JP4286563B2 - Dry preform for composite material, its manufacturing method and manufacturing apparatus - Google Patents

Description

[0001]
[Industrial application fields]
The present invention relates to a dry preform for composite materials with improved curve formability for use in aerospace structures, architectural structures, automobile structures, marine structures, and other structures that require strength. The present invention relates to a manufacturing method and a manufacturing apparatus. In the following description, “dry preform” is a name for a fiber structure before being impregnated and molded by a molding method such as RTM, RFI, or VaRTM.
[0002]
[Prior art]
In general, there is a demand for weight reduction and high strength of aviation / space structures, architectural structures, automobile structures, marine structures, and other various structures that require strength.
[0003]
Conventionally, a metal material having a large mechanical strength corresponding to the required characteristics has been applied to a member having a curved portion among structural materials in an aircraft. In order to obtain the required strength with these metal materials, an enormous weight and the number of parts must be used, and the weight of the entire aircraft tends to be heavy. As a result, design freedom has been deprived, and fuel consumption during actual flight has become enormous, and weight reduction of aircraft materials has become an important factor in aircraft design, manufacturing, and operating costs. It was.
[0004]
In recent aircraft structural materials, for example, the production of aircraft structural materials using high-strength fiber-reinforced composite materials in which a reinforced fiber such as glass fiber, aramid fiber, or carbon fiber is impregnated with a polymer matrix such as epoxy resin has been studied. Many parts have been actually applied. Composite materials are known to be superior in specific strength and specific rigidity compared to metal materials, and are also known to have a high degree of freedom in structural design due to the characteristics of anisotropy due to reinforcing fibers. ing. Moreover, since a large-sized structural member can be integrally formed, the number of parts can be greatly reduced, and the cost can be reduced.
[0005]
On the other hand, regarding the manufacturing method, pipes etc. are installed perpendicular to the thickness direction in accordance with the desired shape, reinforcing fibers are meanderingly stretched, and the pipes etc. are replaced with fibers in the thickness direction, so that the reinforcing fibers are connected. Although a technique for obtaining a fiber base material by integrating the fibers is known (see, for example, Patent Document 1), this method takes time because only one long fiber is meandered and stretched. It is not a good method, and it takes time and effort to replace the pipe with reinforcing fibers in the thickness direction, resulting in high costs.
[0006]
Further, a method is known in which reinforcing fibers are stretched in a curved shape to obtain a reinforcing fiber substrate that is curved and has an irregular cross section (see, for example, Patent Document 2). The orientation is linear, and the reinforcing fibers along the curved shape are not oriented, and sufficient strength as a reinforcing fiber substrate cannot be obtained.
[0007]
In addition, when trying to obtain a shape having a deformed cross section having a curved portion such as a ring shape or a curved shape in part or as a whole, for example, a large number of sheets obtained by finely cutting a prepreg in which a reinforcing fiber is impregnated with a resin in advance. Although a hand lay-up method of pasting a shape into a desired shape has been performed (see, for example, Patent Document 3), most of the work is manual work by hand, making automatic production difficult and manufacturing. Since the number of processes is very large, the production period is long, and a lot of waste materials are produced, there is a problem that productivity is low. In such a case, the annular and curved reinforcing fibers are in a state of being cut off, and sufficient strength cannot be obtained when compared with a similar structural material made of continuous reinforcing fibers, and the cost is very high. It was.
[0008]
In addition, a technology in which reinforcing fibers are stretched with a certain width in an arbitrary fiber orientation, stretched to have a desired thickness, and then continuously integrated by stitching, etc., to create a substrate made of reinforcing fibers (For example, refer to Patent Document 4) is known, but this is basically for making a final shape after once forming an intermediate substrate of a preform, and obtaining a desired shape directly is not possible. Since it is difficult, in order to obtain a final shape, it is necessary to cut or overlap the manufactured intermediate base material, which is very laborious and expensive.
[0009]
In addition, a technology called ATL (auto tape layup) (or fiber placement, etc.) using a prepreg is known (for example, see Patent Document 5). It has actually been applied. This method mainly produces large curved members such as skin parts in aircrafts and rockets, and has the problem that it cannot produce shapes with complicated irregular cross sections such as I-type, L-type, T-type, and hat-type. there were.
[0010]
In addition, a method for producing a reinforcing fiber using a woven fabric is also conventionally known. For example, there are those in which a woven fabric is formed in a desired shape such as a disk shape or a spiral shape (see, for example, Patent Documents 6, 7, 8, 9, 10, and 11). The cost is high because it contains a lot of man-hours, such as cutting and stacking fabrics, and it is expensive, and it takes a lot of work to change the number of fibers in part, which increases costs. It was the cause.
[0011]
In addition, fabrics made of reinforcing fibers having an irregular cross section such as I-type, H-type, and T-type are also known (see, for example, Patent Document 12). In addition, the fiber could not be easily oriented in the necessary part and direction, and because it was a woven fabric, the reinforcing fibers were arranged in a crimped state, so that sufficient strength could not be obtained.
[0012]
In addition, there is known a technique capable of producing a curved structure by changing the fiber structure of the fabric (see, for example, Patent Documents 13 and 14). However, since the fabric is also a fabric, the fibers are crimped. However, it has weaknesses in strength and is not suitable for mass production due to many man-hours, and there is a limit to the shape that can be realized.
[0013]
There is also a method for producing a composite material using a blade base material that is a combination of reinforcing fibers (see, for example, Patent Document 15). The blade base material is deformable because it is basically composed of two crossing orientations, but if the fiber orientation in the base material is not in two directions, the combined reinforcing fibers are constrained and deformable. As a result, the amount of reinforcing fibers in a direction that is not originally required is also increased, resulting in a low degree of design freedom and an increase in weight and dimensions. As with any fabric, braid, or knitted fabric, the fibers in the base material are crimped, so there is a problem of low strength, and the cost is the same as when using fabrics. It was. In addition, there is a new problem that sometimes the strength according to the design cannot be obtained, and the application of composite materials to civil aircraft tends to be delayed (see, for example, Patent Document 16). ).
[0014]
[Patent Document 1]
JP 59-47464 A
[Patent Document 2]
US Pat. No. 5,91,002 specification and drawings
[Patent Document 3]
Japanese Patent Application Laid-Open No. 07-081566
[Patent Document 4]
US Pat. No. 5,809,805 and drawings
[Patent Document 5]
US Pat. No. 6,096,164 and drawings
[Patent Document 6]
JP 57-133242 A
[Patent Document 7]
JP-A-10-217263
[Patent Document 8]
JP 09-207236 A
[Patent Document 9]
Japanese Patent Application Laid-Open No. 2001-073241
[Patent Document 10]
Japanese Patent Laid-Open No. 07-133548
[Patent Document 11]
Japanese Patent Laid-Open No. 2002-3280
[Patent Document 12]
JP-A-57-133241
[Patent Document 13]
JP 63-1220153 A
[Patent Document 14]
Japanese Patent Laid-Open No. 02-191742
[Patent Document 15]
JP-A-10-290851
[Patent Document 16]
JP 2000-328392 A
[0015]
[Problems to be solved by the invention]
The present invention solves the above-mentioned problem, stretches the reinforcing fibers, integrates the stretched reinforcing fibers, and has a high degree of design freedom when forming into a curved shape, and reduces manufacturing time and man-hours. It is an object of the present invention to provide a dry preform for composite materials, a method for manufacturing the same, and a manufacturing apparatus and a manufacturing method thereof, which are less waste materials, less expensive than conventional ones, have no fiber crimp, and have a high density and high strength.
[0016]
[Means for Solving the Problems]
The dry preform for a composite material of the present invention includes a first reinforcing fiber layer stretched at least one layer in a part of an arbitrary shape parallel to a linear axis appropriately set in an arbitrary shape, and the linear axis The reinforcing fiber group constituted by the second reinforcing fiber layer stretched in a plurality of layers in an arbitrary shape at an intersecting angle is integrated, and the portion constituted only by the second reinforcing fiber layer is in the out-of-plane direction. A dry preform for a composite material characterized by having the following deformability: (Claim 1).
[0017]
Further, the dry preform for composite material of the present invention includes a first reinforcing fiber layer stretched at least one layer in a part of an arbitrary shape parallel to a linear axis appropriately set in an arbitrary shape, and the straight line It is constituted by a second reinforcing fiber layer stretched in a plurality of layers in an arbitrary shape at an angle crossing the axis, and the thickness is increased or decreased by increasing or decreasing the range occupied by the first reinforcing fiber layer and the second reinforcing fiber layer. The dry preform for a composite material according to claim 1, characterized in that (2) is changed.
[0018]
Further, the dry preform for composite material of the present invention includes a first reinforcing fiber layer stretched at least one layer in a part of an arbitrary shape parallel to a linear axis appropriately set in an arbitrary shape, and the straight line The reinforcing fiber group composed of the second reinforcing fiber layer stretched in multiple layers in an arbitrary shape at an angle that intersects the axis is integrated by any method of stitching, knitting, or needle punching A dry preform for a composite material according to claim 1 or claim 2 (claim 3).
[0019]
Further, the dry preform for composite material of the present invention includes a first reinforcing fiber layer stretched at least one layer in a part of an arbitrary shape parallel to a linear axis appropriately set in an arbitrary shape, and the straight line The reinforcing fiber group constituted by the second reinforcing fiber layer stretched in a plurality of layers in an arbitrary shape at an angle intersecting with the shaft is integrated with a heat-sealing resin. The dry preform for a composite material according to Item 2 was obtained (Claim 4).
[0020]
The method for producing a dry preform for a composite material according to the present invention includes a first reinforcing fiber layer stretched at least one part of an arbitrary shape in parallel with a linear axis appropriately set to an arbitrary shape, A step of integrating a reinforcing fiber group composed of a plurality of second reinforcing fiber layers stretched in an arbitrary shape at an angle crossing the linear axis, and the first reinforcing fiber layer and the second reinforcing fiber layer A step of bending the reinforcing fiber group composed of the reinforcing fiber layer on the same radius, and a step of deforming a portion constituted only by the second reinforcing fiber layer in an out-of-plane direction to have a curved shape having an irregular cross section. It was set as the manufacturing method of the dry preform for composite materials characterized by having (Claim 5).
[0021]
The method for producing a dry preform for a composite material according to the present invention includes a first reinforcing fiber that is stretched in multiple rows at least in one part of an arbitrary shape in parallel with a linear axis appropriately set to an arbitrary shape. The first reinforcing fiber layer is formed by integrating a reinforcing fiber group composed of a layer and a second reinforcing fiber layer stretched in a plurality of layers in an arbitrary shape at an angle crossing the linear axis Deforming into an arbitrary shape without changing the length of the reinforcing fiber to be formed, and deforming a portion constituted only by the second reinforcing fiber layer in an out-of-plane direction to have a curved shape having an irregular cross section A method for producing a dry preform for a composite material according to claim 5 (claim 6).
[0022]
The method for producing a dry preform for a composite material according to the present invention includes a first reinforcing fiber layer stretched at least one part of an arbitrary shape in parallel with a linear axis appropriately set to an arbitrary shape, , A reinforcing fiber group constituted by a second reinforcing fiber layer stretched in a plurality of layers in an arbitrary shape at an angle crossing the linear axis, integrated by any of stitching, knitting, needle punch, The reinforcing fiber group consisting of the first reinforcing fiber layer and the second reinforcing fiber layer is curved on the same radius, and the part constituted only by the second reinforcing fiber layer is deformed in the out-of-plane direction to have a deformed cross section. It is set as the manufacturing method of the dry preform for composite materials of Claim 5 or Claim 6 characterized by the above-mentioned.
[0023]
The method for producing a dry preform for a composite material according to the present invention includes a first reinforcing fiber layer stretched at least one part of an arbitrary shape in parallel with a linear axis appropriately set to an arbitrary shape, A reinforcing fiber group composed of a plurality of second reinforcing fiber layers stretched in an arbitrary shape at an angle crossing the linear axis is integrated with a heat-sealing resin, and the first reinforcing fiber layer and The reinforcing fiber group composed of the second reinforcing fiber layer is curved on the same radius, and a portion constituted by only the second reinforcing fiber layer is deformed in an out-of-plane direction to have a curved shape having an irregular cross section. The method for producing a dry preform for a composite material according to claim 5 or claim 6 (claim 8).
[0024]
The method for producing a dry preform for a composite material according to the present invention includes a first reinforcing fiber layer stretched at least one part of an arbitrary shape in parallel with a linear axis appropriately set to an arbitrary shape, A reinforcing fiber group composed of a plurality of second reinforcing fiber layers stretched in an arbitrary shape at an angle crossing the linear axis, and the reinforcing fibers constituting the first reinforcing fiber layer A combination of a plurality of curved shapes having a deformed cross-section by changing the portion composed only of the second reinforcing fiber layer in the out-of-plane direction without changing the length. The method for producing a dry preform for a composite material according to claim 5, wherein the reinforcing fiber orientation is arbitrary.
[0025]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of a dry preform for composite material (hereinafter referred to as dry preform), a manufacturing method thereof, and a manufacturing apparatus according to the present invention will be described with reference to the drawings.
[0026]
FIG. 1 illustrates a typical shape of a dry preform produced according to the present invention. The dry preform 1 shown in FIG. 1 has a curved shape having an L-shaped cross section, and a reinforcing fiber group 5 and a reinforcing fiber group 6 having a curved shape having an L-shaped cross section, which will be described later, are integrated. It is manufactured. The manufacturing method will be described below. In the present invention, in addition to the curved shape having an L-shaped cross section as shown in FIG. 1, the curved shape has an irregular U-shaped, I-shaped, Z-shaped, T-shaped, etc. It is possible to produce a dry preform having
[0027]
FIG. 2 simply shows the arrangement of the reinforcing fiber layer a stretched parallel to the linear axis 2 and the reinforcing fiber layer b stretched at an angle intersecting the linear axis 2 in the dry preform 1 shown in FIG. It is the perspective view which showed the outline about the manufacturing method with it. FIG. 2A shows a planar reinforcing fiber group 3 constituted by the reinforcing fiber layer a and the reinforcing fiber layer b. In FIG. 2A, the reinforcing fiber layer a is not deformable in the longitudinal direction because the reinforcing fibers are oriented and stretched parallel to the linear axis 2. In the first place, the reinforcing fibers oriented like the reinforcing fiber layer a are for obtaining the strength in the direction of the linear axis 2 and therefore have the property of not being deformed in the direction of the linear axis 2. The reinforcing fiber layer b is stretched in a fiber orientation that matches the required strength, and the orientation angle of these reinforcing fibers is provided in the range of 0 ° <θ <180 ° with respect to the linear axis 2. Is desirable. The reinforcing fiber layer b having this configuration has a property of being deformed with respect to the direction of the linear axis 2. The inventors of the present invention focused on the difference in properties related to deformation of the reinforcing fiber layer a and the reinforcing fiber layer b as described above.
[0028]
According to the properties of the reinforcing fiber layer a and the reinforcing fiber layer b, the entire reinforcing fiber group 3 in which both the reinforcing fiber layer a and the reinforcing fiber layer b are arranged is the reinforcing fiber group illustrated in FIG. As shown in FIG. 4, the plane can be deformed on the same radius. In the reinforcing fiber group 4 thus deformed, the portion occupied only by the reinforcing fiber layer b further has a deformability in the out-of-plane direction. Therefore, the reinforcing fiber group illustrated in FIG. Thus, a substantially cylindrical shape such as 5 with a hook-like flange is obtained. In the reinforcing fiber group 5 shown in FIG. 2 (C), the reinforcing fiber layer a is arranged on a substantially cylindrical surface, and the reinforcing fiber layer b is arranged in a bowl-shaped portion attached thereto.
[0029]
FIG. 2D shows a reinforcing fiber group 6 in which the reinforcing fiber group 5 and the reinforcing fiber layer a shown in FIG. 2C are arranged symmetrically with respect to the linear axis 2. That is, in the reinforcing fiber group 6, the reinforcing fiber layer b is disposed on the substantially cylindrical surface, and the reinforcing fiber layer a is disposed on the hook-shaped portion attached thereto. By using the reinforcing fiber group 5 and the reinforcing fiber group 6 together and integrating them, a dry preform 1 having a fiber orientation as shown in FIG. 1 is obtained. Conventionally, in order to produce a dry preform 1 having an irregular cross section and a curved shape as shown in FIG. 1 and having axial reinforcing fibers arranged on the entire surface of the substrate, a prepreg material, a cloth material, The use of a knit material, a blade material, etc. requires a great amount of labor, and the production of the dry preform 1 for realizing sufficient strength is expensive and accompanied by difficulty. In addition to obtaining the dry preform 1 with a devised orientation, the process is simplified by devising the manufacturing method and the manufacturing apparatus, and the reinforcing fiber layer a stretched in parallel with the linear axis 2 is disposed. Strengthening and cost reduction were realized.
[0030]
In the present invention, the reinforcing fiber groups 3 to 6 shown in FIG. 2 are most preferably integrated in a planar state as shown in FIG. 2A from the viewpoint of workability. As a specific stitching example when the reinforcing fiber groups 3 to 6 in the states of FIGS. 2A to 2C are integrated by stitching with a sewing machine, a form as shown in FIG. Is mentioned. 3A is a state of a portion stitched to the reinforcing fiber group 3 in FIG. 2A, and FIG. 3B is a portion stitched to the reinforcing fiber group 4 in FIG. The state, FIG. 3 (C) shows the state of the part stitched with respect to the reinforcing fiber group 5 of FIG. 2 (C). As the fiber d used for stitching in this case, any type of fiber that can be applied, such as carbon fiber, aramid fiber, and polyester fiber, can be used. As a form of stitching itself, a linear sewing method as shown in FIG. 3 may be used, but when a desired dry preform has a large thickness or a large degree of deformation, it is generally known as a sewing technique. It is also possible to employ zigzag stitching as shown in FIG. Stitching and knitting by a machine is a method that enables efficient and regular integration of reinforcing fiber groups, and is an effective means for making the process of integrating reinforcing fiber groups simple and quick. Moreover, an integration process can be similarly efficiently performed by performing a needle punch with respect to the reinforcing fiber group 3 of FIG. In addition, a method of using a heat sealing resin in the state of FIG. As a method for including the heat-sealing resin in the reinforcing fiber group, it is most common in the present invention to use a fibrous heat-sealing resin in alignment with the reinforcing fibers. Also by this method, the integration step can be performed efficiently.
[0031]
next , An apparatus for manufacturing a dry preform will be described. FIG. 5 is a perspective view of a reinforcing fiber tensioning jig 7 for manufacturing the reinforcing fiber group 3 in the state of FIG. On the reinforcing fiber tensioning jig 7, a large number of pins 8 are set up in accordance with the tension pitch of the reinforcing fibers. FIG. 6 schematically shows an example in which reinforcing fibers are stretched on the reinforcing fiber stretching jig 7 shown in FIG. In FIG. 6, the reinforcing fiber c enters the tensioning operation from P1, is tensioned to the pin 8 of P2, and is then tensioned to the pin 8 of P3. After that, it is stretched from the pin 8 of P3 to the pin 8 of P4, and further stretched to the pin 8 of P5. According to such a stretching method of the reinforcing fiber c, the reinforcing fiber c is stretched in a V shape, so that the reinforcing fiber c is not only stretched by one reinforcing fiber c as shown in FIG. As shown in the drawing, it can also be performed by multi-row stretching in which a plurality of reinforcing fibers c are stretched simultaneously with a width of an arbitrary stretching range e. The stretched range e of the reinforcing fiber c may have a length extending in the longitudinal direction of any shape. In that case, a large number of stretched ranges e of the reinforcing fibers c may exist within the length in the longitudinal direction, and may be set appropriately according to the situation. In this way, by making the reinforcing fiber tensioning work in multiple rows, the time can be significantly shortened compared to the tensioning work with one reinforcing fiber. The examples shown in FIGS. 6 and 7 show very typical fiber orientations in the + 45 ° direction and the −45 ° direction, but the fiber orientation angle θ can be changed in the range of 0 ° <θ <180 °. it can.
[0032]
Further, when the reinforcing fiber c oriented parallel to the linear axis 2 as shown in FIG. 8 is stretched, the reinforcing fiber stretching device shown in FIG. 9 is used. In this reinforcing fiber tensioning device, a reinforcing fiber guide pipe 9 corresponding to the number of reinforcing fibers in the tensioning range c ′ and a straight line in which a bar 10 for fixing and holding the spacing is set in an arbitrary shape. It is fixed to a movable part 11 that operates parallel to the shaft 2. The movable portion 11 is operated by the driving device 12 and moves on the guide rail 13 in the direction of the linear axis 2. The movable portion 11 is provided with a creel device portion 15 provided with a large number of bobbins 14 wound with reinforcing fibers c. The reinforcing fiber c fed from the creel device unit 15 passes through the guides 16 and 17 and performs the work of stretching the reinforcing fiber c around the pin 8 as needed while the movable part 11 is moving. By using such an apparatus, it is possible to efficiently perform the reinforcing work of reinforcing fibers in the longitudinal direction.
[0033]
Further, the reinforcing fiber c stretched at an angle of 0 ° <θ <180 ° with respect to the linear axis 2 as shown in FIG. 7 is a reinforcing fiber stretch as shown in FIG. Use equipment. This reinforcing fiber tensioning device has a reinforcing fiber guide pipe 9 corresponding to the interval of the pins 8, a bar 10 for fixing the reinforcing fiber guide pipe 9 and maintaining the interval, and further, the reinforcing fiber guide pipe 9 and the bar 10 are provided with a driving device 18 for driving the bar 10 so as to operate at an angle of 0 ° <θ <180 ° with respect to the linear axis 2. The drive device 18 can be operated as shown by an arrow in FIG. 11, for example, and can obtain the required orientation of the reinforcing fibers. If the reinforcing fiber guide pipe 9 is arranged in the range of the width e in FIG. 7, the reinforcing fiber c in the range of the width e can be stretched on the pin 8 at the same time.
[0034]
FIG. 12 illustrates the state of the end portion of the reinforcing fiber group when the reinforcing fiber layers b are stretched in multiple rows in the reinforcing fiber tensioning jig 7. In the case of performing multi-row stretching in which a plurality of reinforcing fibers c are stretched at the same time, a situation occurs in which the range of e in FIG. By installing a drive device that moves in a direction opposite to the direction of rotation during tensioning, the reinforcing fiber c can be pulled back as shown in FIG. Installation work can proceed smoothly.
[0035]
Further, the area in an arbitrary shape is changed between a range in which the reinforcing fibers c oriented parallel to the linear axis 2 are stretched and a range in which the reinforcing fibers c oriented so as to intersect the linear axis 2 at an angle. It is also possible to add an inclined portion to an arbitrary shape. In this case, if the reinforcing fiber layer at the bottom is stretched in the widest range, and the proportion of the plurality of reinforcing fiber layers stretched on it is gradually reduced in an arbitrary shape, it is almost continuously A dry preform with a changed thickness and shape can be obtained, and in the case where a convex part is required in a part of an arbitrary shape, it is possible by increasing the number of reinforcing fiber layers in that part with an appropriate reinforcing fiber orientation. Become. The inventors of the present invention have confirmed through experiments that such a thickness changing method can be significantly reduced in cost compared to the conventional method.
[0036]
By using the reinforcing fiber stretching device shown in FIGS. 9 and 10 together, the reinforcing fiber c can be stretched more efficiently. The inventors have confirmed through experiments that the dry preform 1 according to the present invention can produce a high-quality preform in a much shorter time than the prior art by using the apparatus shown in FIGS. 9 and 10 together. did.
[0037]
【The invention's effect】
As described above, the dry preform for composite material of the present invention is stretched at a first reinforcing fiber layer stretched in parallel with a linear axis appropriately set in an arbitrary shape and at an angle crossing the linear axis. Since the second reinforcing fiber layer is composed of a reinforcing fiber group, the portion composed only of the second reinforcing fiber layer stretched at an angle intersecting the linear axis has a deformable property. Since the dry preform is used, a low-cost dry preform for a composite material having a modified cross-section and used for a curved structural material can be obtained by a simpler process than in the past.
[0038]
In addition, the method for manufacturing a dry preform for composite material according to the present invention is a method for manufacturing a dry preform for composite material used for a structural material, and is a part of an arbitrary shape parallel to a linear axis appropriately set to an arbitrary shape. A step of integrating a first reinforcing fiber layer stretched at least one layer and a reinforcing fiber group stretched in a plurality of layers in an arbitrary shape at an angle crossing the linear axis; and the first reinforcing fiber layer A step of deforming into an arbitrary shape without changing the length of the reinforcing fibers constituting the wire, and a curve having a deformed cross section by deforming a portion composed only of the second reinforcing fiber layer in an out-of-plane direction. The method of manufacturing a dry preform for composite material is characterized by having a process for forming a shape, so there is no need to go through complicated steps as in the prior art, and low cost and high strength dry preform for composite material. It is possible to obtain a conveniently. The method described in the present invention is a production method that can be industrially mass-produced for dry preforms for composite materials used for structural materials having a curved shape having an irregular cross section, which has been conventionally difficult.
[0039]
Also, the above According to the composite material dry preform manufacturing apparatus, in the composite material dry preform manufacturing apparatus used for the structural material, in order to stretch the first reinforcing fiber layer and the second reinforcing fiber layer, Reinforcing fiber guide pipes corresponding to the number of reinforcing fibers to be stretched at one time or the number of rows, a bar for fixing the reinforcing fiber guide pipes and maintaining a gap, the reinforcing fiber guide pipes and the bars A drive device for moving the bar along the linear axis or a drive device for operating the bar at an angle with respect to the linear axis, and a creel device for supplying the reinforcing fiber to the reinforcing fiber guide pipe The apparatus for producing a dry preform for a composite material characterized by comprising: an arbitrary shape parallel to a linear axis appropriately set to an arbitrary shape Very efficiently be produced at least one layer stretched been reinforced fiber layers in a part.
[Brief description of the drawings]
FIG. 1 is a schematic perspective view of a dry preform for composite material according to an embodiment of the present invention.
2A is a schematic perspective view of a planar reinforcing fiber group in a state before the dry preform for composite material having the configuration shown in FIG. 1 is obtained, and FIG. 2B is a schematic view of the reinforcing fiber group of FIG. 1 is a schematic perspective view of the reinforcing fiber group deformed in FIG. 1, (C) is a schematic perspective view of the reinforcing fiber group in which a part of the reinforcing fiber group of (B) is deformed in the out-of-plane direction, and (D) is the shape of FIG. FIG. 2 is a schematic perspective view of a reinforcing fiber group having a reinforcing fiber orientation symmetrical to the reinforcing fiber group (C) necessary for manufacturing the dry preform for composite material.
3A is a schematic perspective view when the reinforcing fiber group of FIG. 2A is stitched, and FIG. 3B is a stitching of the reinforcing fiber group of FIG. 2B. The schematic perspective view at the time of giving, (C) is a schematic perspective view at the time of giving stitching to the reinforcing fiber group of Drawing 2 (C).
FIG. 4 is a schematic plan view of zigzag stitching for a dry preform for composite material according to an embodiment of the present invention.
FIG. 5 is a simplified perspective view of a jig with a pin for tensioning reinforcing fibers in an embodiment of the present invention.
FIG. 6 is a simplified plan view showing a state of reinforcing fiber stretching in the embodiment of the present invention.
FIG. 7 is a plan view schematically showing a typical reinforcing fiber tensioning method in an embodiment of the present invention.
FIG. 8 is a plan view schematically showing a typical reinforcing fiber tensioning method in an embodiment of the present invention.
FIG. 9 is a simplified side view of a reinforcing fiber tensioning device according to an embodiment of the present invention.
FIG. 10 is a simplified side view of a reinforcing fiber tensioning device in different embodiments of the present invention.
FIG. 11 is a plan view showing an operation direction of the reinforcing fiber tensioning device according to the embodiment of the present invention.
12A is a plan view showing a state of reinforcing fiber tensioning at the end portion of the reinforcing fiber tensioning jig according to the embodiment of the present invention, and FIG. 12B is a reinforcement in which the reinforcing fibers are pulled back from the state of FIG. It is a top view showing the mode of reinforcement fiber tension in the fiber tension jig end.
[Explanation of symbols]
1 Dry preform for composite materials
2 linear axes
3, 4, 5, 6 Reinforcing fiber group
7 Reinforcing fiber tension jig
8 pins
9 Reinforcing fiber guide pipe in reinforcing fiber tensioning device
10 bar
11 Moving parts
12 Drive unit
13 Guide rail
14 Bobbins
15 Creel
16, 17 guide
a First reinforcing fiber layer in which reinforcing fibers are stretched parallel to the linear axis
b Second reinforcing fiber layer stretched at an angle where the reinforcing fiber intersects the linear axis
c Reinforcing fiber
d Zigzag stitching
e Tension range of reinforcing fiber
P1, P2, P3, P4, P5 Tension points for reinforcing fibers

Claims (9)

In the dry preform for a composite material used for a structural material, at least one first reinforcing fiber layer stretched in a part of an arbitrary shape parallel to a linear axis appropriately set in an arbitrary shape, and the straight line A reinforcing fiber group constituted by a second reinforcing fiber layer stretched in a plurality of layers in an arbitrary shape at an angle crossing the axis is integrated, and a portion constituted only by the second reinforcing fiber layer is out of plane A dry preform for a composite material characterized by having deformability in a direction. In the dry preform for a composite material used for a structural material, at least one first reinforcing fiber layer stretched in a part of an arbitrary shape parallel to a linear axis appropriately set in an arbitrary shape, and the straight line It is constituted by a second reinforcing fiber layer stretched in a plurality of layers in an arbitrary shape at an angle crossing the axis, and the thickness is increased or decreased by increasing or decreasing the range occupied by the first reinforcing fiber layer and the second reinforcing fiber layer. The dry preform for a composite material according to claim 1, wherein: In the dry preform for a composite material used for a structural material, at least one first reinforcing fiber layer stretched in a part of an arbitrary shape parallel to a linear axis appropriately set in an arbitrary shape, and the straight line The reinforcing fiber group composed of the second reinforcing fiber layer stretched in multiple layers in an arbitrary shape at an angle that intersects the axis is integrated by any method of stitching, knitting, or needle punching The dry preform for a composite material according to claim 1, wherein the dry preform is a composite material. A first reinforcing fiber layer is stretched at least one layer on a part of an arbitrary shape in parallel Oite the composite material for dry preform used in the construction material, suitably set to be a linear axis in an arbitrary shape, The reinforcing fiber group constituted by a second reinforcing fiber layer stretched in a plurality of layers in an arbitrary shape at an angle crossing the linear axis is integrated with a heat-sealing resin. Or the dry preform for composite materials of Claim 2. In the method for producing a dry preform for composite material used for a structural material, at least one or more reinforcing fiber layers stretched in a part of an arbitrary shape in parallel with a linear axis appropriately set to an arbitrary shape; A step of integrating a reinforcing fiber group composed of a plurality of second reinforcing fiber layers stretched in an arbitrary shape at an angle crossing the linear axis, and the first reinforcing fiber layer and the second reinforcing fiber layer A step of bending the reinforcing fiber group composed of the reinforcing fiber layer on the same radius, and a step of deforming a portion constituted only by the second reinforcing fiber layer in an out-of-plane direction to have a curved shape having an irregular cross section. A method for producing a dry preform for a composite material, comprising: In the manufacturing method of a dry preform for composite material used for a structural material, a first reinforcing fiber stretched in multiple rows at least in a part of an arbitrary shape parallel to a linear axis appropriately set to an arbitrary shape A reinforcing fiber group composed of a layer and a second reinforcing fiber layer stretched in multiple layers in an arbitrary shape at an angle intersecting the linear axis, and the first reinforcing fiber layer and the first reinforcing fiber layer Bending a reinforcing fiber group composed of two reinforcing fiber layers on the same radius, and deforming a portion composed only of the second reinforcing fiber layer in an out-of-plane direction to form a curved shape having an irregular cross section. The method for producing a dry preform for a composite material according to claim 5. In the method for producing a dry preform for composite material used for a structural material, at least one or more reinforcing fiber layers stretched in a part of an arbitrary shape in parallel with a linear axis appropriately set to an arbitrary shape; , A reinforcing fiber group constituted by a second reinforcing fiber layer stretched in a plurality of layers in an arbitrary shape at an angle crossing the linear axis, integrated by any of stitching, knitting, needle punch, The reinforcing fiber group consisting of the first reinforcing fiber layer and the second reinforcing fiber layer is curved on the same radius, and the part constituted only by the second reinforcing fiber layer is deformed in the out-of-plane direction to have a deformed cross section. The method for producing a dry preform for a composite material according to claim 5 or 6, characterized by having a curved shape. In the method for producing a dry preform for composite material used for a structural material, at least one or more reinforcing fiber layers stretched in a part of an arbitrary shape in parallel with a linear axis appropriately set to an arbitrary shape; A reinforcing fiber group composed of a plurality of second reinforcing fiber layers stretched in an arbitrary shape at an angle crossing the linear axis is integrated with a heat-sealing resin, and the first reinforcing fiber layer and The reinforcing fiber group composed of the second reinforcing fiber layer is bent on the same radius, and a portion constituted only by the second reinforcing fiber layer is deformed in an out-of-plane direction to have a curved shape having an irregular cross section. A method for producing a dry preform for a composite material according to claim 5 or 6. In the method for producing a dry preform for composite material used for a structural material, at least one or more reinforcing fiber layers stretched in a part of an arbitrary shape in parallel with a linear axis appropriately set to an arbitrary shape; The first reinforcing fiber layer and the second reinforcing fiber are integrated with a reinforcing fiber group constituted by a second reinforcing fiber layer stretched in a plurality of layers in an arbitrary shape at an angle crossing the linear axis. Combining a plurality of reinforced fiber groups composed of layers in the same radius, and a plurality of curved shapes having deformed cross-sections by deforming a portion composed only of the second reinforced fiber layer in an out-of-plane direction 6. The method for producing a dry preform for a composite material according to claim 5, wherein the reinforcing fiber orientation is arbitrary.

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