JP3954611B2 - Method for producing three-dimensional inorganic fiber fabric - Google Patents

Description

The present invention relates to a manufacturing method of a three dimensional inorganic fiber woven fabric has carbon fibers used as a skeletal material for the fiber reinforced resin material, an inorganic fiber fabric, such as glass fibers or silicon carbide fiber laminating a plurality.

In recent years, fiber reinforced resin materials, which are made of carbon fiber woven fabrics and used as skeleton materials, impregnated with resin and molded into a predetermined shape, are used as body materials for rockets, aircraft, trains, and automobiles. It has become. As shown in FIG. 10 , a conventional method for producing a carbon fiber fabric is a method of bundling a plurality of carbon fibers 1 and impregnating them with a resin to form a band-like yarn 2, which is used as warp yarn X and weft yarn Y. The carbon fiber fabric 3 is formed by weaving. Since this uses the yarn 2 formed by impregnating the resin and formed into a belt shape, the flexibility is low, and there is a problem of breaking when the carbon fiber 1 is bent, and handling in the weaving process is troublesome.

In addition, as shown in FIG. 11 , when the carbon fiber fabrics 3 are laminated and stitched, the conventional methods such as the Z-pin method and the stitch method (for example, Patent Document 1) have been used, but when the sewing needle 4 is inserted. There was a problem that the carbon fiber 1 collides with the fiber, causing damage such as fiber breakage or wear, resulting in a decrease in strength. In particular, when used as a skeleton material for fiber-reinforced resin materials that are thin and require high strength, such as rockets and aircraft wings and bodies, thread breakage of the carbon fiber 1 at the time of stitching has become a major problem in reducing strength. It was.
JP2003-342856

The present invention improves the above-mentioned problems, and imparts flexibility to the yarns of inorganic fibers such as carbon fibers, glass fibers, or silicon carbide fibers to prevent breakage during weaving and to laminate this inorganic fiber fabric. When sewing, the collision between the sewing needle and the inorganic fiber is avoided to prevent damage such as thread breakage or abrasion of the fiber, and the production of a high-strength three-dimensional inorganic fiber fabric that is effective as a skeleton material for fiber-reinforced resin materials A method is provided.

In the method for producing a three-dimensional inorganic fiber fabric according to claim 1 of the present invention, a plurality of inorganic fibers are bundled and covered with a water-soluble or combustible sheath yarn to converge. After forming a mesh fabric by weaving the recognition yarn so as to form a gap through which the sewing needle penetrates, a plurality of these fabrics are stacked and set on a table, and / or a sewing machine attached with a CCD camera The table is attached to a feeding device that can move in the XY directions, the position of the recognition thread is recognized by a CCD camera, the feeding device is controlled using the recognition thread as a guide, and a sewing needle is inserted into the gap position. Then, after the laminated fabrics are sutured with sutures, the covered sheath yarns are scoured or incinerated to be opened.

The method for producing a three-dimensional inorganic fiber fabric according to claim 2 of the present invention is characterized in that the inorganic fiber is carbon fiber, glass fiber, or silicon carbide fiber.

The method for producing a three-dimensional inorganic fiber fabric according to claim 3 of the present invention is characterized in that a fiber having a color difference from the inorganic fiber or a fiber subjected to fluorescence treatment is used as the recognition yarn.

According to the method for producing a three-dimensional inorganic fiber fabric according to claim 1 of the present invention, a plurality of inorganic fibers are bundled and covered with a water-soluble or combustible sheath yarn to form a convergent yarn state. since the fabric, Ru prevent breakage due to bending is easy to handle. In addition, since inorganic fiber fabrics are laminated in the state of a mesh-like fabric in which a gap through which a sewing needle penetrates is formed, and stitched between the laminated fabrics, the inorganic fibers that are the in-plane threads of the sewing needle and the mesh-like fabric Can be avoided, and damage such as thread breakage and wear of the inorganic fiber can be prevented. At this time, the recognition yarn is woven into the inorganic fiber fabric, the position of the recognition yarn is image-recognized by the CCD camera, and the position of the sewing needle is calculated by the computer based on this position, and the position coordinate is determined. Even if a mesh-like woven fabric is set obliquely on a table, it can be sewn along the recognition yarn to prevent the inorganic fibers from being cut .

According to the method for producing a three-dimensional inorganic fiber woven fabric according to claim 2, even if the inorganic fiber is a low-flexibility fiber such as carbon fiber, glass fiber or silicon carbide fiber, it is made into a convergent yarn state and then made into a woven fabric. Therefore, handling is easy and breakage due to bending can be prevented.

According to the method for manufacturing a three-dimensional inorganic fiber fabric according to claim 3 , the recognition yarn position can be recognized by the CCD camera by using a fiber having a color difference from the inorganic fiber or a fiber subjected to fluorescence treatment as the recognition yarn. Easy.

Hereinafter an embodiment of the present invention with reference to FIGS be described in detail. First, as shown in FIG. 1 (A), a convergent yarn covered with a water-soluble or combustible sheath yarn 5 using a yarn 2 formed by impregnating a plurality of carbon fibers 1 with a little resin and formed into a belt shape as a core yarn. 6 is formed. As the water-soluble sheath yarn 5, for example, a polyvinyl alcohol yarn that dissolves in hot water is used, and as the combustible sheath yarn 5, for example, a nylon fiber or a polyester yarn that can be incinerated is used.

Further, the covering method may be single winding or double winding as shown in FIG. Next, when the covered converging yarn 6 is plain-woven with a weaving machine as warp yarn X and weft Y, a mesh-like woven fabric 8 in which voids 7 are formed in a lattice shape as shown in FIG. 2 is woven. By covering the plurality of carbon fibers 1 with the sheath yarn 5 as a core yarn in this way, the converging yarn 6 becomes a round yarn and the outer periphery thereof is reinforced with the sheath yarn 5, so that the carbon fiber 1 is bent. It is strong against thread handling, and the preparation and weaving process can be performed smoothly.

If you then sutured by the image recognition, first, as shown in FIG. 3, through a convergence yarn 6 which is covering the reed 15. This ridge 15 has three unit width wings 16 arranged side by side, forming vacant wings 17 having a width half of the unit width on the side, and passing the converging yarns 6 respectively covering the wings 16, and vacant wings the wing 16 adjacent to one side of 17 and weaving through recognition yarns 18 as shown in FIG. 4, mesh-like fabric. 8A sewing needle 4 woven recognition yarn 18 to form a gap 7 which penetrates.

Separately from this, weaving is performed only through the converging yarn 6 covered on the ridge 15 shown in FIG. 3 without inserting the recognition yarn 18, and a mesh 7 in which a gap 7 through which the sewing needle 4 passes is formed as shown in FIG. 2. Two woven fabrics 8B are formed . Overlapping two mesh fabrics 8B without this recognition yarn 18, further a mesh-like fabric 8A containing the recognized yarn 18 superimposed as shown in FIG. 4 at the top, sutured with sutures 11. As the recognition yarn 18, the converged yarn 6 of the covered carbon fiber 1 is gray. The recognition yarn 18 is preferably made of a material that can be opened by scouring or incineration in the same manner as the sheath yarn 5.

In this sewing machine, as shown in FIGS. 6 and 7 , two rails 21 are mounted on a base 20 along a vertical direction, and a table 23 provided with a roller 22 is movable in the vertical direction. Installed. Frame 24 of the table 23 is movably supported in the X direction by a ball screw 26 connected to a motor 25 mounted to the base 20 as shown in FIG.

In addition, as shown in FIG. 6 , motor support bases 28 and 28 are provided upright on both sides of the sewing machine 27, and are supported movably in the Y direction therebetween. Two ball screws 26, 26, two sewing machine drive shafts 30, 30 and a guide rail 41 are attached between the motor support bases 28, 28 in parallel. The upper ball screw 26 is connected to a motor 31 and connected to the lower ball screw 26 via a belt 32 so as to rotate synchronously. The upper sewing machine drive shaft 30 is connected to a motor 33 and is connected to the lower sewing machine drive shaft 30 via a belt 32 so as to rotate synchronously.

A sewing machine support portion 34 is attached to the upper ball screw 26 and the guide rail 41, and is supported so as to be movable in the Y direction. The shuttle 36 attached to the needle plate 35 is attached to the lower ball screw 26 and the lower sewing machine drive shaft 30 and is supported movably in the Y direction. A sewing machine main body 39 is supported on the sewing machine support portion 34 by a cylinder 37 and a guide shaft 38 so as to be movable up and down.

The sewing machine needle 4 attached to the sewing machine body 39 is connected to the upper sewing machine drive shaft 30 via a drive mechanism (not shown), and the sewing machine needle 4 and the lower shuttle 36 move in the Y direction in synchronization. It has become. Further, a CCD camera 40 is attached to the side of the sewing machine main body 39 obliquely downward.

Next, to explain the action of sutured sewing machine 27 having the above structure, first, on the table 23, stacked two meshed fabric 8B without recognition yarns 18 as shown in FIG. 4, further recognition at the top The mesh-shaped woven fabric 8A containing the yarn 18 is set in an overlapping manner. Next, the CCD camera 40 recognizes the image of the mesh fabric 8A superimposed on the top, and detects the portion C where the recognition yarns 18 and 18 intersect. The insertion portion of the sewing needle 4 set at a distance away from the detected crossing portion C in a predetermined XY direction is calculated by a computer, and its position coordinates are determined.

Next, when the motor 25 is driven based on this position information, the table 23 moves in the X direction, and when the motor 31 is driven, the sewing needle 4 and the shuttle 36 move to move in the Y direction, and the position is The mesh fabric 8 is moved to the coordinates. Here, by driving the motor 33, the sewing needle 4 moves up and down, and the shuttle 36 rotates and is sutured by the suture thread 11. In this process, the image is recognized by the CCD camera 40, the crossing portion C of the adjacent recognition threads 18 and 18 is detected, and the position coordinates of the next insertion portion of the sewing needle 4 are calculated. By sequentially suturing while thus the intersection C of the recognition thread 18 and image recognition, and the state shown in FIG.

In this case, when sutured with perforations, as shown in FIG. 8, the needle 4 extends through the gaps 7, PBO fibers as shown in FIG. 4, aramid fibers, is sutured with sutures 11 such as carbon fiber. At this time, as the sewing needle 4, a needle having a spherical ball tip, or a ball pen-shaped ball 12 rotatably supported as shown in FIG. 9 is used. Therefore, even if the tip 4 of the sewing needle 4 formed into a spherical shape collides with the covered converging yarn 6 that is an in-plane yarn of the mesh-like woven fabric 8, the cross-sections of the sewing needles 4 are circular so that they slide on the surface. The converging thread 6 can be sutured without being damaged.

In this way, mesh fabrics 8A and 8B woven with converging yarns 6 covered with water-soluble sheath yarns 5 are overlapped and stitched, and then immersed in hot water to dissolve sheath yarns 5. When scouring, the converged carbon fibers 1 are opened, and a three-dimensional carbon fiber woven fabric 13 in which warp yarns X and weft yarns Y are densely woven as shown in FIG. 5 is formed. The mesh fabric 8 woven with the converging yarn 6 covered with the combustible sheath yarn 5 is burned by the burner, so that the sheath yarn 5 is incinerated, and only the converged carbon fiber 1 remains to open the fiber. As a result, a densely woven three-dimensional carbon fiber fabric 13 is formed.

Therefore, according to the method of the present invention, since the layers are stitched in the state of the mesh fabric 8 in which the gap 7 through which the sewing needle 4 passes is formed, the in-plane thread of the sewing needle 4 and the mesh fabric 8 is used. Collision with a certain carbon fiber 1 is avoided, and damage such as thread breakage or wear of the carbon fiber 1 is prevented. Furthermore, since the three-dimensional carbon fiber fabric 13 is manufactured by stitching and opening it, the strength of the fiber reinforced resin material using this as a skeleton material can be improved.

In this way, the CCD camera 40 recognizes the position of the crossing portion C of the recognition yarn 18 by image processing, and based on this position, the computer inserts the insertion portion of the sewing needle 4 and determines its position coordinates. Therefore, even if the mesh-like woven fabric 8 is set on the frame 24 at an angle, the carbon fiber 1 can be prevented from being cut. Further, as shown in FIG. 3 , the heel 15 has an empty wing 17 formed next to the portion through which the recognition thread 18 is passed, and the position coordinates of the insertion portion of the sewing needle 4 are set in this wide portion. Cutting of the fiber 1 can be prevented.

In the above description, the table 23 is moved in the X direction and the sewing machine 27 is moved in the Y direction. However, the table 23 may be fixed and the sewing machine 27 may be moved in the XY direction, and the sewing machine 27 is fixed. However, a structure in which the table 23 is moved in the XY direction may be used. In this case, the CCD camera 40 may be attached to the table 23. Further, although the case where the converging yarn 6 covered and the fiber having a color difference are used as the recognition yarn 18 is shown, a fluorescent-treated fiber can also be used. In this case, the recognition yarn 18 emitted while emitting ultraviolet rays. Is sewn while being recognized by the CCD camera 40.

In addition, although the case where carbon fiber was used as an inorganic fiber was demonstrated in the said description, the same effect can be acquired even if it uses glass fiber or a silicon carbide type fiber.

Examples of the present invention will be described below. A gray converging yarn 6 is formed by double covering the yarn 2 formed of 6000 carbon fibers 1 in a belt shape with a polyvinyl alcohol yarn as a sheath yarn 5. These are used as warp yarn X and weft yarn Y, and white polyvinyl alcohol yarn is used as recognition yarn 18, and this is woven through a ridge 15 shown in FIG. 3 to form a mesh-like fabric 8A having a width of 40 cm and a length of 1 m. Formed. In this case, the density of the cocoon is 6.5 (wings / cm) for the ground portion, 13.0 (wings / cm) for the free wings, and the total number of warps is 365 (156 carbon fiber converging yarns for the ground portion, carbon for the ear portion) 156 fiber converging yarns, 53 recognition yarns), weft threading number of 16.5 (lines / 吋), and the yarn arrangement was a repetition of 3 carbon fiber converging yarns and 1 recognition yarn.

Similarly, two plain-woven mesh fabrics 8B without forming the recognition yarn 18 were formed. Next, on the table 23 shown in FIGS. 6 and 7 , two mesh fabrics 8B without the recognition yarn 18 are stacked, and further, the mesh fabric 8A with the recognition yarn 18 placed on top is stacked. set. Next, the image of the mesh fabric 8A superimposed on the top is recognized by the CCD camera 40, and a portion C where the recognition yarns 18 and 18 intersect is detected, and a predetermined XY direction is detected from the detected intersection. The computer inserts the insertion portion of the sewing machine needle 4 set at a distance away from the center, and determines its position coordinates.

Next, based on the position coordinates, the table 23 is moved in the X direction, the sewing needle 4 and the shuttle 36 are moved in the Y direction, the mesh fabrics 8A and 8B are moved to the position coordinates, and the sewing needle 4 is moved up and down. The aramid fiber thread is sequentially sutured as the suture thread 11 to the state shown in FIG . Next, the mesh fabrics 8A and 8B stitched in three pieces are dipped in hot water, and the sheath yarn 5 and the recognition yarn 18 formed of polyvinyl alcohol yarn are dissolved and refined to converge as shown in FIG. The carbon fiber 1 was opened, and a densely woven three-dimensional carbon fiber fabric 13 was formed. This three-dimensional carbon fiber fabric 13 did not damage the carbon fiber 1 by the sewing needle 4, and a high strength fabric could be obtained as a skeleton material of the fiber reinforced resin material.

The three- dimensional inorganic fiber fabric produced by the method of the present invention can be widely used as a skeleton material for fiber-reinforced resin materials used as body materials for rockets, aircraft, trains, and automobiles.

(A), (B) is a front view which shows the state which covers carbon fiber and forms the convergence yarn. It is a top view which shows the mesh-shaped textile fabric plain-woven using the converged yarn which covered FIG. It is a front view which shows the wrinkles which passed the convergence yarn and the recognition yarn. It is a top view which shows the state which piled up the mesh-shaped textile fabric which woven the recognition thread | yarn, and was sewn with the suture thread. FIG. 5 is a plan view showing a three-dimensional carbon fiber fabric obtained by opening the stitched mesh fabric shown in FIG. 4 . It is a front view which shows a sewing machine. It is a side view which shows a sewing machine. It is sectional drawing which shows the state which piles up the multiple mesh fabrics which carried out plain weaving, and was sewn with the sewing machine. It is sectional drawing which shows the sewing needle with which the ball was rotatably supported. It is a top view which shows the carbon fiber fabric which plain-woven the conventional strip-shaped carbon fiber yarn. It is sectional drawing which shows the state which piles up several carbon fiber fabrics of FIG. 10 , and is sewn with the sewing machine.

Explanation of symbols

1 Carbon fiber
2 Banded thread
3 Carbon fiber fabric
4 Sewing needle
5 sheath thread

6 Covered converging yarn
7 gap
8 Mesh fabric
9 Carbon fiber fabric
11 Suture
12 balls
13 Three-dimensional carbon fiber fabric
15 筬
16 wings

17 Empty feathers
18 Recognition thread
20 base
21 rails
22 Laura
23 tables
24 frames
25 motor
26 Ball screw

27 Sewing machine
28 Motor support
30 Sewing machine drive shaft
31 motor
32 belts
33 Motor
34 Sewing machine support
35 needle plate
36 Kettle

37 cylinders
38 Guide shaft
39 Sewing machine
40 CCD camera

Claims (3)

Bundling a plurality of inorganic fibers and covering them with water-soluble or combustible sheath yarns to converge, and weaving the covered converged yarns so that a recognition thread is woven and a gap is formed through the sewing needle. After forming a mesh-like woven fabric, a plurality of the woven fabrics are stacked and set on a table, a sewing machine with a CCD camera attached and / or the table is attached to a feeding device that can move in the XY direction, The position of the recognition thread is recognized by a CCD camera, the feeding device is controlled using the recognition thread as a guide, a sewing needle is inserted at the position of the gap, and stitching between the laminated fabrics is performed with the suture, and then the covering is performed. A method for producing a three-dimensional inorganic fiber fabric, characterized in that the sheath yarn is scoured or incinerated for opening. The method for producing a three-dimensional inorganic fiber fabric according to claim 1, wherein the inorganic fibers are carbon fibers, glass fibers, or silicon carbide fibers. The method for producing a three-dimensional inorganic fiber fabric according to claim 1, wherein a fiber having a color difference from the inorganic fiber or a fiber subjected to fluorescence treatment is used as the recognition yarn.