JPH08302537A - Carbon fiber woven fabric, its production thereof and device therefor - Google Patents

Abstract

PURPOSE: To produce the subject woven fabric capable of preventing the slippage of the texture without excessively bending the fibers, useful as a reinforcing material for a composite reinforced material using a plastic or concrete as a matrix material by thermally fusing the cross points of warps to wefts with a meltable resin. CONSTITUTION: One or both of warps 1 and wefts 2 are accompanied with thermally fusible addition fibers 2a and subsequently woven into a coarse plain weave tisssue. The woven fabric is subjected to a thermal treatment to melt the accompanied fibers and thermally fuse the cross points 3 of the warps to the wefts. Non-twisted carbon multifilament yarns are used as the warps and the wefts, and woven in the state of the minimum warp tension.

Description

Detailed Description of the Invention

[0001]

[Field of Industrial Application] This application relates to a carbon fiber woven fabric which can be suitably used as a reinforcing material for a composite reinforcing material using a matrix material such as plastic or concrete.
The manufacturing method and manufacturing apparatus are related.

[0002]

2. Description of the Related Art A entangled woven fabric of carbon fibers has been proposed as a reinforcing material for a composite reinforcing material using plastic or concrete as a matrix material (Japanese Patent Laid-Open No. 3-40834).

This is a structure in which warp yarns and weft yarns made of carbon fibers are regularly arranged in a mesh shape, entanglement yarns are provided along each warp yarn, and each intersection point of the warp yarns and the weft yarns is mechanically bound through the entanglement yarns. Has become. The entangled yarn is a warp,
Threads of lower rigidity than weft threads shall be used. Therefore,
In this product, since the entangled yarn has a lower rigidity than the warp yarn and the weft yarn, the warp yarn and the weft yarn are not unnecessarily bent, and therefore the strength of the warp yarn and the weft yarn is not impaired. Further, since the warp and the weft are bound at each intersection through the entangled yarn, there is no so-called misalignment and it is easy to handle.

[0004]

According to the prior art, the warp yarns and the weft yarns are simply arranged in a mesh form and do not form a woven structure, and the intersections of the warp yarns and the weft yarns are entangled yarns. Since they are tied together, a special heddle for entanglement weaving is required, and the problem of low productivity cannot be avoided. Further, the binding strength of the entangled yarn is not always sufficient, and there is a problem that misalignment is likely to occur during handling. This is because the entangled yarn must be loosely bound so that the carbon fiber is not bent in a harmful manner, and it is difficult to obtain sufficient binding strength.

Therefore, the purpose of each invention according to this application is to
By heat-sealing the intersections of the warp and weft, it is possible to completely prevent misalignment without excessively bending the carbon fiber, and to use a loom that is theoretically equivalent to an ordinary loom for efficiency. An object of the present invention is to provide a carbon fiber woven fabric that can be well produced, and a manufacturing method and a manufacturing apparatus thereof.

[0006]

The structure of the first invention according to the present application for achieving the above object is obtained by weaving a warp and a weft made of non-twisted multifilament carbon fiber into a coarse plain weave design, The main point is that each intersection of the warp and the weft is heat fused through a molten resin.

According to the second aspect of the invention, a warp and a weft made of untwisted multifilament carbon fiber are woven into a coarse plain weave design, and heat-treated to add to one or both of the warp and the weft. The gist is to melt the added yarn and heat-bond each intersection of the warp and the weft.

The added yarn may be spirally wound around the carbon fiber or may be added in parallel.

Further, as the added yarn, a plurality of fibers having different melting temperatures can be added to the carbon fiber.

Further, the warp and the weft may be subjected to sizing treatment after adding the additional yarn to the carbon fiber.

According to a third aspect of the present invention, a weaving machine main body for weaving a warp and a weft made of untwisted multifilament carbon fiber into a coarse plain weave, and one of the warp and the weft by heat-treating the woven fabric from the weaving machine Alternatively, the gist of the present invention is to include a heat treatment device that melts the heat-fusible additive yarns added to both of them and heat-bonds each intersection point of the warp yarn and the weft yarn.

The heat treatment device is provided with a pair of heating rollers that heat the front and back surfaces of the woven fabric by contacting them.
The heating roller may form a pressing roller that sandwiches the woven cloth.

[0013]

According to the construction of the first aspect of the invention, the warp and weft are woven into a coarse plain weave design, and the intersections are heat-sealed, so that the overall integrity is excellent and misalignment occurs. There is no fear. The untwisted multifilament carbon fibers used as the warp and the weft are, for example, pitch-based or PAN-based carbon fiber filaments (diameter 5
(About 10 to 10 μm) are arranged in parallel about 500 to 12,000. The molten resin for heat-sealing the intersections may be of any type as long as it is a thermoplastic having a low melting temperature. For example, in addition to polyamides such as nylon 6, engineering plastics such as polyetherimide, polysulfone, polyetheretherketone, and polyamideimide,
General-purpose plastics such as polyethylene, polystyrene and polycarbonate can also be widely used.

In the plain weave design, the warp yarn arrangement pitch and the weft driving pitch are each about 10 to 100 mm.
Roughly set, and the whole is finished in a mesh shape. If the arrangement pitch and the folding pitch are too fine, the matrix material is difficult to pass through, and the continuity of the matrix material is impaired. If the arrangement pitch is too rough, sufficient strength as a reinforcing material cannot be obtained.

According to the structure of the second invention, the additive yarn added to at least one of the warp yarn and the weft yarn is melted by heat treatment, and the intersection of the warp yarn and the weft yarn is thermally fused. Then, the added yarn at this time forms the molten resin in the first invention, and any thermoplastic resin as described above can be used. However, it is preferable that the added yarn is a multifilament yarn having a single yarn denier of about several d and a total denier of about 200 to 500 d. This is because the multifilament yarn generally exhibits better meltability than a single yarn having a large diameter when heat-treated.

The added yarn may be spirally wound around the carbon fibers forming the warp or weft, or may be added in parallel. According to the former, the integrity of the warp and the weft is excellent, and the opening operation and the weft inserting operation can be stabilized, and according to the latter, the productivity of each preparation step of the warp and the weft can be improved. This is because, in general, the productivity of the latter compounding process is significantly higher than that of the former covering process.

When a plurality of additive yarns having different melting temperatures are used, the additive yarns having a low melting temperature are melted in the preparatory step so that the additive yarns having a high melting temperature are integrally fused with the carbon fibers to form warps. The integrity as a weft can be further improved. That is, it is possible to effectively prevent the trouble that the warp yarns and the weft yarns are scattered at the time of opening and the weft insertion, and the grasping of the weft yarns by the rapier becomes uncertain.

Further, by adding an additive yarn and subjecting it to a sizing treatment, the carbon fiber and the additive yarn can be integrally solidified through the paste, and similarly, troubles at the time of opening and weft insertion can be prevented. can do.

According to the structure of the third aspect of the invention, the loom body weaves the warp and the weft made of untwisted multifilament carbon fiber into a coarse plain weave design. However, at this time, the heat-fusible additive yarn is added to at least one of the warp yarn and the weft yarn. On the other hand, the heat treatment apparatus heat-treats the woven fabric from the main body of the loom, and melts the added yarn to heat-bond the intersections of the warp and the weft, thereby completing the carbon fiber woven fabric according to the first invention. it can. It is preferable that the main body of the loom has a minimum warp tension so that the warp and the weft are not unnecessarily bent or damaged, and the weft is inserted so as not to contact the warp. Also,
As the weft insertion method, a rapier method such as a band rapier or a rod rapier is particularly suitable.

Any heating method can be used for the heat treatment device as long as it can melt the added yarn and heat-bond the intersections of the warp yarns and the weft yarns, but in general, non-contact type indirect heating by hot air or the like. The method is inferior to the contact type direct heating method using a heating roller or the like. With the indirect heating method, it is difficult to make the temperature distribution of the woven fabric sufficiently uniform,
This is because the molten resin often flows away from the intersection. If the heating roller is a pressing roller, the surface of the product can be finished beautifully and the loss of the molten resin can be further reduced.

[0021]

Embodiments Embodiments will be described below with reference to the drawings.

The carbon fiber woven fabric includes warp yarns 1, 1 ..., weft yarns 2,
2 is woven into a coarse plain weave design (Fig. 1).

Each of the warp yarn 1 and the weft yarn 2 is made of non-twisted multifilament carbon fiber. Warp 1,1
... arrangement pitch Wp, weft threads 2, 2 ... driving pitch Wf
Is preferably about 10 to 100 mm. However, it is not always necessary to limit Wp to Wf.

Each intersection 3 of the warp yarns 1, 1 ..., the weft yarns 2, 2 ...
Are heat-sealed via a molten resin (not shown). That is, the carbon fiber woven fabric is woven into a plain weave design, and the intersections 3 of the warp yarns 1, 1 ... Therefore, the warp yarns 1 and the weft yarns 2 do not move relative to each other at each intersection 3, and no harmful misalignment occurs.

Such a carbon fiber woven fabric can be widely used as a reinforcing material for a fiber reinforced composite material by combining it with a matrix material such as plastic or concrete. This is because the carbon fiber has a small weight, a large tensile strength, and a high rigidity, so that a lightweight high-strength composite reinforcing material can be produced.

In the weft preparation step, such a carbon fiber woven fabric is obtained by spirally winding a heat-fusible additive yarn 2a around a weft yarn 2 made of untwisted multifilament carbon fiber (see FIG. 1, FIG. 2), after weaving, heat treatment is performed to melt the added yarn 2a, and the intersections 3 are heat-sealed, whereby the product can be manufactured. That is, the added yarn 2a
Is to form a molten resin for heat-sealing the warp yarn 1 and the weft yarn 2 at each intersection 3, and a thermoplastic resin yarn having an appropriate low melting temperature may be used. In addition, added yarn 2
The winding pitch a of a is the arrangement pitch Wp of the warp yarns 1, 1 ...
Regardless of the driving pitch Wf of the wefts 2, 2, ... Added yarn 2a
This is because the multifilament carbon fibers forming the weft 2 are mechanically held during weft insertion of the weft 2 so that the weft 2 does not come apart.

The carbon fiber woven fabric is composed of heddle 11, 11, reed 1
2. The manufacturing apparatus including the loom main body 10 including the winding roller 13 and the heat treatment device 20 that heat-treats the woven fabric C from the loom main body 10 can continuously produce the product (FIG. 3).

The warp yarns 1, 1 ... Pulled out through a delivery roller (not shown) are opened up and down through heddle 11, 11, and when the weft yarn 2 is wefted by a weft inserting device (not shown), the reeds 12 The weft yarn 2 is driven to a predetermined position, and sent out as the woven fabric C to the heat treatment device 20 via the winding roller 13. The take-up roller 13 is provided with pressure rollers 13a, 13a. Also, warp 1, 1, ...
Has an extremely long running distance from the delivery roller to the take-up roller 13 so as not to bend it unnecessarily, and makes the warp tension almost zero during this time. Furthermore, the healds 11, 11 have warp threads 1, 1, ... Special consideration should be given to the contact area with the warp yarns 1, 1 ...

Woven cloth C from the loom body 10 is paired with heating rollers 21, 21 via guide rollers 21a, 21a.
And guide it to the woven fabric beam CB via the other guide rollers 21b and 21b. The heating rollers 21 and 21 contact the front side and the back side of the woven cloth C, respectively, and uniformly heat the woven cloth C, thereby melting the added yarn 2a added to each weft yarn 2 to form the warp yarn 1 The intersections 3 of the wefts 1, 2 and the wefts 2, 2 can be fused by heat.

[0030]

Other Embodiments Heating rollers 21 and 2 of the heat treatment device 20
1 ... Can be arranged so as to face each other to form a pressing roller that sandwiches the woven cloth C (FIG. 4). Even if the added yarn 2a is melted and becomes a molten resin, it is less likely to be washed away from each of the intersection points 3 and, further, the intersection points 3 are heat-sealed without bending the woven cloth C to form a surface. Can be finished more beautifully.

The additional yarn 2a added to the weft yarn 2 may be wound in parallel with the multifilament carbon fiber forming the weft yarn 2 instead of being wound around the weft yarn 2 (FIG. 5). The additive yarn 2a is the weft yarn 2 regardless of the figure.
One side or more may be provided on each of the upper and lower surfaces, or each of the upper and lower surfaces. That is, the number of the additional yarns 2a can be added to any position of the weft yarns 2.

The added yarn 2a is the added yarn 2 having a different melting temperature.
It is possible to add a1, 2a1, 2a2 and 2a2 in a mixed manner (FIG. 6). Prior to weft insertion, by adding low melting temperature additive yarns 2a1, 2a1 in the weft preparation step, the high melting temperature additive yarns 2a2, 2a2 can be integrally fused to the weft yarn 2. The weft inserting operation can be significantly stabilized. In addition, the added yarn 2a
The melting temperatures of 1, 2a2 are preferably selected to be about 100 ° C. and about 120 ° C., for example. The high melting temperature added yarns 2a2, 2a2 can be heat treated by the heat treatment device 20 to be melted after weaving, and the intersections 3, 3 ... Can be heat fused.

The addition yarns 2a1 and 2a shown in FIG.
Arrangement position and number of 2 can be arbitrarily selected. Further, each of the additive yarns 2a1 and 2a2 may also be spirally wound around the weft yarn 2 as shown in FIG.

Further, the weft yarn 2 to which the additional yarns 2a, 2a1 and 2a2 are added is subjected to a sizing treatment in the weft insertion preparation step, so that the weft yarn 2 itself and the weft yarn 2 and the additional yarns 2a and 2a1 are obtained.
The unity with 2a2 can be further improved.

In the above description, the added yarns 2a, 2a1
2a2 may be added to the warp 1 instead of the weft 2 or in addition to the weft 2. That is, the added yarn 2a,
2a1, 2a2 can be added to one or both of the warp yarns 1, 1 ..., the weft yarns 2, 2 ... Forming the woven fabric C.

3 and 4, the heat treatment device 20 may be installed separately from the loom body 10 instead of being installed in front of the loom body 10. At this time, the woven cloth C from the loom body 10 can be once wound around the woven cloth beam and set in the heat treatment device 20 as a separate step.

[0037]

As described above, according to the first invention of this application, since the intersection points of the warp and the weft are heat-sealed via the molten resin, harmful misalignment can be completely prevented. In addition, the warp and weft woven in a coarse plain weave design do not bend excessively and can be efficiently produced using a loom that is in principle equivalent to a normal loom. There is an effect.

According to the second aspect of the invention, after the weaving, the whole can be heat-treated to melt the additive yarn added to one or both of the warp and the weft so that the intersections of the warp and the weft are heat-sealed. The carbon fiber woven fabric according to the first invention can be efficiently produced, and according to the third invention, the second invention can be carried out as it is by combining the loom body and the heat treatment device.

[Brief description of drawings]

FIG. 1 is a plan view of a carbon fiber woven fabric.

FIG. 2 is an enlarged perspective view of a weft.

FIG. 3 is a conceptual diagram of a manufacturing apparatus.

FIG. 4 is a view corresponding to FIG. 3 showing another embodiment.

FIG. 5 is an enlarged sectional view of a weft showing another embodiment.

FIG. 6 is a view corresponding to FIG. 5 showing another embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Warp 2 ... Weft 2a, 2a1, 2a2 ... Addition yarn 3 ... Intersection 10 ... Loom body 20 ... Heat treatment device 21 ... Heating roller

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁶ Identification number Office reference number FI Technical display location D03D 41/00 D03D 41/00 Z D04H 1/54 D04H 1/54 B D06M 15/00 D06M 15 / 00

Claims (9)

[Claims] 1. A warp and a weft made of non-twisted multifilament carbon fiber are woven into a coarse plain weave design, and the intersections of the warp and the weft are heat fused through a molten resin. Carbon fiber woven fabric. 2. A warp and a weft made of non-twisted multifilament carbon fiber are woven into a coarse plain weave design and heat-treated to melt the heat-fusible additive yarn added to one or both of the warp and the weft. Then, the intersections of the warp and the weft are heat-sealed together to produce a carbon fiber woven fabric. 3. The method for producing a carbon fiber woven fabric according to claim 2, wherein the added yarn is wound around the carbon fiber in a spiral shape. 4. The method for producing a carbon fiber woven fabric according to claim 2, wherein the added yarn is added in parallel with the carbon fiber. 5. The added yarn is based on the carbon fiber,
The method for producing a carbon fiber woven fabric according to claim 2, wherein a plurality of fibers having different melting temperatures are added. 6. The carbon fiber woven fabric according to claim 2, wherein the warp yarn and the weft yarn are subjected to a sizing treatment after the addition yarn is added to the carbon fiber. Method. 7. A loom body for weaving a warp and a weft made of untwisted multifilament carbon fiber into a coarse plain weave, and a woven fabric from the loom body is heat-treated and added to one or both of the warp and the weft. An apparatus for manufacturing a carbon fiber woven fabric, comprising: a heat treatment device that melts the heat-fusible additive yarn and heat-bonds each intersection of the warp yarn and the weft yarn. 8. The carbon fiber woven fabric manufacturing apparatus according to claim 7, wherein the heat treatment apparatus includes a pair of heating rollers that heat the woven cloth by contacting the front and back surfaces of the woven cloth. 9. The carbon fiber woven fabric manufacturing apparatus according to claim 8, wherein the heating roller forms a pressing roller for sandwiching a woven cloth.