JP2834473B2 - Deformed reinforced substrates for composites - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a modified reinforcing substrate for a composite material composed of a fibrous structure, and more particularly, to a method of impregnating a reinforcing substrate when impregnating a matrix resin, metal, or the like. The present invention relates to a reinforcing base material capable of preventing a resin pool from being formed on an outer peripheral surface or an upper surface and a side end surface.

[Conventional technology]

As component parts of mechanical devices that require specific strength and heat resistance of space vehicles, aircraft, automobiles, internal combustion engines, ships, railway vehicles including linear cars, etc., fiber reinforced plastic (FRP), carbon fiber reinforced plastic ( Composite materials such as CFRP), fiber reinforced metal (FRM), and fiber reinforced ceramic (FRCR) have begun to be used.

Such a composite molded article is lightweight, and at the same time, has high strength, synthesis and heat resistance, and is highly evaluated for its usefulness not only in the above-mentioned application fields but also in various industrial fields.

From such a standpoint, the applicant of the present application
No. 194145, JP-A-61-201063, JP-A-61-207657
And JP-A-63-42955 discloses a reinforcing substrate for a composite material and a method for producing the same.

What is the reinforcing substrate? At predetermined intervals, a plurality of yarn guide tubes are aligned in a multi-row, double-row manner so as to correspond to a desired shape and arranged upright, and, for example, the first in the X direction along the arrangement of each yarn guide tube. The yarns are arranged in a meandering manner by the required area, then arranged in a meandering manner in the Y direction by the necessary area, and further, if necessary, arranged in a meandering manner. This is repeated once and repeated a plurality of times. The required three-dimensional shape of the reinforcing base material is made up, and in this state, the second yarn is inserted into each yarn guide tube, and the yarn guide tube is pulled upward, and each yarn guide tube and the second yarn guide tube are connected to each other. , And a third thread, which is to be a kanuki thread, is inserted and connected to each upper loop portion of the second thread.
By tightening the laminate formed by the first and second yarns, a reinforcing base material having excellent form stability is manufactured.

[Problems to be solved by the invention]

The reinforcing base material obtained in this manner is thereafter finished into a composite material molded article by impregnating and curing a matrix resin, for example, an epoxy resin, but in the case of a deformed part having a complicated surface shape, a laminated surface or a surface layer is formed. There is a case where it is desired to improve the strength of the surface along. Further, in the case where the lamination area of the first yarn is gradually reduced along the thickness direction, the surface of the laminated reinforcing base material, particularly the side end face thereof, has a saw-toothed shape due to a change in the lamination area. Steps occur. The step portion often becomes a pool of resin when the matrix resin is impregnated, and a crack is easily generated in this portion when the resin is cured or when a composite material is used.

An object of the present invention is to attach a second yarn to the outer peripheral surface of the base material at a surface layer or an intermediate portion of the reinforcing base material so as to be substantially orthogonal to the first yarn before the penetration of the cannus yarn. Set up
In the case of the middle part, the first yarn is further laminated thereon,
It is an object of the present invention to provide a reinforcing base material that improves the strength characteristics of a laminated surface and a surface along a surface layer of a composite material finally obtained.

Another object of the present invention is to provide a reinforcing substrate having a smooth surface that can prevent the formation of a resin pool on the surface of the reinforcing substrate when impregnated with a matrix resin, a metal, or the like.

Furthermore, an object of the present invention is to provide a laminate formed by the meandering arrangement of the first yarns, wherein the cross-sectional shapes parallel to the XY plane are mutually similar or non-similar in the Z direction. Or,
An object of the present invention is to provide various deformed reinforcing substrates having complicated surface shapes such as a combination of the two.

[Means for solving the problem]

As a means for solving the above-mentioned problems, the present invention provides: (1) a meandering arrangement while sequentially changing the alignment direction in the XY plane, and laminating this in a plurality of layers in the Z direction to form an irregular three-dimensional shape corresponding to the final shape; A third thread which penetrates the laminated first thread and the laminate formed by the first thread in the Z direction, forms a loop on the front surface of the laminate, and continues on the rear face. In the modified reinforcing base material for a composite material, which is composed of a yarn and a fourth yarn to be inserted and connected as a kanuki yarn in the loop of the third yarn, the first yarn As a surface yarn covering the surface of the formed laminate or any intermediate position during the lamination, prior to the insertion of the third and fourth yarns into the surface of the already laminated laminate, It is characterized in that the second yarn is arranged in a meandering manner substantially perpendicular to the alignment direction of the first yarn. Deformed reinforced base material for composite materials.

(2) The layered structure formed by the meandering arrangement of the first yarns is characterized in that the cross-sectional shape parallel to the XY plane has portions which are similar to each other in the Z direction. The deformed reinforcing substrate for a composite material according to claim 1.

And (3) that the cross-sectional shape parallel to the XY plane of the laminate formed by the meandering alignment of the first yarns has a portion that is non-similar to each other in the Z direction. The deformed reinforcing substrate for a composite material according to claim 1, wherein

(4) The cross-sectional shape parallel to the XY plane of the laminate formed by the meandering arrangement of the first yarns is changed in a part similar to each other and non-similar to each other in the Z direction. The deformed reinforcing substrate for a composite material according to claim 1, further comprising:

 Is provided.

Here, the XY plane is a general term for a plane surface and a curved surface.

[Action]

As a surface yarn covering the surface of the laminate formed by repeating the laminating operation in which the first yarns are arranged in a meandering arrangement, the second yarns are arranged so as to be substantially orthogonal to the alignment direction of the first yarns. In the case of the intermediate layer, the first layer is further formed on the intermediate layer by repeating the meandering arrangement, and the second layer is formed on the surface of the final laminate in the above-described manner. ,
The third yarn is arranged in the stack penetrating direction, and the fourth yarn is inserted into the loop of the third yarn formed on the upper surface and the side end surface of the stack as a kanuki yarn, and the stack is tightened. Thereby, a reinforcing substrate having a high fiber density and a smooth surface with improved multidirectional strength characteristics can be manufactured.

〔Example〕

FIG. 1 to FIG. 4 are longitudinal sectional views of a reinforcing substrate and a yarn laminating apparatus for explaining a specific example of the present invention. In these drawings, (1) is a first yarn, (2) is a second yarn used as a surface yarn or an intermediate layer yarn, (3) is a third yarn, (4) Indicates a fourth yarn used as a kanuki yarn, and (5) indicates a base plate used as a positioning support member for the yarn guide tube (6) and the spacer (7).

The base plate (5) includes first to fourth yarns (1).
(2) It is manufactured from a plate body having a flat or curved surface structure according to the shape of the reinforcing base material (8) to be formed by (3) and (4). A fitting support hole (6a) is formed. In the illustrated example, since the reinforcing base material (8) has a curved bottom surface shape, the disposed base plate (5) also has the same curvature radius as the bottom surface portion of the reinforcing base material (8). When fabricating a reinforced substrate (8) having a curved longitudinal cross-sectional shape, a group of spacers (7) (7)... Having the same height as the curved base plate (5) as described above is used. Alternatively, it is possible to use a flat plate as the base plate (5), and to stand a plate having a different height of the spacer (7) on the lower flat base plate (5), so that It is also possible to form a desired curved surface shape on the upper surfaces of the spacers (7) and (7).

Assemble the base plate (5), spacers (7) (7) ... and thread guide tubes (6) (6) ... into a reinforcing base material (8).
After the selection is made so as to conform to the final lamination shape and the arrangement density of the yarn, the lamination operation of the first yarn (1) is started. That is, as shown in FIG. 1, the first yarn (1) is aligned along the Y-axis direction (perpendicular to the paper plane) through the space between the yarn guide tubes (6) (6). After forming the first layer on the meandering separator in the state, the alignment direction is changed to the X-axis direction (parallel to the paper surface), and the meandering arrangement is repeated.
Form a layer. Thereafter, the laminating operation of the first thread (1) is repeated until reaching the upper surface of the reinforcing base material (8) according to the same procedure. The lamination width is reduced every single layer or every several layers.

In forming the reinforcing base material (8), as shown in FIG.
In the case where the yarn (1) is gradually reduced in lamination area from the bottom surface (9) to the top end (10) of the lamination while maintaining a similar lamination shape, for example, FIG. As shown in B), the yarn arrangement area on a certain lamination surface has an arrangement pattern that decreases in a similar manner.

The arrangement pattern of the first yarns (1) in each layer is, for example, meandering in the Y-axis direction, then, meandering in an oblique direction crossing the Y-axis at about 45 °, and subsequently, in the X-axis direction. Direction, further intersect at about 45 ° with the X-axis, and meander in the diagonal direction opposite to the above, and use this as one repeat to sequentially reduce the lamination area in a similar manner to the reinforcing substrate ( 8) is formed.

In a similar manner, the present invention can be similarly applied to the case where the first layer to the last layer have a similar laminated shape, for example, a cone or a pyramid.

On the other hand, when forming the reinforcing base material (8), as shown in FIG. 6, the first thread (1) moves from the bottom surface (11) of the laminate in contact with the upper surface of the base plate (5) to the top surface (12). If the lamination area changes non-similarly, for example,
As shown in FIGS. 7A and 7B, the layers are sequentially stacked in an array form corresponding to the tomographic shape at each position.

In FIG. 8, the yarn arrangement in only the X and Y directions is shown, but this is not essential, and the first arrangement is made according to the final shape of the reinforcing base material (8) and the required strength characteristics. Can be freely selected. For example, an array in the X direction is followed by a 45.degree.
There is a condition such as moving in the direction. Also, instead of forming the first layer to the uppermost layer from one continuous yarn, a new same or different yarn is connected at an appropriate position in the middle of the stacking stage and the stacking operation is repeated. Is also possible.

After completing the laminating operation of the first yarn (1) corresponding to the final shape of the reinforcing base material (8), the first yarn ( The yarn guide tubes (6) (6) are maintained while maintaining an alignment direction (X-axis direction) substantially orthogonal to the final alignment direction (Y-axis direction in the illustrated example) of 1).
The second yarn (2) is arranged in a meandering manner. The second yarn (2) functions as a surface yarn covering substantially the entire upper surface and side end surfaces of the laminate formed by the meandering arrangement of the first yarns (1). Not only the upper surface (13) but also the entire side end surfaces (14) and (15) of the laminate in which the direction change point of the meandering arrangement of the first yarn (1) is exposed as a saw-toothed step. Repeat the meandering arrangement.

After covering the front surface of the laminate of the first yarn (1) with the second yarn (2), the third guide is attached to the yarn guide tube (6) using an appropriate locking pin (16). The yarn (3) is inserted in a bent state, and the yarn guide tube (6) is pulled up above the laminate,
In this state, by removing the yarn guide tube (6) and the locking pin, a loop (3a) of the third yarn (3) is formed on the upper surface (13) and the side end surfaces (14) and (15) of the laminate. Let it form. Then, the intended reinforcing base material (8) is formed by inserting the fourth thread (4) as a kanuki thread into the loop (3a).

Further, the second thread (2) arranged on the surface of the reinforcing base material (8) may be arranged at an intermediate position of the laminate. That is, as shown in FIG. 3, a predetermined number of layers are laminated according to the design, and the second yarn (2) is arranged in one or more layers, and subsequently, the first yarn (1) is further formed thereon. Are laminated in a predetermined number of stages, and in the final stage, the second yarn (2) is laminated.

Thus, by arranging the second yarn (2) as the surface yarn and the intermediate yarn, the direction and magnitude of the load acting on the reinforcing base material (8) and further the composite material are XYZ. The fiber orientation can be freely adjusted not only in the triaxial direction but also in the multiaxial direction or the flow shape of the surface.

FIG. 4 is different from FIG. 3 in the direction of insertion of the fourth yarn (4) which is to be used as the canning yarn. That is, in FIG.
FIG. 4 shows a case where the fourth yarn (4) is inserted in a direction parallel to the second yarn (2). In FIG. 4, the fourth yarn (4) is the second yarn (4). It shows a case where the thread is inserted in a direction intersecting with the yarn (2), and other configurations are the same.

The present invention has been described based on the embodiment. However, according to the same lamination procedure, the present invention has a similar cross-sectional shape along the laminating direction shown in FIGS. The solid spindle-shaped reinforcing base material (17), the solid pyramid-shaped reinforcing base material (18), the solid frustum-shaped reinforcing base material (19), or FIG. 10 (A) ( (B) As shown in (C), the unequal side reinforcing base material (20) and the wedge-shaped reinforcing base material (21) each having a non-similar cross-sectional shape along the laminating direction and having a gradually decreasing cross-sectional area. ), It is possible to manufacture a complicated shape such as a hollow bowl-shaped reinforcing substrate (22), that is, a so-called irregularly shaped reinforcing substrate.

As a material for forming the reinforcing substrate (8), yarns such as glass fiber, carbon fiber, aramid fiber, alumina fiber, and silicon fiber can be used. As matrix resin, epoxy resin, polyimide resin, or the like can be used. Can be used. In some cases, carbon or aluminum may be used instead of the resin.

〔The invention's effect〕

According to the present invention, by arranging the second yarn, the entire area of the upper surface and the side end surfaces of the reinforcing base material can be finished to have a smooth surface without any level difference, which has been a problem in the prior art. The generation of accumulated resin is effectively avoided. Also, for special applications, fibers that can be freely adapted when the direction of the load acting on the reinforced substrate, and therefore the composite material, is along the surface of the substrate or when it is complicated in multiple directions. It is possible to give an orientation. Therefore, regardless of whether the cross-sectional shape changes in a similar manner or non-similarly along the laminating direction, the state-of-the-art technology for improving the quality of the deformed reinforcing base material for composite materials. The remarkable effect which greatly exceeds is exhibited.

[Brief description of the drawings]

1 to 4 are longitudinal sectional views of a reinforcing substrate and a yarn laminating apparatus for explaining one embodiment of the present invention, and FIG. 5 is a diagram of a reinforcing substrate in which the laminating shape is similar and the laminating area is sequentially reduced. FIG. 6 is a perspective view showing one specific example, FIG. 6 is a perspective view showing one specific example of a reinforcing base material having a non-similar lamination shape, and a lamination area is sequentially changed, and FIGS. 7 (A) and (B) are FIGS. 8A and 8B are plan views illustrating examples of meandering arrangement patterns of the yarns in the reinforcing base material shown in FIG. 5, and FIGS. 9 (A), 9 (B) and 9 (C) are perspective views of a reinforcing base material having a similar lamination shape and a laminating area decreasing gradually, and FIG. 10 (A). ) (B)
(C) is a perspective view of a reinforcing base material whose lamination shape is non-similar and the lamination area changes sequentially. It is a perspective view of the shape which goes. (1) First thread, (2) Second thread, (3) Third thread, (4) Fourth thread.

Claims (4)

(57) [Claims] A first yarn which is arranged in a meandering manner while sequentially changing the alignment direction in an XY plane, is laminated in a plurality of layers in a Z direction, and is laminated in an irregular three-dimensional shape corresponding to a final shape; A third thread that penetrates the laminate formed by the first thread in the Z direction, forms a loop on the surface of the laminate, and is continuous on the back face; A fourth thread that is inserted and bound in the loop of the thread as a kanuki thread
In the deformed reinforcing substrate for a composite material composed of the yarn of the above, as a surface yarn covering the surface of the laminate formed by the first yarn or any intermediate position in the course of lamination,
The third yarn and the fourth yarn are placed on the surface of the already laminated body.
Characterized in that the second yarns are arranged in a meandering manner substantially perpendicularly to the alignment direction of the first yarns prior to the insertion of the first yarn. 2. The laminated body formed by the meandering arrangement of the first yarns has a cross-sectional shape parallel to the XY plane having portions which are similar to each other in the Z direction. The deformed reinforcing substrate for a composite material according to claim 1, wherein 3. The laminated body formed by the meandering arrangement of the first yarns has a section in which the cross-sectional shape parallel to the XY plane changes non-similarly to each other in the Z direction. The deformed reinforcing substrate for a composite material according to claim 1, wherein: 4. The sectional shape parallel to the XY plane of the laminate formed by the meandering arrangement of the first yarns is changed in a part similar to each other in the Z direction and in a part similar to the non-similar shape. The deformed reinforcing substrate for a composite material according to claim 1, further comprising: