JP4063183B2 - Method for producing three-dimensional fiber structure - Google Patents

Description

The present invention relates to the production how the three-dimensional fiber structure.

  Fiber reinforced composites are widely used as lightweight structural materials. Among fiber reinforced composite materials, those using a three-dimensional woven fabric (three-dimensional fiber structure) as a reinforcing material have very high strength and are considered to be used for structural materials such as aircraft, and are partially used. Such a structural material is not linear but needs to be curved in the longitudinal direction. For example, since the fuselage of an aircraft is formed in a cylindrical shape, there are many applications in which the structural members formed in an arc shape are connected to be used in an annular shape.

  As a method of manufacturing an arc-shaped three-dimensional fiber structure, there is a method in which after forming a woven fabric into a flat plate shape with reinforcing fibers oriented in three dimensions, the three-dimensional woven fabric is shaped by following a jig having a predetermined shape. (For example, refer to Patent Document 1).

  In addition, a spiral woven fabric has been proposed as a reinforcing fiber material for a fan-shaped or disk-shaped composite material with a hole (see, for example, Patent Document 2 and Patent Document 3). These spiral woven fabrics are arranged such that some wefts are folded in the middle of the radial direction so that the density of the weft yarns arranged to extend in the radial direction is substantially uniform. In the method of manufacturing a spiral woven fabric disclosed in Patent Document 3, when weaving by a weaving mechanism having basic operations of opening, weft insertion, and punching, a large number of warps 61 are individually controlled one by one, and sent out. The weft thread 62 is wefted with other kinds of weft insertion widths in which the distance from the ear thread on one side to the turning point in the opposite direction varies stepwise. And as shown in FIG. 14, the fabric 64 after being beaten with the scissors 63 is formed into a cone shape with an apex angle of 5 degrees or more and less than 15 degrees, and the large diameter portion faces the one ear thread side. The plurality of take-up rollers 65 arranged in a staggered manner are wound in a zigzag manner, and the take-up roller 65 is rotated and taken up under no tension of the warp 61, so that the fabric 64 is bent toward the small diameter side of the take-up roller 65.

  In addition, as a method of manufacturing a three-dimensional fiber structure having a curved portion or a bent portion, a jig formed so as to be decomposable in accordance with the shape of the three-dimensional fiber structure to be manufactured is used. There is a method of laminating a plurality of yarn layers in which yarns are folded back to form a laminated yarn group, and joining the laminated yarn groups with thickness direction yarns arranged in a direction orthogonal to each yarn layer (for example, , See Patent Document 4).

In a method of joining laminated yarn groups with thickness direction yarns (hereinafter sometimes referred to as a lamination method), a three-dimensional fiber structure having an irregular cross section such as an I shape or a T shape cannot be directly produced. However, a method of manufacturing a linear three-dimensional fiber structure having an irregular cross section by joining a plurality of flat plate-like three-dimensional fiber structures with stitches is known (for example, see Non-Patent Document 1). For example, when manufacturing a three-dimensional fiber structure with a T-shaped irregular cross section, two flat plate-like three-dimensional fiber structures 71 manufactured by a lamination method are prepared as shown in FIG. Then, as shown in FIG. 15 (b), two three-dimensional fiber structures 71 are overlapped and stitched 72 is applied to a part thereof to join both three-dimensional fiber structures 71, and then stitch 72 is applied. By bending the unfinished portion, a three-dimensional fiber structure F having a T-shaped cross section is obtained as shown in FIG. In addition, as shown by the chain line in FIG. 15C, the third three-dimensional fiber structure 71 may be joined by the stitch 72 as shown by the chain line in order to maintain the shape of the bent portion.
JP 2003-73176 A (paragraphs [0007], [0017], [0018] in FIG. 1, FIG. 1) JP 56-73138 A (pages 1 and 2 of the specification, FIGS. 1 to 3) JP-A-2-33346 (pages 2 and 3 of the specification, FIGS. 1 and 2) Japanese Patent Laid-Open No. 11-1843 (paragraphs [0041] to [0051] of the specification, FIGS. 1 and 4) (Research Report No.1101 on Innovative Aircraft Technology Development, Japan Aerospace Industry Association, Innovative Aircraft Technology Development Center, March 2000, p.20-23)

  However, in the method of forming a linear three-dimensional fabric by following a jig having a predetermined shape as in the method of manufacturing a three-dimensional fiber structure disclosed in Patent Document 1, the three-dimensional fabric is a flat plate. It is possible to bend to a state where the curvature is small, but it is difficult to bend in the case of a three-dimensional fabric having an irregular cross section such as an I shape, a T shape, or an L shape. Further, in the case of a three-dimensional woven fabric formed of high strength and high elastic modulus fibers such as carbon fiber and aramid fiber, it is more difficult to bend.

  In addition, by using the spiral woven fabric disclosed in Patent Document 2 and Patent Document 3 and applying the method for manufacturing a three-dimensional fiber structure having a modified cross section described in Non-Patent Document 1, the cross section is elongated in a modified cross section. It is conceivable to produce a three-dimensional fiber structure curved in the direction. For example, when cut into a fan shape, a plurality of spiral woven fabrics are stacked and joined with a thread in the thickness direction to form a fan-shaped plate-like three-dimensional fiber structure. Then, a part of the three-dimensional fiber structure is stitched, and a portion where the stitch is not applied is bent to form a three-dimensional fiber structure that is curved in the longitudinal direction with an irregular cross section.

  However, the spiral woven fabrics disclosed in Patent Document 2 and Patent Document 3 are intended for spiral woven fabrics having a large curvature, that is, a small curvature radius, and the spiral radii having a curvature radius of several meters, such as aircraft structural members. In order to weave a woven fabric, there is a problem that a very large apparatus is required as a loom. In addition, since the spiral woven fabric is formed of warp and weft, a bias yarn arranged at an angle of ± 45 degrees, for example, is arranged with respect to a yarn arranged along the longitudinal direction as a three-dimensional fiber structure. I can't. Therefore, the physical properties are insufficient as a reinforcing material for composite materials having high strength requirements.

  Further, as a method of forming a fan-shaped plate-like three-dimensional fiber structure, as shown in FIG. 16, a yarn layer composed of x yarn 67 and y yarn 68 (may further include a yarn layer made of bias yarn) It is conceivable to cut out a fan-shaped three-dimensional fiber structure 70 having a predetermined curvature and width from a three-dimensional woven fabric 69 in which the yarns are connected by a thickness direction thread (not shown). However, in this case, not only is the portion that is wasted increased, but the yarn arrangement is not curved with a predetermined curvature but is linear, making it difficult to obtain a high-strength three-dimensional fiber structure.

The present invention was made in view of the above problems, purpose of that is used in a state of being connected to the beam and an annular curved shape, the cross-sectional shape perpendicular to the longitudinal direction of the irregular shape fiber to provide a method for producing three-dimensional fiber structure suitable as a three-dimensional fiber structure intermediate in the production of three-dimensional fiber structure that can be used as a suitable reinforcing material for the production of reinforced composite materials It is in .

To achieve pre-Symbol purpose, a first aspect of the present invention, by using the fiber bundle arranging jig having a fiber array portion of the frustoconical peripheral surface shape, on the fiber bundle arranging jig And a laminated yarn group forming step of forming a laminated yarn group having at least biaxial orientation by laminating a plurality of yarn layers so as to include at least a yarn layer composed of yarns arranged in parallel with the end of the truncated cone. . And a laminated yarn group joining step of joining the laminated yarn groups with thickness direction yarns while being held by the fiber bundle arranging jig, and after forming the truncated cone cylindrical three-dimensional fiber structure, the truncated cone cylinder The fan-shaped plate-like three-dimensional fiber structure is formed by cutting and expanding the three-dimensional fiber structure in a direction perpendicular to the circumferential direction.

  In the present invention, a plurality of yarn layers including a yarn layer made of yarns arranged at least in parallel with an end portion of the truncated cone on a fiber arrangement portion having a shape forming the peripheral surface of the truncated cone of the fiber bundle arranging jig. Are laminated to form a laminated yarn group having at least biaxial orientation. Then, the arranged laminated yarn groups are joined by the thickness direction yarns while being held by the fiber bundle arranging jig to form a three-dimensional fiber structure having a fan-like plate-like portion. Therefore, among the yarns (fiber bundles) constituting the three-dimensional fiber structure having the fan-shaped plate-like portion, when arranging the fiber bundles (0 degree arrangement yarn) extending along the longitudinal direction of the three-dimensional fiber structure, the fibers By increasing the tension applied to the bundle, the fiber bundle can be easily pressed onto the fiber arrangement portion. As a result, the fiber bundles can be arranged in a flat state on the fiber arrangement part with high accuracy and in parallel in the same direction, and the fiber bundles can be arranged so as to obtain a three-dimensional fiber structure having a high fiber volume content. It becomes easy to do, and the physical property of the composite material which used this three-dimensional fiber structure as a reinforcing material improves.

The invention according to claim 2 uses the fiber bundle arranging jig having a fiber arrangement portion having a shape that forms a peripheral surface of the truncated cone or a part of the peripheral surface of the truncated cone. A laminated yarn group forming step of forming a laminated yarn group having at least biaxial orientation by laminating a plurality of yarn layers so as to include at least a yarn layer composed of yarns arranged in parallel with an end of the truncated cone. ing. In addition, there is provided a laminated yarn group joining step in which the laminated yarn group is intermittently moved in one direction while being held by the fiber bundle arranging jig and sequentially joined with a thickness direction yarn at a predetermined position. Then, after the laminated yarn group joined by the thickness direction yarn in the laminated yarn group joining step is sequentially removed from the fiber bundle arranging jig, it is cut to a predetermined length and a fan-like plate-like three-dimensional fiber structure Form.

In this invention, unlike the manufacturing method of the invention described in claim 1 , a fan-shaped plate-like three-dimensional fiber structure in which 0-degree arranged yarns are arranged with a predetermined curvature can be continuously produced. The three-dimensional fiber structure can be produced efficiently.

A third aspect of the present invention is the invention according to the second aspect , wherein the fan-like plate-like portion is a continuous shape of the laminated yarn group joined by the thickness direction yarns sequentially removed from the fiber bundle arranging jig. After being stored as a belt-like three-dimensional fiber structure, it is cut to a predetermined length to form a fan-like plate-like three-dimensional fiber structure. In this invention, the laminated yarn group sequentially removed from the fiber bundle arranging jig is not immediately cut into a predetermined length and stored as a fan-like plate-like three-dimensional fiber structure, but stored as a band-like three-dimensional fiber structure. Then, it is cut into a predetermined length to form a fan-like plate-like three-dimensional fiber structure. Therefore, three-dimensional fiber structures having different lengths can be freely produced.

The invention according to claim 4 is the invention according to any one of claims 1 to 3 , wherein the yarn arranged parallel to the end of the truncated cone with respect to the fiber arrangement portion is the yarn. All the yarns that make up the layer are arranged simultaneously. In the present invention, it is easier to arrange the yarns arranged in parallel with the end of the truncated cone in a plurality of times and efficiently and in parallel with each other with high accuracy.

Invention of Claim 5 is a manufacturing method of the three-dimensional fiber structure by which the cross-sectional shape orthogonal to a longitudinal direction was unusual shape, and was curvedly formed along the longitudinal direction. In this manufacturing method, to use the claims 1 to three-dimensional fiber structure produced by the production method according to any one of claims 4 as a three-dimensional fiber structure intermediates. Then, in a state where a plurality of the three-dimensional fiber structure intermediates are laminated in the thickness direction, at least one arcuate peripheral edge of the three-dimensional fiber structure intermediate is left, and the three-dimensional fiber structure intermediate bonds are bonded by a bonding thread. And a bending step of bending the arc-shaped peripheral edge portion that has not been joined by the joining yarn at a right angle with the fan plate-like portion.

  In this invention, in a state where a plurality of fan-plate-like three-dimensional fiber structure intermediates are stacked in the thickness direction, at least one arc-shaped peripheral edge of the three-dimensional fiber structure intermediate is left and bonded by the binding yarn. . Thereafter, the arc-shaped peripheral edge portion that is not joined by the joining yarn is bent at a right angle with respect to the fan-shaped plate-like portion, thereby forming a three-dimensional fiber structure having a different cross-sectional shape perpendicular to the longitudinal direction. Therefore, among the yarns (fiber bundles) constituting the fan-shaped plate-like three-dimensional fiber structure intermediate, the yarns extending along the longitudinal direction of the three-dimensional fiber structure intermediate can be accurately arranged in parallel in the same direction. The physical properties of the composite material using the three-dimensional fiber structure as a reinforcing material can be improved.

According to the invention described in 請 Motomeko 1 to claim 4, in cross-sectional shape different shape perpendicular to the longitudinal direction, three-dimensional fiber in the production of three-dimensional fiber structure which is curved along the longitudinal direction A fan-plate-shaped three-dimensional fiber structure suitable as a structural intermediate can be easily produced. In addition, according to the fifth aspect of the present invention, a three-dimensional fiber structure having a different cross-sectional shape orthogonal to the longitudinal direction and being curved along the longitudinal direction can be easily manufactured .

(First embodiment)
A first embodiment in which the present invention is embodied in a three-dimensional fiber structure having an I-shaped (I-shaped) cross-sectional shape will be described below with reference to FIGS.

  1A is a schematic perspective view of a three-dimensional fiber structure 11, FIG. 1B is a schematic perspective view of a three-dimensional fiber structure intermediate showing an arrangement state of arranged yarns, and FIG. 1C is an arrangement state of thickness direction yarns. The schematic perspective view of the three-dimensional fiber structure intermediate body which shows these, (d) And (e) is a schematic perspective view of the three-dimensional fiber structure in the middle of manufacture. FIG. 2 is a schematic perspective view of a fiber bundle arranging jig, FIG. 3A is a schematic cross-sectional view taken along line AA in FIG. 3B, and FIG. It is a schematic cross section in the BB line. 4A is a schematic perspective view showing an arrangement state of fiber bundles having an arrangement angle of −45 degrees, FIG. 4B is a schematic perspective view showing an arrangement state of fiber bundles having an arrangement angle of 90 degrees, and FIG. FIG. 5 is a schematic perspective view showing an arrangement state of fiber bundles having an angle of 0 degrees, and (b) is a schematic perspective view showing an arrangement state of fiber bundles having an arrangement angle of +45 degrees.

  As shown to Fig.1 (a), the cross-sectional shape orthogonal to a longitudinal direction has a different shape, and the three-dimensional fiber structure 11 is curvedly formed along the longitudinal direction. The three-dimensional fiber structure 11 corresponds to the I-shaped cross-sectional shape, and forms a right angle with the fan face plate portion 11a at the lower end of the fan face plate portion 11a as one fan face plate portion 11a. In this way, the plate-like portion 11b is formed on both sides, and the plate-like portion 11c is formed on both sides so as to be perpendicular to the fan-side plate-like portion 11a at the upper end of the fan-like plate-like portion 11a. That is, the three-dimensional fiber structure 11 is formed in a modified cross section having a plurality of plate-like portions that are perpendicular to each other. And the three-dimensional fiber structure 11 is curvedly formed with a fixed curvature along the longitudinal direction. Although the state of curvature varies depending on the purpose of use, for example, when used as a structural material for an aircraft fuselage, the radius of curvature is about several meters (2 to 5 m).

  The dimensions of each part of the three-dimensional fiber structure 11 are such that, for example, when used for a structural material constituting an annular part of an aircraft fuselage, the height H of the fan-shaped plate-like part 11a is 70 to 120 mm and the width W of the plate-like part 11b. Is formed to 15 to 40 mm. Further, the length L varies depending on the number of the structural members constituting the annular portion and the radius of curvature, but if the radius of curvature is 5 m and the number is 4, the length L is formed to be about 8 m.

  The both ends of the three-dimensional fiber structure 11 are formed in a shape that can form a ring when a plurality of three-dimensional fiber structures are connected to each other in the longitudinal direction. The three-dimensional fiber structure 11 is formed such that the bisector of the angle formed by the extension portions of both end faces passes through the center of the three-dimensional fiber structure 11.

  In the three-dimensional fiber structure 11, a layered yarn group having at least biaxial orientation (in this embodiment, 4-axis orientation) including a yarn layer made of 0-degree arranged yarns arranged in concentric arcs is a thickness direction yarn. It is comprised from the fan-plate-shaped three-dimensional fiber structure intermediate body 12 (three-dimensional fiber structure) formed by combining. A part of the three-dimensional fiber structure intermediate body 12 is laminated by a binding thread (stitch) 13 in a state where a plurality of the three-dimensional fiber structure intermediate bodies 12 are laminated in the thickness direction. It is bent on both sides at right angles to the face plate portion 11a.

  As shown in FIG.1 (b), the laminated yarn group 14 which comprises the three-dimensional fiber structure intermediate body 12 is the 0 degree | times arrangement | sequence thread | yarn 15, the 90 degree arrangement | sequence thread | yarn 16, the +45 degree | times arrangement thread | yarn 17, and the -45 degree | times arrangement | sequence. And the yarn 18. The 0-degree array yarns 15 are arranged in parallel to each other so as to form an arc having the same center, that is, in a concentric arc shape. The 90-degree array yarn 16 is arranged so as to be orthogonal to the 0-degree array yarn 15, and the + 45-degree array yarn 17 is arranged at an angle of +45 degrees with respect to the 0-degree array yarn 15. 18 are arranged at an angle of −45 degrees with respect to the 0-degree array yarn 15. That is, in the fan-shaped plate-like portion 11a, the arrangement yarn angle of each yarn layer of the laminated yarn group 14 is constant with respect to the 0 degree arrangement yarn 15 arranged in the concentric arc shape.

  And as shown in FIG.1 (c), the lamination thread group 14 is couple | bonded by the thickness direction thread | z, and the three-dimensional fiber structure intermediate body 12 is comprised. A carbon fiber fiber bundle is used for each of the arranged yarns 15 to 18, and a polyaramid fiber fiber bundle is used for the thickness direction yarn z. The fiber bundle made of carbon fiber is composed of carbon fiber non-twisted multifilaments, and the number of multifilaments is about 3000 to 24000 filaments.

Next, the manufacturing method of the three-dimensional fiber structure 11 is demonstrated.
The manufacturing method of the three-dimensional fiber structure 11 includes a laminated yarn group forming step, a three-dimensional fiber structure intermediate forming step (laminated yarn group joining step), a three-dimensional fiber structure intermediate joining step, and a bending step. .

  First, the configuration of a fiber bundle arranging jig used for manufacturing a three-dimensional fiber structure as the three-dimensional fiber structure intermediate 12 will be described. The fiber bundle arranging jig is used for the laminated yarn group forming step and the three-dimensional fiber structure intermediate forming step.

  As shown in FIGS. 3A and 3B, the fiber bundle arranging jig 19 has a truncated cone-shaped support plate 22 as a fiber arranging portion with respect to a column 21 erected on the base plate 20. Is fixed via a bracket 23. The support plate 22 is formed so that the peripheral lengths of both end portions thereof are equal to the lengths of the arc portions at both ends of the fan-plate-like three-dimensional fiber structure intermediate body 12 to be formed. As shown in FIG. 2, the support plate 22 is formed with an opening 22a extending along the width direction at one place.

  On one end (upper end in this embodiment) side of the support plate 22, a small-diameter support ring 24 is supported by the arm portion 24 a with respect to the support column 21 so as to be rotatable with respect to the support column 21 and the support plate 22. Has been. On the other end (lower end in this embodiment) side of the support plate 22, a large-diameter support ring 25 is rotatably supported with respect to the support tube 26 and the support plate 22 on a support tube 26 provided on the base plate 20. Has been.

  The outer diameters of the support rings 24 and 25 are formed to be approximately the same as the outer diameter of the end portion of the support plate 22. Internal gears 24 b and 25 a are formed on the inner surfaces of the support rings 24 and 25. Both internal gears 24b and 25a are formed with the same diameter and the same number of teeth. On the base plate 20, a rotary shaft 27 is disposed at a position inside the support rings 24 and 25 so as to extend in the vertical direction. A gear 28 that meshes with the internal gear 24b and a gear 29 that meshes with the internal gear 25a are fixed to the rotary shaft 27 so as to be integrally rotatable. The rotating shaft 27 is driven to rotate by a motor via a gear or a winding transmission mechanism (not shown). That is, both the support rings 24 and 25 are rotated at the same rotational speed via the gears 28 and 29 as the rotary shaft 27 rotates. The upper end of the rotating shaft 27 is set to a height that does not interfere with the support ring 24. Also, illustration of the teeth of the internal gears 24b, 25a is omitted.

  As shown in FIG. 2, a large number of pins 30 are fixed to the support rings 24, 25 at a predetermined pitch so as to protrude toward the outside of the support rings 24, 25. The same number of pins 30 are fixed to the support rings 24 and 25, respectively. The fixing positions of the pins 30 are the support rings 24 in a state where the outer peripheral surface of the fiber bundle arranging jig 19 is developed in a fan shape. , 25 pins 30 are set to exist on a straight line passing through the center of curvature of the peripheral edge of the fan surface. The support plate 22, the support rings 24 and 25, and the pin 30 constitute a fiber array portion having a shape that forms the peripheral surface of the truncated cone.

  In addition, illustration of the pin 30 is abbreviate | omitted in FIG. 3 (a), (b). Moreover, if the composite material finally manufactured is used for the fuselage frame of an aircraft and the curvature radius is 5 m, the curvature radius of the fan-plate-shaped three-dimensional fiber structure intermediate body 12 is also 5 m. For example, if a ring is formed by four composite materials, the length of the composite material is 7.85 m, and the fiber bundle arrangement necessary for manufacturing the corresponding three-dimensional fiber structure intermediate 12 is used. The jig 19 has a radius of the support ring 24 of 1.25 m and a radius of the support ring 25 of 1.29 m. On the other hand, the width of the three-dimensional fiber structure intermediate 12 is about 0.15 m. However, in each figure, the ratio of the length and width of the three-dimensional fiber structure intermediate 12 and the ratio of the diameter and width of the fiber bundle arranging jig 19 are shown as values different from the actual values.

  Next, a method for forming the three-dimensional fiber structure intermediate 12 using the fiber bundle arranging jig 19 will be described. First, a plurality of yarn layers are laminated on the outer peripheral surface of the fiber bundle arranging jig 19 to form a laminated yarn group 14 having a four-axis orientation. As shown in FIG. 5B, the yarn layer includes a +45 degree arrangement yarn layer 31 constituted by +45 degree arrangement yarns 17 arranged so as to form an angle of approximately +45 degrees with the circumferential direction of the support plate 22. As shown in FIG. 4B, there is a 90-degree array yarn layer 32 constituted by 90-degree array yarns 16 arranged in a direction orthogonal to the circumferential direction of the support plate 22. Further, as shown in FIG. 5 (a), the thread layer includes a 0 degree array thread layer 33 constituted by 0 degree array threads 15 arranged along the circumferential direction of the support plate 22, and FIG. 4 (a). As shown in FIG. 4, there is a −45 degree arrangement yarn layer 34 constituted by a −45 degree arrangement yarn 18 arranged so as to form an angle of about −45 degrees with the circumferential direction of the support plate 22.

  The 90-degree array yarn 16, the + 45-degree array yarn 17, and the -45-degree array yarn 18 are arrayed so as to be folded back while being locked to the pins 30 of the support rings 24 and 25, respectively. However, for convenience of illustration, in FIGS. 4A, 4 </ b> B, and 5 </ b> B, illustration of portions where the respective array yarns 16 to 18 are locked to the pins 30 is omitted. The arrangement of the arrangement yarns 16 to 18 is started in a state where one end is fixed to one of the support rings 24 and 25. The arrangement of the 0-degree arrangement yarn 15 is started with one end fixed to the support plate 22. In the 0 degree arrangement yarn 15, all the yarns are arranged at the same time.

  Each of the arranged yarns 16 to 18 corresponds to the arrangement pitch of the pins 30 even if one yarn is arranged so that the yarns are sequentially folded back while being locked to the pins 30 of the support rings 24 and 25. You may arrange simultaneously using the head which can be supplied at intervals. When the array yarns 16 to 18 are folded in a state of being locked to the pins 30, the head is folded after moving along the circumferential direction of the distance corresponding to the number of the array yarns.

  The arrangement order of the thread layers 31 to 34 is not particularly limited, but the 90 degree arrangement yarn layer 32 and the 0 degree arrangement yarn layer 33 are arranged between the +45 degree arrangement yarn layer 31 and the −45 degree arrangement yarn layer 34. The configuration is preferred.

  After the respective yarn layers 31 to 34 are laminated in a predetermined layer (for example, two each of the yarn layers 31 to 34) and the laminated yarn group 14 is formed on the fiber bundle arranging jig 19, the laminated yarn group 14 is turned into a fiber bundle. The yarn layers of the laminated yarn group 14 are joined by the thickness direction yarn z while being held by the arrangement jig 19. Thickness direction yarn z, that is, insertion of thickness direction yarn z into laminated yarn group 14 is basically the same thickness as the device described in Patent Document 4 previously proposed by the present applicant. This is done using a directional thread insertion device. The thickness direction thread insertion device is configured to be able to reciprocate a needle support 36 on which thickness direction thread insertion needles 35 are fixed in a row at a position corresponding to the opening 22 a of the support plate 22. The needle support 36 has a standby position where the thickness direction thread insertion needle 35 cannot be engaged with the laminated yarn group 14 held by the fiber bundle arranging jig 19, and a needle hole (not shown) on the opposite side of the laminated yarn group 14. Is moved to a working position penetrating the laminated yarn group 14 to a position.

  Then, the forward movement of the needle support 36 causes the thickness direction thread insertion needle 35 to penetrate the laminated thread group 14, and the portion of the thickness direction thread z held by the thickness direction thread insertion needle 35 is the laminated thread group 14. It will be in the state which protrudes from the back side. From this state, the needle support 36 is slightly moved back, and each thickness direction thread z connected to the thickness direction thread insertion needle 35 becomes a loop shape. In this state, after the ear thread (retaining thread) is inserted into the loop portion of each thickness direction thread z, the needle support 36 is moved back to the standby position, and the thickness direction thread z is inserted in a folded shape. .

  Next, both the support rings 24 and 25 are rotated by one pitch of the thickness direction yarn z, and the laminated yarn group 14 is moved by the same distance with respect to the opening 22a. In this state, the needle support 36 is again driven in the same manner as described above, and the thickness direction thread z is inserted in a folded manner at the next location. Thereafter, the rotation of the support rings 24 and 25 and the reciprocation of the needle support 36 are alternately performed, and the reciprocation of the needle support 36 is completed after the two support rings 24 and 25 are rotated once. Thus, the operation of inserting the thickness direction yarn z into the laminated yarn group 14, that is, the joining operation of the laminated yarn group 14, is completed, and the truncated cone cylindrical three-dimensional fiber structure is formed.

  The stage in which the arranged yarns 15 to 18 are arranged by the head is a laminated yarn group forming step. Further, the stage in which the thickness direction thread z is inserted by the thickness direction thread insertion needle 35 at the position corresponding to the opening portion 22a and the layered thread group 14 is joined by the thickness direction thread z is three-dimensional. This is a fiber structure intermediate forming step (laminated yarn group binding step).

  Next, the laminated yarn group 14 is cut in one place along the arrangement direction of the 90-degree arrangement yarns 16. That is, after the truncated cone-shaped cylindrical three-dimensional fiber structure is cut in a direction orthogonal to the circumferential direction, the portions locked to the pins 30 of the array yarns 16 to 18 are sequentially removed and deployed. The formation of the three-dimensional fiber structure intermediate 12 is completed.

  Next, a three-dimensional fiber structure intermediate bonding step is performed. In the three-dimensional fiber structure intermediate bonding step, as shown in FIG. 1D, both of the three-dimensional fiber structure intermediates 12 are stacked in a state where two three-dimensional fiber structure intermediates 12 are laminated in the thickness direction. These are joined by the joining yarn 13 leaving the arc-shaped peripheral edge.

  Next, a bending process is performed. In the bending step, as shown in FIG. 1 (e), the arc-shaped peripheral edge that is not joined by the joining yarn 13 is bent at a right angle to the fan-shaped plate-like part 11a. The arc-shaped peripheral edge portion is bent so as to project at right angles to both sides with respect to the fan-shaped plate-like portion 11a. And the other three-dimensional fiber structure intermediate body 12 is couple | bonded by the coupling | bonding thread | yarn 13 at the part bent on both sides, and plate-shaped part 11b, 11c is comprised. Thus, the manufacture of the three-dimensional fiber structure 11 shown in FIG.

  The three-dimensional fiber structure 11 formed as described above is impregnated with a thermosetting resin and cured to form a composite material having a deformed cross section and a shape curved in the longitudinal direction. As a highly rigid structural material, for example, it is used so as to constitute an annular portion of an aircraft fuselage. As the thermosetting resin, an epoxy resin, an unsaturated polyester resin, a phenol resin, a polyimide resin, a vinyl ester resin, or the like is used.

This embodiment has the following effects.
(1) The cross-sectional shape orthogonal to the longitudinal direction of the three-dimensional fiber structure 11 is different, and is curved and formed along the longitudinal direction. Both end portions of the three-dimensional fiber structure 11 are end portions in the longitudinal direction. When the parts are connected to each other, the ring is formed into a shape that can be formed. Therefore, if a fiber reinforced composite material is manufactured by impregnating and curing a matrix such as a resin in the three-dimensional fiber structure 11, a fiber reinforced composite material used in a state of being connected to a curved beam or an annular shape. It can be preferably used.

  (2) The three-dimensional fiber structure 11 has a fan-like plate shape, and a three-dimensional fiber structure intermediate 12 having a shape in which a bisector of an angle formed by extension lines at both ends of the fan face bisects the fan face. In addition, a part is bonded by the bonding yarn 13 while being stacked in a plurality of thickness directions. The three-dimensional fiber structure intermediate 12 is formed by joining at least biaxially oriented laminated yarn groups 14 including a 0 degree arrangement yarn layer 33 composed of 0 degree arrangement yarns 15 arranged in a concentric circular arc shape with a thickness direction yarn z. Is formed. And the circular-arc-shaped peripheral part of the three-dimensional fiber structure intermediate body 12 is bend | folded and formed at right angles to the fan-shaped plate-shaped part 11a. Therefore, if a fiber reinforced composite material is manufactured by impregnating and curing a matrix such as a resin in the three-dimensional fiber structure 11, a fiber reinforced composite material used in a state of being connected to a curved beam or an annular shape. It can be preferably used.

  (3) The three-dimensional fiber structure 11 is formed in a modified cross section having a plurality of plate-like portions 11b and 11c and a fan-like plate-like portion 11a that form a right angle. Therefore, when a composite material using the three-dimensional fiber structure 11 as a reinforcing material is used for a structural material such as a beam, the bending moment is increased if the weight is the same as in the case of a rectangular cross section. In this case, the weight can be reduced.

  (4) The three-dimensional fiber structure 11 is formed in an I-shaped cross section. Therefore, the three-dimensional fiber structure 11 is suitable as a reinforcing material for a fiber-reinforced composite material used for a structural material of an aircraft fuselage.

  (5) The composite material is configured using the three-dimensional fiber structure 11 as a reinforcing material and a thermosetting resin as a matrix. Therefore, although the matrix is also inferior in heat resistance compared to carbonized carbon / carbon composites, it has sufficient heat resistance as an aircraft structural material and is easier to manufacture than carbon / carbon composites. The cost is also cheaper.

  (6) In a state where a plurality of fan-shaped plate-like three-dimensional fiber structure intermediate bodies 12 are laminated in the thickness direction, the three-dimensional fiber structure intermediate body 12 is bonded by the binding yarn 13 leaving the arc-shaped peripheral edge, The three-dimensional fiber structure 11 is formed by bending the arc-shaped peripheral edge not joined by the joining yarn 13 at a right angle to the fan-shaped plate-like part 11a. Therefore, the three-dimensional fiber structure 11 curved in the longitudinal direction with a deformed cross section can be formed more easily than manufacturing with a three-dimensional brader or a three-dimensional loom.

  (7) Using a fiber bundle arranging jig 19 having a frustoconical fiber arrangement portion, a laminated yarn group 14 having a four-axis orientation is formed on the fiber bundle arranging jig 19, and the laminated yarn group 14 are joined by a thickness direction thread z to form a three-dimensional fiber structure having a truncated cone shape. Therefore, among the yarns (fiber bundles) constituting the fan-shaped plate-like three-dimensional fiber structure intermediate body 12, the yarns extending along the longitudinal direction of the three-dimensional fiber structure intermediate body 12 (0 degree arrangement yarn 15) are arranged. By increasing the tension applied to the fiber bundle, the fiber bundle can be easily pressed onto the fiber array portion (the surface of the support plate 22). As a result, the fiber bundles can be arranged in a flat state on the fiber arrangement part with high accuracy and in parallel in the same direction, and the fiber bundles can be arranged so as to obtain a three-dimensional fiber structure having a high fiber volume content. It becomes easy to do, and the physical property of the composite material which used this three-dimensional fiber structure 11 as a reinforcing material improves.

  (8) Since the yarn layers 31 to 34 need not be arranged at the same time, it is not necessary to provide an arrangement head for arranging the arrangement yarns 15 to 18 for each of the arrangement yarns 15 to 18. Therefore, the number of parts can be reduced by sharing the arrangement head.

  (9) With respect to the yarn arranged in parallel to the end of the truncated cone with respect to the fiber arrangement portion (0 degree arrangement yarn 15), all the threads constituting the 0 degree arrangement yarn layer 33 are arranged at the same time. Therefore, as compared with the case where the yarns arranged in parallel with the end of the truncated cone are arranged in a plurality of times, it is easy to arrange the yarns so as to be parallel to each other with high accuracy and accuracy.

(Second Embodiment)
Next, a second embodiment will be described with reference to FIGS. In this embodiment, the manufacturing method of the three-dimensional fiber structure intermediate 12 is different from that of the first embodiment, and the step of manufacturing the three-dimensional fiber structure 11 from the three-dimensional fiber structure intermediate 12 is the first step. This is the same as the embodiment. That is, the three-dimensional fiber structure intermediate bonding process and the bending process are the same. In the first embodiment, after forming a truncated cone-shaped three-dimensional fiber structure, the fan-plate-shaped three-dimensional fiber structure intermediates 12 are manufactured one by one by cutting and developing at one place. . On the other hand, in this embodiment, a three-dimensional fiber structure intermediate body is formed by forming a band-shaped three-dimensional fiber structure having a continuous fan-like plate shape and cutting the band-shaped three-dimensional fiber structure into a predetermined length. 12 is greatly different from the first embodiment. The same parts as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

  FIG. 6 is a schematic perspective view showing a state in which the 0-degree array yarns 15 are arranged at the time of manufacturing the belt-like three-dimensional fiber structure, and FIG. 7 is a belt-like three-dimensional structure in which each of the yarn layers 31 to 34 is laminated. It is a model expanded view which shows the arrangement | sequence state of each arrangement | sequence thread 15-18 at the time of forming a fiber structure. In addition, although the strip | belt-shaped three-dimensional fiber structure is curved actually, it is illustrated in linear form on account of illustration.

  The fiber bundle arranging jig 19 used in this embodiment is basically the same as that used in the first embodiment except that a predetermined number of layers are stacked and the thickness direction yarn z is used. In order to make it easier to sequentially remove the combined laminated yarn group 14 from the pin 30, the length of the pin 30 is not so long. In addition, a guide for sequentially removing the laminated yarn group 14 joined by the thickness direction yarn z from the pin 30 is provided as necessary.

  In this embodiment, the arrangement of the array yarns 15 to 18 constituting each of the yarn layers 31 to 34 is simultaneously performed in a predetermined region, except for the preparation stage. Therefore, unlike the case of the above-described embodiment, an array head is provided for each array thread 15-18 of each thread layer 31-34. The arrangement head that arranges the 0-degree arrangement yarn 15 is held at a predetermined position, and the arrangement heads that arrange the 90-degree arrangement yarn 16, the + 45-degree arrangement yarn 17 and the -45-degree arrangement yarn 18 reciprocate at the predetermined positions, respectively. Is done.

  As shown in FIG. 7, the arrangement heads 43a, 43b, 42a, 42b, 44a, 44b, 45a, 45b for supplying the arrangement yarns 15-18 for each area necessary for the arrangement of the arrangement yarns 15-18 are shown. Is placed. The arrangement heads 42a and 42b arrange the +45 degree arrangement yarn 17, the arrangement heads 43a and 43b arrange the 0 degree arrangement yarn 15, the arrangement heads 44a and 44b arrange the 90 degree arrangement yarn 16, and the arrangement heads 45a and 45b. Arranges the -45 degree arrangement yarn 18.

  The arrangement heads 43a and 43b arrange a plurality of 0-degree arrangement yarns 15 at the same time, while the other arrangement heads 42a, 42b, 44a, 44b, 45a, and 45b are + 45-degree arrangement yarns 17, 90-degree arrangement yarns 16, and -45. Each of the degree array yarns 18 can be arranged one by one.

  In this embodiment, the strip-shaped three-dimensional fiber structure 41 is formed as follows. First, as a preparation stage, the arrangement of the first-45-degree arrangement yarn 18 is started from the vicinity of the opening 22a, and the arrangement head 45a is arranged at a position corresponding to a predetermined arrangement area. Next, the arrangement of the 90-degree arrangement yarn 16 of the first layer is started from the vicinity of the opening 22a, and the arrangement head 44a is arranged at a position corresponding to a predetermined arrangement area. Next, the arrangement of the 0-degree arrangement yarn 15 of the first layer is started from the vicinity of the opening 22a, and the arrangement head 43a is arranged at a position corresponding to a predetermined arrangement area. Next, the arrangement of the first +45 degree arrangement yarns 17 starts from the vicinity of the opening 22a, and the arrangement head 42a is arranged at a position corresponding to a predetermined arrangement area. Next, the arrangement of the −45 degree arrangement yarn 18 of the second layer is started from the vicinity of the opening 22a, and the arrangement head 45b is arranged at a position corresponding to a predetermined arrangement area. Next, the arrangement of the 90-degree arrangement yarn 16 of the second layer is started from the vicinity of the opening 22a, and the arrangement head 44b is arranged at a position corresponding to a predetermined arrangement area. Next, the arrangement of the 0-degree arrangement yarn 15 of the second layer is started from the vicinity of the opening 22a, and the arrangement head 43b is arranged at a position corresponding to a predetermined arrangement area. Next, the arrangement of the +45 degree arrangement yarns 17 in the second layer is started from the vicinity of the opening 22a, and the arrangement head 42b is arranged at a position corresponding to a predetermined arrangement area.

  In addition, the edge part of each arrangement | sequence thread 15-18 is fixed to the edge part fixing member which is not shown in figure. The end fixing member is disposed near the opening 22a in an initial state, and is moved intermittently when weaving is started, and is taken up by a winding unit that winds up the woven belt-like three-dimensional fiber structure 41. It is supposed to be fixed.

  After the preparation step is completed, weaving of the band-shaped three-dimensional fiber structure 41 is started. When weaving is started, the support rings 24 and 25 are intermittently driven, and the array yarns 15 to 18 are arrayed in the array regions by the array heads 42a to 45a and 42b to 45b. A portion where the +45 degree arrangement yarns 17 are arranged in the arrangement region of the +45 degree arrangement yarns 17 in the second layer is a laminated yarn group 14 in which each of the arrangement yarns 15 to 18 is composed of a total of eight yarn layers. Thus, the thickness direction thread z is inserted by the thickness direction thread insertion needle 35 in a state where the portion corresponds to the opening 22a, and the laminated yarn group 14 is joined by the thickness direction thread z.

  A stage in which the arrangement yarns 15 to 18 are arranged in the arrangement regions by the arrangement heads 42a to 45a and 42b to 45b is a laminated yarn group forming process. In addition, the stage in which the thickness direction thread z is inserted by the thickness direction thread insertion needle 35 at the position corresponding to the opening 22a in the layered thread group 14 and the layered thread group 14 is joined by the thickness direction thread z is the layered thread group. It becomes a joining process.

  The laminated yarn group 14 is held in a state of being locked to the pin 30 until the insertion of the thickness direction yarn z is completed, and the engagement with the pin 30 is sequentially released after the insertion of the thickness direction yarn z is completed. Is done. Since the carbon fibers hardly extend, even if the array yarns 16 to 18 locked to the pins 30 are removed from the pins 30, the band-shaped three-dimensional fiber structures 41 do not flicker, and the band-shaped three-dimensional fiber structures 41 are sequentially formed. There is no problem even if it is removed.

  Both the support rings 24 and 25 are driven intermittently so as to be stopped when the thickness direction thread z is being inserted. The woven belt-like three-dimensional fiber structure 41 is wound up by a winding unit (not shown). That is, the strip-shaped three-dimensional fiber structure 41 is sequentially removed from the fiber bundle arranging jig 19 from the portion where the joining with the thickness direction thread z is completed, and is wound around the winding portion. A removal guide (not shown) is provided at a position where the strip-shaped three-dimensional fiber structure 41 is removed from the pin 30.

This embodiment has the following effects in addition to the same effects as (1) to (7) and (9) of the first embodiment.
(10) The formation of the three-dimensional fiber structure intermediate 12 forms the band-shaped three-dimensional fiber structure 41 having a shape in which the fan-shaped plate-like portions are continuous, and the band-shaped three-dimensional from the portion where the bonding by the thickness direction thread z is completed. The fiber structure 41 is sequentially removed from the fiber bundle arranging jig 46, and then the band-shaped three-dimensional fiber structure 41 is cut into a predetermined length. Therefore, the fan-plate-shaped three-dimensional fiber structure intermediate body 12 having a predetermined curvature can be efficiently manufactured, and the cross-sectional shape perpendicular to the longitudinal direction is different, and the three-dimensional fiber is curved along the longitudinal direction. The structure 11 can be manufactured efficiently.

  (11) When forming the belt-like three-dimensional fiber structure 41, the belt-like three-dimensional fiber structure 41 is sequentially removed from the fiber bundle arranging jig 19 from the portion where the joining by the thickness direction thread z is completed, and at the winding part Wind up. Therefore, the long strip-shaped three-dimensional fiber structure 41 can be formed and stored, and the three-dimensional fiber structure intermediate body 12 can be manufactured by sequentially cutting as necessary. Moreover, the three-dimensional fiber structure intermediate body 12 from which length differs can be manufactured freely.

  (12) The arrangement heads 43a and 43b for arranging the 0-degree arrangement yarn 15 need only be held at a fixed position after the preparation stage. The arrangement heads 42a, 42b and 44a for arranging the other arrangement yarns 16 to 18 are sufficient. , 44b, 45a, 45b need only be moved to a position corresponding to a predetermined array area after the preparation stage, and it is not necessary to secure a large space for the movement.

(Third embodiment)
Next, a third embodiment will be described with reference to FIGS. In this embodiment, a belt-like three-dimensional fiber structure 41 having a shape in which fan-like plate-like portions are continuous is formed, and the belt-like three-dimensional fiber structure 41 is cut into a predetermined length to obtain a three-dimensional fiber structure intermediate 12. Is the same as the second embodiment, but the configuration of the fiber bundle arranging jig is greatly different. FIG. 8 is a schematic perspective view of a main part of the fiber bundle arranging jig, and FIG. 9 is a schematic cross-sectional view cut between a pair of belts.

  In the fiber bundle arranging jig 19, support rings 24 and 25 are provided to be rotatable relative to the support plate 22. In the fiber bundle arranging jig 46 of this embodiment, both the support rings 24 and 25 are provided. The fiber arrangement portion in between is rotated in synchronization with both support rings 24 and 25. Moreover, the point from which the regulation pin is provided in the said fiber arrangement | sequence part differs from 2nd Embodiment. The same parts as those of the second embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

  In this embodiment, the fiber array portion provided between the support rings 24 and 25 is provided at a position corresponding to a substantially half-circular portion of the support rings 24 and 25. As shown in FIG. 8, the fiber array portion includes plates 48 fixed at predetermined intervals so as to extend in the vertical direction between a pair of endless belts 47a and 47b. It is installed. As shown in FIG. 9, the belts 47 a and 47 b are wound around the driving pulley 50, the driven pulley 51 and the guide plate 52, respectively, and are configured to draw a substantially semicircular circular orbit as the driving pulley 50 rotates. Has been. Both belts 47a and 47b are driven at the same speed in synchronism with both support rings 24 and 25, respectively. In the drawing, the regulation pin 49 is easy to understand and is shown larger than the pin 30, but actually, the regulation pin 49 is formed short so as to be easily separated from the laminated yarn group 14 near the drive pulley 50.

  Between the support rings 24 and 25, a support plate 53 having a shape obtained by cutting the truncated cone into a half is disposed in a portion supported by the support column 21 at a portion other than the circulation region of the belts 47 a and 47 b. Has been. In the support plate 53, an opening 53 a through which the thickness direction thread insertion needle 35 can enter is formed near the drive pulley 50. The position of the opening 53a is such that the regulation pin 49 is detached from the laminated yarn group 14 that moves in a position corresponding to the opening 53a, and the upper and lower ends of the laminated yarn group 14 are held in a state of being locked to the pins 30, After the thickness direction thread z is inserted into the laminated yarn group 14 at the opening 53a, the pin 30 is set at a position where it can be easily detached from the laminated yarn group 14.

  For ease of understanding, FIG. 9 shows that the plate 48 and the support plate 53 are arranged vertically like the support column 21 and the plate 48 moves on the peripheral surface of the support ring 25. Since the plate 48 and the support plate 53 form the side surface of the truncated cone, the plate 48 and the support plate 53 are inclined with respect to the column 21.

  In this embodiment, as in the second embodiment, the support rings 24 and 25 are intermittently rotated with the arrangement heads 42a to 45a and 42b to 45b being arranged at eight positions, as in the second embodiment. At the same time, the thickness direction thread z is inserted into the laminated yarn group 14 while the support rings 24 and 25 are stopped. Then, both belts 47a and 47b are moved in synchronization with the rotation of the support rings 24 and 25.

Therefore, this embodiment has the following effects in addition to the same effects as those of the second embodiment.
(13) The plate 48 constituting the fiber array portion disposed between the support rings 24 and 25 is moved in synchronization with the rotation of the support rings 24 and 25. Therefore, unlike the second embodiment and the first embodiment, the laminated yarn group 14 does not slide on the surface of the fiber arrangement portion, and the fiber bundle is in a position facing the fiber arrangement portion of the lamination yarn group 14. Can prevent fluffing.

  (14) When the 0-degree array yarn 15 is tensioned and the 0-degree array yarn 15 is arranged in pressure contact with the fiber array portion, the 0-degree array yarn 15 may be displaced upward depending on the inclination angle of the plate 48. However, since the regulation pin 49 protrudes from the fiber array portion (plate 48), there is no such a possibility, and the 0-degree array yarn 15 can be accurately arrayed at a predetermined position.

In addition, embodiment is not limited to the above, For example, you may actualize as follows.
In the method of continuously forming the band-shaped three-dimensional fiber structure 41 as in the second and third embodiments, the configuration in which the pair of support rings 24 and 25 are used as the configuration for moving the laminated yarn group 14 is used. Instead, an endless belt 54 may be used as shown in FIG. FIG. 10 is a schematic cross-sectional view corresponding to FIG. Both belts 54 are wound around a drive pulley 55, a driven pulley 56, and a guide plate 57, and are configured to draw a substantially semicircular orbit as the drive pulley 55 rotates. Pins 58 are provided on the outer peripheral surface of the belt 54 so as to protrude perpendicularly to the belt 54 at regular intervals. The guide plate 57 is formed in an arc shape with a curvature that allows the pin 58 to move along a predetermined curved surface. Both belts 54 are driven in synchronism with the arc portion at the same angular velocity. In this configuration, the fiber bundle arranging jig 46 can be downsized as compared with the configuration using the support rings 24 and 25.

  ○ The support plate 22 is not limited to the truncated cone shape as the fiber bundle arranging jig 19, and as shown in FIG. 11A, a cylindrical portion 22 b having the same diameter as the support ring 24 is formed on the upper side of the truncated cone shape. It is good also as a shape formed and the cylindrical part 22c of the same diameter as the support ring 25 was formed in the lower side. Moreover, as shown in FIG.11 (b), it is good also as a shape by which the cylindrical part 22c of the same diameter as the support ring 25 was formed under the truncated cone cylindrical part. When the fiber bundle arranging jig 19 having the shape shown in FIG. 11A is used, the three-dimensional fiber structure intermediate having the shape shown in FIG. 12, that is, the shape having the belt-like portions 12b on both peripheral edges of the fan-like portion 12a. 12 is obtained. In this case, the lengths of the arcs extending in parallel with the corresponding peripheral edges of the fan-shaped portions of the portions corresponding to the cylindrical portions 22b and 22c are equal. Therefore, the three-dimensional fiber structure 11 having a constant flange length can be obtained by bending the portions corresponding to the cylindrical portions 22b and 22c at a right angle to the fan-shaped plate-like portion 11a.

  ○ The cross-sectional shape of the three-dimensional fiber structure 11 is not limited to an I-shape, and as shown in FIG. 13A, a J / T shape in which J and T are combined, or as shown in FIG. As described above, the shape may be a T shape, or may have a bent portion that is perpendicular to the fan-shaped plate-like portion 11a, such as an L shape or an H shape.

  O Another three-dimensional fiber structure intermediate body 12 may be overlapped on the plate-like portions 11b and 11c bent at a right angle with respect to the fan-like plate-like portion 11a and not bonded by the bonding yarn 13. However, the combination of another three-dimensional fiber structure intermediate 12 stabilizes the shape of the three-dimensional fiber structure 11 and increases the strength.

The plate-like parts 11b and 11c are not limited to the structure bent at a right angle with respect to the fan-like plate-like part 11a, but may be bent at an angle with respect to the fan-like plate-like part 11a.
The arrangement sequence of the array yarns 15 to 18 is that the array yarns 16 to 18 other than the 0-degree array yarn 15 may be arranged first when the belt-like three-dimensional fiber structure 41 is continuously formed. When the three-dimensional fiber structure intermediate 12 is formed by batch operation using the bundle arranging jig 19, the arrangement order is arbitrary. However, in the case of the 4-axis orientation, it is preferable that the 0 degree arrangement yarn 15 and the 90 degree arrangement yarn 16 are arranged between the +45 degree arrangement yarn 17 and the −45 degree arrangement yarn 18.

  The fan-shaped plate-like portion 11a and the plate-like portions 11b and 11c constituting the three-dimensional fiber structure 11 are at least biaxially oriented including the yarn layer 33 composed of the 0-degree arranged yarns 15 arranged in a concentric arc shape. It is only necessary that the laminated yarn group 14 is formed by being joined by a thickness direction yarn. For example, in the laminated yarn group 14, the 0-degree arranged yarn 15 and the 90-degree arranged yarn 16 are in-plane biaxial orientation, or the 0-degree arranged yarn 15, the + 45-degree arranged yarn 17 and the -45-degree arranged yarn 18 are triaxial. It is good also as orientation. The orientation of the laminated yarn group 14 is determined by the strength required for the composite material using the three-dimensional fiber structure 11 as a reinforcing material, and the 4-axis orientation increases in strength in all directions.

  ○ When the three-dimensional fiber structure intermediate 12 is formed by batch operation using a jig in which the entire circumferential surface of the truncated cone constitutes a fiber arrangement part as in the first embodiment, a fiber bundle arrangement jig A plurality of three-dimensional fiber structure intermediates 12 may be formed at a time using a size that can form a plurality of three-dimensional fiber structure intermediates 12 as 19.

  ○ In the method of continuously forming the band-shaped three-dimensional fiber structure 41 as in the second and third embodiments, the band-shaped three-dimensional fiber structure 41 is wound around the winding portion and stored without being wound. The original fiber structure 41 may be cut at a stage where a predetermined length is formed, and the three-dimensional fiber structure intermediate body 12 may be sequentially formed. When the strip-shaped three-dimensional fiber structure 41 is wound around the winding portion and stored, the strip-shaped three-dimensional fiber structure 41 is stored in a state where an unnecessary bending force is applied to the strip-shaped three-dimensional fiber structure 41, which is not preferable. However, if it is stored in the state of the three-dimensional fiber structure intermediate 12, such a situation does not occur.

  In the method of continuously forming the strip-shaped three-dimensional fiber structure 41 as in the second and third embodiments, the array yarns are arrayed one by one as the array heads 42a, 42b, 44a, 44b, 45a, 45b. It is good also as a structure which arranges not only a structure but two or more simultaneously.

  In the method of continuously forming the strip-shaped three-dimensional fiber structure 41 as in the second and third embodiments, the arrangement yarns of each layer are predetermined from the vicinity of the opening 22a (53a) by the arrangement heads at the preparation stage. Weaving is started after being arranged up to the position corresponding to the arrangement region of the above, but the method is not limited to this. Weaving may be started while each array head starts arraying from a predetermined array region. In this case, the end of the belt-shaped three-dimensional fiber structure 41 at the beginning of weaving is incompletely laminated, but a completely laminated belt-like three-dimensional fiber structure 41 is obtained from the middle. Therefore, a preparation stage is not necessary.

  (Circle) the fiber arrangement | sequence part provided between both the support rings 24 and 25 in a 3rd Example is not restricted to the substantially half circumference part of both the support rings 24 and 25. FIG. If the arrangement by each arrangement head is possible, it may be more than half or less.

  ○ When arranging the arranged yarns 15 to 18, it is preferable to arrange the arranged yarns while expanding the fiber bundles constituting the arranged yarns. When carbon fibers are used as the array yarns 15 to 18, using thick yarns (yarns having a large number of fibers) is advantageous in reducing manufacturing time and cost. When using a thick thread (for example, a thread having more than 12,000 fibers), it is necessary to arrange the threads while expanding them.

  In the first to third embodiments, the number of pins 30 protruding from both support rings 24 and 25 or the number of pins 58 provided to both belts 54 in other embodiments may not necessarily be equal. Good. It is preferable in terms of the physical properties of the composite material using the three-dimensional fiber structure 11 as a reinforcing material that the 90-degree array yarn 16 is arranged in a state orthogonal to the 0-degree array yarn 15, but depending on the required performance, it may deviate from the orthogonal state. In this case, the number of pins 30 of both support rings 24 and 25 may not be equal. The number of pins 58 is also the same.

In the fan-shaped plate-like portion 11a, the arrangement yarn angle of each yarn layer of the laminated yarn group 14 may not be constant with respect to the 0 degree arrangement yarn 15 arranged in a concentric arc shape.
○ Fiber bundles are not limited to carbon fibers, but use inorganic fibers such as boron fibers and silicon carbide fibers depending on the use of the composite, organic materials with high strength and high modulus such as aramid fibers and ultrahigh molecular weight polyethylene fibers. Fiber untwisted multifilaments may be used.

  In addition to the aramid fiber, carbon fiber, glass fiber, or polyester fiber may be used as the thickness direction thread z. Polyester fibers are weaker than aramid fibers, carbon fibers, and glass fibers, but can be used under conditions that do not require bond strength.

  ○ Inorganic fibers such as carbon fibers and silicon carbide fibers are generally vulnerable to bending, so the three-dimensional fiber structure intermediate 12 is formed of inorganic fibers such as carbon fibers and silicon carbide fibers, and the three-dimensional fiber structure intermediate 12 is bonded. For the binding yarn 13 to be used, an organic fiber having a high strength and a high elastic modulus such as an aramid fiber, a polyester fiber or an ultrahigh molecular weight polyethylene fiber may be used. Polyester fibers are weaker than aramid fibers and ultrahigh molecular weight polyethylene fibers, but can be used under conditions that do not require bond strength.

  ○ If the heat resistance requirement is high as a composite material, use a three-dimensional fiber structure 11 made of carbon fiber, impregnate and cure the resin, and then fire it to form a carbon / carbon composite material Good.

  As a composite matrix resin, a thermoplastic resin may be used instead of a thermosetting resin depending on the application. However, the use of a thermosetting resin as the matrix resin can produce a higher-strength composite material than when a thermoplastic resin is used.

The following technical idea (invention) can be understood from the embodiment.
(1) A method of manufacturing a pre-Symbol fiber bundle arranging for the band three-dimensional fiber structure that has been removed from the jig successively cut into a predetermined length three-dimensional fiber structure intermediate to form three-dimensional fiber structure.

2 before Symbol fiber bundle arranging jig are pins projecting an array yarn while being intermittently rotated at the same rotation speed in synchronization with each other at positions corresponding to both ends of the truncated cone is locked A method for manufacturing a three-dimensional fiber structure, comprising: a support ring; and a frustoconical cylindrical fiber bundle array disposed between the support rings.

(3) pre-Symbol fiber bundle arranging unit manufacturing method of three-dimensional fiber structure which is movable at the same speed as the two support rings.

(A) is a schematic perspective view of the three-dimensional fiber structure of 1st Embodiment, (b), (c) is a schematic perspective view of a three-dimensional fiber structure intermediate body, (d), (e) is in the middle of manufacture. The model perspective view of a three-dimensional fiber structure. The model perspective view of the jig for fiber bundle arrangement | sequence. (A) is a schematic cross section in the AA line of (b) of the jig for fiber bundle arrangement | sequence, (b) is a schematic cross section in the BB line of (a). (A) is a model perspective view which shows the arrangement state of the fiber bundle of arrangement angle -45 degree | times, (b) is a model perspective view which shows the arrangement state of the fiber bundle of arrangement angle 90 degree | times. (A) is a schematic perspective view which shows the arrangement state of the fiber bundle of arrangement angle 0 degree, (b) is a schematic perspective view which shows the arrangement state of the fiber bundle of arrangement angle +45 degree | times. The model perspective view of the jig for fiber bundle arrangement | sequence of 2nd Embodiment. The model expanded view which shows the arrangement | sequence state of each arrangement | sequence thread. The model perspective view of the jig for fiber bundle arrangement | sequence of 3rd Embodiment. The schematic cross section similarly cut | disconnected between a pair of belts of the fiber bundle arrangement | sequence jig | tool. The schematic cross section corresponding to FIG. 9 of another embodiment. (A), (b) is a model perspective view of the jig | tool for fiber bundle arrangement | sequence of another embodiment. The schematic plan view (development figure) of the three-dimensional fiber structure intermediate body of another embodiment. (A), (b) is a model perspective view of the three-dimensional fiber structure of another embodiment. The top view of the manufacturing apparatus of a helical fabric. (A)-(c) is a model perspective view which shows the manufacturing method of the three-dimensional fiber structure of an irregular cross section. The schematic diagram of the state which cut | disconnected the flat three-dimensional fiber structure in the fan surface shape.

Explanation of symbols

  L: Length, z: Thickness direction yarn, 11: Three-dimensional fiber structure, 11a: Fan plate, 11b, 11c: Plate, 12: Three-dimensional fiber structure intermediate, 13: Bond yarn, 14 ... Laminated yarn group, 15 ... 0 degree arrangement yarn, 19,46 ... Fiber bundle arrangement jig, 31-34 ... Yarn layer, 41 ... Striped three-dimensional fiber structure.

Claims (5)

  Using a fiber bundle arranging jig having a fiber arrangement portion in the shape of a peripheral surface of a truncated cone, the yarn bundle arranged on the fiber bundle arranging jig at least in parallel with the end portion of the truncated cone A laminated yarn group forming step of forming a laminated yarn group having at least biaxial orientation by laminating a plurality of yarn layers so as to include a yarn layer;
  A laminated yarn group joining step of joining the laminated yarn groups with thickness direction yarns while being held by the fiber bundle arranging jig;
With
  After forming the truncated cone-shaped cylindrical three-dimensional fiber structure, the fan-shaped plate-shaped three-dimensional fiber structure is formed by cutting and expanding the truncated cone-shaped cylindrical three-dimensional fiber structure in a direction perpendicular to the circumferential direction. A method for manufacturing a three-dimensional fiber structure. Using a fiber bundle arranging jig having a fiber arrangement part having a shape that forms a part of the peripheral surface of the truncated cone or a part of the circumferential surface of the truncated cone, and at least on the fiber bundle arranging jig A laminated yarn group forming step of forming a laminated yarn group having at least biaxial orientation by laminating a plurality of yarn layers so as to include a yarn layer composed of yarns arranged in parallel with the ends;
  A laminated yarn group joining step in which the laminated yarn group is intermittently moved in one direction while being held by the fiber bundle arranging jig and sequentially joined with a thickness direction yarn at a predetermined position;
With
  After the laminated yarn group joined by the thickness direction yarn in the laminated yarn group joining step is sequentially removed from the fiber bundle arranging jig, it is cut into a predetermined length to form a fan-plate-like three-dimensional fiber structure. A method for producing a three-dimensional fiber structure. After storing the laminated yarn group joined by the thickness direction yarns sequentially removed from the fiber bundle arranging jig as a belt-like three-dimensional fiber structure having a continuous fan-like plate-like portion, it is cut to a predetermined length. The method for producing a three-dimensional fiber structure according to claim 2, wherein a fan-like plate-like three-dimensional fiber structure is formed . The yarn arranged in parallel to the end of the truncated cone with respect to the fiber arrangement portion, all the yarns constituting the yarn layer are arranged at the same time. A method for producing a three-dimensional fiber structure. The cross-sectional shape orthogonal to the longitudinal direction is an irregular shape, a manufacturing method of a three-dimensional fiber structure that is curved along the longitudinal direction,
  The three-dimensional fiber structure manufactured by the manufacturing method according to any one of claims 1 to 4 is used as a three-dimensional fiber structure intermediate, and the three-dimensional fiber structure intermediate is laminated in a plurality of thickness directions. A three-dimensional fiber structure intermediate bonding step in which at least one arcuate peripheral edge of the three-dimensional fiber structure intermediate is left and bonded by a bonding thread;
  A bending step of bending the arc-shaped peripheral edge that is not joined by the binding yarn;
The manufacturing method of the three-dimensional fiber structure provided with.

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