer 3, and the fiber bundles 4 are vertically stacked on the base layer 3. A second fiber guide 42 for guiding the user can be provided.
Specifically, the first fiber guide 41 is formed in a shape that partitions a plurality of fiber bundles 4, and is provided so as to be able to move forward and backward with respect to the second fiber guide 42 on the upstream side of the guide of the second fiber guide 42. The second fiber guide 42 is an expandable and contractible annular body through which a plurality of fiber bundles 4 are inserted, and the fibers are expanded by expanding the second fiber guide 42 while the first fiber guide 41 is advanced. The bundles 4 are arranged in parallel and guided onto the base layer 3, and the second fiber guide 42 shrinks while the first fiber guide 41 is retracted so that the fiber bundles 4 are vertically stacked and guided onto the base layer 3. Can be done.
As a result, the guide state of the fiber bundle 4 can be switched smoothly and surely, and the vertical movement of the fiber guide 7B is minimized, so that the fiber bundle 4 can be guided to a position close to the sewing needle 8. ..

As shown in FIGS. 17 and 18, for example, the fiber guide 7C is a rotating body having a recess 45 formed along the outer periphery thereof, and the recess 45 is more than the first guide portion 46 and the first guide portion 46. The fiber guide 7C has a second guide portion 47 having a narrow groove width and a deep groove depth, and the fiber guide 7C has a first position C1 that guides the fiber bundles 4 in parallel on the base layer 3 by the first guide portion 46. , The second guide portion 47 can be rotatably provided between the second position C2 in which the fiber bundles 4 are vertically stacked and guided on the base layer 3.
As a result, the guide state of the fiber bundle 4 can be switched smoothly and surely, and since the fiber guide 7C does not move up and down, the fiber bundle 4 can be guided to a position close to the sewing needle 8. Further, the switching mechanism 25 of the fiber guide 7C can be simplified.
The rotation angle of the fiber guide 7C between the first position C1 and the second position C2 is set to about 90 degrees in FIG. 18, but the rotation angle is not limited to this, and the fiber bundle 4 may be overlapped or guided in parallel. It is appropriately selected according to the form of.

As a sewing machine for manufacturing a preform according to the present embodiment, for example, as shown in FIG. 6, the drop position P of the sewing needle 8 with respect to the base layer 3 is set according to the switching of the guide state of the fiber bundle 4 by the fiber guides 7A to 7F. An example includes a form including a control unit 13 that controls and changes the stitch patterns S1 and S2 of the sewing thread 18.

The control unit 13 controls the drop position P of the sewing needle 8, for example, among the movement control of the holding frame 12, the staggered swing control of the fiber guides 7A to 7F, the rotation control of the rotating body 15, and the reciprocating drive control of the sewing needle 8. It can be carried out by controlling one kind or a combination of two or more kinds of.
The drop position P of the sewing needle 8 may be arranged, for example, on the side of the sewn fiber bundle 4, or may be arranged so as to be hidden behind the sewn fiber bundle 4.

Examples of the stitch patterns S1 and S2 include, as shown in FIG. 6, a form in which the staggered spacing L1 in the width direction of the fiber bundle 4 and / or the staggered spacing L2 in the longitudinal direction of the fiber bundle 4 are different.
As shown in FIG. 7A, the stitch pattern S1 may be composed of only the stitches s3 straddling one fiber bundle 4 arranged in parallel, but the stitching speed may be increased. From the viewpoint, for example, as shown in FIGS. 6 (a) and 7 (b), the stitch s2 straddling a plurality of fiber bundles 4 arranged in parallel and one fiber bundle 4 arranged in parallel are straddled. It is preferably composed of stitches s3.
As the stitch pattern S2, for example, as shown in FIG. 6B, there is a form composed of stitches s1 straddling a plurality of fiber bundles 4 stacked one above the other.
The stitches s1 to s3 are intended to be portions connecting between a pair of continuous drop positions P in the sewing thread (upper thread) 18.

As the sewing machine for manufacturing a preform according to the present embodiment, for example, as shown in FIG. 10, a mode including a feeding amount control mechanism 27 for controlling the feeding amount of the fiber bundle 4 fed from the bobbin 5 can be mentioned.

The structure, placement location, etc. of the feeding amount control mechanism 27 are not particularly limited. Examples of the feeding amount control mechanism 27 include a mechanism for reducing the feeding amount of the fiber bundle 4, a mechanism for increasing the feeding amount of the fiber bundle 4, and the like. These mechanisms may be used alone or in combination.
As a mechanism for reducing the feeding amount, for example, a brake 27 can be mentioned. As shown in FIG. 25, the brake 27 may be in the form of gripping the fiber bundle 4 and applying a braking force to the fiber bundle 4, but from the viewpoint of preventing the fiber bundle 4 from breaking or the like, the bobbin 5 may be used. In this case, the brake 27 may apply the braking force to the tubular shaft 5a constituting the bobbin 5, or may apply the braking force to the disk 5b constituting the bobbin 5. It may be given.
As a mechanism for increasing the feeding amount, for example, a feeding force is applied to the fiber bundle 4 to increase the feeding amount of the fiber bundle 4, and a rotational force is applied to the bobbin 5 to increase the feeding amount of the fiber bundle 4. The form and the like can be mentioned.

As shown in FIG. 10, for example, it is preferable that the feeding amount control mechanism 27 is provided corresponding to all of the plurality of bobbins 5. When sewing the fiber bundles 4 guided in parallel in a curved shape, the amount of feeding of the plurality of fiber bundles 4 can be controlled to gradually increase from the inside of the curve to the outside of the curve, and the fiber bundles 4 due to the difference in circumference can be controlled. This is because the bias can be effectively suppressed.

As the sewing machine for manufacturing a preform according to the present embodiment, for example, as shown in FIGS. 20 to 22, the fiber bundle 4 unwound from the bobbin 5 is cut to stop the supply onto the base layer 3 and is cut. Examples thereof include a fiber bundle supply mechanism 51, 55 for reinserting the fiber bundle 4 onto the base layer 3.

The fiber bundle supply mechanism 51 includes, for example, as shown in FIG. 20, a cutter 52 for cutting the fiber bundle 4, and the fiber guide 7A includes a plurality of division guides 50 for guiding each of the plurality of fiber bundles 4. Each split guide 50 can be provided so as to be swingable along the guide direction of the fiber bundle 4.
As shown in FIG. 22, the fiber bundle supply mechanism 55 can include, for example, a cutter 56 for cutting the fiber bundle 4 and a delivery unit 57 for sending the cut fiber bundle 4 onto the base layer 3.

The sewing machine for manufacturing a preform according to the reference embodiment includes a base layer 3 and a fiber bundle 4 sewn on the base layer 3, and the preform 2 is a core material of a composite material (for example, FIG. 12). 1A to 1F of sewing machines for manufacturing (see), for example, as shown in FIG. 1, a plurality of bobbins 5 around which a fiber bundle 4 is wound and a fiber bundle 4 unwound from the plurality of bobbins 5 as a base layer 3. The fiber guides 7A to 7F guided upward, the sewing needle 8 for sewing the fiber bundle 4 guided by the fiber guides 7A to 7F to the base layer 3, and the fiber bundle 4 unwound from the bobbin 5 are cut and moved onto the base layer 3. Examples include a fiber bundle supply mechanism 51, 55 (see, for example, FIGS. 20 to 22), which are provided with fiber bundle supply mechanisms 51 and 55 (see, for example, FIGS. 20 to 22), which stop the supply of the fiber bundle and recharge the cut fiber bundle 4 onto the base layer 3.
In the sewing machine for manufacturing a preform according to this reference embodiment, it does not matter whether or not the guide state of the fiber bundle 4 is switched by the fiber guides 7A to 7F. Further, as each configuration of the preform manufacturing sewing machine according to the present reference embodiment, for example, each configuration described in the preform manufacturing sewing machine according to the above embodiment can be applied.

The base layer 3 is a layer for sewing the fiber bundle 4. The base layer 3 may have any structure. That is, for example, a fiber aggregate (woven fabric, non-woven fabric, knitted fabric, etc.), a metal sheet (foil, plate, etc.), a resin sheet (film, plate, etc.) and the like can be mentioned.
From the viewpoint of sewing the fiber bundle 4 to the base layer 3, the base layer 3 is preferably a woven fabric. When the base layer 3 is a woven fabric, the fiber bundle 4 is easily sewn, the restraint on the sewing thread 18 at the time of sewing is high, the flexibility as the base layer 3 is excellent, and the matrix resin (not yet). It has an advantage that it is easy to impregnate the layer with a solidified product).
The fiber bundle 4 may be sewn only on one surface of the base layer 3, but may be sewn on both sides of the base layer 3.

In a preform in which the base layer 3 is a woven fabric and the fiber bundle 4 (reinforcing fiber bundle) is sewn on the base layer 3, crimps are generated in the fiber bundle 4 as compared with the preform in which the fiber bundle itself is made into a woven fabric. Can be prevented. Having a crimp causes the transmission of force in the thickness direction through the crimp, but by suppressing the crimp, the transmission of the force in the thickness direction can be suppressed. Therefore, the impact resistance of the obtained composite material in the thickness direction can be further increased.

Further, according to the means of sewing, the degree of restraint of the fiber bundle 4 can be freely controlled by the tension of the sewing thread 18. Therefore, for example, while firmly fixing the fiber bundle 4 to the base layer 3, the mobility of the fiber bundle 4 (movability to the base layer 3 and / or mobility between the fiber bundles 4) can be reduced. Compared to the preform made by weaving, more can be secured. As a result, the flexibility of the sewing region R formed by the base layer 3 and the fiber bundle 4 can be kept high.
When a woven fabric is used as the base layer 3, the composition of the woven fabric is not limited, but it is preferable that the woven fabric is woven by a constituent yarn having a lower fineness than the fiber bundle 4 to be sewn.

When a woven fabric is used as the base layer 3, the woven fabric may have any structure, but preferably has a flat structure such as 1 × 1, 2 × 2, 3 × 3. The plain weave is preferably finer than 5x5, more preferably 4x4 or finer, still more preferably 3x3 or finer, and particularly preferably 2x2 or finer.

Further, the same fibers as the reinforcing fibers constituting the fiber bundle 4 may be used for the constituent yarns constituting the base layer 3, but different fibers may be used. Specifically, various resin fibers, vegetable fibers and the like can be used. Among these, as the resin constituting the resin fiber, polyamide (aliphatic polyamide, aromatic polyamide, etc.), polyester (polyester having a constituent unit derived from aromatic dicarboxylic acid, etc.) and the like can be used. Further, as the plant fiber, cotton fiber, hemp fiber and the like can be used.
When the base layer 3 is a woven fabric, its basis weight is not limited, but may be, for example, 1 g / m ² or more and 1000 g / m ² or less (further, 50 g / m ² or more and 500 g / m ² or less). can.

The fiber bundle 4 is a bundle of fibers formed by bundling continuous fibers. The continuous fibers constituting the fiber bundle 4 preferably include reinforcing fibers. The fiber bundle 4 may be composed of only reinforcing fibers, or may contain fibers other than reinforcing fibers (non-reinforcing fibers). However, when non-reinforcing fibers are contained, it is preferably 10% by mass or less with respect to 100% by mass of the entire fiber bundle. The fiber bundle and the continuous fibers constituting the fiber bundle may or may not have a twist.
Further, the fiber bundle 4 may be bundled in any way. A plurality of continuous fibers may be simply aligned, or a plurality of continuous fibers may be bound using a thread (thread for bundling), and an adhesive, an adhesive, and heat may be used. The continuous fibers may be bound and bundled via another agent such as a fusing agent, or may be bundled by another method.

The number of continuous fibers constituting one fiber bundle 4 is not limited, but may be, for example, 3000 or more. When the number of continuous fibers constituting the fiber bundle 4 is 3000 or more, it is possible to exhibit excellent strength as a preform while being flexible. The number is not limited, but can be, for example, 3000 or more and 100,000 or less, further 5000 or more and 70,000 or less, further 7,000 or more and 50,000 or less, and further 10,000. The number can be 30,000 or more and 30,000 or less.

The continuous fiber may be an inorganic material fiber, an organic material fiber, or a combination thereof. Examples of the inorganic material fiber include carbon fiber (PAN-based carbon fiber, pitch-based carbon fiber), glass fiber, metal fiber and the like. Only one of these may be used, or two or more thereof may be used in combination. Examples of the organic material fiber include aromatic polyamide (aramid fiber, trade name "Kevlar" and the like), polybenzazole resin fiber (poly-paraphenylene benzobisoxazole fiber, trade name "Zylon" and the like) and the like. Only one of these may be used, or two or more thereof may be used in combination.

The fiber form of the continuous fiber is not limited, and may be a span yarn, a filament yarn, or a combined form thereof, but among these, the filament yarn is preferable. Further, the continuous fiber may be a monofilament, a multifilament, or a combination thereof.

<Manufacturing method of preform>
As shown in FIG. 12, the method for manufacturing a preform according to the present embodiment has, for example, a base layer 3 and a fiber bundle 4 sewn on the base layer 3, and serves as a core material of a composite material. A preform 2 is obtained by using the preform manufacturing sewing machines 1A to 1F according to the above embodiment, which is a method for manufacturing the reform 2.

The preform 2 includes a sewing region R in which the fiber bundle 4 is sewn to the base layer 3. The sewing region R includes, for example, a thin sewing region R1 to which the parallel-guided fiber bundles 4 are sewn, and a thick sewing region R2 to which the overlap-guided fiber bundles 4 are sewn. However, depending on the selection of the guide state of the fiber bundle 4 by the fiber guides 7A to 7F of the sewing machines 1A to 1F, only one of the thin stitch region R1 and the thick stitch region R2 may be included.

In the sewing region R, the laminated fiber bundles 4 or the parallel guided fiber bundles 4 are sewn in a plane so as to be arranged in a plurality of rows with respect to the base layer 3.
In the sewing region R, the fiber bundle 4 may be sewn and arranged in a plane so as to be arranged in a plurality of rows with respect to the base layer 3, but for example, the fiber bundle may be arranged so as to fill a predetermined surface. 4 can be aligned and sewn. Further, the fiber bundle 4 can be folded and sewn so as to fill a predetermined surface. Specifically, the fiber bundle 4 can be folded and arranged in a bellows shape, or can be folded and arranged by winding it in a spiral shape (circular spiral, polygonal spiral, etc.).
As these sewing modes, only one type may be used, and two or more types may be used in combination. Further, as a matter of course, sewing modes other than these can be used.

In the sewing region R, the fiber bundles 4 guided in layers or the fiber bundles 4 guided in parallel may be spread as one layer and sewn, or may be spread in multiple layers so as to have two or more layers. It may be sewn. Further, the front and back surfaces of the base layer 3 may be spread and sewn.
Further, as described above, when two or more layers are laid and sewn, or when the front and back surfaces are laid and sewn, the arrangement direction of the fiber bundles 4 constituting one layer and the other adjacent layers are configured. The fiber bundles 4 to be arranged may be arranged in parallel with each other, but they may be arranged so as to be crossed so that the arrangement directions are different. In this case, for example, the crossing angle can be 90 degrees or less (0 degrees <θ ≦ 90 degrees).

The preform 2 is usually used as a core material of a composite material by cutting off a base layer 3 constituting a non-sewn region R3 in which the fiber bundle 4 is not sewn. This cutting can be performed using, for example, a blade (scissors, a cutter, a cutting mold, etc.) or a laser.

The composite material (fiber reinforced plastic) can have, for example, a preform and a matrix resin in which the preform is embedded.
In the composite material, the matrix resin is the resin in which the preform is embedded. More specifically, it is a resin that is impregnated and fixed (cured in the case of a curable resin and solidified in the case of a thermoplastic resin) so as to spread inside the preform. As the impregnation method and the fixing method of the matrix resin, various conventionally known methods can be used.

The type of matrix resin is not limited, and various resins can be used. That is, a curable resin may be used, a thermoplastic resin may be used, or these may be used in combination. Examples of the curable resin include epoxy resin, polyester resin (curable polyester resin), urethane resin and the like. On the other hand, examples of the thermoplastic resin include a polyolefin resin, an acrylic resin, a polyester resin (thermoplastic polyester resin), and a polyamide resin.

Further, as the preform, only one single-sided preform composed of a base layer and a fiber bundle sewn on one surface of the base layer may be arranged, or the single-sided preform may be placed so that the base layers face each other. It may be placed facing each other. When two single-sided preforms are used in this way, the impact resistance of the obtained composite material can be efficiently improved by facing the base layers to each other.

The dimensions such as the shape, size and thickness of the composite material are not particularly limited, and the use thereof is not particularly limited. This composite material can be used, for example, as an exterior material for automobiles, railroad vehicles, ships, airplanes, etc., an interior material, a structural material (body shell, a vehicle body, an aircraft fuselage), a shock absorbing material, and the like. Among these, automobile supplies include automobile exterior materials, automobile interior materials, automobile structural materials, automobile shock absorbers, engine room interior parts, and the like.
Specifically, bumpers, spoilers, cowlings, front grilles, garnishes, bonnets, trunk lids, cowl louvers, fender panels, rocker moldings, door panels, roof panels, instrument panels, center clusters, door trims, quarter trims, roof flying, Pillar garnish, deck trim, tonoboard, package tray, dashboard, console box, kicking plate, switch base, seat backboard, seat frame, armrest, sun visor, intake manifold, engine head cover, engine undercover, oil filter housing, for automobiles Examples include housings for electronic parts (ECUs, TV monitors, etc.), energy absorbers such as air filter boxes and rush boxes, and body shell components such as front-end modules.

Further, for example, interior materials such as buildings and furniture, exterior materials, structural materials and the like can be mentioned. That is, it can be a door surface material, a door structural material, a surface material of various furniture (desk, chair, shelf, chest of drawers, etc.), a structural material, a unit bath, a septic tank, and the like. In addition, it can also be used as a packaging body, an accommodating body (tray or the like), a protective member, a partition member, or the like. Further, it can be a molded body such as a housing and a structure of a home electric appliance (thin TV, refrigerator, washing machine, vacuum cleaner, mobile phone, portable game machine, notebook computer, etc.).

The composite material may be produced in any manner, and can be produced, for example, by an RTM (Resin Transfer Molding) method, a VaRTM (Vacum Assisted Resin Transfer Molding) method, an autoclave method, a heat pressing method, or the like. Of the above, in the RTM method and the VaRTM method, there is a shaping step in which the preform is placed in a molding die to shape it, and a thermosetting resin is filled in the molding die to be cured or filled with a thermoplastic resin. A form including a matrix forming step of solidifying can be adopted. Further, the VaRTM method is different from the RTM method in that it includes a decompression step of depressurizing the inside of the cavity in order to assist the resin impregnation into the preform. Further, among the above, the autoclave method is a method of heating and curing a preform impregnated with a thermosetting resin in an autoclave, and the hot pressing method is a method of heating and applying a preform impregnated with a thermosetting resin by a hot press. It is a method of pressure curing.
In the method for producing this composite material, other steps can be provided in addition to the above steps. Other steps include, for example, a preform precursor forming step for obtaining a preform precursor, a cutting step for obtaining a preform from the preform precursor, a solidification step for solidifying the resin after embedding the resin, and the like. Examples thereof include a molding process for removing unnecessary portions of the solidified resin. In these steps, only one kind may be used, or two or more kinds may be used in combination.

Hereinafter, the present invention will be specifically described with reference to the drawings.

<Example 1>
As shown in FIG. 12, the sewing machine 1A for manufacturing a preform according to the first embodiment is a sewing machine for manufacturing a preform 2 which is a core material of a composite material. The preform 2 has a base layer 3 (woven fabric 3) and a fiber bundle 4 sewn on the base layer 3. The fiber bundle 4 is configured by bundling a large number of continuous fibers including reinforcing fibers such as carbon fibers. Further, the sewing region R of the fiber bundle 4 is a thin sewing region R1 to which the parallel-guided fiber bundle 4 described later is sewn, and a thick sewing region R2 to which the overlap-guided fiber bundle 4 described later is sewn. And, including.

The preform 2 is used as a core material by cutting the base layer 3 constituting the non-sewn region R3 to which the fiber bundle 4 is not sewn with a cutting tool, a laser, or the like. A composite material is obtained by arranging the preform 2 in a molding die, shaping it, filling the molding die with a thermosetting resin, and then filling it with a curing or thermoplastic resin to solidify it.

As shown in FIGS. 1 and 2, the sewing machine 1A includes a plurality of bobbins 5 around which a fiber bundle 4 is wound, a fiber guide 7A for guiding a fiber bundle 4 unwound from the plurality of bobbins 5 onto a base layer 3, and fibers. It includes a sewing needle 8 for sewing the fiber bundle 4 guided by the guide 7A to the base layer 3. Further, the sewing machine 1A includes a sewing machine head 11, a holding frame 12 that is movably provided below the sewing machine head 11 and holds the base layer 3, and a control unit 13 that controls the operation of each part of the sewing machine 1A. Is equipped with.

The sewing machine head 11 has a cylindrical rotating body 15 that can rotate around the axis of the sewing needle 8. The bobbin 5 and the fiber guide 7A are mounted on the rotating body 15. Specifically, the bobbin 5 is rotatably supported around the horizontal axis by the rotating body 15 via the support arm 16. Further, the rotating body 15 is provided with a fiber guide 7A via a support arm 17 so as to be swingable to the left and right in the sewing advancing direction.

The control unit 13 includes a reciprocating drive mechanism 21 that reciprocates a needle rod 9 having a sewing needle 8 at its tip up and down, a moving mechanism 22 that moves the holding frame 12 in a plane direction, a rotating mechanism 23 that rotates a rotating body 15, and a fiber. It is electrically connected to a swing mechanism 24 that swings the guide 7A, a switching mechanism 25 that switches the guide state of the fiber guide 7A, and a brake 27 (for example, an electromagnetic brake 27) for controlling the feeding amount of the fiber bundle 4. ing. Then, the control unit 13 reciprocates drive control of the needle bar 9, movement control of the holding frame 12, swing control of the fiber guide 7A (that is, staggered swing control), and rotation of the rotating body 15 based on predetermined sewing data. Control, switching control of the fiber guide 7A, and operation control of the brake 27 are performed.

The control process by the control unit 13 may be realized by either hardware or software, and preferably a microcontroller (microcomputer) including a CPU, a storage device (ROM, RAM, etc.), an input / output circuit, and the like. It can be configured by providing peripheral circuits such as an input / output interface at the center. Further, reference numeral 18 in FIG. 1 indicates a sewing thread (upper thread), reference numeral 19 indicates a bobbin thread, and reference numeral 10 indicates a hook.

As shown in FIG. 8, a plurality of (three in the figure) bobbins 5 are arranged side by side so that the shaft ends of adjacent bobbins 5 face each other. Each of these bobbins 5 is arranged so that its axes intersect on the same horizontal plane. Further, each bobbin 5 has a cylinder shaft 5a around which the fiber bundle 4 is wound, and a disk 5b provided on the shaft end side of the cylinder shaft 5a (see FIG. 2).

As shown in FIG. 3, the fiber guide 7A is formed in a hollow box shape, and has one introduction port 31 for introducing a plurality of fiber bundles 4 (three in the figure) and a plurality of fiber guides 4 for leading out each fiber bundle 4. It has a lead-out port 32 and. A guide bar 33 for suppressing the upward movement of the fiber bundle 4 unwound from the bobbin 5 is provided between the fiber guide 7A and the bobbin 5. Further, on the downstream side of the outlet 32 of the fiber guide 7A, a guide bar 34 for suppressing the upward movement of the fiber bundle 4 led out from the outlet 32 is provided. The guide bar 34 is formed with recesses 35 that guide a plurality of fiber bundles 4 along the outer periphery thereof. The guide bars 33 and 34 are attached to the rotating body 15.

As shown in FIGS. 4 and 5, the fiber guide 7A has a state A in which a plurality of fiber bundles 4 unwound from the plurality of bobbins 5 are arranged in parallel and guided onto the base layer 3, and a plurality of fiber bundles 4 are moved up and down. It is provided so as to be switchable between the state B and the state B which is superposed on the base layer 3 and guided onto the base layer 3. Specifically, the fiber guide 7A is rotatably provided between the first position C1 in which the plurality of outlets 32 do not overlap in the vertical direction and the second position C2 in which the plurality of outlets 32 overlap in the vertical direction. ing. The fiber guide 7A is rotatably provided around an axis along the guide direction of the fiber bundle 4 or around an axis along a direction inclined up and down in the guide direction.

As the switching mechanism 25 of the fiber guide 7A, for example, a mechanism that rotatably supports the fiber guide 7A on the support arm 17 and rotates the fiber guide 7A by the driving force of a drive source such as a motor or a cylinder is adopted. Can be done.

As shown in FIGS. 4A and 5A, the fiber guide 7A is located at the first position C1 so that the adjacent fiber bundles 4 are separated from each other at predetermined intervals in the width direction. The bundles 4 are arranged in parallel and guided onto the base layer 3. Further, as shown in FIGS. 4 (b) and 5 (b), the fiber guide 7A is located at the second position C2, and the centers of the plurality of fiber bundles 4 in the width direction substantially coincide with each other in the width direction. The fiber bundles 4 are stacked one above the other and guided onto the base layer 3.

The control unit 13 controls the drop position P of the sewing needle 8 with respect to the base layer 3 according to the switching of the guide state of the fiber bundle 4 by the fiber guide 7A, and changes the stitch patterns S1 and S2 of the sewing thread 18. In each of these stitch patterns S1 and S3, as shown in FIG. 6, the staggered spacing L1 in the width direction of the fiber bundle 4 and the staggered spacing L2 in the longitudinal direction of the fiber bundle 4 are different. The stitch pattern S1 is composed of a stitch s2 straddling a plurality of fiber bundles 4 arranged in parallel and a stitch s3 straddling one fiber bundle 4 (see FIG. 6A). Further, the stitch pattern S2 is composed of stitches s1 straddling a plurality of fiber bundles 4 stacked one above the other (see FIG. 6B).

The brake 27 is for controlling the feeding amount (discharge amount) of the fiber bundle 4 delivered from the bobbin 5. The brake 27 is provided on each bobbin 5 so as to apply a braking force to the bobbin 5. Specifically, the brake 27 is arranged in the tubular shaft 5a constituting the bobbin 5.

Next, the operation of the sewing machine 1A configured as described above will be described. First, the bobbin 5 around which the fiber bundle 4 is wound is set on the support arm 16, and the fiber bundle 4 is unwound from the bobbin 5 and passed through the fiber guide 7A to be guided to the vicinity of the drop position P of the sewing needle 8. In this state, the control unit 13 controls the reciprocating drive of the needle bar 9, the movement control of the holding frame 12, the swing control of the fiber guide 7A (that is, the staggered swing control), and the rotating body based on the predetermined sewing data. The rotation of the 15 is controlled, and the well-known staggered sewing operation is performed by the sewing needle 8 and the kettle 10. Further, the control unit 13 performs switching control of the fiber guide 7A and operation control of the brake 27 based on predetermined sewing data.
During the staggered sewing operation, the rotation of the rotating body 15 is controlled so that the fiber bundle 4 guided by the fiber guide 7A faces the sewing advancing direction.

When the fiber bundle 4 is sewn linearly with the sewing machine 1A to form the thin stitch region R1 of the preform 2, as shown in FIGS. 8 and 9, the fiber guide 7A located at the first position C1 is used. A plurality of fiber bundles 4 are guided on the base layer 3 in a state of being arranged in parallel, and sewing is performed with the stitch pattern S1.
On the other hand, when the fiber bundle 4 is sewn in a straight line to form the thick stitch region R2 of the preform 2, a plurality of fiber bundles 4 are vertically stacked by the fiber guide 7A located at the second position C2. In this state, it is guided onto the base layer 3 and sewn with the stitch pattern S2.
When the fiber bundle 4 is sewn in a straight line, the brake 27 is not normally operated.

When the fiber bundle 4 is sewn in a curved shape to form the thin stitch region R1 of the preform 2, as shown in FIGS. 10A and 11A, the fiber guide located at the first position C1 is formed. A plurality of fiber bundles 4 are guided on the base layer 3 in a state of being arranged in parallel by 7A, and sewing is performed with the stitch pattern S1. At this time, the brake 27 is operated and an appropriate braking force is applied to each bobbin 5. Specifically, a strong braking force is applied to the rightmost bobbin 5 in FIG. 10A, a medium braking force is applied to the central bobbin 5, and a weak braking force is applied to the leftmost bobbin 5. As a result, the amount of feeding of the plurality of fiber bundles 4 gradually decreases from the outside of the curve toward the inside of the curve, so that the bias of the fiber bundles 4 due to the difference in peripheral length is suppressed.

In this embodiment, the embodiment in which the brake 27 is operated so as to apply the braking force to all the bobbins 5 is exemplified, but the present invention is not limited to this, and for example, depending on the size of the radius of curvature of the curved portion or the like. The brake 27 to be activated may be selected.

When the fiber bundle 4 is sewn in a curved shape to form the thick stitch region R2 of the preform 2, as shown in FIGS. 10 (b) and 11 (b), the fiber guide located at the second position C2. By 7A, a plurality of fiber bundles 4 are guided onto the base layer 3 in a state of being stacked vertically, and sewing is performed with the stitch pattern S2. At this time, the brake 27 is not normally operated.

From the above, according to the sewing machine 1A of the present embodiment, the fiber guides 7A for guiding the fiber bundles 4 unwound from the plurality of bobbins 5 onto the base layer 3 and the fiber guides 7A around which the fiber bundles 4 are wound are used. A sewing needle 8 for sewing the guided fiber bundle 4 to the base layer 3 is provided. The fiber guide 7A is divided into a state A in which the fiber bundles 4 unwound from the plurality of bobbins 5 are arranged in parallel and guided onto the base layer 3, and a state B in which the fiber bundles 4 are vertically stacked and guided onto the base layer 3. It is provided so that it can be switched. As a result, the fiber bundles 4 unwound from the plurality of bobbins 5 are sewn to the base layer 3 at the same time, so that the sewing speed of the fiber bundles 4 can be increased, that is, the production speed of the preform 2 can be increased. Further, if necessary, the fiber bundles 4 are arranged in parallel by the fiber guide 7A and supplied onto the base layer 3, or the fiber bundles 4 are vertically stacked and supplied onto the base layer 3, so that the thickness of the fiber bundles 4 is changed and sewn. be able to. Therefore, it is possible to cope with the preform 2 having a complicated shape, and it is possible to improve the degree of freedom in designing the preform 2. Further, when the type of the fiber bundle 4 is used properly for a plurality of bobbins 5, the degree of freedom in designing the preform 2 can be further improved.

In particular, according to the sewing machine 1A of this embodiment, if the amount of fiber used for the preform 2 (product) is 1, the more the sewing amount per unit time increases, the shorter the manufacturing time will be. High speed is possible. On the other hand, the difference from the case where the wide fiber bundle 4 is simply used is a mode in which the fiber bundle 4 is sewn as thinly as possible to avoid the case where the fiber bundle 4 becomes too thick and causes a problem with the product. Can be selected during sewing. In summary, it is possible to sew a large amount of fiber bundles 4 at a time, which can contribute to shortening the manufacturing time. In addition, the degree of freedom in design can be increased by controlling the thickness of the product.

Further, in this embodiment, the control unit 13 changes the stitch patterns S1 and S2 of the sewing thread 18 by controlling the drop position P of the sewing needle 8 with respect to the base layer 3 according to the switching of the guide state of the fiber bundle 4 by the fiber guide 7A. To prepare for. Thereby, the fiber bundle 4 can be sewn with the stitch patterns S1 and S2 suitable for the guide state of the fiber bundle 4 by the fiber guide 7A.

Further, in this embodiment, a brake 27 for controlling the amount of feeding of the fiber bundle 4 delivered from the bobbin 5 is provided. As a result, when the fiber bundles 4 supplied side by side on the base layer 3 are sewn in a curved shape (particularly when sewn in a curved shape having an extremely small radius of curvature), the amount of the fiber bundles 4 drawn out by the brake 27 is extended. By controlling the above, the fiber bundle 4 can be sewn while suppressing the bias of the fiber bundle 4 due to the difference in peripheral length.

Further, in this embodiment, the brake 27 is provided so as to apply a braking force to the bobbin 5. Thereby, as compared with the form in which the braking force is applied to the fiber bundle 4, it is possible to prevent the fiber bundle 4 from breaking or the like and control the feeding amount of the fiber bundle 4.

Further, in the present embodiment, the fiber guide 7A has a plurality of outlets 32 for leading out the fiber bundle 4, a first position C1 in which the plurality of outlets 32 do not overlap in the vertical direction, and a plurality of outlets 32. It is rotatably provided between the second position C2 that overlaps in the vertical direction. As a result, the guide state of the fiber bundle 4 can be smoothly and surely switched, and the switching mechanism 25 of the fiber guide 7A can be simplified.

<Example 2>
Next, the preform manufacturing sewing machine 1B according to the second embodiment will be described. However, the same reference numerals are given to the configurations substantially the same as those of the sewing machine 1A according to the first embodiment, and the detailed description is omitted. A certain fiber guide 7B will be mainly described in detail.

As shown in FIG. 13, the sewing machine 1B has a fiber guide 7B for guiding a plurality of bobbins 5 and a fiber bundle 4 unwound from the plurality of bobbins 5 onto the base layer 3, and a fiber bundle 4 guided by the fiber guide 7B. Is provided with a sewing needle 8 for sewing to the base layer 3. Further, the sewing machine 1B includes a sewing machine head 11, a holding frame 12 that is movably provided below the sewing machine head 11 and holds the base layer 3, and a control unit 13 that controls the operation of each part of the sewing machine 1B. It is equipped with.

The fiber guide 7B includes a first fiber guide 41 for arranging the fiber bundles 4 in parallel and guiding them onto the base layer 3, a second fiber guide 42 for stacking the fiber bundles 4 vertically and guiding them onto the base layer 3. It is equipped with.

As shown in FIGS. 14 and 15, the first fiber guide 41 is formed in a comb shape that partitions a plurality of fiber bundles 4. The first fiber guide 41 is provided on the upstream side of the second fiber guide 42 so as to be able to move forward and backward with respect to the second fiber guide 42 (that is, slide along the guide direction of the fiber bundle 4). Further, the second fiber guide 42 is an expandable and contractible annular body through which a plurality of fiber bundles 4 are inserted. The second fiber guide 42 is formed of an elastic material such as rubber, and is expanded into a flat elliptical shape by stretching the left and right ends outward, and is reduced by releasing the stretching.

As the switching mechanism 25 of the fiber guide 7B, for example, the first fiber guide 41 is slidably supported on the support arm 17, and the first fiber guide 41 is slid by the driving force of a drive source such as a motor or a cylinder. A mechanism can be adopted in which the support arm 17 is provided with a grip portion that grips and stretches both left and right ends of the second fiber guide 42, and the grip portion is operated by the driving force of a drive source such as a motor or a cylinder.

Further, in this embodiment, the expandable and contractible annular body (second fiber guide 42) formed by the elastic body is exemplified, but the present invention is not limited to this, and for example, the expandable and contractible annular body by a shutter mechanism, a link mechanism, or the like. May be.

When the thin stitch region R1 of the preform 2 is formed by the sewing machine 1B, as shown in FIGS. 14A and 15A, the second fiber guide 42 is in a state where the first fiber guide 41 is advanced. Is expanded, the fiber bundles 4 are guided onto the base layer 3 in a state where the fiber bundles 4 are arranged in parallel by the first fiber guide 41, and sewing is performed with the stitch pattern S1.
On the other hand, when forming the thick stitch region R2 of the preform 2, as shown in FIGS. 14 (b) and 15 (b), the second fiber guide 42 is reduced while the first fiber guide 41 is retracted. By doing so, the fiber bundles 4 are guided onto the base layer 3 in a state where the fiber bundles 4 are vertically stacked by the second fiber guide 42, and sewing is performed with the stitch pattern S2.

From the above, according to the sewing machine 1B of the second embodiment, the operation and effect are substantially the same as those of the sewing machine 1A of the first embodiment, the guide state of the fiber bundle 4 can be switched smoothly and surely, and the fiber guide 7B can be switched. Since the vertical movement is minimized, the fiber bundle 4 can be guided to a position close to the sewing needle 8.

<Example 3>
Next, the sewing machine 1C for manufacturing a preform according to the third embodiment will be described. However, the same reference numerals are given to the configurations substantially the same as those of the sewing machine 1A according to the first embodiment, and the detailed description is omitted. A certain fiber guide 7C will be mainly described in detail.

As shown in FIG. 16, the sewing machine 1C has a fiber guide 7C for guiding a plurality of bobbins 5 and a fiber bundle 4 unwound from the plurality of bobbins 5 onto the base layer 3, and a fiber bundle 4 guided by the fiber guide 7C. Is provided with a sewing needle 8 for sewing to the base layer 3. Further, the sewing machine 1C includes a sewing machine head 11, a holding frame 12 that is movably provided below the sewing machine head 11 and holds the base layer 3, and a control unit 13 that controls the operation of each part of the sewing machine 1C. Is equipped with.

The fiber guide 7C is a rotating body (specifically, a rotating roller) in which an annular recess 45 is formed along the outer circumference. As shown in FIGS. 17 and 18, the recess 45 has a first guide portion 46 and a second guide portion 47 having a groove width narrower and a groove depth deeper than that of the first guide portion 46. There is. The first guide portion 46 and the second guide portion 47 are arranged apart from each other in the circumferential direction of the recess 45. Further, the recess 45 is formed in a tapered shape in which the groove width becomes narrower and the groove depth becomes deeper from the first guide portion 46 toward the second guide portion 47. Then, the fiber guide 7C has a first position C1 in which the fiber bundles 4 are arranged in parallel in the first guide portion 46 and guided on the base layer 3, and the fiber bundles 4 are vertically stacked on the base layer 3 in the second guide portion 47. It is rotatably provided between the second position C2 to be guided.

The switching mechanism 25 of the fiber guide 7C is, for example, a mechanism in which the fiber guide 7C is rotatably supported around the horizontal axis on the support arm 17 and the fiber guide 7C is rotated by the driving force of a drive source such as a motor or a cylinder. Can be adopted.

When the thin stitch region R1 of the preform 2 is formed by the sewing machine 1C, as shown in FIGS. 17 (a) and 18 (a), the first guide portion of the fiber guide 7C located at the first position C1. The fiber bundles 4 are guided onto the base layer 3 in a state of being arranged in parallel by the 46, and sewing is performed with the stitch pattern S1.
On the other hand, when forming the thick stitch region R2 of the preform 2, as shown in FIGS. 17B and 18B, the second guide portion 47 of the fiber guide 7C located at the second position C2 is used. The fiber bundles 4 are guided onto the base layer 3 in a state of being stacked vertically, and sewing is performed with the stitch pattern S2.

From the above, according to the sewing machine 1C of the third embodiment, the operation and effect are substantially the same as those of the sewing machine 1A of the first embodiment, the guide state of the fiber bundle 4 can be switched smoothly and surely, and the fiber guide 7C can be used. Since there is no vertical movement, the fiber bundle 4 can be guided to a position close to the sewing needle 8.

<Example 4>
Next, the preform manufacturing sewing machine 1D according to the fourth embodiment will be described. However, the same reference numerals are given to the configurations substantially the same as those of the sewing machine 1A according to the first embodiment, and the detailed description is omitted. A fiber guide 7D and a fiber bundle supply mechanism 51 will be mainly described in detail.

As shown in FIG. 19, the sewing machine 1D has a fiber guide 7D for guiding a plurality of bobbins 5 and a fiber bundle 4 unwound from the plurality of bobbins 5 onto the base layer 3, and a fiber bundle 4 guided by the fiber guide 7D. Is provided with a sewing needle 8 for sewing to the base layer 3. Further, the sewing machine 1D includes a sewing machine head 11, a holding frame 12 that is movably provided below the sewing machine head 11 and holds the base layer 3, and a control unit 13 that controls the operation of each part of the sewing machine 1D. Is equipped with.

As shown in FIG. 19, the fiber guide 7D includes a plurality of division guides 50 that guide each of the plurality of fiber bundles 4 (three in the figure). Each split guide 50 is integrally rotatably provided between the first position C1 and the second position C2 (see FIGS. 4 and 5). Further, each division guide 50 is provided so as to be swingable around a horizontal axis orthogonal to the guide direction of the fiber bundle 4.

The sewing machine 1D is provided with a fiber bundle supply mechanism 51 that cuts the fiber bundle 4 unwound from the bobbin 5 to stop the supply onto the base layer 3 and re-injects the cut fiber bundle 4 onto the base layer 3. There is. The fiber bundle supply mechanism 51 includes a cutter 52 that cuts the fiber bundle 4 guided by each division guide 50.

As shown in FIG. 20, the cutter 52 is arranged above each division guide 50. The cutter 52 is provided so as to be displaceable (specifically swingable) between a cutting position for cutting the fiber bundle 4 and a standby position separated from the fiber bundle 4. Further, a plurality of cutters 52 are provided corresponding to the plurality of bobbins 5.

As the fiber bundle supply mechanism 51, for example, the cutter 52 and the split guide 50 are swingably supported on the support arm 18, and the cutter 52 and the split guide 50 are swung by the driving force of a drive source such as a motor or a cylinder. It is possible to adopt a mechanism to make it.

In the fiber bundle supply mechanism 51, the fiber bundle 4 is guided onto the base layer 3 by each division guide 50 of the fiber guide 7D while the cutter 52 is located in the standby position, and sewing is performed (see FIG. 20 (a)). ). Then, when the fiber bundles 4 supplied side by side on the base layer 3 are sewn in a curved shape, the cutter 52 swings to the cutting position, so that the fiber bundles 4 are cut and held (FIG. 20 (FIG. 20). b) See). Next, the split guide 50 swings backward and is flipped up (see FIG. 20 (c)). After that, the cutter 52 swings to the standby position at an appropriate timing such as at the end of curved sewing, and the split guide 50 swings forward and swings down vigorously, so that the cut fiber bundle 4 Is repopulated on the base layer 3 (see FIGS. 20 (d) and 20 (e)).

According to the fiber bundle supply mechanism 51, when the fiber bundles 4 supplied in parallel on the base layer 3 are sewn in a curved shape, the fiber bundles 4 are cut according to the radius of curvature of the curved portion, thereby forming the circumference. The fiber bundle 4 is sewn while suppressing the bias of the fiber bundle 4 due to the length difference (see FIGS. 21 (b) and 21 (c)). When the fiber bundles 4 supplied side by side on the base layer 3 are sewn in a straight line, the fiber bundle supply mechanism 51 is not normally operated (see FIG. 21A).

From the above, according to the sewing machine 1D of the fourth embodiment, it is possible to sew a wide complicated shape at a stretch while exhibiting substantially the same action and effect as the sewing machine 1A of the first embodiment, which contributes to reduction of manufacturing time and materials. can.

In this embodiment, a plurality of fiber bundle supply mechanisms 51 (that is, a cutter 52 and a division guide 50) provided for all of the plurality of bobbins 5 are exemplified, but the present invention is not limited to this, and for example, a plurality of. The fiber bundle supply mechanism 51 may be provided corresponding to at least one or more bobbins 5 among the bobbins 5. For example, one fiber bundle supply mechanism 51 may be provided corresponding to one bobbin 5. However, the function of the fiber bundle supply mechanism 51 is exhibited in parallel sewing when a large number of bobbins 5 (for example, bobbins 5 such as 5 units and 10 units) are lined up.

<Example 5>
Next, the sewing machine 1E for manufacturing a preform according to the fifth embodiment will be described. However, the same reference numerals are given to the configurations substantially the same as those of the sewing machine 1A according to the first embodiment, and the detailed description is omitted. A certain fiber bundle supply mechanism 55 will be mainly described in detail.

This sewing machine 1E has a fiber guide 7E (same configuration as the fiber guide 7A) that guides a plurality of bobbins 5 and a fiber bundle 4 unwound from the plurality of bobbins 5 onto the base layer 3, and a fiber bundle guided by the fiber guide 7E. A sewing needle 8 for sewing 4 to the base layer 3 is provided. Further, the sewing machine 1E includes a sewing machine head 11, a holding frame 12 that is movably provided below the sewing machine head 11 and holds the base layer 3, and a control unit 13 that controls the operation of each part of the sewing machine 1E. Is equipped with.

As shown in FIG. 22, the sewing machine 1E cuts the fiber bundle 4 unwound from the bobbin 5 to stop the supply onto the base layer 3, and re-injects the cut fiber bundle 4 onto the base layer 3. It is provided with a bundle supply mechanism 55. The fiber bundle supply mechanism 55 includes a cutter 56 for cutting the fiber bundle 4 guided by the fiber guide 7E, and a delivery unit 57 for sending the cut fiber bundle 4 onto the base layer 3. The cutter 56 is provided so as to be displaceable (specifically swingable) between a cutting position for cutting the fiber bundle 4 and a standby position separated from the fiber bundle 4. Further, the delivery unit 57 is configured to grip and send out the fiber bundle 4. Further, a plurality of cutters 56 and delivery portions 57 are provided corresponding to a plurality of bobbins 5.

The fiber bundle supply mechanism 55 is, for example, a mechanism that supports the cutter 56 and the delivery portion 57 in a displaceable manner on the support arm 17 and displaces the cutter 56 and the delivery portion 57 by the driving force of a drive source such as a motor or a cylinder. Can be adopted.

In the fiber bundle supply mechanism 55, the fiber bundle 4 is guided onto the base layer 3 by the fiber guide 7E in a state where the cutter 56 is located in the standby position, and sewing is performed (see FIG. 22A). Then, when the fiber bundles 4 supplied in parallel on the base layer 3 are sewn in a curved shape, the cutter 56 swings to the cutting position, so that the fiber bundles 4 are cut and held (FIG. 22 (b). )reference). Next, the cutter 56 swings to the standby position, and the delivery portion 57 grips the fiber bundle 4 (see FIG. 22 (c)). After that, the delivery unit 57 advances to release the grip of the fiber bundle 4 at an appropriate timing such as at the end of the curved sewing, so that the cut fiber bundle 4 is re-loaded onto the base layer 3 ( 22 (d) (e)).

According to the fiber bundle supply mechanism 55, when the fiber bundles 4 supplied in parallel on the base layer 3 are sewn in a curved shape, the fiber bundles 4 are cut according to the radius of curvature of the curved portion, thereby forming the circumference. The fiber bundle 4 is sewn while suppressing the bias of the fiber bundle 4 due to the length difference (see FIGS. 21 (b) and 21 (c)). When the fiber bundles 4 supplied in parallel on the base layer 3 are sewn in a straight line, the fiber bundle supply mechanism 55 is not normally operated (see FIG. 21A).

From the above, according to the sewing machine 1E of the fifth embodiment, it is possible to sew a wide complicated shape at a stretch while exhibiting substantially the same action and effect as the sewing machine 1A of the first embodiment, which contributes to reduction of manufacturing time and materials. can.

In this embodiment, a plurality of fiber bundle supply mechanisms 55 (that is, a cutter 56 and a delivery unit 57) provided for all of the plurality of bobbins 5 are exemplified, but the present invention is not limited to this, and for example, a plurality of fiber bundle supply mechanisms 55 are provided. The fiber bundle supply mechanism 55 may be provided corresponding to at least one or more of the bobbins 5. For example, one fiber bundle supply mechanism 55 may be provided corresponding to one bobbin 5. However, the function of the fiber bundle supply mechanism 55 is exhibited in parallel sewing when a large number of bobbins 5 (for example, bobbins 5 such as 5 units and 10 units) are lined up.

Further, in this embodiment, the delivery unit 57 that grips the fiber bundle 4 and sends it forward is illustrated, but the present invention is not limited to this, and for example, the delivery unit 57 that presses against the surface of the fiber bundle 4 and sends it forward may also be used. good. Further, the holding of the cut fiber bundle 4 may be performed by the cutter 56 or by the delivery unit 57.

<Example 6>
Next, the preform manufacturing sewing machine 1F according to the sixth embodiment will be described. However, the same reference numerals are given to the configurations substantially the same as those of the sewing machine 1A according to the first embodiment, and the detailed description is omitted. A design fiber 58 and a bobbin 59 will be mainly described in detail.

The sewing machine 1F has a fiber guide 7F (same configuration as the fiber guide 7A) that guides a plurality of bobbins 5 and a fiber bundle 4 unwound from the plurality of bobbins 5 onto the base layer 3, and a fiber bundle guided by the fiber guide 7F. A sewing needle 8 for sewing 4 to the base layer 3 is provided. Further, the sewing machine 1F includes a sewing machine head 11, a holding frame 12 that is movably provided below the sewing machine head 11 and holds the base layer 3, and a control unit 13 that controls the operation of each part of the sewing machine 1F. Is equipped with.

As shown in FIG. 23, the sewing machine 1F includes a bobbin 59 around which design fibers 58 distinguishable from the fiber bundle 4 are wound while being sewn to the base layer 3. The design fiber 58 is guided on the base layer 3 together with the fiber bundle 4 by the fiber guide 7F (same configuration as the fiber guide 7A). As a result, the pattern of the design fiber 58, which is distinguished from the fiber bundle 4, appears in the sewing region R of the preform 2 obtained by the sewing machine 1F.

From the above, according to the sewing machine 1F of the sixth embodiment, the operation and effect are substantially the same as those of the sewing machine 1A of the first embodiment, and the design of the preform 2 can be dramatically improved.

It should be noted that the present invention is not limited to the above-mentioned examples, and various modifications can be made within the scope of the present invention according to the purpose and use. That is, in the above embodiment, the sewing machines 1A to 1F provided with one sewing machine head 11 are exemplified, but the present invention is not limited to this, and for example, the multi-headed sewing machines 1A to 1F provided with a plurality of sewing machine heads 11 may be used.

Further, in the above embodiment, the sewing machines 1A to 1F having three bobbins 5 are exemplified, but the sewing machines are not limited to this, and may be, for example, sewing machines 1A to 1F having two or four or more bobbins 5.

Further, in the above embodiment, the embodiment in which the brake 27 is operated when the fiber bundles 4 guided in parallel on the base layer 3 are sewn in a curved shape is exemplified, but the present invention is not limited to this, and for example, the fiber bundles. The brake 27 may be operated when switching between the overlapping guidance and the parallel guidance of 4, so that the guiding state of the fiber bundle 4 can be switched more smoothly.

Further, each configuration of the above embodiment may be used in combination. For example, the fiber guide 7C of the sewing machine 1C of the third embodiment may be adopted instead of the guide bar 34 of the sewing machine 1A of the first embodiment.

The above examples are for illustration purposes only and are not to be construed as limiting the invention. Although the present invention has been described with reference to examples of typical embodiments, the wording used in the description and illustration of the invention is understood to be descriptive and exemplary rather than limited wording. As detailed herein, modifications may be made within the scope of the appended claims without departing from the scope or spirit of the invention in its form. Although specific structures, materials and examples have been referred to herein in detail of the invention, it is not intended to limit the invention to the disclosures herein, but rather the invention is claimed in the accompanying claims. It shall cover all functionally equivalent structures, methods and uses within the scope.

The present invention is not limited to the embodiments detailed above, and various modifications or modifications can be made within the scope of the claims of the present invention.

The present invention is widely used as a TFP (Tailored Fiber Placement) technique for producing a preform which is a core material of a composite material.

1A to 1F; sewing machine for preform manufacturing, 2; preform, 3; base layer, 4; fiber bundle, 5; bobbin, 7A to 7F; fiber guide, 8; sewing needle, 13; control unit, 18; sewing thread, 27. Brake, 51, 55; Fiber feeder, A; Overlap guide state, B; Parallel guide state, P; Drop position, S1, S2; Stitch pattern.

Claims (6)

A sewing machine having a base layer and a fiber bundle sewn on the base layer to manufacture a preform which is a core material of a composite material.
With a plurality of bobbins around which the fiber bundle is wound,
A fiber guide that guides the fiber bundles unwound from the plurality of bobbins onto the base layer, and
A sewing needle for sewing the fiber bundle guided by the fiber guide to the base layer is provided.
The fiber guide is a state in which the fiber bundles unwound from a plurality of bobbins are arranged in parallel and guided onto the base layer, and at least two fiber bundles of the fiber bundles are vertically stacked and guided onto the base layer. A sewing machine for preform manufacturing, which is characterized by being provided so as to be switchable between the state in which the sewing machine is used and the state in which the sewing machine is used. The sewing machine for manufacturing a preform according to claim 1, further comprising a control unit for controlling the drop position of the sewing needle with respect to the base layer to change the stitch pattern of the sewing thread according to the switching of the guide state of the fiber bundle by the fiber guide. .. The sewing machine for manufacturing a preform according to claim 1 or 2, further comprising a feeding amount control mechanism for controlling the feeding amount of the fiber bundle fed from the bobbin. The sewing machine for manufacturing a preform according to claim 3, wherein the feeding amount control mechanism is a brake that applies a braking force to the bobbin. Any of claims 1 to 4, further comprising a fiber bundle supply mechanism that cuts the fiber bundle unwound from the bobbin to stop the supply onto the base layer and re-injects the cut fiber bundle onto the base layer. The sewing machine for manufacturing preforms described in item 1. A method for producing a preform having a base layer and a fiber bundle sewn on the base layer and serving as a core material of a composite material.
A method for producing a preform, which comprises obtaining the preform by using the sewing machine for producing the preform according to any one of claims 1 to 5.

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