JPH06184906A - Fibrous structure and its production - Google Patents

Abstract

PURPOSE:To provide a fibrous structure where the ends of at least two plates are adjacent to each other at an angle, so designed that each of the plates is provided with filament yarn-arranged faces in the longitudinal, lateral and two diagonal directions and these filament yarn-arranged faces are ensured to cross over the joints for the plates and continue to the other plate(s). CONSTITUTION:Using a laminating frame 11 planted with pullable guide pins 12, yarns 2 are hooked on the guide pins 12, endlessly folded back and arranged in the X, Y, V and W directions, respectively, thus laminatedly providing filament yarn-arranged faces 9X, 9Y, 9V and 9W. These faces are caulkedly bound through z filament yarns in a chain stitch form using latch needles 4 and perforating needles 17.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a fiber structure for reinforcing composite materials and a method for producing the same.

[0002]

2. Description of the Related Art As a material for forming mechanical devices such as aircrafts, automobiles, railway vehicles, ships, etc., which require strength, or as a building member for buildings, they are reinforced by fiber structures such as glass fiber woven fabrics and carbon fiber woven fabrics. Molded resin products (FR
P) is used. Further, carbon fiber reinforced carbon composites (C / C composites) such as carbon fiber / carbon matrix, graphite fiber / carbon matrix or graphite fiber / graphite matrix are used as materials for forming mechanical devices requiring heat resistance of 1000 ° C or higher. Is used.

The resin molded product and the C / C composite reinforced by such a fiber structure are light in weight, and at the same time have a large physical and chemical strength. Its usefulness has been evaluated in the industrial field.

The strength characteristics of such resin molded products and C / C composites are greatly influenced by the structure of a fiber structure, for example, a woven fabric, which is incorporated in the matrix as a reinforcing base material. Therefore, the structure of these fiber structures is designed so that the arrangement density of the fiber yarns constituting the fiber structure can be increased as much as possible for the purpose of improving the strength of the finally obtained resin molded product or C / C composite. To be done.

Japanese Unexamined Patent Publication No. 1-292162 discloses in FIG.
7-Fiber structure 3 having an increased array density by the method shown in FIGS.
It is shown. This fibrous structure 3 is shown in FIG. 17 and FIG.
As shown in FIG. 8, a large number of guide pins 1 erected vertically and horizontally in a matrix arrangement are used as guides, and FIGS.
As shown in (D), the yarns 2 of the fiber are sequentially run in the lateral direction, the longitudinal direction, and the two oblique directions to form a four-layer array surface by the yarns 2.
The arrangement surface is repeatedly laminated to obtain the thickness D1 of the plate portion 3a and the width D2 of the plate portions 3b1 and 3b2.
The guide pin 1 has a tubular shape as shown in FIG. 20, and in order to caulk and connect the laminated layers P on the arrangement surface, the leading wire 7 or other suitable hooking tool is inserted into the guide pin 1, and the guide pin 1 is pulled out to be laminated. Caulking thread 5 supplied below P
Is pulled up above the stack P by the leading wire 7, the thread 6 is passed through the loop portion 5a of the caulking yarn 5, and the above operations are repeated to caulk the stack P on the array surface.

[0006]

In order to increase the strength of the fibrous structure 3, the arrangement planes in which the yarns run in the longitudinal, lateral and two oblique directions along the surface of each plate portion are It is important that they are formed and that these arrangement planes are continuous beyond the boundary of each plate. However, in the yarn arranging method described above, in the plate portion 3a in the middle of FIG. 17, an arranging face is formed in which the yarns run in a total of four directions, that is, the longitudinal direction, the lateral direction, and the two oblique directions. On the other hand, in the plate portions 3b1 and 3b2 at both ends, there is no yarn in the oblique direction along the surface thereof. Due to the arrangement relationship of the guide pins 1, the yarn 2 is slanted in the direction along the surface of the plate portions 3b1 and 3b2 as shown in FIGS.
Cannot be run, so the plate parts 3b1, 3
The mechanical strength of b2 is considerably weaker than that of the plate portion 3a.

However, the fiber structure 3 is attached to the plate portion 3a.
And plate portions 3b1 and 3b2 are formed separately,
The yarn arrangement surface in the direction of both plate portions 3a, 3b1, 3
b2 can be formed. However, if the plate portions 3a, 3b1 and 3b2 are separately formed in this way, the plate portions 3a, 3b1 and 3b2 will be joined by some joining means after the formation, and the fiber structure having the joining portion will not be joined to that portion. It is not practical because its strength is weak.

Further, since the yarn arranging surface having four layers as basic units shown in FIGS. 19A to 19D does not extend from the plate portion 3a to the plate portions 3b1 and 3b2, the plate portion 3a is formed.
The force for connecting the plate portions 3b1 and 3b2 to each other is very weak. The plate portion 3a and the plate portions 3b1 and 3b2 are
They are joined only by the caulking thread 5. Therefore, the strength of the fiber structure 3 as a whole is not sufficient.

There is a strong demand for the fibrous structure to be used not only in the form of a single plate, but also in a more complicated form having two or more plate portions forming an angle with each other. With respect to the fiber structure having such a complicated shape, it has not been possible to form a yarn array surface extending over two or more plate portions in the conventional technique as described above. Therefore, the usage of the fiber structure is
It was very limited due to strength constraints.

However, by bending a flat plate-like fiber structure in which the yarn arrangement surfaces in the vertical and horizontal directions and the oblique direction are laminated, a complicated shape such as an L shape can be formed. However, in this case, since the fibrous structure is thick, compressive stress is generated inside the bent portion and tensile stress is generated outside, and there is a problem in strength.

An object of the present invention is to provide an integrated fiber structure in which two or more plate portions are at an angle to each other and the end portions are continuous with each other, and the yarn arrangement is continuous across the continuous end portions of the plate. The surface under uniform thread tension,
Each plate part is repeatedly arranged in the vertical and horizontal directions and in two oblique directions to be laminated in a plurality of stages.

[0012]

A feature of the present invention is that, in a monolithic fiber structure in which two or more plate portions are at an angle to each other and the end portions are continuous, the plate portions are transversely and longitudinally crossed. Is defined as the X and Y directions, and the diagonally crossing direction is defined as the V and W directions, and the two or more plate portions are continuously crossed across the continuous end portions of the plate portions. And

By the X yarn arrangement surface formed by the endless folded arrangement meandering in the X direction, the Y yarn arrangement surface formed by the endless folded arrangement meandering in the Y direction, and the endless folded arrangement meandering in the V direction. The formed V yarn arrangement surface and the W yarn arrangement surface formed by the endless folded arrangement meandering in the W direction are laminated in a plurality of stages so as to form a desired thickness by repeating arrangement, and laminated. This is because the yarn array surface is crimped by z-threads which meander through in an endless folded arrangement in a direction perpendicular to the surface of the plate portion.

Another feature of the present invention is that when the fiber structure is manufactured, the yarns are run on a laminating frame with guide pins to laminate X, Y, V and W yarn arranging faces. After forming, the laminated arrangement surface is pressed with a press plate, the press plate is partially removed and sewn with a z thread to join them, then the guide pin is pulled out from the frame body, and the frame body is removed from the fiber structure. To do.

Another feature of the present invention is that two or more fibrous structures are adjacent to each other, and the adjoining portions are integrated by caulking by a common z thread.
At this time, the tips of the guide pins of the two stacking frame bodies facing each other are fitted together, and the guide pins are slidable with respect to the frame body so that the frame bodies can approach each other.

[0016]

[Function] The force acting on the plate portion of the fiber structure is the mechanical condition under which the plate portion is placed, that is, tension, compression,
By bending or twisting, not only the vertical and horizontal directions of the plate portion but also the diagonal direction. It is important to match the yarn arrangement direction of the plate portion with the direction of this force, or to bring the yarn arrangement direction as close as possible to increase the strength of the fiber structure with a relatively small amount of fibers. In the fibrous structure according to the present invention, the yarns run in each plate portion in a total of four directions, which are vertical and horizontal directions and two oblique directions, and the direction of the force acting on the plate portion,
The angle difference from the direction of the yarn arrangement that receives this force is reduced, and the stress of the yarn is reduced. Moreover, since the yarn arrangement surfaces in the four directions are continuous across the continuous end portions of the plate portion, the strength of the continuous portion of the plate portion is high.

On the other hand, in the conventional fiber structure, one plate portion can be arranged in four directions along the surface.
In the other plate portion, the yarn arrangement along the surface is vertical (see FIG. 19).
(B) The yarn 2) and the lateral (caulking yarn 5) are only two directions, and the diagonal yarns cannot be arranged. Therefore, the stress of the yarns is generally large, and the yarns are easily broken. was there. Further, when a fiber structure having two or more plate portions is formed by the conventional technique, it is not possible to form a yarn array surface that extends in the surface direction of another plate portion beyond the adjacent portion of the plate portions. The strength of the adjacent part was insufficient.

Further, when the fiber structure is manufactured, the yarn arranging surface arranged on the laminating frame is pressed by the press plate, so that the laminating density of the arranging surface is increased and the laminating density is increased. Since the press plate is partly removed in the increased state, the part where the press plate is removed still maintains a high lamination density, and in this state, the zigzag caulking connection is performed, so that the high density fiber structure is obtained. The body is obtained.

Further, when two or more fiber structures are integrated, a common z-thread can be used to simultaneously caulk and connect the thread arrangement surfaces and the fiber structures can be integrated at the same time. The body can be manufactured efficiently.

[0020]

An embodiment of the present invention will be described below with reference to the drawings. 1 to 4 show a first embodiment of the simplest-form fiber structure of the present invention. Figure 1 shows two plate parts 1
The appearance of the fiber structure 10 in which the ends of 0a and 10b are continuous at right angles is shown. In each plate portion 10a, 10b, there are four directions that cross the plate portion 10a, 10b along the surface thereof, in this case, the X and Y directions intersecting at right angles, and the angle difference in a slanted form of ± 45 ° with these directions. Forming V and W
The yarn runs in four directions.

Here, as shown in FIG. 3, the yarns running in each direction are X yarns 2X, Y yarns 2Y, V yarns 2V and W yarns 2W, which are formed by a meandering endless folded arrangement of these yarns. The yarn arrangement surface to be formed is X yarn arrangement surface 9X, Y yarn arrangement surface 9
The Y and V yarn arrangement surface 9V and the W yarn arrangement surface 9W are used. Each yarn arrangement surface is repeatedly laminated in the order of, for example, the W yarn arrangement surface 9W, the Y yarn arrangement surface 9Y, the V yarn arrangement surface 9V, the X yarn arrangement surface 9X, and the required thickness of the plate portions 10a and 10b. D3 is formed.

The laminated yarn array surface is shown in FIG. 4 (B).
As shown in (C), the plate portions 10a and 10b are sewn together by the chain stitch method by the z thread 2z that meanders through in the thickness direction (z direction) and is joined.

Next, a method of manufacturing the fiber structure 10 will be described. A laminating frame 11 as shown in FIG. 2 is used for this manufacturing. This frame body 11 corresponds to the shape of the fiber structure 10, and is composed of a rectangular frame body 11a and a U-shaped frame body 11b connected to the frame body 11a at a right angle.
On the edge of the frame body 11, guide pins 12 facing the outside of the frame body 11 are planted so that they can be extracted at a pitch interval corresponding to the arrangement interval of the yarns.

Threads are hooked on the guide pins 12 of the frame 11 and endlessly folded and arranged so that the yarn array surface is the frame 11.
It is formed on the convex side or back side (front side of the frame body 11 in FIG. 2). As shown in FIG. 2, the yarns are arranged by, for example, reciprocating a yarn feeding cylinder 14 attached to the tip of an arm 13 of a robot driven by NC control along the yarn arrangement direction. In this embodiment, as shown in FIG. 3 (A), the W yarn 2W is run and the W yarn 2W
It is endlessly folded and arrayed in the direction, and this array is repeated until. Then, as shown in FIG.
The yarn 2Y is continuous with the yarn 2Y, and the Y yarn 2Y is endlessly folded and arranged in the Y direction, and this arrangement is repeated until. Next, as shown in FIG. 3C, the Y yarn 2Y is continuous with the V yarn 2V, the V yarn 2V is endlessly folded and arranged in the V direction, and this arrangement is repeated until. Next, as shown in FIG. 3D, the V yarn 2V is continuous with the X yarn 2X, the X yarn 2X is endlessly folded and arranged in the X direction, and this arrangement is repeated until.

In the above steps, the W, Y, V, and X yarn array surfaces are laminated in this order, and the plate portion 10 having the required thickness D3 is obtained by repeating this step an appropriate number of times.
a and 10b are formed.

Next, as shown in FIG. 4A, the plate portion 10a is formed.
Both the front and back surfaces of (10b) are clamped by a large number of elongated press plates 15. Although not shown, the driving means of the press plate 15 can use various press devices. The width of the press plate 15 is set so that the guide pin 1 does not interfere with the guide pin 12.
It is slightly narrower than the interval of 2. It should be noted that a narrow groove in which the guide pin 12 is housed may be formed on both side surfaces of the press plate 15. The yarn array surface 9 laminated by the pressing force of the press plate 15 is compressed with high density. While maintaining this compressed state, the press plates 15 are removed as one set of two front and back sides at one place, and the spatula needle 4 is used to remove the elongated plate portions 10a (10b) between the press plates 15 as shown in FIG. (B)
As shown in (C), the z thread 2z is made to meander through the plate portion 10a (10b) by the chain stitch method, whereby the stacked thread array surfaces 9 are caulked and joined.

When the spatula needle 4 is moved up and down, the perforating needle 17 is integrally fixed to the member 16 to which the spatula needle 4 is attached.
However, the plate portion 10a is inserted prior to the position where the spatula needle 4 is inserted so that the spatula needle 4 is smoothly inserted.
Make a hole in (10b). The distance between the spatula needle 4 and the piercing needle 17 is equal to the pitch of the chain stitch of the z yarn 2z.

After caulking and joining the yarn array surface 9, the frame 11
Remove the guide pin 12 from the fiber structure 10
Then, the frame body 11 is removed. The end portions and the corners of the fiber structure 10 hitting the frame body 11 could not pass the spatula needle 4 and the perforation needle 17 because the frame body 11 was an obstacle, so after removing the frame body 11, the The spatula needle 4 and the piercing needle 17 are passed through, and this portion is caulked and joined by a chain stitch method. Since the guide pin 12 is removed and the portion where the frame body 11 is abutted after the frame body 11 is removed is caulked and coupled in the following embodiments, the description will be given in the following embodiments. Omit it.

Through the above steps, the L-shaped fiber structure 10 as shown in FIG. 1 is manufactured. This fibrous structure 10 is
As shown in FIG. 3, since the yarn array surface is formed in four directions X, Y, V, and W along the surfaces of both plate portions 10a and 10b, stress is applied not only in the longitudinal and lateral directions but also in the diagonal direction. However, the mechanical strength is great. Moreover, since the Y yarn 2Y, the V yarn 2V, and the W yarn 2W are continuous to the other plate portion across the continuous end portions of both plate portions 10a and 10b, the strength of the continuous portion is large. Therefore, the strength of the fiber structure 10 as a whole is improved.

Next, a second embodiment of the present invention will be described with reference to FIGS. In this embodiment, as shown in FIG. 4, a rectangular bottom plate portion 20a and three side wall plate portions 20b, 20 rising from three sides of the bottom plate portion 20a.
The present invention relates to a fiber structure 20 composed of c and 20d. The bottom plate portion 20a and the side wall plate portions 20b to 20d cross in four directions along the surface thereof, in this case, at right angles.
The yarn runs in four directions, namely, the Y direction and the V direction and the W direction forming an angle difference of ± 45 ° with respect to these directions.

Here, as shown in FIG. 8, the yarns running in each direction are X yarns 2X, Y yarns 2Y, V yarns 2V and W yarns 2W, which are formed by a meandering endless folded arrangement of these yarns. The yarn arrangement surface to be formed is X yarn arrangement surface 9X, Y yarn arrangement surface 9
The Y and V yarn arrangement surface 9V and the W yarn arrangement surface 9W are used. In this embodiment, the yarn arrangement planes are repeatedly laminated in the order of the X yarn arrangement plane 9X, the Y yarn arrangement plane 9Y, the V yarn arrangement plane 9V, and the W yarn arrangement plane 9W to form the plate portions 20a to 20d. A required thickness D4 is formed.

The laminated yarn array surface is shown in FIG. 4 (B).
Similar to (C), the plate portions 20a to 20d are caulked and joined together by a chain stitch method by a z yarn 2z that meanders through the plate portions 20a to 20d in the thickness direction (z direction).

Next, a method of manufacturing the fiber structure 20 will be described. For this production, a cubic frame 21 for stacking, which corresponds to the shape of the fiber structure 20 as shown in FIGS. 6 and 7, is used. On the edge of the frame body 21, guide pins 22 facing outward of the frame body 21 are arranged at a pitch interval corresponding to the arrangement interval of the yarns.
Are planted so that they can be extracted.

The yarn 2 is hooked on the guide pin 22 of the frame 21 and endlessly folded and arranged so that the yarn array surface is the frame 2
It is formed in the space between one crosspiece. The arrangement of the yarn 2 is shown in FIG.
As shown in FIG. 3, the yarn feeding cylinder 14 fixed to the tip of the arm 13 of the robot is reciprocated along the yarn arranging direction. In this embodiment, as shown in FIG. 8A, the X yarn 2X is run, the X yarn 2X is endlessly folded and arranged in the X direction, and this arrangement is repeated until. As a result, the X yarn array surface 9X is formed on the three side wall plate portions 20b to 20d.

Next, as shown in FIG. 8 (B), the yarns that have been reached are continued and then run, and the yarns are endlessly folded and arranged between the bottom plate portion 20a and the side wall plate portion 20c. At this time, the yarn of the bottom plate portion 20a is the X yarn 2X, and the yarn of the side wall plate portion 20c is the Y yarn 2Y.
Is. By repeating this arrangement, the X yarn arrangement surface 9X is formed on the bottom plate portion 20a, and the Y yarn arrangement surface 2Y is formed on the side wall plate portion 20c.

Next, as shown in FIG. 8 (C), the yarns that have come up are made continuous and the Y yarn 2Y is run, and the bottom plate portion 20a and the side wall plate portions 20b and 20d are endlessly folded and arranged. The Y yarn array surface 9Y is formed.

Next, as shown in FIG. 8D, the Y yarn 2
Y is continued to the V yarn 2V, and the V yarn 2V is endlessly folded and arranged in the V direction to form a V yarn arrangement surface 9V.

Next, as shown in FIG.
V is continued to the W yarn 2W, and the W yarn 2W is endlessly folded and arranged up to a circle 10 in the W direction to form a W yarn arrangement surface 9W.

In the above steps, the X, Y, V and W yarn array surfaces are laminated in this order, and by repeating this step an appropriate number of times, the plate portion 20a having the required thickness D4.
~ 20d are formed.

Next, as shown in FIG. 9, plate portions 20a-2
Both the front and back sides of 0d are pressed by a large number of elongated press plates 15. Although not shown, the driving means of the press plate 15 can use various press devices. The width of the press plate 15 is set so that it does not interfere with the guide pins 22.
It is slightly narrower than the interval. By the pressing force applied by the press plate 15, the stacked yarn array surfaces are compressed with high density.
While maintaining this compressed state, the press plate 15 is removed only in one place by removing two front and back sheets as a set, and using a spatula needle 4,
Plate portions 20a that are elongated and exposed between the press plates 15
Similarly to FIGS. 4 (B) and 4 (C), the z yarn 2z is made to meander through the plate portions 20a to 20d by the chain stitch method, and this is repeated for all the press plates 15, so that the laminated yarn is laminated. Caulking and joining the row arrangement surfaces.

Through the above steps, the fiber structure 20 as shown in FIG. 5 is manufactured. This fibrous structure 20 has four directions X along the surfaces of the plate portions 20a to 20d as shown in FIG.
Since the yarn array surface is formed of Y, V, and W, the mechanical strength is large not only in the longitudinal and transverse directions but also in the oblique directions. Moreover, since the yarns on the yarn array surface are continuous across the continuous end portions of at least two plate portions, the strength of the continuous portion is high and the fiber structure 20
The overall strength is improved.

Next, a third embodiment of the present invention will be described with reference to FIG. This example relates to a fiber structure 30 having an H-shaped cross section as shown in FIG. The fibrous structure 30 is formed by joining two U-shaped fibrous structures 30a and 30b adjacent to each other back to back.
As in the first and second embodiments, 0a and 30b have yarn arrangement surfaces formed in four directions along the surface, that is, X, Y, V and W directions, and these yarn arrangement surfaces are repeatedly laminated. Thus, the required thickness D5 of the fiber structures 30a and 30b is formed. The laminated yarn array surface is shown in FIG. 4 (B).
Similar to (C), z-threads penetrating in the thickness direction are used for caulking. This z-thread is a fiber structure 3
In the back-to-back double part of 0a, 30b, a common z thread penetrates through the double part, whereby both fibrous structures 30a, 30b are integrated.

The fiber structure 30 is manufactured by using a pair of U-shaped laminating frames 31a and 31b as shown in FIG. 10 (B), and the fiber structures 30a and 30b are formed until the middle of the manufacturing process.
It is divided into two parts. On the edges of the frame members 31a and 31b, the frame members 31a and 31b are arranged at a pitch interval corresponding to the arrangement interval of the yarns.
A guide pin 32 that faces the outside of b is planted so that it can be extracted. The guide pins 32a and 32b at the central portions of the frame bodies 31a and 31b are slidably attached to the frame bodies 31a and 31b, and one guide pin 32a has a tubular shape and the other one, as shown in FIG. The guide pin 32b is tapered so that it can be fitted into the tubular portion 32b.

Guide pins 32 of the frames 31a and 31b
The yarn 2 is hooked on and folded back endlessly to form a yarn arrangement surface in the space between the crosspieces of the frame bodies 31a and 31b. As in the case of FIG. 2, the yarns 2 are arranged by reciprocating the yarn feeding cylinder 14 fixed to the tip of the arm 13 of the robot along the yarn arrangement direction.

After the yarn arrangement surface is repeatedly laminated on each frame 31a, 31b as many times as necessary, as shown in FIG. 10 (B),
The frames 31a and 31b are arranged so that they are back to back, the guide pins 32a and 32b are aligned with each other as shown in FIG. 10C, and the frames 31a and 31b are shown in FIG. 10B.
Of the guide pin 32
b is inserted into the tip of the cylindrical guide pin 32a as shown in FIG. Even after the guide pins 32a and 32b are fitted and coupled to each other, the frame bodies 31a and 31b are further pulled together until they do not move. At this time, the guide pin 32
The a and 32b slide outward relative to the frame bodies 31a and 31b by the amount that the distance between the frame bodies 31a and 31b is shortened, and the rear ends thereof project from the frame bodies 31a and 31b.

Next, as in the first and second embodiments, the laminated yarn array surface is pressed by the press plate 15 as shown in FIG. 4 (A).
After that, the press plates 15 are removed as one set of two front and back sides at only one place, and a spatula needle 4 is used to form a plate portion exposed between the press plates 15 in an elongated manner, as shown in FIG.
Similar to (C), the z-thread 2z is made to meander through by a chain stitch method, and this is repeated for all the press plates 15, whereby the stacked yarn array surfaces are caulked and joined.

By using the above-mentioned method for combining fiber structures, fiber structures having various shapes as shown in FIG. 11 can be produced. FIG. 1A shows two L-shaped fiber structures 40.
This is a T-shaped fiber structure 40 obtained by combining a and 40b. (B) shows two fiber structures 41a and 41b
To form a Z-shaped fiber structure 41.
(C) is a fiber structure 42 in which a plate-shaped fiber structure 42b is combined with an L-shaped fiber structure 42a. (D) is an L-shaped fiber structure 4 on both sides of the rectangular tube-shaped fiber structure 43a.
It is the fiber structure 43 which united 3b and 43c.
(E) is a fibrous structure 44 in which an L-shaped fibrous structure 44b is united to one side of a rectangular tubular fibrous structure 44a.
(F) is a fiber structure 45 in which two L-shaped fiber structures 45b and 45c are combined with a box-shaped fiber structure 45a with one side cut away. (G) shows three U-shaped cross-section fiber structures 46a, 46b, 46c in order downward, upward,
It is the fiber structure 46 that is united side by side with the downward direction.

Next, examples of the present invention relating to a tubular fiber structure will be described below. 12 and 13 show examples of the triangular tubular fiber structure 47 including the three plate portions 47a, 47b and 47c. The X yarns 2X, Y yarns 2Y, V yarns 2V and W yarns are shown. The 2W endless folded arrangement forms the X yarn arrangement surface 9X, the Y yarn arrangement surface 9Y, the V yarn arrangement surface 9V, and the W yarn arrangement surface 9W. Each of the yarn arrangement planes is, for example, the W yarn arrangement plane 9W, the Y yarn arrangement plane 9Y, the V yarn arrangement plane 9V, and the X yarn arrangement plane 9X are repeatedly laminated in this order to use the plate portions 47a, 47b, 47c. Has a thickness D6. It is to be noted that (1) to (3) in FIG.

14 and 15 show four plate parts 4
The present invention relates to a quadrangular tubular fiber structure 48 composed of 8a to 48d, the X yarn array surface 9X of the X yarn 2X, and the Y yarn 2Y.
Y yarn arrangement surface 9Y, V yarn 2V V yarn arrangement surface 9V,
The W yarn array surface 9W of the W yarn 2W is formed. By repeatedly stacking these yarn array surfaces, a desired thickness D7 of the plate portions 48a to 48d is formed. It should be noted that the symbols (1) to (5) in FIG.

FIG. 16 relates to a cylindrical fibrous structure 49. Four directions along the surface of the fibrous structure 49, X and Y directions which are perpendicular to each other in this embodiment, and oblique directions with respect to these directions. The yarns are arranged along the V and W directions forming an angle difference of 45 °. The yarn arranging surface formed by the yarns is repeatedly formed and laminated in the same manner as in the above-described embodiment to form the required thickness D8 of the fiber structure 49.

The fiber structure 4 shown in FIGS. 12 and 14 is used.
For manufacturing 7, 48, a stacking frame body (not shown) corresponding to each shape is used.

FIG. 16 shows a method for manufacturing the cylindrical fibrous structure 49.
The laminating frame 50 as shown in (B) is used. The frame 50 includes upper and lower ring portions 50a and these ring portions 50a.
A plurality of connecting portions 50b for connecting the guides, and a large number of guide pins 51 are planted at the edge of the frame body 50 at a pitch corresponding to the arrangement interval of the yarns. To arrange the yarns, hook the yarns on the guide pins 51 and press X,
The yarns are endlessly folded and arranged in the Y, V and W directions, and the yarn arrangement surface is laminated on the frame 51 in the same manner as in the above embodiment. Strictly speaking, the cylindrical portion formed by the yarn arrangement surface is the connecting portion 50.
There is a small angle difference between both sides of b, but the connecting portion 50b
The angle difference decreases with an increase in the number of s, and a substantially cylindrical fiber structure is obtained. Therefore, the phrase "two or more plate portions form an angle with each other and the end portions are continuous" in claim 1 constitutes a curved surface substantially like the cylindrical portion of the present embodiment. It should be understood to include the plate portion.

In each of the fiber structures shown in FIGS. 12 to 16, after the yarn array surface is formed, the pressing force applied to the yarn array surface by the press plate 15 and the z thread are formed in the same manner as in FIGS. 4B and 4C. It is completed by performing crimping and joining with a strip.

In the fiber structure obtained as described above,
A fiber-reinforced resin molded article is produced by impregnating a resin such as an epoxy resin as a matrix and performing a curing treatment, and a C / C composite is produced by using the fiber of the carbon yarn and the matrix. The material of the yarn is
In addition to carbon fibers, graphite fibers, glass fibers, aramid fibers, ceramic fibers, alumina fibers, aromatic polyester fibers, etc., or mixed fibers of two or more of these fibers can be used.

Although one embodiment of the present invention has been described above, the present invention is not limited to the above embodiment and various modifications can be made. For example, the arrangement order of the yarns in the X, Y, V, and W directions is not particularly determined, and the yarns may be formed in any order. Moreover, these four directions do not necessarily have to be 45 ° and are evenly spaced. The yarn array surface can be distributed and formed in four optimum directions in consideration of the stress direction generated in the fiber structure.

The end of one yarn arrangement surface and the start of another adjacent yarn arrangement surface do not necessarily have to be continuous. For example, in FIG. 8, the X yarn 2X may be formed up to and after which the Y yarn 2Y may be formed. Depending on the shape of the fiber structure, the position of the array start end that is convenient for forming each yarn array surface may be selected.

It is also within the technical scope of the present invention to polymerize the yarn arrangements in the X, Y, V and W directions to additionally form the yarn arrangements in the other directions. Further, the caulking connection of the yarn arrangement surface by the z yarns does not necessarily have to be the chain stitch system, and other stitch systems known in the technical field of fabrics can be adopted. Also, the density of the zigzag penetrating meandering may be partially increased, whereby the strength can be partially improved.

[0058]

As described above, according to the present invention, in a fibrous structure in which two or more plate portions are continuous with each other at an angle with respect to each other, a total of four longitudinal and lateral and two oblique directions are provided on each plate portion. Since the yarn array surface extending in the direction is formed and these yarn array surfaces are traversed by a continuous portion of two or more plate portions, one plate portion has a yarn arrangement in four directions as in the conventional case. However, in the other plate portion, the strength of the fiber structure is improved by the number of the arrangement directions and the yarn arrangement surface is 2 as compared with the fiber structure in which the yarn arrangements are provided only in the vertical and horizontal directions. Since it extends over more than one plate part and is continuous in the surface direction, the strength at the continuous end part of the plate part can be remarkably increased, and it can withstand all load conditions such as tensile, compression, bending and torsional loads. Providing high strength fiber structure Yellow, can be greatly expanded its range of applications. In addition, since the direction of the yarn arrangement increases in four directions along the surface of the plate part, the load acting on the fiber structure is efficiently supported by each yarn arrangement, so high strength is achieved with a small amount of yarn. it can. In addition, since the yarn array surface was formed in the shape of the final product from the beginning by the uniform tension of the yarn, compression and pulling in the bending part were made more than in the case of bending the flat fiber structure into the final product. It is advantageous in terms of strength as much as no initial stress remains.

Further, according to the present invention, in the production of a fiber structure, the laminated yarn arrangement surfaces are pressed by a press plate, the press plate is partially removed, and the zipped yarn is caulked from the removed portion. Therefore, a fiber structure having a high lamination density and therefore a high strength can be obtained.

Further, according to the present invention, the plate portions of the two fiber structures can be connected by the z-thread for caulking and connecting which penetrates back and forth in the thickness direction of the fiber structure. The body can be manufactured and its range of applications can be expanded. At this time, since the z-thread simultaneously performs the caulking connection of the thread arrangement surface and the integration of the fiber structure, the fiber structure having a complicated shape can be efficiently manufactured.

[Brief description of drawings]

FIG. 1 is a perspective view of an L-shaped fiber structure according to a first embodiment of the present invention.

FIG. 2 is a stacking frame for manufacturing the fibrous structure.

3 (A), (B), (C) and (D) are perspective views showing the order of forming the yarn array surface.

FIG. 4A is a perspective view of a yarn array surface clamped by a press plate, and FIGS. 4B and 4C are cross-sectional views of the yarn array surface to be caulked.

FIG. 5 is a perspective view of a fiber structure according to a second embodiment of the present invention.

FIG. 6 is a perspective view of a stacking frame body for manufacturing the fiber structure.

FIG. 7 is a perspective view of a stacking frame body for manufacturing the fiber structure.

8 (A), (B), (C), (D) and (E) are perspective views showing the order of forming the yarn array surface.

FIG. 9 is a perspective view of the fiber structure in a state of being pressed by a press plate.

FIG. 10A is a perspective view of a fiber structure according to a third embodiment, FIG. 10B is a perspective view of a stacking frame for manufacturing the fiber structure, and FIGS. The side view before and after connecting a guide pin.

11 (A), (B), (C), (D), (E), (F), and (G) are perspective views of a bonded fiber structure.

FIG. 12 is a perspective view of a triangular tubular fiber structure.

13 (A), (B), (C) and (D) are perspective views showing the order of forming the yarn array surface.

FIG. 14 is a perspective view of a square tubular fiber structure.

15 (A), (B), (C), and (D) are perspective views showing the order of forming the yarn array surface.

16A is a perspective view of a cylindrical fiber structure, FIG.
FIG. 3B is a perspective view of a stacking frame body for manufacturing the fiber structure.

FIG. 17 is a perspective view of a conventional fiber structure being manufactured.

FIG. 18 is a plan view of the same fiber structure.

19 (A), (B), (C) and (D) are plan views showing the order of forming the yarn array surface.

FIG. 20 is a sectional view of a yarn array surface to be caulked.

[Explanation of symbols]

 2 thread 2X X thread 2Y Y thread 2V V thread 2W W thread 2z z thread 9X X thread array surface 9Y Y thread array surface 9V V thread array surface 9W W thread array surface 4 Vera needle 10,20,30,40 to 49 Fiber structure 10a, 10b, 20a to 20d Plate part 11,21,31 Laminating frame 12,22,32,51 Guide pin 13 Robot arm 14 Yarn feeding cylinder 15 Press plate 17 Perforating needle

Claims (8)

[Claims] 1. A monolithic fibrous structure in which two or more plate portions are mutually angled and end portions are continuous with each other, and the longitudinal and transverse directions along the surface of each plate portion are X and Y directions. And a diagonally traversing direction is defined as the V and W directions, the two or more plate portions are respectively continuous across the continuous end portions of the plate portions, and X X formed by an endless folded array that meanders in the direction
Y formed by a yarn array surface and an endless folded array that meanders in the Y direction
V formed by a yarn array surface and an endless folded array that meanders in the V direction
The yarn arrangement surface and the W yarn arrangement surface formed by the endless folded arrangement meandering in the W direction are laminated in a plurality of stages to form a desired thickness by repeating arrangement, and the laminated yarn arrangement surface Is a fiber structure obtained by caulking and joining by z-threads that meander through in an endless folded arrangement in a direction perpendicular to the surface of the plate portion. 2. The fiber structure according to claim 1, which has a rectangular bottom plate portion and three continuous side wall plate portions rising from three sides of the bottom plate portion. 3. The fiber structure according to claim 1, wherein the plurality of plate portions are continuous in a tubular shape. 4. A fibrous structure according to claim 1, wherein at least two fibrous structures are adjacent to each other, and the two fibrous structures are connected by a common z-thread penetrating adjacent surfaces. 5. A shape corresponding to a desired shape of a monolithic fiber structure in which two or more plate portions are at an angle with each other and whose end portions are continuous with each other, and are drawn out at a pitch interval matching the arrangement density of yarns. The X, Y, V and W yarn array surface according to claim 1 is formed by hooking and running a yarn on the guide pin with respect to a stacking frame body in which possible guide pins are planted. Forming a plate part having a desired thickness by stacking the arrayed surfaces in a plurality of stages in a repetitive array, a step of pressing both front and back surfaces of the plate part with a plurality of elongated press plates, the press plate, front and back press plates As a set, removing the sets one by one, and each time the press plates are removed, a step of caulking the plate portion exposed between the press plates with a z thread along the longitudinal direction, and a frame for stacking the guide pins. Pull it out of your body, A method for manufacturing a fibrous structure, comprising the step of removing the laminating frame from the plate portion. 6. The fiber structure according to claim 5, further comprising a step of, after removing the laminating frame body from the plate portion, caulking a portion of the plate portion, which overlaps the laminating frame body, with a z thread. Body manufacturing method. 7. The method for producing a fiber structure according to claim 4, wherein a yarn is provided on the guide pin for the first stacking frame body having a shape corresponding to a desired shape of one of the fiber structures. Forming an X, Y, V, and W yarn array surface according to claim 1 by hooking and running, and stacking the array surface in a plurality of stages in a repeating array to form a plate portion having a desired thickness, A second stacking frame body having a shape corresponding to a desired shape of the other fiber structure, in a portion corresponding to an adjacent portion of the fiber structure, at a pitch interval matching the array density of yarns, A cylindrical guide pin that can be inserted into the tip of the guide pin of the first stacking frame body, the tip of which corresponds, is slidably planted, and the other parts have the same thread arrangement density. Ordinary guide pins that can be extracted at a suitable pitch interval are planted The X, Y, V and W yarn array surface according to claim 1 is formed by hooking and running a thread on the guide pin with respect to the second stacking frame, and the array surface is repeatedly arrayed. To form a plate portion having a desired thickness by stacking in a plurality of stages by inserting the slidable guide pins of the first and second stacking frame bodies into the stacking frame bodies by inserting the tips of the guide pins into each other. A step of pulling together, a step of pressing both front and back surfaces of each plate portion and an adjacent plate portion with a plurality of elongated press plates, and removing the press plates one by one, with the front and back press plates as one set, Each time it is removed, a step of caulking the exposed single plate portion and the adjacent double plate portion between the press plates with a z thread along the longitudinal direction, and the guide pin to the first and second Remove from the stacking frame The first and step for removing the second laminating frame body from the plate portion, the manufacturing method of the fiber structure consisting of. 8. The production of a fibrous structure according to claim 5, wherein a hole is preliminarily formed in a portion of the plate portion through which the z-thread is penetrated, and the z-thread is drawn into the hole with a spatula needle. Method.