JPWO2018083735A1 - 複合材料用強化基材、複合材料および複合材料用強化基材の製造方法 - Google Patents
複合材料用強化基材、複合材料および複合材料用強化基材の製造方法 Download PDFInfo
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Abstract
Description
図4を参照して、強化基材100の製造装置300について説明する。
図6を参照して、複合材料10の成形装置400について説明する。
次に、実施形態に係る強化基材100、101、102の製造方法を説明する。
次に、実施形態に係る複合材料10の成形方法を説明する。複合材料10の成形方法は、生産性が高く量産に適したRTM(Resin Transfer Molding)成形法を用いる。RTM成形法にあっては、強化基材100を成形型410(図6を参照)に配置し、樹脂200を含浸させて硬化させることによって複合材料10を成形する。
第1の領域111および第2の領域112を合計した領域に対して第1の領域111が占める割合を70%とした。
第1の領域111および第2の領域112を合計した領域に対して第1の領域111が占める割合を30%とした。
第1の領域111および第2の領域112を合計した強化繊維110全体に対して第1の領域111が占める割合を0%とした。すなわち、強化繊維110をレギュラートゥ114のみで構成した。
硬化に伴う樹脂200の収縮率を4%として繊維層(図13を参照)における強化繊維110の体積含有率を50%とする場合は、理論上、繊維層において最大2%程度の複合材料の収縮が発生することが分かった。一方、反力層では、第1の領域111および第2の領域112を合計した領域に対して第1の領域111が占める割合によって複合材料の収縮率が変化することが分かった。
11 第1の領域、
12 第2の領域、
13 第3の領域、
100、101、102 強化基材(複合材料用強化基材)、
110 強化繊維、
111 第1の領域、
112 第2の領域、
113 ラージトゥ(第1の繊維束)、
114 レギュラートゥ(第2の繊維束)、
120 補助繊維、
130 ステッチ糸、
140 積層体、
200 樹脂、
300 強化基材の製造装置、
310 ボビン、
320 配向部、
330 積層部、
340 ステッチ部、
341 編み針、
350 ベルトコンベア、
360 巻き取りローラ、
410 成形型、
420 プレス部、
430 樹脂注入部、
500 制御部、
H1 強化基材の第1の領域の厚み、
H2 強化基材の第2の領域の厚み、
H3 複合材料の第1の領域の厚み、
H4 複合材料の第2の領域の厚み。
Claims (20)
- 複合材料を成形するときに使用される強化基材であって、
繊維方向が一方向に配列された強化繊維を含む第1の領域と、
前記繊維方向と同一方向に配列された前記強化繊維を含み、前記第1の領域よりも厚みが薄い第2の領域と、を有し、
前記第1の領域および前記第2の領域は、前記繊維方向に対して交差する方向に沿って平面的に交互に並べられてなる、複合材料用強化基材。 - 前記第1の領域は、前記強化繊維が複数本束ねられた第1の繊維束を含み、
前記第2の領域は、前記第1の繊維束よりも少ない本数の前記強化繊維が束ねられた第2の繊維束を含む、請求項1に記載の複合材料用強化基材。 - 前記第1の領域および前記第2の領域は、厚み方向に直交する面のうち一方の面を同じ平面に揃えてなる、請求項1または請求項2に記載の複合材料用強化基材。
- 前記繊維方向に対して交差する方向に沿うように前記強化繊維に積層され、前記強化繊維の少なくとも一部に接合されて、前記強化繊維を保持する補助繊維をさらに有する、請求項1〜3のいずれか1項に記載の複合材料用強化基材。
- 前記強化繊維と前記補助繊維とを縫合して接合するステッチ糸をさらに有する、請求項4に記載の複合材料用強化基材。
- 前記補助繊維は、前記強化繊維よりも弾性係数が低い、請求項4または請求項5に記載の複合材料用強化基材。
- 前記補助繊維は、前記強化繊維よりも引張破断伸びが大きい、請求項4〜6のいずれか1項に記載の複合材料用強化基材。
- 強化基材に樹脂が配置されてなる複合材料であって、
繊維方向が一方向に配列された強化繊維を含む第1の領域と、
前記繊維方向と同一方向に配列された前記強化繊維を含み、前記第1の領域よりも厚みが薄い第2の領域と、
前記第2の領域と厚み方向に重なり合うように形成され、前記樹脂の体積含有率が前記第2の領域よりも高い第3の領域と、を有し、
前記第1の領域および前記第2の領域は、前記繊維方向に対して交差する方向に沿って平面的に交互に並べられてなる、複合材料。 - 前記第1の領域は、前記強化繊維が複数本束ねられた第1の繊維束を含み、
前記第2の領域は、前記第1の繊維束よりも少ない本数の前記強化繊維が束ねられた第2の繊維束を含む、請求項8に記載の複合材料。 - 前記第1の領域および前記第2の領域は、厚み方向に直交する面のうち一方の面を同じ平面に揃えてなる、請求項8または請求項9に記載の複合材料。
- 前記繊維方向に対して交差する方向に沿うように前記強化繊維に積層され、前記強化繊維の少なくとも一部に接合されて、前記強化繊維を保持する補助繊維をさらに有する、請求項8〜10のいずれか1項に記載の複合材料。
- 前記強化繊維と前記補助繊維とを縫合して接合するステッチ糸をさらに有する、請求項11に記載の複合材料。
- 前記補助繊維は、前記強化繊維よりも弾性係数が低い、請求項11または請求項12に記載の複合材料。
- 前記補助繊維は、前記強化繊維よりも引張破断伸びが大きい、請求項11〜13のいずれか1項に記載の複合材料。
- 繊維方向が一方向に配列された強化繊維を含む第1の領域と、前記繊維方向と同一方向に配列された前記強化繊維を含み、前記第1の領域の厚みよりも厚みが薄い第2の領域とを形成するように前記強化繊維を配置し、
前記繊維方向に対して交差する方向に沿って平面的に交互に並べるように前記第1の領域および前記第2の領域を配置する、複合材料用強化基材の製造方法。 - 前記強化繊維を配置する際に、前記強化繊維が複数本束ねられた第1の繊維束を前記第1の領域に配置し、前記第1の繊維束よりも少ない本数の前記強化繊維が束ねられた第2の繊維束を前記第2の領域に配置する、請求項15に記載の複合材料用強化基材の製造方法。
- 前記第1の領域および前記第2の領域を配置する際に、前記第1の領域および前記第2の領域の厚み方向に直交する面のうち一方の面が同じ平面に揃うように配置する、請求項15または請求項16に記載の複合材料用強化基材の製造方法。
- 前記繊維方向に対して交差する方向に沿うように補助繊維を前記強化繊維に積層し、
前記強化繊維の少なくとも一部を前記補助繊維に接合して保持する、請求項15〜17のいずれか1項に記載の複合材料用強化基材の製造方法。 - 前記強化繊維と前記補助繊維とをステッチ糸によって縫合して接合する、請求項18に記載の複合材料用強化基材の製造方法。
- 前記第1の領域および前記第2の領域における前記強化繊維の配置を基に、前記補助繊維の配置および前記ステッチ糸によって縫合する位置を制御する、請求項19に記載の複合材料用強化基材の製造方法。
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