JPH10315343A - Three-dimensional integrated reinforced structural member - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance the stability of every physical property such as interlayer peel strength, dimensional stability, breaking tenacity, tear strength and rigidity at a limit temperature in a reinforced structural member such as FRP by upgrading these physical properties. SOLUTION: A warp 4 is properly introduced into plural rows 3 of chain stitch network respectively which extend side by side in the longitudinal direction forming rows one after another, and front/back base fabrics 1, 2 composed of the rows 3 of the parallel chain stitch network and warps 4 are interlooped. At the same time, the rows 3 of the chain stitch network of the front/back base fabrics 1, 2 are mutually connected with plural connecting yarns 5 to form a triaxial, three-dimensional integrated structure. Further, the structure is processed into a solid or hollow reinforcing material of a desired shape and then is formed into a reinforced structural member with a matrix by curing it.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reinforced structural member such as a reinforced resin plate known as FRP or the like.
The present invention relates to a reinforced structural member such as an FRP, a reinforced ceramic plate, a concrete plate and the like having a three-dimensional integrated structure and improved rigidity, peel strength and tear strength.

[0002]

2. Description of the Related Art FRP (fiber reinforced plastic) is widely used in various fields as a member having excellent mechanical strength, but is generally formed by curing an unsaturated polyester based on glass fiber. Recently, ERTP using a thermoplastic resin is also being developed.

[0003] In addition to the above unsaturated polyester resins, thermosetting resins such as epoxy resins, phenol resins, furan resins, diallyl phthalate resins, curable acrylic resins, and silicon resins are used to make large products relatively simple. Since it can be molded with simple equipment and inexpensive molds, it is used for production in a wide range of fields such as home appliances, construction, heat exchangers, motor boats, yachts, containers, purification tanks, automobile bodies and sports cars. ing.

[0004] The substrate used in the above-mentioned conventional FRP and the like is mainly the above-mentioned glass fiber, and this glass fiber is used in the form of string-like roving, chopped strand yarn, mat, cloth, or prepreg. When creating the original structure, the cloth,
Lamination is performed by laminating prepregs.

[0005]

However, the strength of FRP varies depending on the state of the fiber, and although there is an aspect due to the molding method, the fiber content is the most important factor.
Increasing the fiber content leads to an increase in the strength of the FRP, but in the case of the above-mentioned glass fibers, it is only 60 to 70% for the cloth with the highest content and only 10 to 20% for the few chopped strands. There is no situation. Recently, the use of ceramics has been studied, and the use of carbon fiber as a base material has been considered. However, the fiber content is still in a state of 60 to 70%.

On the other hand, in the case of laminating a prepreg or the like for forming a three-dimensional structure, even if a required three-dimensional structure is obtained by laminating, each layer is separated as a separate layer. The peeling strength of the sample was inferior, especially at the limit temperature, and the practical range was inevitably restricted.

The present invention has been made in view of the above-mentioned situation, and in order to cope with this, in particular, by finding a three-axis, three-dimensionally integrated warp knitted fabric base material by using a special double Russell machine, the present invention has been developed.
An object of the present invention is to improve the strength, tear strength, rigidity, etc., as well as the delamination strength and dimensional stability of a reinforced structural member such as P, and to enhance the stability of each of these physical properties at a limit temperature.

[0008]

That is, in order to meet the above-mentioned object, the present invention is based on the use of a warp knitted fabric having a three-axis, three-dimensional integral structure as a reinforcing material. Where three axes,
The three-dimensional integrated structure means both base cloths of an XY biaxial plane composed of a large number of chain stitch rows that are knitted at least at a required interval and that are arranged in parallel in the front and rear, and wefts inserted perpendicular to the stitch rows. Has a structure in which the two base fabrics are connected to each other by a connecting yarn for connecting the base fabrics in the Z-axis direction by integral knitting, and has a required thickness.

The present invention has a fundamental feature in that the above-mentioned reinforcing material is used. Specifically, it is as described in each claim. Claim 1 is a basic configuration in which weft yarns are appropriately inserted into a large number of parallel stitch rows extending in the longitudinal direction in front and rear rows, respectively. While knitting the front and rear base fabrics each composed of a stitch row and a weft, respectively, and connecting the chain stitch rows of the front and back base cloths to each other with a large number of connecting yarns to form a three-axis, three-dimensional integrated structure, It is characterized by a structure in which the body is formed into a required shape as a reinforcing material and cured by a matrix.

[0010] A second aspect of the present invention is a hollow reinforced structural member having a particularly light weight as a modification of the basic structure, wherein a part of a connecting thread connecting portion of the three-dimensionally integrated structure is partially removed. In this configuration, a hollow portion is formed, a molding material is inserted into a required shape, and the molding is cured and formed by a matrix, and the molding material is removed to form a hollow product.

The third, fourth and fifth aspects of the present invention show that the front and rear base fabrics may each be a single layer or a plurality of layers extending before, during and after the present invention. No. 2 is a bundled yarn obtained by bunching filaments.

Claims 6 and 7 are specific contents of the knitted fabric forming material and the matrix in the reinforced structural member of the present invention. In the former, natural fibers such as cotton, glass fibers, carbon fibers, whiskers, silicon carbide fibers, and alumina fibers are used. And one or more combinations selected from inorganic fibers such as zirconia fibers and organic fibers such as nylon, aramid, polyester, and polyacrylic resins. The latter, that is, as a matrix, an epoxy resin, a phenol resin, and an unsaturated resin. At least one selected from thermosetting or thermoplastic synthetic resins such as polyester resin, birnester resin, epoxy acrylate resin, furan resin, polyamide resin, polyethylene resin, and vinyl chloride resin, rubber, and concrete is used. .

[0013] Claim 9 relates to an effective ceramic reinforced structural member particularly corresponding to a novel use.
A structure in which a reinforcing material consisting of a three-dimensional integrated structure is formed using ceramic fibers such as carbon fibers, silicon carbide fibers, alumina fibers, and zirconia fibers, and is impregnated with a ceramic liquid in a required shape, fired, and cured. It is characterized by.

[0014]

The reinforcing structural member of the present invention uses a knitted fabric obtained by integrally knitting the front and rear base fabrics and the connecting yarns as described above as a reinforcing material. Unlike the case of simply laminating like a body, the delamination strength is remarkably improved as an integral structure, and when weaving or the like is used as the weft, the strength, tear strength, rigidity are also increased, and dimensional stability is improved. At the same time, there is no change in physical properties even at normal temperature or under a limit (absolute) temperature. In addition, since the reinforcing material is a knitted fabric, the length, width, and shape of the reinforced structural member of the present invention are free, and can be applied to products in a wide range of fields.

[0015]

Embodiments of the present invention will be described below with reference to the accompanying drawings.

FIG. 1 shows an example of a reinforcing material used for a reinforcing structural member according to the present invention. In the drawing, reference numerals 1 and 2 denote two front and rear rows of chain stitch rows 3 which are knitted and extend in the longitudinal direction, respectively.
And the front and rear base fabrics knitted and formed by the weft yarns 4 inserted in the weft direction with respect to the chain stitch rows 3, and 5 is an opposing chain stitch row 3 facing the front and rear base cloths 1 and 2. Alternately engage in zigzag between the loops that
The three knitting of the chain stitches, the insertion of the weft, and the connection of the base cloth by the connecting yarn 5 are integrally knitted by using a special double weft cell machine with a weft insertion device. It constitutes a reinforcing material of the invention reinforced structural member.

That is, in the above-mentioned double Russell machine, the front needle row and the rear needle row perform chain knitting, respectively, to form the front and rear chain stitch rows 3, 3, and appropriately insert the weft 4 in the weft direction. While the front and rear base fabrics 1 and 2 are formed by the chain stitch rows 3 and the wefts 4 respectively before and after, the chain stitches at the zigzag positions are appropriately connected and connected between the front and rear chain stitch rows 3 by the connection yarns 5. The front and rear base fabrics 1 and 2 are connected
As a result, a warp knitted fabric integrally joined and connected is obtained.

This warp knitted fabric is a flat base fabric 1 in the XY axis direction.
And 2 and a connecting yarn 5 in the Z-axis direction for connecting the two base fabrics 1 and 2.
To form a three-dimensional integrated structure. The knitted fabric has an advantage that the thickness, width, and length between the base fabrics can be appropriately adjusted depending on the knitting condition, and can be arbitrarily controlled.

In the reinforcing material consisting of the front and rear base fabrics 1 and 2 and the connecting yarn 5, the yarn material used for the chain stitch forming yarn and the inserted weft 4 and the connecting yarn 5 during knitting are used and intended. It is appropriately selected depending on, for example, in addition to natural fibers such as cotton, glass fibers, rock wool, carbon fibers, whiskers, silicon carbide fibers, alumina fibers, inorganic fibers or ceramic fibers such as zirconia fibers, nylon, aramid, polyester Organic fibers such as polyacrylic synthetic fibers are used. In particular, when a ceramic reinforced structural member is produced, it is effective to use ceramic fibers. In particular, the knitting of knitted fabrics has been considered difficult, and hardly any ceramic fibers have been used.

Further, the above-mentioned respective yarn materials are not limited to one kind, and a plurality of combinations are also possible. In particular, the material of the weft 4 is preferably a long fiber filament,
In addition, it is preferable that the number is appropriately reduced, bundled, and inserted and used in a roving form. In particular, it is also effective to multi-layer orient the weft to dramatically improve the strength. A yarn having a diameter of about 20 μ to 70 μ per single yarn is generally used. On the other hand, the thickness of the reinforcing material in the Z-axis direction constituting the three-dimensional integrated structure can be appropriately formed from about 1 mm to about 200 mm, and is adjusted according to the purpose of use.

Thus, the reinforcing material having the three-dimensional and three-dimensional structure composed of the three-dimensional warp knitted fabric constructed as described above is cured by impregnating the reinforcing material with the matrix 7 as a binder as shown in FIG. Made into the required reinforced structural members. The reinforcing material is formed into a predetermined form before the matrix impregnation. The matrix 7 is an epoxy resin,
Thermosetting resins such as phenolic resins, unsaturated polyester resins, vinyl ester resins, epoxy acrylate resins, and furan resins are common, but thermoplastic resins that have recently attracted attention for their purposes, for example, polyamide, polycarbonate, polyethylene, Polypropylene, ABS,
A vinyl chloride resin may be used, and rubber such as natural or synthetic rubber or concrete in the case of concrete molding may be used as a matrix.

In particular, in the case of forming a three-dimensional integrated structure made of ceramic fibers in the case of forming a ceramic structure, and impregnating and hardening the reinforcing material in a required shape, an Al ₂ O ₃ solution or a SiO ₂ solution is used as a ceramic solution. In addition, a usable ceramic solution is used, but the ceramic solution needs to be fired. Therefore, after impregnation, it is fired and hardened. The sintering usually utilizes a known electric furnace and plasma. The heating temperature, the sintering temperature, and the like are determined by the components used, and are not necessarily constant, and an appropriate temperature is applied according to each. Although the amount of matrix impregnation with a resin or ceramic solution depends on the warp knitted fabric reinforcing material forming the reinforcing material, the amount of the fiber material and the like in the present invention and the amount of the resin or ceramics is as large as 90% or more of the former. And it is recognized that there is a remarkable effect in improving the strength as a reinforced structural member.

The above description is particularly for the case where a solid simple reinforcing material as shown in FIG. 1 is used. In order to reduce the weight of the three-dimensional structural member, the reinforcing material is replaced with a hollow structural reinforcing material. It is effective to do.

FIG. 3 shows the structure of such a hollow structural reinforcing material. The structure of the base fabric, the weft and the connecting yarn are the same as described above, but a part of the connecting portion by the connecting yarn 5 is removed. A hollow portion 6 is formed in this portion. In the formation of the hollow portion 6, the use of the connecting yarn in that portion may be stopped during warp knitting, or the connecting yarn in the portion may be removed after knitting. For the reinforcing material in which the hollow portion 6 is thus formed, a molding material is appropriately inserted into the hollow portion to form an arbitrary shape upon molding, then impregnation and hardening molding are performed, and then the molding material is removed. Thereby, a reinforced structural member having the hollow portion 6 is obtained. The same reference numerals as in FIG. 1 indicate the same parts. Such a reinforced structural member using the reinforcing material having the hollow portion 6 is much lighter than a solid structural member, and is extremely suitable in terms of handling.

The reinforced structural member described above has a simple shape as shown in the figure, but since the reinforced material is a warp-knitted fabric made of a fibrous material, the width, thickness and length can be freely set. Also, the shape can be easily formed into an arbitrary shape. Therefore, the reinforcing material can be preliminarily hardened and formed by matrix impregnation according to the form corresponding to the product form to be obtained.

As the molding method, RTM molding, RIM molding, stamping, drawing, etc. can be used.
Injection, blow, compression, and vacuum forming means can also be used, and can be selectively adopted according to the product to be obtained.

The products thus obtained are widely applied to various fields such as construction, construction, transportation, vehicles, aircraft, home appliances, space, precision parts, ships, semiconductors, heat exchange, etc., and their range is extremely wide. Further, it can be used as needed for products and integrated circuits in the functional polymer field.

[0028]

As described above, the present invention requires a warp knitted fabric having a three-axis, three-dimensional integrated structure formed by integrally knitting a base fabric on both sides and a connecting yarn for connecting the two base fabrics as a reinforcing material. Of the shape and without, formed by curing with a matrix,
Compared to conventional fabrics such as glass fiber or other short fibers, long fibers, or mats or other flat fabrics, this is a triaxial, three-dimensional, three-dimensional knitted fabric. The amount is extremely large, and the conventional one has a fiber content of at most 60 to 70%, but can show 90% or more, and remarkably improves the strength as a reinforced structural member. It works. Moreover, since the reinforcing material in the present invention has a three-axis, three-dimensional integral structure, the delamination strength can be remarkably superior to that of a conventional three-dimensional structure by lamination, and the strength of the product after curing and molding, In addition to remarkably improving the physical properties such as the degree of tear and dimensional stability, it is also very effective as a structure exceeding the conventional thickness of a three-dimensional structure by improving the rigidity by three-dimensional formation. Further, when the reinforcing material is a hollow structure, the weight becomes extremely light, and the practicality is increased in accordance with the purpose of use. In particular, in the present invention, since the warp knitted fabric is used, the production efficiency is high, and its knitting structure enables the production of porous reinforcing members and porous ceramics. It has the utility of being able to create various products. The combination of the ceramic fiber and the ceramic solution has an effect of easily producing a product corresponding to high heat, such as purification of high-temperature water which could not be used in conventional resin curing.

[Brief description of the drawings]

FIG. 1 is a partial perspective view showing one example of a reinforcing material used for a reinforcing structural member of the present invention.

FIG. 2 is a reinforced structural member using the reinforcing material shown in FIG. 1;
FIG. 3 is a partial cross-sectional view taken along line AA of FIG.

FIG. 3 is a partial perspective view showing an example of a hollow reinforcing material used for the reinforcing structural member of the present invention.

[Explanation of symbols]

 1, 2 Base cloth 3 Chain stitch row 4 Weft 5 Connecting thread 6 Hollow section 7 Matrix

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI B29K 309: 02

Claims (8)

[Claims] 1. A front and a back base fabric consisting of a parallel chain stitch row and a weft is knitted by appropriately inserting a weft into a plurality of side-by-side chain stitch rows extending in the length direction in a front and rear row, respectively. A triaxial, three-dimensional integrated structure is formed by connecting the chain stitch rows of the base fabric to each other with a number of connecting yarns,
A three-dimensional integrated reinforced structural member, wherein the structural body is formed into a required shape as a reinforcing material, and is formed by curing with a matrix. 2. Knitting a back and forth base cloth composed of parallel chain stitch rows and weft yarns by appropriately inserting wefts into a plurality of parallel chain stitch rows extending in the length direction in front and rear rows, respectively.
The chain stitch rows of the two base fabrics are connected to each other by a large number of connecting yarns to form a three-axis, three-dimensional integrated structure, a part of the connecting portion formed by the connecting yarns is removed, and a hollow portion is formed in the portion. A three-dimensional integral hollow reinforced structural member characterized by being formed and inserted with a mold material, formed into a required shape as a reinforcing material, hardened and formed by a matrix, and removed from the mold material. 3. The three-dimensionally integrated reinforced structural member according to claim 1, wherein the base fabric composed of a large number of chain stitch rows and wefts arranged in parallel is one layer each in the front and rear. 4. The three-dimensionally integrated reinforced structural member according to claim 1, wherein the base fabric composed of a large number of side-by-side chain stitch rows and wefts has a plurality of layers. 5. The three-dimensional integrated reinforcing structure according to claim 1, wherein the weft inserted into the base fabric comprising a number of parallel stitch rows and the weft is a bundled bundle of a number of filaments. Element. 6. The chain stitch row forming yarn, weft yarn and connecting yarn are made of natural fibers such as cotton, glass fibers, carbon fibers, whiskers, silicon carbide fibers, alumina fibers, inorganic fibers such as zirconia fibers, and nylon, aramid, polyester, and the like. The three-dimensional integral reinforced structural member according to any one of claims 1 to 5, wherein the reinforced structural member is one or a combination of two or more selected from organic fibers such as polyacrylic. 7. A matrix comprising an epoxy resin, a phenol resin, an unsaturated polyester resin, a vinyl ester resin,
The three-dimensional integral body according to any one of claims 1 to 6, which is at least one selected from a synthetic resin such as an epoxy acrylate resin, a furan resin, a polyamide resin, a polyethylene resin, and a vinyl chloride resin, a rubber, and concrete. Reinforced structural members. 8. A reinforcing material comprising a structure having a three-axis, three-dimensional integral structure according to claim 1 or 2 is formed using ceramic fibers, and is impregnated with a ceramic liquid in a required shape, fired and cured. A three-dimensionally integrated reinforced structural member characterized by the following.