JP3656395B2

JP3656395B2 - 3D fiber structure

Info

Publication number: JP3656395B2
Application number: JP06678098A
Authority: JP
Inventors: 義治安居; 藤夫堀
Original assignee: Toyota Industries Corp
Current assignee: Toyota Industries Corp
Priority date: 1998-03-17
Filing date: 1998-03-17
Publication date: 2005-06-08
Anticipated expiration: 2018-03-17
Also published as: JPH11269755A

Description

【０００１】
【発明の属する技術分野】
本発明は三次元繊維構造体に係り、詳しくは補強リブを有する板状の三次元繊維構造体に関するものである。
【０００２】
【従来の技術】
繊維強化複合材（ＦＲＰ複合材）は軽量の構造材料として広く使用されている。複合材用補強基材として三次元織物（三次元繊維構造体）がある。この三次元織物を骨格材として、樹脂あるいは無機物をマトリックスとした複合材はロケット、航空機、自動車、船舶及び建築物の構造材として幅広い用途が期待されている。
【０００３】
そして、航空機の胴体等に使用されるスティフナー付プレートを、三次元繊維構造体を骨格材とした耐衝撃性に優れた三次元繊維構造体複合材で製作することが考えられている。例えば、ＮＡＳＡ（米国航空宇宙局）の報告書ＮＡＳＡ／ＴＰ−９７−２０６２３４には、図１６（ａ）に示すように、ユニ・ウィーブ織物（Uni-Weave fabric）を複数枚積層して形成したＴ字状の補強リブ７０と、図１６（ｂ）に示すように、ユニ・ウィーブ織物を複数枚積層して形成した平板７１とを結合糸で縫い合わせて製造した三次元繊維構造体Ｗ（図１６（ｃ）に図示）が開示されている。補強リブ７０及び基板７１はそれぞれ配向角が０°、４５°、−４５°及び９０°のユニ・ウィーブ織物を複数枚積層して面内４軸とし、結合糸を含めて５軸構成となっている。
【０００４】
特開平１−２０７４６５号公報には、平板部上に断面Ｔ字状やＩ字状の突条部が複数本形成された異形断面の三次元織物と、その製造方法が開示されている。この三次元織物は、三次元織物の断面形状に対応して多数本の長さ方向糸を複数行、複数列に配列し、幅方向糸を隣接する長さ方向糸群の行間に、長さ方向糸と直交する状態で幅方向に往復させながら挿入する工程と、垂直方向糸を長さ方向糸の列間に長さ方向糸と直交する状態で上下方向に往復させながら挿入する工程とを繰り返して製造される。
【０００５】
特開平３−２８６８４１号公報には、平板状のプリプレグと、ほぼＬ字状に屈曲させた２枚のプリプレグを接合してほぼＴ字状に形成したプリプレグとを図１６と同様に接合した状態でファイバで縫合する複合材構造物の製造方法が開示されている。
【０００６】
特開平６−１８４９０６号公報には、複数の板状部が接続部において屈曲状態で連続する形状に形成された三次元繊維構造体が開示されている。この三次元繊維構造体は隣接する板状部の接続部の強度を高めるため、両板状部に跨がって連続する糸をその構成要素として持っている。この三次元繊維構造体は屈曲状態で連続する板状部を構成するように、糸の配列方向が異なる糸層が所定数積層形成された積層糸群を厚さ方向糸で結合して構成する。また、二つの三次元繊維構造体を合体して異なる断面形状の三次元繊維構造体を製造する方法が開示されている。例えば、コ字形の三次元繊維構造体を背中合わせに合体させてＨ状断面の三次元繊維構造体を製造することが開示されている。
【０００７】
また、特開平４−２８９２４３号公報には、複数の板状部がＴ字状に接合された接合部を有する形状に形成され、各板状部がその厚さ方向の成分を含む少なくとも３軸で構成され、隣接する板状部の接合部と交差する方向に延びるとともに各板状部の厚さ方向と直交する面に沿って配列され、かつ接合部を挟む両板状部に跨って連続する糸をその構成要素として持つ三次元織物（三次元繊維構造体）が開示されている。この三次元織物は図１７に示すように、多数の規制部材７２に貫通された状態で断面Ｌ字状に形成された積層糸群７３，７４と、平板状の積層糸群７５を組み合わせ、各積層糸群７３〜７５を貫通する規制部材７２を順次厚さ方向糸ｚと順次置換して積層糸群７３〜７５を結合することにより形成される。
【０００８】
【発明が解決しようとする課題】
特開平１−２０７４６５号公報に開示された三次元織物は、平板部や突条部が面内２軸で厚さ方向の糸を含めても３軸構成で、かつ屈曲状態で連続する面に跨って配列される糸がないため、複合材を形成した時の物性が不十分となる。
【０００９】
その他の従来技術の三次元繊維構造体（三次元織物）は、各板状部が少なくとも面内３軸で構成され、かつ屈曲状態で連続する面に跨って配列される糸が存在する。従って、特開平１−２０７４６５号公報に開示された三次元織物を骨格材とした複合材より物性（特に強度や耐衝撃性）の優れた複合材を形成することができる。
【００１０】
しかし、前記従来の三次元繊維構造体は、平板部と補強リブとを結合する結合糸（厚さ方向糸）は、いずれも平板部の厚さ方向と平行に配列されるため、平板部及び補強リブの平面が対向する位置においてのみ両者を貫いて結合に寄与する。従って、補強リブの屈曲部と平板部とが対向する箇所、即ち、図１７において鎖線で囲んだ領域では、両者を貫いて結合に寄与する結合糸が存在しない。その結果、複合材を製造したときに、応力集中が生じやすい箇所の強度が不十分となり、それを補うため三次元繊維構造体全体の強度を高める必要が生じて、三次元繊維構造体が厚くなるという問題がある。
【００１１】
本発明は前記の問題点に鑑みてなされたものであって、その目的は基板部と補強リブとが厚さ方向糸により結合された三次元繊維構造体の、補強リブと基板部との接続部の強度を大きくして、同じ要求物性であれば複合材を薄くできる三次元繊維構造体を提供することにある。
【００１２】
【課題を解決するための手段】
前記の目的を達成するため、請求項１に記載の発明では、三次元繊維構造体で構成された基板部と、三次元繊維構造体で構成された補強リブとが厚さ方向糸により結合された三次元繊維構造体であって、前記補強リブはほぼ直角に屈曲された状態で連続する板状部を有し、前記板状部の一つが前記基板部に垂直となるように基板部に結合されるとともに、前記補強リブと前記基板部とを結合する厚さ方向糸は、前記補強リブと前記基板部との平面部が対応する位置においては、前記基板部の厚さ方向と平行に配列され、前記補強リブの屈曲部と対応する位置においては、前記基板部の厚さ方向に対して交差する状態で屈曲部及び基板部を貫通するように配列されている。
【００１３】
請求項２に記載の発明では、請求項１に記載の発明において、前記補強リブは少なくとも前記基板部との結合部付近がＴ字状に形成されている。
請求項３に記載の発明では、請求項１又は請求項２に記載の発明において、前記基板部及び前記補強リブは、それぞれ複数の糸層を積層して形成された面内３軸以上の配向となる積層糸群と、その厚さ方向に配列された厚さ方向糸とを含む少なくとも４軸で構成されている。
【００１４】
請求項４に記載の発明では、請求項３に記載の発明において、前記基板部、補強リブ及び厚さ方向糸が全てカーボン糸で形成されている。
請求項１に記載の発明の三次元繊維構造体では、補強リブの屈曲部と対応する位置において、基板部の厚さ方向に対して交差する状態で屈曲部及び基板部を貫通するように配列された厚さ方向糸が存在する。従って、補強リブに横方向からの力が作用したとき、前記厚さ方向糸がその力を担うため、強度が高くなる。
【００１５】
請求項２に記載の発明では、請求項１に記載の発明において、補強リブは少なくとも基板部との結合部付近がＴ字状に形成されているため、横方向のどちら側から力が作用しても曲げに対して良好な強度を確保できる。
【００１６】
請求項３に記載の発明では、請求項１又は請求項２に記載の発明において、基板部及び補強リブは、それぞれ複数の糸層を積層して形成された面内３軸以上の配向となる積層糸群と、その厚さ方向に配列された厚さ方向糸とを含む少なくとも４軸で構成されているため、物性（特に強度や耐衝撃性）の優れた複合材を得ることができる。
【００１７】
請求項４に記載の発明では、請求項３に記載の発明において、前記基板部、補強リブ及び厚さ方向糸が全てカーボン糸で形成されているため、他の材質製の糸やカーボン糸と他の材質製の糸とを組み合わせて使用した場合に比較して、複合材としたときの物性が向上する。
【００１８】
【発明の実施の形態】
（第１の実施の形態）
以下、本発明を具体化した第１の実施の形態を図１〜図１２に従って説明する。図１及び図２に示すように、三次元繊維構造体Ｗは基板部１と補強リブ２とが厚さ方向糸ｚにより結合されて構成されている。基板部１は平板状に形成され、補強リブ２は基板部１との結合部付近がＴ字状となる断面形状に形成されている。この実施の形態では補強リブ２はＬ字状断面の三次元繊維構造体ＷＬを接合して、全体の断面形状がＴ字状に形成されている。補強リブ２はほぼ直角に屈曲された状態で連続する板状部２ａ，２ｂ，２ｃを有し、板状部２ａ，２ｂ，２ｃのうちの一つの板状部２ａが基板部１に垂直となるように基板部１に結合されている。補強リブ２は互いに平行に複数（この実施の形態では２個）設けられている。
【００１９】
基板部１及び補強リブ２は、それぞれ複数の糸層（ｘ糸層、ｙ糸層及びバイアス糸層）を積層して形成された面内４軸の配向となる積層糸群３と、その厚さ方向に配列された厚さ方向糸ｚとを含む５軸の三次元繊維構造体で構成されている。図３（ａ）〜（ｄ）はＬ字状断面の三次元繊維構造体ＷＬの積層糸群３を構成する各糸層の糸の配列を示す模式図である。
【００２０】
図３（ｂ）に示すように、ｘ糸層は三次元繊維構造体の厚さ方向と直交する面内において、幅方向又は長さ方向の一方（この実施の形態では幅方向）に沿って配列された第１の面内配列糸ｘからなり、１本の糸が折り返し状に配列されて形成されている。図３（ａ）に示すように、ｙ糸層はｘ糸層と平行な面内で第１の面内配列糸ｘと直交する方向に配列された第２の面内配列糸ｙからなり、１本の糸が折り返し状に配列されて形成されている。図３（ｃ），（ｄ）に示すように、バイアス糸層はｘ糸層と平行な面内で両面内配列糸ｘ，ｙに対して所定の角度（この実施の形態では４５°及び−４５°）で交差するように折り返し状に平行に配列されたバイアス糸Ｂ1 ，Ｂ2 からなる。バイアス糸Ｂ1 ，Ｂ2 は屈曲部４と交差する状態で両板状部２ａ，２ｂに跨がって連続するように配列されている。また、基板部１を構成するｘ糸層、ｙ糸層及びバイアス糸層も同様に構成されている。即ち、基板部１及び補強リブ２は、配向角が９０°の第１の面内配列糸ｘと、配向角が０°の第２の面内配列糸ｙと、配向角が４５°のバイアス糸Ｂ1 と、配向角が−４５°のバイアス糸Ｂ2 とで積層糸群３が構成されている。なお、配向角とは糸が三次元繊維構造体Ｗの長手方向となす角度を意味する。
【００２１】
図１に示すように、補強リブ２と基板部１とはその平面部が対応する位置においては、厚さ方向糸ｚが基板部１の厚さ方向と平行に配列されている。また、補強リブ２の屈曲部４と対応する位置においては、厚さ方向糸ｚは基板部１の厚さ方向に対して交差する状態で、屈曲部４及び基板部１を貫通するように配列されている。基板部１の厚さ方向と交差するように配列される厚さ方向糸ｚが基板部１となす角度θは、４０°〜７０°の範囲が好ましい。厚さ方向糸ｚは基板部１の表面側（補強リブ２が接合される面と同じ側）で折り返すように底面側から挿入されるとともに、表面側において幅方向に配列された抜け止め糸（図示せず）により抜け止めされている。厚さ方向糸ｚが抜け止め糸と共同で各糸層を締め付けることにより、各糸層が結合されている。
【００２２】
なお、各糸を構成する繊維の材質としては複合材の用途に応じてカーボン繊維、ガラス繊維、セラミック繊維、ポリアラミド繊維等種々のものが使用される。この実施の形態においては、各糸としてカーボン糸が使用されている。カーボン糸にはカーボン繊維のロービング（トウ）が使用されている。ロービング（トウ）とは細い単繊維のフィラメントを多数本束ねた実質無撚りの繊維束を意味する。
【００２３】
前記のように構成された三次元繊維構造体Ｗは繊維強化複合材の強化材（骨格材）として使用され、マトリックスとして樹脂や無機物が使用される。例えば、カーボン／カーボン複合材を構成する場合は、三次元繊維構造体Ｗに樹脂を含浸、硬化させた後、焼成して製作する。
【００２４】
前記のように構成された三次元繊維構造体Ｗを骨格材とした複合材の補強リブに横方向からの荷重（力）が作用した場合、補強リブ２の屈曲部４（コーナ部）に大きな応力が作用する。第２の面内配列糸ｙ及びバイアス糸Ｂ1 ，Ｂ2 が屈曲部４と交差する方向に延びるとともに両板状部２ａ，２ｂ、２ａ，２ｃに跨がって配列されているため、それらの糸が屈曲部４に作用する応力に耐える方向の力を分担するように有効に寄与する。また、屈曲部４及び基板部１を貫通するように配列された厚さ方向糸ｚも、屈曲部４に作用する応力に補強リブに作用する力が作用したとき、前記厚さ方向糸ｚがその力に耐える方向の力を分担するため、複合材の強度が向上する。
【００２５】
次に前記のように構成された三次元繊維構造体Ｗの製造方法の一例を説明する。三次元繊維構造体Ｗを製造する場合、図４に示すようなほぼＬ字状の枠体５を使用して、本願出願人が先に提案した方法（特開平９−１３７３３６号公報）でＬ字状の三次元織物（三次元繊維構造体）を２体製作する。また、四角形状の枠体を使用して基板部１となる平板状の積層糸群３を１体製作する。
【００２６】
Ｌ字状の枠体５は厚さ方向糸ｚの挿入区域と対応する領域６を囲むように形成された本体５ａと、本体５ａの外側に取り外し可能に所定ピッチで立設された多数の規制部材としてのピン７と、枠体５のコーナ部に取り外し可能にねじ（図示せず）により固定された支持バー８とから構成されている。支持バー８の角部にもピン７が取り外し可能に嵌合されている。四角形状の枠体は四角形の枠体本体に、所定ピッチでピンが取り外し可能に立設されている。
【００２７】
積層糸群３に厚さ方向糸ｚを挿入する厚さ方向糸挿入装置は、特開平８−２１８２４９号公報、特開平９−１３７３３６号公報で本願出願人が提案した装置と基本的に同様に構成されている。次に厚さ方向糸挿入装置を図６に従って説明する。図６は厚さ方向糸挿入装置９の概略部分平面図である。
【００２８】
厚さ方向糸挿入装置９は積層糸群３が配列された枠体５を取付け部材１０を介して一対の支持ブラケット１１間（片側のみ図示）に支持し、厚さ方向糸ｚを１列ずつ同時に挿入するようになっている。取付け部材１０はボルトにより枠体５に固定されるとともに、支持ブラケット１１の支持片１２にボルト１３により固定されるようになっている。
【００２９】
厚さ方向糸挿入装置９のベースプレート１４の前側（図６の下側）には支持テーブル１５が図６の左右方向に移動可能に配設され、支持テーブル１５上に支持ブラケット１１が立設されている。支持テーブル１５は図示しない送り装置により所定ピッチずつ移動されるようになっている。なお、図６に示す支持テーブル１５の位置は、厚さ方向糸ｚの挿入がほとんど終了に近づいた時点における位置である。
【００３０】
ベースプレート１４には支持テーブル１５より後側に一対のブラケット１６（一方のみ図示）が立設され、両ブラケット１６間には一対のガイドロッド１７が支持テーブル１５の移動方向と平行に架設されている。ガイドロッド１７には支持プレート１８が摺動可能に支持されている。支持プレート１８はブラケット１６に固定されたエアシリンダ１９のピストンロッド１９ａに連結され、エアシリンダ１９の作動により所定の距離を往復移動可能となっている。
【００３１】
支持プレート１８の前後両端には一対の支持ブラケット２０が立設され、支持ブラケット２０間に平行に架設されたガイドロッド（図示せず）に移動体２１が摺動可能に支持されている。移動体２１の前端には針支持体２２が固定され、針支持体２２の前部に厚さ方向糸挿入針（以下、単に挿入針という）２３がピン７の配列ピッチと対応する所定ピッチで１列に水平に固定されている。針支持体２２は前側の支持ブラケット２０に形成された孔（図示せず）を貫通する状態で配設されている。
【００３２】
移動体２１はモータ２４により駆動されるボールネジ機構２５の作動により、針支持体２２とともに待機位置と作用位置とに移動される。挿入針２３は待機位置では支持ブラケット１１に支持された積層糸群３と係合不能となり、作用位置では針孔２３ａ（図１１に図示）が積層糸群３の反対側となる位置まで積層糸群３を貫通する。
【００３３】
支持ブラケット２０には上下一対の支持ロッド２６が支持ブラケット２０を貫通した状態で摺動可能に支持されている。支持プレート１８には後側の支持ブラケット２０寄りに、ブラケット２７を介してエアシリンダ２８が前後方向に延びるように固定されている。両支持ロッド２６は後端側が連結板２９を介して互いに連結され、連結板２９がエアシリンダ２８のピストンロッド２８ａに連結されている。両支持ロッド２６の前端には穿孔針支持体３０が固定され、穿孔針支持体３０には穿孔針３１が挿入針２３と対応した所定ピッチで１列に固定されている。穿孔針３１の列はエアシリンダ１９の作動時における支持プレート１８の移動距離と等しい間隔を保って挿入針２３の列と平行に配置されている。エアシリンダ２８の作動により穿孔針支持体３０は穿孔針３１が支持ブラケット１１に支持された積層糸群３と係合不能な待機位置と、積層糸群３を貫通する作用位置とに移動される。
【００３４】
ベースプレート１４上には前側の支持ブラケット２０の近傍にエアシリンダ３２が前後方向に延びるように配設され、そのピストンロッド３２ａの先端にブラケット３３を介して押圧部材３４が固定されている。押圧部材３４は挿入針２３列の配列方向に沿って延びる断面Ｌ字状に形成され、挿入針２３あるいは穿孔針３１の通過を許容する櫛歯部を備え、挿入針２３あるいは穿孔針３１を挟んだ状態で積層糸群３を押圧可能となっている。
【００３５】
押圧部材３４は支持ブラケット１１に支持された積層糸群３に対して挿入針２３及び穿孔針３１の待機位置側に配設され、挿入針２３列の挿入位置近傍において挿入針２３列の移動方向に沿って移動可能に配設されている。エアシリンダ３２の作動により押圧部材３４は支持ブラケット１１に支持された積層糸群３と係合して積層糸群３を挿入針２３列の前進側へ押圧する作用位置と、積層糸群３と係合不能な待機位置とに移動される。
【００３６】
支持ブラケット１１に支持された積層糸群３を挟んで押圧部材３４と反対側には、一対のプレスブロック３５，３６が配設されている。両プレスブロック３５，３６は積層糸群３との接触部の幅がピン７の配列ピッチより広く形成され、各プレスブロック３５，３６は積層糸群３の上方において別個に揺動可能に支持された一対のレバー（図示せず）の先端にそれぞれ固定されている。両プレスブロック３５，３６は押圧部材３４と対向する位置でかつ、挿入針２３又は穿孔針３１の進入を許容する隙間が生じるように互いに近接して配設されている。そして、図示しないエアシリンダの作動による前記各レバーの揺動により、各プレスブロック３５，３６が積層糸群３を針列の後退側へ押圧する作用位置と、積層糸群３と係合不能な待機位置とに移動される。
【００３７】
積層糸群３の支持位置の下方には挿入針２３列が積層糸群３を貫通する位置と対応する位置に、抜け止め糸挿通用針（以下、単に抜け止め糸針という）３７が挿入針２３列の配列方向に沿って移動可能に配設されている（図１１にその一部を図示）。抜け止め糸針３７は先端にベラを有し、図示しない駆動装置により往復動されて、作用位置に配置されたときの挿入針２３列に連なる厚さ方向糸ｚのループを貫通する作用位置と、積層糸群３と対応する位置から退避した待機位置とに配置されるようになっている。
【００３８】
なお、図示の都合上、図１及び図２に示す概略図と、図４、図１０及び図１１等とでは、厚さ方向糸ｚの挿入ピッチと、枠体に立設されたピン７のピッチや本数、あるいは三次元繊維構造体Ｗの長さと幅との比等が異なる。
【００３９】
次に前記のように構成された枠体５及び厚さ方向糸挿入装置９を使用して補強リブ２を有する三次元繊維構造体Ｗを製造する手順を説明する。
枠体５を支持ブラケットに固定した状態で、第１の面内配列糸ｘ、第２の面内配列糸ｙ及びバイアス糸Ｂ1 ，Ｂ2 がそれぞれピン７と係合する状態で折り返すようにして、図３（ａ）〜（ｄ）に示すようにそれぞれ配列される。そして、図５に示すように、枠体５の外側にｘ糸層、ｙ糸層及びバイアス糸層が所定の複数層積層された積層糸群３が形成される。また、四角形状の枠体上に第１の面内配列糸ｘ、第２の面内配列糸ｙ及びバイアス糸Ｂ1 ，Ｂ2 がそれぞれピンと係合する状態で折り返すようにして配列され、ｘ糸層、ｙ糸層及びバイアス糸層が所定の複数層積層された平板状の積層糸群３が形成される。
【００４０】
なお、積層糸群３の密度を高めるとともに厚さを調整するため、各糸層の配列が完了するたび、あるいは適宜の糸層が形成された時点毎に、糸層が上から押圧部材で押圧されて積層糸群３が圧縮される。
【００４１】
次に厚さ方向糸挿入装置９を使用して、Ｌ字状の両積層糸群３に厚さ方向糸ｚが公知の方法で挿入される。ただし、厚さ方向糸ｚはハンドリングを可能にする程度の粗い間隔で予備的に挿入される。そして、図７に示すように、厚さ方向糸ｚが粗く挿入されたＬ字状の三次元繊維構造体ＷＬが２体作成される。
【００４２】
次に２体の三次元繊維構造体ＷＬを接合させて、ほぼＴ字状の三次元繊維構造体ＷＴを形成する。このとき、二つの枠体５に挿通されているピン７の一部を共通化して、図８に示すように、２個の枠体５で三次元繊維構造体を支持した状態で、２体の三次元繊維構造体ＷＬの接合部に、正規の密度で厚さ方向糸ｚが挿入される。Ｌ字状の積層糸群３に厚さ方向糸ｚを挿入するときと、Ｔ字状の三次元繊維構造体ＷＴに厚さ方向糸ｚを挿入するときとで、枠体５を支持するのに異なる形状の支持片１２が使用される。
【００４３】
なお、一部のピン７を共通化する際、図７に示すように、一方の枠体５のピン７としてパイプを使用し、他方の枠体５のピン７として先端が尖ったピンを使用し、尖ったピン７をパイプ製のピン７に当接させて押し出すと、作業が容易になる。
【００４４】
次にＴ字状の三次元繊維構造体ＷＴの端部を基板部１に接合するサイズに合わせて所定の位置で切断して枠体５から取り外すと、図９に示すように、基板部１との接合部に粗いピッチで厚さ方向糸ｚが挿入されたＴ字状の三次元繊維構造体ＷＴが得られる。なお、三次元繊維構造体ＷＴを切断する際に積層糸群３を構成する糸が乱れないように、切断部近傍の厚さ方向糸ｚの挿入密度を高めておくのが好ましい。
【００４５】
次に図１０（ａ）に示すように、平板状の積層糸群３が形成された枠体３８に治具３９，４０を使用して、Ｔ字状の三次元繊維構造体ＷＴを基板部１に対する補強リブ２の所定の接合位置に取り付ける。治具３９はほぼ門型に形成されるとともに、その両端にボルト挿通孔（図示せず）が形成された取付部３９ａを備えている。また、治具４０を介して三次元繊維構造体ＷＴの中央の板状部２ａを挟持する挟持部３９ｂが所定間隔で形成されている。治具４０は図１１に示すように、三次元繊維構造体ＷＴとほぼ同じ長さの平板で形成されている。そして、図１０（ａ）に示すように、各三次元繊維構造体ＷＴはそれぞれ一対の治具４０に挟まれた状態で治具３９の挟持部３９ｂに挟持される。治具３９は六角穴付きボルト４１により枠体３８に固定される。
【００４６】
次に枠体３８を厚さ方向糸挿入装置９の支持ブラケット１１に固定して、厚さ方向糸ｚの挿入を行う。図１１は厚さ方向糸ｚの挿入状態を示す模式斜視図である。このとき、Ｔ字状の三次元繊維構造体ＷＴあるいはＬ字状の積層糸群３への厚さ方向糸ｚの挿入時に使用されたプレスブロック３５，３６と異なる形状のプレスブロック４２，４３が使用される。図１１に示すように、プレスブロック４２，４３には積層糸群３と対向する側に、Ｔ字状の三次元繊維構造体ＷＴ及び治具４０と干渉しないための凹部４４が形成されている。
【００４７】
そして、支持テーブル１５が挿入開始位置に配置され、挿入針２３、穿孔針３１、押圧部材３４及びプレスブロック４２，４３が待機位置に配置された状態から積層糸群３及びＴ字状の三次元繊維構造体ＷＴの積層糸群３との接合部への厚さ方向糸ｚの挿入作業が開始される。
【００４８】
先ずエアシリンダ３２が作動されて押圧部材３４が作用位置に配置される。次に両プレスブロック４２，４３が作用位置に配置され、押圧部材３４及び両プレスブロック４２，４３により積層糸群３は穿孔針３１列と対応する箇所が圧縮状態に保持される。その状態でエアシリンダ２８が作動されて穿孔針３１が積層糸群３を貫通する位置まで前進した後、元の位置まで後退する。穿孔針３１は押圧部材３４及び両プレスブロック４２，４３にガイドされながら移動し、穿孔針３１が多少曲がっていても穿孔針３１は積層糸群３に対して垂直に挿通される。積層糸群３は押圧部材３４及び両プレスブロック４２，４３によって押圧されているため、穿孔針３１の前進時に各糸の配列が乱れることはない。積層糸群３を構成する繊維が押圧部材３４及び両プレスブロック４２，４３の圧縮作用によりある程度密に配置された状態にあるため、穿孔針３１の抜き跡に孔が形成される。
【００４９】
次にエアシリンダ１９が突出作動されて支持プレート１８とともに穿孔針３１列及び挿入針２３列が移動され、挿入針２３列が穿孔針３１の抜き跡の孔と対向する位置に配置される。その状態でプレスブロック４２が待機位置に配置された後、モータ２４が作動され、挿入針２３が前進して作用位置に配置される。挿入針２３は針孔２３ａが積層糸群３の前方に出るまで積層糸群３に挿通される。挿入針２３が前進端に達した後、モータ２４が逆転されて挿入針２３がわずかに後退させられる。その結果、積層糸群３から針孔２３ａに連なる厚さ方向糸ｚが抜け止め糸針３７の通過を許容するループを形成した状態となる。
【００５０】
次に抜け止め糸針３７が作動され、抜け止め糸（図示せず）が前記ループに挿通される。その後、モータ２４が逆転されて挿入針２３が後退し、積層糸群３から離脱して待機位置に配置される。また、プレスブロック４２が再び作用位置に配置される。この状態で張力調整部（図示せず）の作用により厚さ方向糸ｚが引き戻され、積層糸群３内に挿入された厚さ方向糸ｚが抜け止め糸により抜け止めされた状態で締付けられる。次にエアシリンダ１９が作動され、支持プレート１８とともに穿孔針３１列及び挿入針２３列が初期位置に戻される。また、エアシリンダ３２が作動されて押圧部材３４が待機位置に配置され、プレスブロック４２，４３も待機位置に配置される。以上により厚さ方向糸ｚの１回の挿入サイクルが完了する。そして、平板状の積層糸群３及びＴ字状の三次元繊維構造体ＷＴの積層糸群３との接合部に対して、Ｔ字状の三次元繊維構造体ＷＴの屈曲部４と対応する位置を除いた幅方向全域にわたって厚さ方向糸ｚが１列分挿入される。
【００５１】
なお、図１１では挿入針２３及び穿孔針３１の各ピッチが模式的に等ピッチに図示されているが、屈曲部４と対応する位置では、挿入針２３及び穿孔針３１は針支持体２２及び穿孔針支持体３０から取り外されている。
【００５２】
次に支持テーブル１５が厚さ方向糸ｚの挿入ピッチ分移動され、穿孔針３１が積層糸群３への次回の厚さ方向糸挿入位置と対向する状態となる。以下、前記と同様にして順次厚さ方向糸ｚの挿入サイクルが実行される。そして、図１０（ｂ）に示すように、平板状の積層糸群３とＴ字状の三次元繊維構造体ＷＴとが、その屈曲部４と対応する位置を除いた箇所において厚さ方向糸ｚで結合された三次元繊維構造体が形成される。
【００５３】
次に基板部１及び補強リブ２の屈曲部４と対応する位置への厚さ方向糸ｚの挿入が行われる。このとき、図１２に示すように、治具３９，４０を取り外し、枠体３８を支持する支持ブラケット１１と支持テーブル１５の間に規制治具４５を挟んだ状態で、支持ブラケット１１を支持テーブル１５に固定する。規制治具４５は枠体３８の角度を厚さ方向糸ｚの挿入角度と対応するように規制する役割を果たす。そして、屈曲部４と対応する位置に基板部１の厚さ方向に対して交差する状態で、厚さ方向糸ｚを屈曲部４及び基板部１を貫通するように挿入する。なお、治具３９，４０を取り付けたままで、厚さ方向糸ｚの挿入を行ってもよい。図１２の角度で厚さ方向糸ｚの挿入を行った後、規制治具４５を１８０°反転させた状態で支持ブラケット１１を支持し、図１２の状態に対して、枠体３８が支持テーブル１５と垂直な面に対して対称となる状態で、再び屈曲部４と対応する位置に厚さ方向糸ｚを挿入する。そして、厚さ方向糸ｚの挿入が終了した後、各ピン７が枠体３８から取り外されて、基板部１の周縁が所定の位置で切断されて三次元繊維構造体Ｗの製造が完了する。
【００５４】
この実施の形態では以下の効果を有する。
（１）三次元繊維構造体Ｗの補強リブ２の屈曲部４と対応する位置においては、厚さ方向糸ｚが基板部１の厚さ方向に対して交差する状態で屈曲部４及び基板部１を貫通するように配列されている。従って、補強リブ２を単に接着あるいは一体成形した場合に比較して、基板部１と補強リブ２とが厚さ方向糸ｚにより結合された三次元繊維構造体Ｗの、補強リブ２と基板部１との接続部の強度が大きくなり、同じ要求物性であれば三次元繊維構造体Ｗを骨格材とした複合材を薄くできる。
【００５５】
（２）厚さ方向糸ｚによって結合される積層糸群３を構成する各糸層の糸が、ピン７（規制部材）を基準として折り返し状に配列されるため、糸を緊張した状態で配列でき、かつその状態で厚さ方向糸ｚが挿入される。従って、クロス（平面上の織物）を積層してステッチ縫いで各クロスを結合した三次元繊維構造体に比較して、糸の真直度が良好で高品質（物性が良い）の三次元繊維構造体Ｗが得られる。
【００５６】
（３）補強リブ２は少なくとも基板部１との結合部付近がＴ字状に形成されているため、横方向のどちら側から力が作用しても曲げに対して良好な強度を確保できる。
【００５７】
（４）三次元繊維構造体Ｗは基板部１及び補強リブ２とも、それぞれ複数の糸層を積層して形成された面内３軸以上（面内４軸）の配向となる積層糸群３と、その厚さ方向に配列された厚さ方向糸ｚとを含む４軸以上（５軸）で構成されている。従って、物性（特に強度や耐衝撃性）の優れた複合材を得ることができる。
【００５８】
（５）補強リブ２と基板部１とを一体にして製織する方法では面内３軸以上の三次元織物を製造するには、機構が非常に複雑になり、効率良く三次元織物を製造するのが難しい。しかし、複数の糸層を積層して形成された面内３軸以上（面内４軸）の配向となる積層糸群３を厚さ方向糸ｚで結合した、三次元繊維構造体Ｗの場合は、面内４軸であっても、比較的容易に製造できる。
【００５９】
（６）基板部１、補強リブ２及び厚さ方向糸ｚが全てカーボン糸で形成されているため、他の材質製の糸やカーボン糸と他の材質製の糸とを組み合わせて使用した場合に比較して、複合材としたときの物性が向上する。例えば、糸としてガラス繊維製の糸を使用すると、カーボン糸に比較して重量が大きくなる。また、ポリアラミド繊維は吸水率が大きく、複合材を形成する際に物性低下の要因となる。
【００６０】
（７）三次元繊維構造体Ｗを構成するバイアス糸Ｂ1 ，Ｂ2 が、第１及び第２の面内配列糸ｘ，ｙに対してほぼ±４５°の角度で交差するように配列されている。従って、他の角度で配列した場合に比較して、斜め方向からの力に対して最も有効に機能する。
【００６１】
（８）各糸層を構成する糸として、少なくとも当該糸層内で連続した１本の糸が使用されているため、各糸を適切な張力を付与した状態で配列するのが容易となり、複合材としたときの物性の向上に寄与する。
【００６２】
（９）厚さ方向糸ｚの挿入時に、枠体３に保持された積層糸群３が、押圧部材３４により位置決めされた状態で、押圧部材３４と、プレスブロック４２，４３とにより押圧される。従って、押圧部材３４がガイドとしての役割を果たし、穿孔針３１による積層糸群３の所定位置への孔の形成が容易になる。
【００６３】
（１０）補強リブ２用のＴ字状の三次元繊維構造体ＷＴを製作する際、厚さ方向糸ｚがハンドリングを可能にする程度の粗い間隔で予備的に挿入されたＬ字状の三次元繊維構造体ＷＬを２体製作して、それを組み合わせた後、正規のピッチで厚さ方向糸ｚを挿入する。従って、予備的な厚さ方向糸ｚの挿入を行わずにＬ字状の積層糸群３を接合して、厚さ方向糸ｚの挿入を行う場合に比較して、Ｔ字状の三次元繊維構造体ＷＴの製作、及び基板部１との接合のための厚さ方向糸ｚの挿入作業が容易になる。
【００６４】
（第２の実施の形態）
次に第２の実施の形態を図１３に従って説明する。この実施の形態では基板部１と補強リブ２用のＴ字状の三次元繊維構造体ＷＴとを結合する厚さ方向糸ｚの挿入方法が前記実施の形態と異なっている。前記実施の形態と同一部分は同一符号を付して詳しい説明は省略する。
【００６５】
前記実施の形態ではＴ字状の三次元繊維構造体ＷＴの長手方向と直交する方向に一列ずつ、厚さ方向糸ｚが順次挿入されたが、この実施の形態ではＴ字状の三次元繊維構造体ＷＴの長手方向と平行に一列ずつ、厚さ方向糸ｚが順次挿入される。三次元繊維構造体ＷＴを挟持する治具４０は三次元繊維構造体ＷＴより長く形成され、その両端が枠体３８のピン７の間を通って積層糸群３の幅より外側に配置された状態で治具３９の挟持部３９ｂに挟持される。そして、プレスブロック４２，４３を使用せず、治具４０及び押圧部材３４によって、積層糸群３及び三次元繊維構造体ＷＴの押圧が行われる。また、治具３９は取付部３９ａを突設せずに、治具３９の支柱の底部にネジ穴（図示せず）が形成され、枠体３８側に形成されたボルト挿通孔（図示せず）を貫通するボルトにより、枠体３８に固定されるようになっている。
【００６６】
従って、この実施の形態においても、前記実施の形態の（１）〜（１０）の効果が得られる。また、前記実施の形態の厚さ方向糸挿入装置９に比較して、プレスブロック４２，４３を省略できるため、構造が簡単になるとともに、挿入工程数も少なくなって、厚さ方向糸ｚの挿入に必要な時間の短縮が図れる。
【００６７】
なお、実施の形態は前記に限定されるものではなく、例えば、次のように具体化してもよい。
○ 補強リブ２の形状は三次元繊維構造体Ｗの長手方向あるいは幅方向と平行に延びる構成に限らず、図１４に示すように、基板部１との接合部がＴ字状で、かつ全体として格子に形成されたものであってもよい。このような補強リブ２を備えた三次元繊維構造体Ｗを形成する場合は、先ず、第１の実施の形態と同様にして所定の長さのＴ字状の三次元繊維構造体ＷＴを製作する。次に、その一部を切断して、図１５に示す形状の三次元繊維構造体ＷＴを製作する。また、同様にして、図１５に示す形状の三次元繊維構造体ＷＴと組み合わせることにより、図１４に示す形状の三次元繊維構造体ＷＴが構成される三次元繊維構造体ＷＴを所定の長さのＴ字状の三次元繊維構造体ＷＴの一部を切断して形成する。そして、適切な治具を使用して基板部１に接合した状態で支持して、厚さ方向糸ｚを挿入することにより、三次元繊維構造体Ｗが得られる。
【００６８】
○ 三次元繊維構造体Ｗを構成する基板部１及び補強リブ２は、それぞれ複数の糸層を積層して形成された面内３軸以上の配向となる積層糸群３と、その厚さ方向に配列された厚さ方向糸ｚとを含む少なくとも４軸で構成されていればよい。例えば、配向角が０°、６０°及び−６０°に配列した糸で面内３軸の積層糸群３を構成したり、面内４軸の積層糸群３を構成する場合にバイアス糸Ｂ1 ，Ｂ2 の配向角を±４５°以外の配向角としてもよい。
【００６９】
○ 補強リブ２の形状は基板部１から垂直に突出する部分が単純な平板に限らず、先端側がＴ字状やＬ字状であってもよい。また、基板部１との接合部がＴ字状に限らず、Ｌ字状としてもよい。
【００７０】
○ 厚さ方向糸ｚの配列は抜け止め糸と共同で各糸層を締め付ける配列のものに限らず、例えば特開平６−１８４９０６号公報に開示された繊維構造体のように、チェーンステッチ方式で厚さ方向糸ｚ自身が抜け止め機能を果たすように各糸層を貫通して締め付ける構成としてもよい。また、厚さ方向糸ｚが積層糸群３の表側から裏側へ挿通される工程と、裏側から表側へ挿通される工程とが交互に繰り返された配列方法としてもよい。
【００７１】
○ 基板部１は必ずしも平板に限らず、曲率の小さな円弧面であってもよい。
○ 積層糸群３の厚さや繊維の種類によっては穿孔針３１による孔開けを行わずに、直接挿入針２３を挿入して厚さ方向糸ｚを挿入してもよい。この場合は穿孔針３１及びその駆動装置が不要な分、厚さ方向糸挿入装置９の構成が簡単になる。
【００７２】
○ 基板部１の幅が広い場合は、厚さ方向糸ｚの挿入を１列同時に行わずに、複数回に分けて行ってもよい。
○ 積層糸群３に対して挿入針２３の突出側に配置されるプレスブロック４２，４３は２個一組に限らず、１個でもよい。１個とする場合はプレスブロックが作用位置に配置された状態で挿入針２３が積層糸群３に挿通されたとき、挿入針２３の突出側における厚さ方向糸ｚのループの形成に支障を来さない側に配置する。
【００７３】
○ 基板部１及び補強リブ２を積層糸群３を厚さ方向糸ｚで結合した三次元繊維構造体で形成する代わりに、クロス（好ましくはユニ・ウィーブ織物）を複数枚積層して形成したものを厚さ方向糸ｚで結合した三次元繊維構造体で形成してもよい。また、基板部１及び補強リブ２の一方をクロスから形成した三次元繊維構造体で形成し、他方を積層糸群３から形成した三次元繊維構造体で形成してもよい。
【００７４】
前記各実施の形態から把握できる請求項記載以外の技術的思想（発明）について、以下にその効果とともに記載する。
（１）請求項３に記載の発明において、前記積層糸群は互いに直交する状態で配列される第１及び第２の面内配列糸と、前記第１及び第２の面内配列糸に対してほぼ±４５°の角度で交差するように配列されているバイアス糸とにより面内４軸で構成されている。この場合、バイアス糸を他の角度で配列した場合に比較して、斜め方向からの力に対して最も有効に機能し、複合材としたときの物性が向上する。
【００７５】
（２）三次元繊維構造体で構成された基板部と、三次元繊維構造体で構成されるとともに基板部との結合部がほぼＴ字状となる補強リブとが厚さ方向糸により結合された三次元繊維構造体の製造方法において、
Ｌ字状に形成された積層糸群を２体形成するとともにハンドリングが可能な程度の粗さで予備的に厚さ方向糸を挿入し、その後、２体を接合するとともに接合部に正規のピッチで厚さ方向糸ｚを挿入したＴ字状の三次元繊維構造体を形成し、その三次元繊維構造体を基板部を構成する平板状の積層糸群の所定位置に、治具を使用して配置した状態に保持し、補強リブの屈曲部と対応する位置以外の箇所に所定ピッチで厚さ方向糸を挿入し、その後、補強リブの屈曲部と対応する位置に基板部の厚さ方向に対して交差する状態で屈曲部及び基板部を貫通するように厚さ方向糸を挿入する三次元繊維構造体の製造方法。この場合、基板部との結合部がほぼＴ字状となる補強リブを有する三次元繊維構造体を、全体を同時に製織する方法に比較的して簡単に製造できる。
【００７６】
【発明の効果】
以上詳述したように請求項１〜請求項４に記載の発明によれば、基板部と補強リブとが厚さ方向糸により結合された三次元繊維構造体の、補強リブと基板部との接続部の強度が大きくなり、同じ要求物性であれば三次元繊維構造体を骨格材とした複合材を薄くできる。
【００７７】
請求項２に記載の発明によれば、補強リブは少なくとも基板部との結合部付近がＴ字状に形成されているため、横方向のどちら側から力が作用しても曲げに対して良好な強度を確保できる。
【００７８】
請求項３に記載の発明では、基板部及び補強リブは、それぞれ複数の糸層を積層して形成された面内３軸以上の配向となる積層糸群と、その厚さ方向に配列された厚さ方向糸とを含む少なくとも４軸で構成されているため、物性（特に強度や耐衝撃性）の優れた複合材を得ることができる。
【００７９】
請求項４に記載の発明では、基板部、補強リブ及び厚さ方向糸が全てカーボン糸で形成されているため、他の糸やカーボン糸と他の糸とを組み合わせて使用した場合に比較して、複合材としたときの物性が向上する。
【図面の簡単な説明】
【図１】（ａ）は第１の実施の形態の三次元繊維構造体の模式断面図、（ｂ）は（ａ）の部分拡大図。
【図２】同じく模式斜視図。
【図３】積層糸群を構成する糸の配列状態を示す模式斜視図。
【図４】積層糸群の形成に使用する枠体の概略斜視図。
【図５】枠体上に積層糸群を形成した状態の概略斜視図。
【図６】厚さ方向糸挿入装置の概略部分平面図。
【図７】Ｌ字状三次元繊維構造体の支持状態を示す模式端面図。
【図８】Ｔ字状三次元繊維構造体の支持状態を示す模式端面図。
【図９】Ｔ字状三次元繊維構造体の模式図。
【図１０】（ａ）はＴ字状三次元繊維構造体の支持治具を示す模式断面図、（ｂ）は同じく厚さ方向糸挿入後の状態を示す模式断面図。
【図１１】厚さ方向糸挿入装置の作用を説明する模式斜視図。
【図１２】厚さ方向糸挿入装置の作用を説明する一部破断模式側面図。
【図１３】別の実施の形態の治具の作用を説明する模式斜視図。
【図１４】別の三次元繊維構造体の模式斜視図。
【図１５】同じく製作途中の補強リブを示す模式斜視図。
【図１６】従来の三次元織物の製造方法を示す模式斜視図。
【図１７】別の従来の三次元織物の製造方法を示す模式断面図。
【符号の説明】
１…基板部、２…補強リブ、２ａ，２ｂ，２ｚ…板状部、３…積層糸群、４…屈曲部、ｘ…第１の面内配列糸、ｙ…第２の面内配列糸、ｚ…厚さ方向糸、Ｂ1 ，Ｂ2 …バイアス糸、Ｗ，ＷＴ…三次元繊維構造体。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a three-dimensional fiber structure, and more particularly to a plate-like three-dimensional fiber structure having reinforcing ribs.
[0002]
[Prior art]
Fiber reinforced composite materials (FRP composite materials) are widely used as lightweight structural materials. There is a three-dimensional fabric (three-dimensional fiber structure) as a reinforcing base material for composite materials. A composite material using this three-dimensional woven fabric as a skeleton material and a resin or an inorganic material as a matrix is expected to be used widely as a structural material for rockets, aircraft, automobiles, ships, and buildings.
[0003]
Then, it is considered that a plate with a stiffener used for an aircraft fuselage or the like is made of a three-dimensional fiber structure composite material having a three-dimensional fiber structure and having excellent impact resistance. For example, in NASA (National Aeronautics and Space Administration) report NASA / TP-97-206234, as shown in FIG. 16 (a), a plurality of Uni-Weave fabrics were laminated. A three-dimensional fiber structure W manufactured by stitching T-shaped reinforcing ribs 70 and a flat plate 71 formed by laminating a plurality of uni-weave fabrics as shown in FIG. 16 (c)). The reinforcing rib 70 and the substrate 71 are each composed of a plurality of uni-weave fabrics having orientation angles of 0 °, 45 °, −45 °, and 90 ° to form a 4-axis in-plane structure, and a 5-axis structure including a binding yarn. ing.
[0004]
Japanese Patent Application Laid-Open No. 1-207465 discloses a three-dimensional woven fabric having a modified cross-section in which a plurality of ridges having a T-shaped or I-shaped cross section are formed on a flat plate portion, and a manufacturing method thereof. This three-dimensional woven fabric has a plurality of longitudinal threads arranged in multiple rows and multiple columns corresponding to the cross-sectional shape of the three-dimensional fabric, and the widthwise yarns are arranged between adjacent longitudinal yarn groups in the longitudinal direction. Repeat the process of inserting while reciprocating in the width direction in a state orthogonal to the yarn, and inserting the vertical thread while reciprocating in the vertical direction in a state orthogonal to the length direction thread between rows of the lengthwise threads. Manufactured.
[0005]
In JP-A-3-286411, a flat prepreg and a prepreg formed by joining two prepregs bent substantially in an L shape to form a substantially T shape are joined in the same manner as in FIG. Discloses a method for manufacturing a composite structure that is stitched with a fiber.
[0006]
Japanese Patent Application Laid-Open No. 6-184906 discloses a three-dimensional fiber structure in which a plurality of plate-like portions are formed in a continuous shape in a bent state at a connection portion. In order to increase the strength of the connecting portion between adjacent plate-like portions, this three-dimensional fiber structure has a continuous thread as a constituent element across both plate-like portions. This three-dimensional fiber structure is formed by joining together a group of laminated yarns in which a predetermined number of yarn layers having different yarn arrangement directions are laminated with thickness direction yarns so as to form a plate-like portion that is continuous in a bent state. Also disclosed is a method of manufacturing two-dimensional fiber structures having different cross-sectional shapes by combining two three-dimensional fiber structures. For example, it is disclosed that a U-shaped three-dimensional fiber structure is combined back to back to produce a three-dimensional fiber structure having an H-shaped cross section.
[0007]
Japanese Patent Laid-Open No. 4-289243 discloses at least three axes in which a plurality of plate-like portions are formed in a shape having a joined portion joined in a T shape, and each plate-like portion includes a component in its thickness direction. Continuing across both plate-like parts that are arranged along a plane orthogonal to the thickness direction of each plate-like part and that extend in a direction intersecting the joint part of adjacent plate-like parts, and sandwiching the joint part A three-dimensional woven fabric (three-dimensional fiber structure) having a thread to be used as a constituent element is disclosed. As shown in FIG. 17, this three-dimensional woven fabric is a combination of laminated yarn groups 73 and 74 formed in an L-shaped section in a state of being penetrated by a large number of regulating members 72 and a flat laminated yarn group 75, and each laminated yarn group. It is formed by joining the laminated yarn groups 73 to 75 by sequentially replacing the regulating members 72 penetrating 73 to 75 with the thickness direction yarn z.
[0008]
[Problems to be solved by the invention]
The three-dimensional woven fabric disclosed in JP-A-1-207465 has a three-axis configuration in which the flat plate portion and the protruding portion include two-axis in-plane and a thread in the thickness direction, and a continuous surface in a bent state. Since there is no yarn arranged across, physical properties when the composite material is formed become insufficient.
[0009]
In other prior art three-dimensional fiber structures (three-dimensional woven fabrics), there exist yarns in which each plate-like portion is constituted by at least three in-plane axes and arranged across a continuous surface in a bent state. Therefore, it is possible to form a composite material having excellent physical properties (particularly strength and impact resistance) as compared with a composite material using a three-dimensional woven fabric disclosed in JP-A-1-207465 as a skeleton material.
[0010]
However, in the conventional three-dimensional fiber structure, since the binding yarns (thickness direction yarns) that join the flat plate portion and the reinforcing rib are all arranged in parallel with the thickness direction of the flat plate portion, Only at the position where the planes of the reinforcing ribs are opposed to each other, they penetrate both and contribute to the coupling. Therefore, in a portion where the bent portion of the reinforcing rib and the flat plate portion are opposed to each other, that is, in a region surrounded by a chain line in FIG. As a result, when the composite material is manufactured, the strength of the portion where stress concentration tends to occur becomes insufficient, and it is necessary to increase the strength of the entire three-dimensional fiber structure to compensate for it, and the three-dimensional fiber structure becomes thicker. There is a problem of becoming.
[0011]
The present invention has been made in view of the above-mentioned problems, and its purpose is to connect a reinforcing rib and a substrate portion of a three-dimensional fiber structure in which the substrate portion and the reinforcing rib are joined by a thread in the thickness direction. An object of the present invention is to provide a three-dimensional fiber structure in which the strength of the part is increased and the composite material can be thinned with the same required physical properties.
[0012]
[Means for Solving the Problems]
In order to achieve the above-mentioned object, in the invention according to claim 1, the base plate portion constituted by the three-dimensional fiber structure and the reinforcing rib constituted by the three-dimensional fiber structure are coupled by the thickness direction yarn. The reinforcing rib has a plate-like portion that is bent substantially at a right angle, and one of the plate-like portions is perpendicular to the substrate portion. The thickness direction yarns that are combined and connect the reinforcing rib and the substrate portion are: In the position where the plane portions of the reinforcing rib and the substrate portion correspond, they are arranged in parallel with the thickness direction of the substrate portion, At positions corresponding to the bent portions of the reinforcing ribs, the reinforcing ribs are arranged so as to penetrate the bent portion and the substrate portion in a state intersecting with the thickness direction of the substrate portion.
[0013]
According to a second aspect of the present invention, in the first aspect of the present invention, the reinforcing rib is formed in a T shape at least in the vicinity of the coupling portion with the substrate portion.
According to a third aspect of the present invention, in the first or second aspect of the present invention, the substrate portion and the reinforcing rib each have an in-plane triaxial orientation formed by laminating a plurality of yarn layers. And at least four axes including a thickness direction yarn arranged in the thickness direction.
[0014]
According to a fourth aspect of the present invention, in the third aspect of the present invention, the substrate portion, the reinforcing rib, and the thickness direction yarn are all formed of carbon yarn.
In the three-dimensional fiber structure according to the first aspect of the present invention, at a position corresponding to the bending portion of the reinforcing rib, the three-dimensional fiber structure is arranged so as to penetrate the bending portion and the substrate portion while intersecting the thickness direction of the substrate portion. There is a thickness direction thread. Accordingly, when a force from the lateral direction acts on the reinforcing rib, the thickness direction yarn bears the force, and thus the strength is increased.
[0015]
In the invention described in claim 2, in the invention described in claim 1, since the reinforcing rib is formed in a T shape at least in the vicinity of the coupling portion with the substrate portion, a force acts from either side in the lateral direction. Even so, a good strength against bending can be secured.
[0016]
In the invention according to claim 3, in the invention according to claim 1 or 2, the substrate portion and the reinforcing rib each have an in-plane triaxial orientation formed by laminating a plurality of yarn layers. Since it is composed of at least four axes including the laminated yarn group and the thickness direction yarn arranged in the thickness direction, a composite material having excellent physical properties (particularly strength and impact resistance) can be obtained.
[0017]
In the invention of claim 4, in the invention of claim 3, since the substrate portion, the reinforcing rib and the thickness direction yarn are all formed of carbon yarn, Compared with a combination of yarns made of other materials, the physical properties of the composite material are improved.
[0018]
DETAILED DESCRIPTION OF THE INVENTION
(First embodiment)
Hereinafter, a first embodiment of the present invention will be described with reference to FIGS. As shown in FIGS. 1 and 2, the three-dimensional fiber structure W is configured by joining a substrate portion 1 and a reinforcing rib 2 with a thickness direction thread z. The substrate portion 1 is formed in a flat plate shape, and the reinforcing rib 2 is formed in a cross-sectional shape in which the vicinity of the joint portion with the substrate portion 1 is T-shaped. In this embodiment, the reinforcing rib 2 is joined to a three-dimensional fiber structure WL having an L-shaped cross section, and the entire cross-sectional shape is formed in a T shape. The reinforcing rib 2 has plate-like portions 2 a, 2 b, 2 c that are bent substantially at a right angle, and one of the plate-like portions 2 a, 2 b, 2 c is perpendicular to the substrate portion 1. It couple | bonds with the board | substrate part 1 so that it may become. A plurality of reinforcing ribs 2 (two in this embodiment) are provided in parallel with each other.
[0019]
The substrate portion 1 and the reinforcing rib 2 are each a laminated yarn group 3 formed by laminating a plurality of yarn layers (x yarn layer, y yarn layer, and bias yarn layer) and having an in-plane 4-axis orientation, and its thickness. It is composed of a five-axis three-dimensional fiber structure including thickness direction yarns z arranged in the direction. FIGS. 3A to 3D are schematic views showing the arrangement of yarns in each yarn layer constituting the laminated yarn group 3 of the three-dimensional fiber structure WL having an L-shaped cross section.
[0020]
As shown in FIG. 3B, the x-yarn layer is along one of the width direction and the length direction (in the width direction in this embodiment) in a plane orthogonal to the thickness direction of the three-dimensional fiber structure. It consists of the arranged first in-plane arranged yarn x, and one yarn is arranged in a folded shape. As shown in FIG. 3 (a), the y yarn layer is composed of second in-plane arrangement yarns y arranged in a direction perpendicular to the first in-plane arrangement yarn x in a plane parallel to the x yarn layer, One thread is formed in a folded shape. As shown in FIGS. 3C and 3D, the bias yarn layer has a predetermined angle with respect to the double-sided array yarns x and y in a plane parallel to the x yarn layer (in this embodiment, 45 ° and − 45 °), and the bias yarns B1 and B2 are arranged in parallel in a folded shape so as to intersect each other. The bias yarns B1 and B2 are arranged so as to extend over both plate-like portions 2a and 2b while intersecting with the bent portion 4. In addition, the x yarn layer, the y yarn layer, and the bias yarn layer constituting the substrate unit 1 are similarly configured. In other words, the substrate portion 1 and the reinforcing rib 2 have a first in-plane array yarn x with an orientation angle of 90 °, a second in-plane array yarn y with an orientation angle of 0 °, and a bias with an orientation angle of 45 °. The laminated yarn group 3 is composed of the yarn B1 and the bias yarn B2 having an orientation angle of -45 °. The orientation angle means the angle formed by the yarn with the longitudinal direction of the three-dimensional fiber structure W.
[0021]
As shown in FIG. 1, the thickness direction thread z is arranged in parallel with the thickness direction of the board | substrate part 1 in the position where the plane part corresponds to the reinforcement rib 2 and the board | substrate part 1. As shown in FIG. Further, at a position corresponding to the bent portion 4 of the reinforcing rib 2, the thickness direction thread z is arranged so as to penetrate the bent portion 4 and the substrate portion 1 in a state intersecting with the thickness direction of the substrate portion 1. Has been. The angle θ formed by the thickness direction thread z arranged so as to intersect the thickness direction of the substrate portion 1 and the substrate portion 1 is preferably in the range of 40 ° to 70 °. The thickness direction thread z is inserted from the bottom surface side so as to be folded back on the surface side of the substrate portion 1 (the same side as the surface to which the reinforcing rib 2 is joined), and the retaining threads ( (Not shown). The thread layers are joined together by the thickness direction thread z fastening the thread layers together with the retaining thread.
[0022]
Various materials such as carbon fiber, glass fiber, ceramic fiber, and polyaramid fiber are used as the material of the fibers constituting each yarn depending on the use of the composite material. In this embodiment, carbon yarn is used as each yarn. Carbon fiber roving (tow) is used for the carbon yarn. Roving (tow) means a substantially untwisted fiber bundle in which a large number of thin filaments are bundled.
[0023]
The three-dimensional fiber structure W configured as described above is used as a reinforcing material (skeleton material) of a fiber-reinforced composite material, and a resin or an inorganic material is used as a matrix. For example, in the case of constituting a carbon / carbon composite material, the three-dimensional fiber structure W is impregnated with resin and cured, and then fired and manufactured.
[0024]
When a load (force) from the lateral direction is applied to the reinforcing rib of the composite material using the three-dimensional fiber structure W configured as described above as a skeleton material, the bending portion 4 (corner portion) of the reinforcing rib 2 is large. Stress acts. Since the second in-plane array yarn y and the bias yarns B1 and B2 extend in the direction intersecting the bent portion 4 and are arranged across the plate-like portions 2a, 2b, 2a, and 2c, these yarns Effectively contributes to share the force in the direction to withstand the stress acting on the bent portion 4. Further, the thickness direction thread z arranged so as to penetrate through the bent portion 4 and the substrate portion 1 also has the thickness direction thread z when the force acting on the reinforcing rib acts on the stress acting on the bent portion 4. Since the force in a direction to withstand the force is shared, the strength of the composite material is improved.
[0025]
Next, an example of a method for manufacturing the three-dimensional fiber structure W configured as described above will be described. When manufacturing the three-dimensional fiber structure W, a substantially L-shaped frame 5 as shown in FIG. 4 is used, and the method previously proposed by the applicant of the present application (Japanese Patent Laid-Open No. 9-137336) Two pieces of three-dimensional woven fabric (three-dimensional fiber structure) are manufactured. Further, one flat laminated yarn group 3 to be the substrate portion 1 is manufactured using a rectangular frame.
[0026]
The L-shaped frame 5 has a main body 5a formed so as to surround a region 6 corresponding to the insertion area of the thickness direction thread z, and a number of restrictions erected on the outer side of the main body 5a at a predetermined pitch. It is comprised from the pin 7 as a member, and the support bar 8 fixed to the corner part of the frame 5 by the screw (not shown) so that removal was possible. The pin 7 is also detachably fitted to the corner portion of the support bar 8. The quadrangular frame is erected on the quadrangular frame body so that pins can be removed at a predetermined pitch.
[0027]
The thickness direction yarn inserting device for inserting the thickness direction yarn z into the laminated yarn group 3 has basically the same configuration as the device proposed by the present applicant in Japanese Patent Laid-Open Nos. 8-218249 and 9-137336. Has been. Next, the thickness direction thread insertion device will be described with reference to FIG. FIG. 6 is a schematic partial plan view of the thickness direction thread insertion device 9.
[0028]
The thickness direction yarn inserting device 9 supports the frame 5 in which the laminated yarn groups 3 are arranged between the pair of support brackets 11 (only one side is shown) via the attachment member 10 and simultaneously the thickness direction yarns z one row at a time. It is supposed to be inserted. The attachment member 10 is fixed to the frame body 5 by bolts, and is fixed to the support piece 12 of the support bracket 11 by bolts 13.
[0029]
A support table 15 is disposed on the front side (lower side in FIG. 6) of the base plate 14 of the thickness direction thread insertion device 9 so as to be movable in the left-right direction in FIG. 6, and the support bracket 11 is erected on the support table 15. ing. The support table 15 is moved by a predetermined pitch by a feeding device (not shown). Note that the position of the support table 15 shown in FIG. 6 is the position at the time when the insertion of the thickness direction thread z is almost finished.
[0030]
A pair of brackets 16 (only one is shown) is erected on the rear side of the support table 15 on the base plate 14, and a pair of guide rods 17 are installed between the brackets 16 in parallel with the moving direction of the support table 15. . A support plate 18 is slidably supported on the guide rod 17. The support plate 18 is connected to a piston rod 19 a of an air cylinder 19 fixed to the bracket 16, and can reciprocate a predetermined distance by the operation of the air cylinder 19.
[0031]
A pair of support brackets 20 are erected at both front and rear ends of the support plate 18, and a movable body 21 is slidably supported by guide rods (not shown) that are installed in parallel between the support brackets 20. A needle support 22 is fixed to the front end of the movable body 21, and a thickness direction thread insertion needle (hereinafter simply referred to as an insertion needle) 23 has a predetermined pitch corresponding to the arrangement pitch of the pins 7 at the front portion of the needle support 22. It is fixed horizontally in one row. The needle support 22 is arranged in a state of penetrating a hole (not shown) formed in the front support bracket 20.
[0032]
The moving body 21 is moved to the standby position and the operating position together with the needle support 22 by the operation of the ball screw mechanism 25 driven by the motor 24. The insertion needle 23 cannot be engaged with the laminated yarn group 3 supported by the support bracket 11 at the standby position, and the laminated yarn group 3 is moved to a position where the needle hole 23a (shown in FIG. To penetrate.
[0033]
A pair of upper and lower support rods 26 are slidably supported on the support bracket 20 while penetrating the support bracket 20. An air cylinder 28 is fixed to the support plate 18 near the rear support bracket 20 via a bracket 27 so as to extend in the front-rear direction. Both support rods 26 are connected to each other via a connecting plate 29 on the rear end side, and the connecting plate 29 is connected to a piston rod 28 a of an air cylinder 28. A piercing needle support 30 is fixed to the front ends of both support rods 26, and piercing needles 31 are fixed to the piercing needle support 30 in one row at a predetermined pitch corresponding to the insertion needle 23. The rows of the piercing needles 31 are arranged in parallel with the rows of the insertion needles 23 while maintaining an interval equal to the moving distance of the support plate 18 when the air cylinder 19 is operated. By the operation of the air cylinder 28, the piercing needle support 30 is moved to a standby position where the piercing needle 31 cannot be engaged with the laminated yarn group 3 supported by the support bracket 11 and an operating position penetrating the laminated yarn group 3.
[0034]
On the base plate 14, an air cylinder 32 is disposed in the vicinity of the front support bracket 20 so as to extend in the front-rear direction, and a pressing member 34 is fixed to the tip of the piston rod 32a via a bracket 33. The pressing member 34 is formed in an L-shaped cross section extending along the direction in which the insertion needles 23 are arranged, and includes a comb tooth portion that allows the insertion needle 23 or the perforation needle 31 to pass therethrough. In this state, the laminated yarn group 3 can be pressed.
[0035]
The pressing member 34 is disposed on the standby position side of the insertion needle 23 and the punching needle 31 with respect to the laminated yarn group 3 supported by the support bracket 11, and in the movement direction of the insertion needle 23 row in the vicinity of the insertion position of the insertion needle 23 row. It is arranged to be movable along. When the air cylinder 32 is actuated, the pressing member 34 is engaged with the laminated yarn group 3 supported by the support bracket 11 to press the laminated yarn group 3 toward the advance side of the insertion needle 23 row, and the laminated yarn group 3 cannot be engaged. To the proper standby position.
[0036]
A pair of press blocks 35, 36 are disposed on the opposite side of the pressing member 34 across the laminated yarn group 3 supported by the support bracket 11. Both press blocks 35 and 36 are formed such that the width of the contact portion with the laminated yarn group 3 is wider than the arrangement pitch of the pins 7, and each press block 35 and 36 is supported above the laminated yarn group 3 so as to be swingable separately. Are fixed to the tip of each lever (not shown). Both press blocks 35, 36 are arranged close to each other at a position facing the pressing member 34 so as to create a gap that allows the insertion needle 23 or the piercing needle 31 to enter. An operation position in which each press block 35, 36 presses the laminated yarn group 3 toward the retracted side of the needle row by the swing of each lever by an air cylinder (not shown), and a standby position where the laminated yarn group 3 cannot be engaged. And moved to.
[0037]
Below the position where the laminated yarn group 3 is supported, a retaining thread insertion needle (hereinafter simply referred to as retaining thread needle) 37 is inserted at a position corresponding to the position where the inserting needle 23 row penetrates the laminated thread group 3. Are arranged so as to be movable along the arrangement direction (a part of which is shown in FIG. 11). The retaining thread needle 37 has a spatula at the tip, is reciprocated by a driving device (not shown), and has a working position that penetrates a loop of the thickness direction thread z connected to the row of insertion needles 23 when arranged at the working position. In addition, it is arranged at the standby position retracted from the position corresponding to the laminated yarn group 3.
[0038]
For the convenience of illustration, in the schematic diagrams shown in FIGS. 1 and 2 and FIGS. 4, 10 and 11, etc., the insertion pitch of the thickness direction thread z and the pin 7 erected on the frame body The pitch, the number, or the ratio between the length and width of the three-dimensional fiber structure W are different.
[0039]
Next, a procedure for manufacturing the three-dimensional fiber structure W having the reinforcing rib 2 using the frame body 5 and the thickness direction thread insertion device 9 configured as described above will be described.
With the frame 5 fixed to the support bracket, the first in-plane array yarn x, the second in-plane array yarn y, and the bias yarns B1 and B2 are folded in a state of engaging with the pins 7, respectively. They are arranged as shown in FIGS. Then, as shown in FIG. 5, a laminated yarn group 3 in which a plurality of predetermined layers of x yarn layers, y yarn layers, and bias yarn layers are laminated outside the frame body 5 is formed. Further, the first in-plane array yarn x, the second in-plane array yarn y, and the bias yarns B1 and B2 are arranged on the quadrangular frame so as to be folded in a state of being engaged with the pins, and the x yarn layer Then, a flat laminated yarn group 3 in which a predetermined number of y yarn layers and bias yarn layers are laminated is formed.
[0040]
In addition, in order to increase the density of the laminated yarn group 3 and adjust the thickness, the yarn layer is pressed from above by the pressing member every time the arrangement of the yarn layers is completed or every time an appropriate yarn layer is formed. Thus, the laminated yarn group 3 is compressed.
[0041]
Next, using the thickness direction yarn inserting device 9, the thickness direction yarn z is inserted into the L-shaped laminated yarn group 3 by a known method. However, the thickness direction thread z is preliminarily inserted at such a rough interval as to allow handling. Then, as shown in FIG. 7, two L-shaped three-dimensional fiber structures WL into which the thickness direction thread z is inserted roughly are created.
[0042]
Next, two three-dimensional fiber structures WL are joined to form a substantially T-shaped three-dimensional fiber structure WT. At this time, a part of the pin 7 inserted into the two frame bodies 5 is made common, and as shown in FIG. The thickness direction yarn z is inserted at a regular density into the joint portion of the three-dimensional fiber structure WL. To support the frame 5 when inserting the thickness direction thread z into the L-shaped laminated yarn group 3 and when inserting the thickness direction thread z into the T-shaped three-dimensional fiber structure WT. Different shaped support pieces 12 are used.
[0043]
When some of the pins 7 are used in common, as shown in FIG. 7, a pipe is used as the pin 7 of one frame 5 and a pin with a sharp tip is used as the pin 7 of the other frame 5 If the sharp pin 7 is pushed against the pipe-made pin 7 and pushed out, the operation becomes easy.
[0044]
Next, when the end portion of the T-shaped three-dimensional fiber structure WT is cut at a predetermined position according to the size to be bonded to the substrate portion 1 and removed from the frame body 5, as shown in FIG. Thus, a T-shaped three-dimensional fiber structure WT in which the thickness direction thread z is inserted at a rough pitch at the joint portion is obtained. In addition, it is preferable to increase the insertion density of the thickness direction yarn z in the vicinity of the cut portion so that the yarn constituting the laminated yarn group 3 is not disturbed when the three-dimensional fiber structure WT is cut.
[0045]
Next, as shown in FIG. 10 (a), jigs 39 and 40 are used for the frame body 38 on which the flat laminated yarn group 3 is formed, so that the T-shaped three-dimensional fiber structure WT is attached to the substrate portion 1. It attaches to the predetermined joining position of the reinforcement rib 2 with respect to. The jig 39 is formed in a substantially gate shape, and includes a mounting portion 39a having bolt insertion holes (not shown) formed at both ends thereof. In addition, sandwiching portions 39b that sandwich the central plate-like portion 2a of the three-dimensional fiber structure WT via the jig 40 are formed at predetermined intervals. As shown in FIG. 11, the jig 40 is formed of a flat plate having substantially the same length as the three-dimensional fiber structure WT. Then, as shown in FIG. 10A, each three-dimensional fiber structure WT is sandwiched between the sandwiching portions 39 b of the jig 39 while being sandwiched between the pair of jigs 40. The jig 39 is fixed to the frame body 38 by a hexagon socket head bolt 41.
[0046]
Next, the frame 38 is fixed to the support bracket 11 of the thickness direction thread insertion device 9, and the thickness direction thread z is inserted. FIG. 11 is a schematic perspective view showing an insertion state of the thickness direction thread z. At this time, press blocks 42 and 43 having shapes different from the press blocks 35 and 36 used when inserting the thickness direction yarn z into the T-shaped three-dimensional fiber structure WT or the L-shaped laminated yarn group 3 are used. Is done. As shown in FIG. 11, in the press blocks 42 and 43, concave portions 44 for preventing interference with the T-shaped three-dimensional fiber structure WT and the jig 40 are formed on the side facing the laminated yarn group 3.
[0047]
Then, the laminated yarn group 3 and the T-shaped three-dimensional fiber from the state in which the support table 15 is disposed at the insertion start position and the insertion needle 23, the punch needle 31, the pressing member 34, and the press blocks 42, 43 are disposed at the standby position. Insertion of the thickness direction thread z into the joint portion of the structure WT with the laminated yarn group 3 is started.
[0048]
First, the air cylinder 32 is operated and the pressing member 34 is arranged at the operating position. Next, both the press blocks 42 and 43 are disposed at the operating position, and the pressing member 34 and the two press blocks 42 and 43 hold the laminated yarn group 3 in a compressed state at a position corresponding to the row of perforated needles 31. In this state, the air cylinder 28 is actuated to advance the punch needle 31 to a position penetrating the laminated yarn group 3, and then retract to the original position. The piercing needle 31 moves while being guided by the pressing member 34 and the press blocks 42, 43, and the piercing needle 31 is inserted perpendicularly to the laminated yarn group 3 even if the piercing needle 31 is slightly bent. Since the laminated yarn group 3 is pressed by the pressing member 34 and the press blocks 42 and 43, the arrangement of the yarns is not disturbed when the punch needle 31 is advanced. Since the fibers constituting the laminated yarn group 3 are in a state of being densely arranged to some extent by the compression action of the pressing member 34 and the press blocks 42 and 43, a hole is formed in the trace of the punch needle 31.
[0049]
Next, the air cylinder 19 is protruded to move the 31 rows of the piercing needles and the 23 rows of the insertion needles together with the support plate 18, and the 23 rows of the insertion needles are arranged at positions facing the holes of the traces of the piercing needles 31. In this state, after the press block 42 is disposed at the standby position, the motor 24 is operated, and the insertion needle 23 is advanced and disposed at the operating position. The insertion needle 23 is inserted into the laminated yarn group 3 until the needle hole 23a comes out in front of the laminated yarn group 3. After the insertion needle 23 reaches the forward end, the motor 24 is reversed to slightly retract the insertion needle 23. As a result, the thread in the thickness direction z continuous from the laminated yarn group 3 to the needle hole 23a forms a loop that allows the retaining yarn needle 37 to pass therethrough.
[0050]
Next, the retaining thread needle 37 is actuated, and a retaining thread (not shown) is inserted through the loop. Thereafter, the motor 24 is reversely rotated, the insertion needle 23 is retracted, and is separated from the laminated yarn group 3 and is placed at the standby position. Further, the press block 42 is again arranged at the operating position. In this state, the thickness direction yarn z is pulled back by the action of a tension adjusting section (not shown), and the thickness direction yarn z inserted into the laminated yarn group 3 is tightened in a state in which the thickness direction yarn z is retained by the retaining yarn. Next, the air cylinder 19 is actuated, and the perforation needle 31 row and the insertion needle 23 row together with the support plate 18 are returned to the initial positions. Further, the air cylinder 32 is operated, the pressing member 34 is disposed at the standby position, and the press blocks 42 and 43 are also disposed at the standby position. Thus, one insertion cycle of the thickness direction yarn z is completed. And the position corresponding to the bending part 4 of the T-shaped three-dimensional fiber structure WT with respect to the joint part with the laminated thread group 3 of the flat-shaped laminated yarn group 3 and the T-shaped three-dimensional fiber structure WT. One row of thickness direction yarns z is inserted over the entire width direction.
[0051]
In FIG. 11, the pitches of the insertion needle 23 and the perforation needle 31 are schematically shown as equal pitches. However, at a position corresponding to the bent portion 4, the insertion needle 23 and the perforation needle 31 are the needle support 22 and It has been removed from the piercing needle support 30.
[0052]
Next, the support table 15 is moved by the insertion pitch of the thickness direction yarn z, and the punch needle 31 is in a state of facing the next thickness direction yarn insertion position into the laminated yarn group 3. Thereafter, the insertion cycle of the thickness direction yarn z is sequentially executed in the same manner as described above. Then, as shown in FIG. 10 (b), the thickness direction yarn z at a place where the flat laminated yarn group 3 and the T-shaped three-dimensional fiber structure WT are excluded from the positions corresponding to the bent portions 4. A three-dimensional fiber structure bonded with is formed.
[0053]
Next, the thickness direction thread z is inserted into a position corresponding to the bent portion 4 of the substrate portion 1 and the reinforcing rib 2. At this time, as shown in FIG. 12, the jigs 39 and 40 are removed, and the support bracket 11 is attached to the support table with the restriction jig 45 sandwiched between the support bracket 11 and the support table 15 that support the frame body 38. 15 is fixed. The regulating jig 45 plays a role of regulating the angle of the frame body 38 so as to correspond to the insertion angle of the thickness direction thread z. Then, the thickness direction thread z is inserted into the position corresponding to the bent portion 4 so as to penetrate the bent portion 4 and the substrate portion 1 while intersecting the thickness direction of the substrate portion 1. Note that the thickness direction thread z may be inserted with the jigs 39 and 40 attached. After the insertion of the thickness direction thread z at the angle of FIG. 12, the support bracket 11 is supported in a state where the restriction jig 45 is inverted by 180 °. In a state of being symmetric with respect to a plane perpendicular to 15, the thickness direction thread z is inserted again at a position corresponding to the bent portion 4. Then, after the insertion of the thickness direction thread z is completed, each pin 7 is removed from the frame body 38, and the periphery of the substrate portion 1 is cut at a predetermined position to complete the manufacture of the three-dimensional fiber structure W. .
[0054]
This embodiment has the following effects.
(1) At the position corresponding to the bent portion 4 of the reinforcing rib 2 of the three-dimensional fiber structure W, the bent portion 4 and the substrate portion in a state where the thickness direction thread z intersects the thickness direction of the substrate portion 1. 1 are arranged so as to penetrate 1. Therefore, compared to the case where the reinforcing rib 2 is simply bonded or integrally formed, the reinforcing rib 2 and the substrate portion of the three-dimensional fiber structure W in which the substrate portion 1 and the reinforcing rib 2 are joined by the thickness direction thread z. The strength of the connecting portion with 1 is increased, and the composite material using the three-dimensional fiber structure W as a skeleton material can be thinned if the required physical properties are the same.
[0055]
(2) Since the yarns of the respective yarn layers constituting the laminated yarn group 3 joined by the thickness direction yarns z are arranged in a folded manner with reference to the pins 7 (regulating members), the yarns can be arranged in a tensioned state. And the thickness direction thread | z is inserted in the state. Therefore, a three-dimensional fiber structure with better straightness and high quality (good physical properties) compared to a three-dimensional fiber structure in which crosses (woven fabrics on a plane) are laminated and stitches are stitched together. A body W is obtained.
[0056]
(3) Since the reinforcing rib 2 is formed in a T shape at least in the vicinity of the coupling portion with the substrate portion 1, it is possible to secure a good strength against bending regardless of which side the force is applied.
[0057]
(4) In the three-dimensional fiber structure W, both the substrate portion 1 and the reinforcing rib 2 are formed by laminating a plurality of yarn layers, and the laminated yarn group 3 having an in-plane orientation of 4 or more (4 in-plane) orientations. And four or more axes (5 axes) including the thickness direction yarns z arranged in the thickness direction. Therefore, a composite material having excellent physical properties (particularly strength and impact resistance) can be obtained.
[0058]
(5) In the method of weaving the reinforcing rib 2 and the substrate portion 1 together, the mechanism becomes very complicated to produce a three-dimensional fabric having three or more in-plane axes, and the three-dimensional fabric is efficiently produced. It ’s difficult. However, in the case of the three-dimensional fiber structure W in which the laminated yarn group 3 formed by laminating a plurality of yarn layers and having an orientation of three or more in-plane (four in-plane) orientations is joined by the thickness direction yarn z. Even with four axes in the plane, it can be manufactured relatively easily.
[0059]
(6) Since the substrate portion 1, the reinforcing rib 2 and the thickness direction yarn z are all formed of carbon yarns, a yarn made of another material or a combination of a carbon yarn and a yarn made of another material is used. Compared to the above, the physical properties of the composite material are improved. For example, when a glass fiber yarn is used as the yarn, the weight is increased compared to the carbon yarn. In addition, polyaramid fibers have a high water absorption rate, which becomes a factor of deterioration of physical properties when forming a composite material.
[0060]
(7) The bias yarns B1 and B2 constituting the three-dimensional fiber structure W are arranged so as to intersect with the first and second in-plane arranged yarns x and y at an angle of approximately ± 45 °. . Therefore, it functions most effectively with respect to a force from an oblique direction as compared with the case where it is arranged at another angle.
[0061]
(8) Since at least one continuous yarn in the yarn layer is used as the yarn constituting each yarn layer, it is easy to arrange the yarns with appropriate tension applied, Contributes to the improvement of physical properties when used as a material.
[0062]
(9) When the thickness direction thread z is inserted, the laminated yarn group 3 held by the frame 3 is pressed by the pressing member 34 and the press blocks 42 and 43 while being positioned by the pressing member 34. Accordingly, the pressing member 34 plays a role as a guide, and it becomes easy to form a hole at a predetermined position of the laminated yarn group 3 by the punch needle 31.
[0063]
(10) When manufacturing the T-shaped three-dimensional fiber structure WT for the reinforcing rib 2, the L-shaped tertiary inserted preliminarily at such a coarse interval that the thickness direction thread z can be handled. After two original fiber structures WL are manufactured and combined, the thickness direction thread z is inserted at a regular pitch. Therefore, compared to the case where the L-shaped laminated yarn group 3 is joined without inserting the preliminary thickness direction yarn z and the thickness direction yarn z is inserted, the T-shaped three-dimensional fiber is inserted. Manufacture of the structure WT and insertion of the thickness direction thread z for joining with the substrate part 1 are facilitated.
[0064]
(Second Embodiment)
Next, a second embodiment will be described with reference to FIG. In this embodiment, the insertion method of the thickness direction thread z for joining the base plate portion 1 and the T-shaped three-dimensional fiber structure WT for the reinforcing rib 2 is different from the above embodiment. The same parts as those of the above-mentioned embodiment are denoted by the same reference numerals and detailed description thereof is omitted.
[0065]
In the above embodiment, the thickness direction yarns z are sequentially inserted one by one in the direction perpendicular to the longitudinal direction of the T-shaped three-dimensional fiber structure WT. In this embodiment, the T-shaped three-dimensional fiber is inserted. Thickness direction yarns z are sequentially inserted one by one in parallel with the longitudinal direction of the structure WT. The jig 40 for sandwiching the three-dimensional fiber structure WT is formed longer than the three-dimensional fiber structure WT, and both ends thereof pass between the pins 7 of the frame body 38 and are arranged outside the width of the laminated yarn group 3. Is clamped by the clamping part 39b of the jig 39. Then, without using the press blocks 42 and 43, the laminated yarn group 3 and the three-dimensional fiber structure WT are pressed by the jig 40 and the pressing member 34. Further, the jig 39 does not project the mounting portion 39a, and a screw hole (not shown) is formed at the bottom of the post of the jig 39, and a bolt insertion hole (not shown) formed on the frame 38 side. ) Is fixed to the frame body 38 by bolts penetrating through the).
[0066]
Therefore, also in this embodiment, the effects (1) to (10) of the above embodiment can be obtained. Further, since the press blocks 42 and 43 can be omitted as compared with the thickness direction thread insertion device 9 of the above embodiment, the structure is simplified and the number of insertion steps is reduced. The time required for insertion can be shortened.
[0067]
The embodiment is not limited to the above, and may be embodied as follows, for example.
The shape of the reinforcing rib 2 is not limited to the configuration extending in parallel with the longitudinal direction or the width direction of the three-dimensional fiber structure W, and as shown in FIG. May be formed on the lattice. When forming the three-dimensional fiber structure W having such a reinforcing rib 2, first, a T-shaped three-dimensional fiber structure WT having a predetermined length is manufactured in the same manner as in the first embodiment. To do. Next, a part thereof is cut to produce the three-dimensional fiber structure WT having the shape shown in FIG. Similarly, by combining the three-dimensional fiber structure WT having the shape shown in FIG. 14 with the three-dimensional fiber structure WT having the shape shown in FIG. 15, the three-dimensional fiber structure WT having the shape shown in FIG. A part of the T-shaped three-dimensional fiber structure WT is cut and formed. And it supports in the state joined to the board | substrate part 1 using an appropriate jig | tool, and the three-dimensional fiber structure W is obtained by inserting the thickness direction thread | z.
[0068]
○ The substrate portion 1 and the reinforcing rib 2 constituting the three-dimensional fiber structure W are each a laminated yarn group 3 formed by laminating a plurality of yarn layers and having an in-plane orientation of three or more axes, and in the thickness direction thereof. What is necessary is just to be comprised by the at least 4 axis | shaft including the arranged thickness direction thread | yarn z. For example, the bias yarns B1 and B2 are used when the in-plane triaxial laminated yarn group 3 is constituted by yarns arranged at an orientation angle of 0 °, 60 ° and −60 °, or when the in-plane four-axial laminated yarn group 3 is constituted. The orientation angle may be an orientation angle other than ± 45 °.
[0069]
The shape of the reinforcing rib 2 is not limited to a simple flat plate projecting vertically from the substrate portion 1, and the tip side may be T-shaped or L-shaped. Further, the joint portion with the substrate portion 1 is not limited to the T shape, and may be an L shape.
[0070]
○ The arrangement of the thickness direction thread z is not limited to the arrangement in which each thread layer is tightened together with the retaining thread, but for example, a chain stitch method like a fiber structure disclosed in Japanese Patent Laid-Open No. 6-184906. The thickness direction thread z itself may be configured to be tightened through each thread layer so as to perform a retaining function. Moreover, it is good also as the arrangement | sequence method by which the process by which the thickness direction thread | z was inserted from the front side of the laminated yarn group 3 to the back side and the process by which it was inserted from the back side to the front side were repeated alternately.
[0071]
The substrate unit 1 is not necessarily a flat plate but may be an arc surface with a small curvature.
O Depending on the thickness of the laminated yarn group 3 and the type of fiber, the insertion needle 23 may be inserted directly and the thickness direction thread z may be inserted without drilling with the punch needle 31. In this case, the configuration of the thickness direction thread inserting device 9 is simplified because the punching needle 31 and its driving device are unnecessary.
[0072]
O When the width | variety of the board | substrate part 1 is wide, you may divide into multiple times, without performing the insertion of the thickness direction thread | z in 1 row simultaneously.
The number of press blocks 42 and 43 arranged on the protruding side of the insertion needle 23 with respect to the laminated yarn group 3 is not limited to two, and may be one. In the case of one, when the insertion needle 23 is inserted into the laminated yarn group 3 with the press block arranged at the operating position, the formation of the loop of the thickness direction thread z on the protruding side of the insertion needle 23 is hindered. Place it on the side not to be used.
[0073]
○ Instead of forming the substrate portion 1 and the reinforcing rib 2 with a three-dimensional fiber structure in which the laminated yarn group 3 is joined by the thickness direction yarn z, a plurality of cloths (preferably uni-weave fabrics) are laminated. May be formed of a three-dimensional fiber structure bonded with a thickness direction thread z. Alternatively, one of the substrate portion 1 and the reinforcing rib 2 may be formed from a three-dimensional fiber structure formed from a cloth, and the other may be formed from a three-dimensional fiber structure formed from a laminated yarn group 3.
[0074]
Technical ideas (inventions) other than the claims that can be grasped from the respective embodiments will be described below together with the effects thereof.
(1) In the invention according to claim 3, the laminated yarn group is a first and second in-plane arranged yarn arranged in a state orthogonal to each other, and the first and second in-plane arranged yarn It is composed of four in-plane axes with bias yarns arranged so as to intersect at an angle of approximately ± 45 °. In this case, as compared with the case where the bias yarns are arranged at other angles, it functions most effectively with respect to the force from the oblique direction, and the physical properties of the composite material are improved.
[0075]
(2) A substrate portion made of a three-dimensional fiber structure and a reinforcing rib made of a three-dimensional fiber structure and having a substantially T-shaped joint to the substrate portion are joined by a thickness direction thread. In the method for producing a three-dimensional fiber structure,
Form two L-shaped layered yarn groups and insert thickness direction yarns preliminarily with a roughness that allows handling, and then join the two yarns together with a regular pitch at the joint. A T-shaped three-dimensional fiber structure with a thickness direction thread z inserted therein is formed, and the three-dimensional fiber structure is arranged at a predetermined position of a flat laminated yarn group constituting the substrate portion using a jig. The thread in the thickness direction is inserted at a predetermined pitch at a position other than the position corresponding to the bent portion of the reinforcing rib, and then the position corresponding to the bent portion of the reinforcing rib with respect to the thickness direction of the substrate portion. A method of manufacturing a three-dimensional fiber structure in which a thread in the thickness direction is inserted so as to penetrate the bent portion and the substrate portion in a state of crossing each other. In this case, a three-dimensional fiber structure having a reinforcing rib whose joint portion with the substrate portion is substantially T-shaped can be manufactured relatively easily by a method of weaving the whole at the same time.
[0076]
【The invention's effect】
As described above in detail, according to the first to fourth aspects of the present invention, the three-dimensional fiber structure in which the substrate portion and the reinforcing rib are joined by the thread in the thickness direction is provided between the reinforcing rib and the substrate portion. If the strength of the connecting portion is increased and the required physical properties are the same, the composite material using the three-dimensional fiber structure as a skeleton material can be thinned.
[0077]
According to the invention described in claim 2, since the reinforcing rib is formed in a T shape at least in the vicinity of the connecting portion with the substrate portion, it is good against bending regardless of which side of the lateral direction the force acts. High strength can be secured.
[0078]
In the invention according to claim 3, the substrate portion and the reinforcing rib are each a laminated yarn group formed by laminating a plurality of yarn layers and having an in-plane triaxial orientation and a thickness arranged in the thickness direction. Since it is composed of at least four axes including the vertical thread, a composite material having excellent physical properties (particularly strength and impact resistance) can be obtained.
[0079]
In the invention according to claim 4, since the substrate portion, the reinforcing rib and the thickness direction yarn are all formed of carbon yarn, it is compared with the case where other yarn or carbon yarn and other yarn are used in combination. Thus, the physical properties of the composite material are improved.
[Brief description of the drawings]
1A is a schematic cross-sectional view of a three-dimensional fiber structure according to a first embodiment, and FIG. 1B is a partially enlarged view of FIG.
FIG. 2 is a schematic perspective view of the same.
FIG. 3 is a schematic perspective view showing an arrangement state of yarns constituting a laminated yarn group.
FIG. 4 is a schematic perspective view of a frame used for forming a laminated yarn group.
FIG. 5 is a schematic perspective view of a state in which laminated yarn groups are formed on a frame.
FIG. 6 is a schematic partial plan view of a thickness direction thread insertion device.
FIG. 7 is a schematic end view showing a support state of an L-shaped three-dimensional fiber structure.
FIG. 8 is a schematic end view showing a support state of a T-shaped three-dimensional fiber structure.
FIG. 9 is a schematic diagram of a T-shaped three-dimensional fiber structure.
10A is a schematic cross-sectional view showing a support jig for a T-shaped three-dimensional fiber structure, and FIG. 10B is a schematic cross-sectional view showing a state after insertion of a thread in the thickness direction.
FIG. 11 is a schematic perspective view illustrating the operation of the thickness direction thread insertion device.
FIG. 12 is a partially cutaway schematic side view illustrating the operation of the thickness direction thread insertion device.
FIG. 13 is a schematic perspective view for explaining the operation of a jig according to another embodiment.
FIG. 14 is a schematic perspective view of another three-dimensional fiber structure.
FIG. 15 is a schematic perspective view showing a reinforcing rib that is also being manufactured.
FIG. 16 is a schematic perspective view showing a conventional method for producing a three-dimensional fabric.
FIG. 17 is a schematic cross-sectional view showing another conventional method for producing a three-dimensional fabric.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Board | substrate part, 2 ... Reinforcement rib, 2a, 2b, 2z ... Plate-shaped part, 3 ... Laminated yarn group, 4 ... Bending part, x ... 1st in-plane arrangement | sequence thread, y ... 2nd in-plane arrangement | positioning thread | yarn, z: Thickness direction yarn, B1, B2 ... Bias yarn, W, WT ... Three-dimensional fiber structure.

Claims

A three-dimensional fiber structure in which a base plate composed of a three-dimensional fiber structure and a reinforcing rib composed of a three-dimensional fiber structure are joined by a thread in the thickness direction,
The reinforcing rib has a plate-like portion that is bent substantially at a right angle, and one of the plate-like portions is coupled to the substrate portion so as to be perpendicular to the substrate portion, and the reinforcing rib and the Thickness direction yarns connecting the substrate portion are arranged in parallel with the thickness direction of the substrate portion at a position where the plane portions of the reinforcement rib and the substrate portion correspond to each other, In the corresponding position, the three-dimensional fiber structure arranged so as to penetrate the bent portion and the substrate portion in a state of intersecting with the thickness direction of the substrate portion.

The three-dimensional fiber structure according to claim 1, wherein the reinforcing rib is formed in a T shape at least in the vicinity of a joint portion with the substrate portion.

The substrate portion and the reinforcing rib each include a laminated yarn group formed by laminating a plurality of yarn layers and having an in-plane triaxial orientation and at least thickness direction yarns arranged in the thickness direction. The three-dimensional fiber structure according to claim 1 or 2, comprising four axes.

The three-dimensional fiber structure according to claim 3, wherein the substrate portion, the reinforcing rib and the thickness direction yarn are all formed of carbon yarn.