US20200032433A1 - Fiber structure and fiber reinforced composite material - Google Patents

Fiber structure and fiber reinforced composite material Download PDF

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Publication number
US20200032433A1
US20200032433A1 US16/484,230 US201816484230A US2020032433A1 US 20200032433 A1 US20200032433 A1 US 20200032433A1 US 201816484230 A US201816484230 A US 201816484230A US 2020032433 A1 US2020032433 A1 US 2020032433A1
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Prior art keywords
fabric
yarns
fiber structure
fixing portions
outermost
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US16/484,230
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English (en)
Inventor
Mari KAWAHARA
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Toyota Industries Corp
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Toyota Industries Corp
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Assigned to KABUSHIKI KAISHA TOYOTA JIDOSHOKKI reassignment KABUSHIKI KAISHA TOYOTA JIDOSHOKKI ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KAWAHARA, Mari
Publication of US20200032433A1 publication Critical patent/US20200032433A1/en
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    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D5/00—Selvedges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B32B5/262—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by one fibrous or filamentary layer being a woven fabric layer
    • B32B5/263—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by one fibrous or filamentary layer being a woven fabric layer next to one or more woven fabric layers
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D1/00—Woven fabrics designed to make specified articles
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D11/00—Double or multi-ply fabrics not otherwise provided for
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M17/00—Producing multi-layer textile fabrics
    • D06M17/04—Producing multi-layer textile fabrics by applying synthetic resins as adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/105—Ceramic fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/02—Reinforcing materials; Prepregs

Definitions

  • the present invention relates to a fiber structure made of a multilayer fabric having first yarns and second yarns and a fiber-reinforced composite material using the fiber structure.
  • the first yarns and the second yarns are 11) bundles of reinforcing fibers.
  • Fiber-reinforced composite materials are widely used as lightweight structural materials.
  • a fiber structure is a reinforcing base material for a fiber-reinforced composite material, and the fiber-reinforced composite material formed by combining the fiber structure with resin as a matrix is used as structural materials for airplanes, vehicles, buildings, and the like.
  • the fiber structure is made of a multilayer fabric.
  • a laminated fabric as a multilayer fabric is formed by, for example, laminating several single-layer fabrics formed by plain weave. In some cases, such laminated several single-layer fabrics are joined with each other in the lamination direction to form the laminated fabrics.
  • the fiber structure is carried or shaped, of fabric edges of the fiber structure, for example, one fabric edge in which each ends of warps extending in a yarn main axis direction of the warps are located has a possibility of fraying. Then, wefts extending orthogonally to the warps may be pulled out from the frayed fabric edge.
  • tapes are attached to fabric edges of a fiber structure in Patent Document 1.
  • Patent Document 1 Japanese Patent Application Publication No. 2002-249957
  • Patent Document 1 to prevent the fraying of the fabric edge of the fiber structure, the tapes which are separate members from the fiber structure are needed, increasing costs for manufacturing the fiber structure. Furthermore, the tapes used to prevent the fraying may adversely affect the combining of the fiber structure with a matrix.
  • a fiber structure includes a multilayer fabric including first yarns and second yarns arranged orthogonally to the first yarns, the first yarns and the second yarns being bundles of reinforcing fibers.
  • the fiber structure includes a first fabric edge of the multilayer fabric wherein ends of the first yarns are located in a yarn main axis direction of the first yarns, a second fabric edge of the multilayer fabric wherein ends of the second yarns are located in a yarn main axis direction of the second yarns, and fabric-style fixing portions disposed in at least one of the first fabric edge and the second fabric edge.
  • the fabric-style fixing portions are formed by entangling the reinforcing fibers of yarns of the first yarns and the second yarns overlapped in a lamination direction of the multilayer fabric.
  • the fabric-style fixing portions are formed in at least one of an outermost yarn and ends of one of the two types of yarns, Of the one of the two types of yarns arranged side by side in a yarn main axis direction of the other of the two types of yarns forming the fabric edges, the outermost yarn is located closest to the ends of the other of the two types of yarns.
  • the ends of the one of the two types of yarns are located closer to the ends than the outermost yarn in the yarn main axis direction of the one of the two types of yarns.
  • the reinforcing fibers of each yarn overlapped with the outermost yarn in the lamination direction are entangled with each other, thereby preventing pulling out of the outermost yarn from the fabric edge.
  • the reinforcing fibers are entangled at a position closer to the ends of the one of the two types of yarns than the outermost yarn in the yarn main axis direction of the one of the two types of yarns, thereby preventing pulling out of the outermost yarn over the ends of the one of the two types of yarns.
  • the fabric-style fixing portions prevent the fraying in the fabric edge.
  • the fabric-style fixing portions are formed by entangling the reinforcing fibers of yarns overlapped in the lamination direction. Therefore, no separate members are needed to prevent the fraying in the fabric edge.
  • the fabric-style fixing portions may be disposed only in the outermost yarn in the fiber structure.
  • the fiber structure does not have the fabric-style fixing portions more inside than the outermost yarn extending in a yarn main axis direction of the one of the two types of yarns. This configuration minimizes twisting of the reinforcing fibers caused by forming the fabric-style fixing portions.
  • the first yarns and the second yarns of the fiber structure may be made of discontinuous fibers.
  • the discontinuous fibers are entangled in many portions between the yarns overlapped in the lamination direction, thereby effectively preventing the fraying.
  • the fiber-reinforced composite material to solve the above issues is formed by impregnating a reinforcing base material made of a fiber structure with matrix resin.
  • the aforesaid fiber structure corresponds to the fiber structure according to any one of claims 1 to 3 .
  • the fabric-style fixing portions prevents the fraying of the fabric edges of the fiber structure.
  • the fabric-style fixing portions are formed by entangling the reinforcing fibers of yarns overlapped in the lamination direction. Therefore, no separate members are needed to prevent the fraying in the fabric edges Therefore, in the fiber-reinforced composite material formed by impregnating the fiber structure with matrix resin, no separating members will adversely affect the combining of the matrix resin.
  • FIG. 1 is a view schematically showing a fiber-reinforced composite material of a present embodiment.
  • FIG. 2 is a partial plan view showing a fiber structure of the present embodiment.
  • FIG. 3 is a view of the fiber structure of the present embodiment as viewed in the direction indicated by arrow A of FIG. 2 .
  • FIG. 4 is a view of the fiber structure of the present embodiment as viewed in the direction indicated by arrow B of FIG. 2 .
  • FIG. 5 is an enlarged view showing a fabric-style fixing portion.
  • FIG. 6 is a schematic view showing a fiber structure formed by 3D-weave.
  • FIG. 7 is a view showing another embodiment of fabric-style fixing portions.
  • FIG. 8 is a view showing still another embodiment of fabric-style fixing portions.
  • a fiber structure and a fiber-reinforced composite material according to an embodiment of the present invention will now be described with reference to FIG. 1 to FIG. 5 .
  • a fiber-reinforced composite material 10 is formed by impregnating a reinforcing base material being a fiber structure 11 made of a multilayer fabric with matrix resin Ma.
  • matrix resin Ma for example, thermosetting epoxy resin is used.
  • the fiber structure 11 is formed by laminating a plurality of fabrics 20 .
  • each fabric 20 is formed by interlacing a plurality of warps 21 with a plurality of wefts 31 , and has a rectangular shape in a plan view.
  • the warps 21 and the wefts 31 correspond to first yarns and second yarns, respectively.
  • Each fabric 20 is formed by plain weave to interlace the warps 21 and the wefts 31 .
  • the wefts 31 are arranged orthogonally to the warps 21 .
  • the warps 21 and the wefts 31 are made of discontinuous fibers 11 a .
  • Organic fibers and inorganic fibers that are the reinforcing fibers may be used as the discontinuous fibers 11 a .
  • the organic fibers include aramid fibers, poly(p-phenylenebenzobisoxazole) fibers, ultra-high molecular weight polyethylene fibers, and the like.
  • the inorganic fibers include carbon fibers, glass fibers, ceramic fibers, and the like.
  • the form of yarn bundles made of the discontinuous fibers 11 a includes a spun yarn, a stretch-broken yarn, and the like.
  • the direction in which a yarn main axis L 1 of the warps 21 extends is defined as the first direction X of the fiber structure 11 .
  • the direction in which a yarn main axis L 2 of the wefts 31 extends, and orthogonal to the first direction X is defined as the second direction Y of the fiber structure 11 .
  • the plurality of the warps 21 are arranged side by side in the second direction Y of the fiber structure 11 and parallel to each other in the fiber structure 11 .
  • the plurality of the wefts 31 are arranged side by side in the first direction X of the fiber structure 11 and parallel to each other in the fiber structure 11 . Referring to FIG.
  • the fabrics 20 overlapped in the lamination direction are configured such that the warps 21 of one fabric 20 overlap with the wefts 31 of the other fabric 20 in the fiber structure 11 .
  • the one fabric 20 is laminated on the other fabric 20 .
  • the fabrics 20 overlapped in the lamination direction are bound in the lamination direction by binder yarns (not shown).
  • the fiber structure 11 includes opposite first fabric edges 12 of the multilayer fabric where the ends 21 a of the warps 21 are located in a yarn main axis direction of the warps 21 (the first direction X).
  • the wefts 31 are located more inside than the end 21 a of the warps 21 in the first direction X (closer to the center of the fiber structure 11 ).
  • the outermost weft 31 located closest to the ends 21 a of the warps 21 and at the outermost side is an outermost weft 32 as the outermost yarn.
  • the warps 21 correspond to one of the two types of yarns
  • the wefts 31 correspond to the other of the two types of yarns.
  • the outermost weft 32 is arranged beside the ends 21 a of the warps 21 . Therefore, in the first fabric edge 12 , the outermost weft 32 is located at a position closer to the center of the fiber structure 11 than the end 21 a of the warps 21 .
  • the fiber structure 11 includes opposite second fabric edges 13 of the multilayer fabric where the ends 31 a of the wefts 31 are located in the yarn main axis direction of the wefts 31 (the second direction Y).
  • the warps 21 are located more inside than the end 31 a of the wefts 31 in the second direction Y (closer to the center of the fiber structure 11 ).
  • the outermost warp 21 located closest to the ends 31 a of the wefts 31 and at the outermost side is an outermost warp 22 as the outermost yarn.
  • the outermost warp 22 is located at a position closer to the center of the fiber structure 11 than the end 31 a of the wefts 31 .
  • the wefts 31 correspond to the one of the two types of yarns
  • the warps 21 correspond to the other of the two types of yarns.
  • the outermost warp 22 is arranged beside the ends 31 a of the wefts 31 .
  • the fiber structure 11 includes fabric-style fixing portions 14 in each of the first fabric edges 12 and each of the second fabric edges 13 .
  • the fabric-style fixing portions 14 disposed in the first fabric edge 12 are formed by needle punching on the outermost weft 32 .
  • the fabric-style fixing portions 14 disposed in the first fabric edge 12 are formed to entangle the discontinuous fibers 11 a of the outermost weft 32 and the warps 21 overlapping the outermost weft 32 in the lamination direction with each other in each fabric 20 .
  • the fabric-style fixing portions 14 disposed in the first fabric edge 12 are formed to entangle the discontinuous fibers 11 a of the outermost weft 32 of the one fabric 20 and the warps 21 of the other fabric 20 with each other between the fabrics 20 overlapped in the lamination direction.
  • the fabric-style fixing portions 14 are formed to entangle the discontinuous fibers 11 a of the wefts 31 overlapped in the lamination direction with each other, which is not illustrated.
  • the fabric-style fixing portions 14 disposed in the second fabric edge 13 are formed by needle punching on the outermost warp 22 .
  • the fabric-style fixing portions 14 disposed in the second fabric edge 13 are formed to entangle the discontinuous fibers 11 a of the outermost warp 22 and the wefts 31 overlapping the outermost warp 22 in the lamination direction with each other in each fabric 20 .
  • the fabric-style fixing portions 14 disposed in the second fabric edge 13 are formed to entangle the discontinuous fibers 11 a of the outermost warp 22 of the one fabric 20 and the wefts 31 of the other fabric 20 with each other between the fabrics 20 overlapped in the lamination direction.
  • the fabric-style fixing portions 14 are formed to entangle the discontinuous fibers 11 a of the wefts 31 overlapped in the lamination direction with each other, which is not illustrated.
  • the discontinuous fibers 11 a are twisted and entangled in a complicated manner between the warps 21 and the wefts 31 , between the warps 21 , and between the wefts 31 , overlapped in the lamination direction.
  • the warps 21 and the wefts 31 are made of the discontinuous fibers 11 a , so that the discontinuous fibers 11 a are entangled in many portions at the fabric-style fixing portions 14 .
  • the fiber structure 11 made of a multilayer fabric configured as described above is impregnated with matrix resin Ma, and then the matrix resin Ma is cured, thereby producing the fiber-reinforced composite material 10 .
  • the impregnation and the cure of the matrix resin Ma is performed by, for example, RTM (resin transfer molding) method.
  • RTM resin transfer molding
  • the fabric-style fixing portions 14 disposed in the fiber structure 11 prevent the fraying in the first fabric edge 12 and the second fabric edge 13 .
  • the fabric-style fixing portions 14 are formed by entangling the reinforcing fibers of yarns of the warps 21 and the wefts 31 overlapped in the lamination direction of the multilayer fabric. Therefore, the fraying of the first fabric edge 12 and the second fabric edge 13 is prevented without using a separate member, resulting in saving of a manufacturing cost.
  • the fraying is prevented without using a separating member. This means that, unlike the case in which separating members are added to prevent the fraying, a failure in impregnation of the matrix resin Ma (an adverse effect on the combining of the matrix resin Ma) does not occur, and the fiber-reinforced composite material 10 does not lower a strength on account of separate members.
  • the fabric-style fixing portions 14 disposed in the first fabric edge 12 are formed by needle punching on the outermost weft 32 .
  • This needle punching entangles the discontinuous fibers 11 a of the outermost weft 32 having a possibility of being pulled out from the first fabric edge 12 and the warps 21 with each other, thereby preventing the outermost weft 32 from being pulled out.
  • the fabric-style fixing portions 14 disposed in the second fabric edge 13 are formed by needle punching on the outermost warp 22 . This needle punching entangles the discontinuous fibers 11 a of the outermost warp 22 having a possibility of being pulled out from the second fabric edge 13 and the wefts 31 , thereby preventing the outermost warp 22 from being pulled out.
  • the fabric-style fixing portions 14 disposed in each of the first fabric edges 12 and in each of the second fabric edges 13 are formed by needle punching on the outermost weft 32 and on the outermost warp 22 , respectively. Therefore, the fiber structure 11 does not have the fabric-style fixing portions 14 more inside than the outermost weft 32 in the first direction X (closer to the center of the fiber structure 11 ), and more inside than the outermost warp 22 in the second direction Y (closer to the center of the fiber structure 11 ).
  • the warps 21 and the wefts 31 are made of the discontinuous fibers 11 a .
  • the discontinuous fibers 11 a are entangled in many portions between the warps 21 and the wefts 31 , between the warps 21 , and between the wefts 31 , overlapped in the lamination direction. Therefore, the fraying in the fabric-style fixing portions 14 is prevented, that is, the fraying in the first fabric edge 12 and the second fabric edge 13 is also prevented effectively.
  • the warps 21 and the wefts 31 need not necessarily be made of the discontinuous fibers 11 a , and may be continuous yarns which are formed by bundling several hundreds to several tens of thousands of continuous fibers.
  • a fiber structure 40 may be a multilayer fabric formed by 3D-weave.
  • the fiber structure 40 includes warp layers 41 , 43 , 45 in each of which the warps 21 corresponding to the first yarns are arranged parallel to each other, and weft layers 42 , 44 , 46 in each of which the wefts 31 corresponding to the second yarns are arranged to each other.
  • the fiber structure 40 includes the first warp layer 41 , the first weft layer 42 , the second warp layer 43 , the second weft layer 44 , the third warp layer 45 , and the third weft layer 46 in this order from top to bottom.
  • the first warp layer 41 , the first weft layer 42 , the second warp layer 43 , the second weft layer 44 , the third warp layer 45 , and the third weft layer 46 are bound by binder yarns 48 in the lamination direction.
  • the binder yarns 48 are warps used for holding the shape of the fiber structure 40 .
  • the fiber structure 40 includes the fabric-style fixing portions 14 in opposite first fabric edges 51 in which the ends 21 a of the warps 21 are located in the yarn main axis direction of the warps 21 . Furthermore, the fiber structure 40 includes the fabric-style fixing portions 14 in opposite second fabric edges in which the ends 31 a of the wefts 31 are located in the yarn main axis direction of the wefts 31 , which is not illustrated.
  • a plurality of the fabric-style fixing portions 14 may be disposed along the first direction X by needle punching on the wefts 31 which are located more inside than the outermost weft 32 in the first direction X. Similar to the first fabric edge 12 , in each second fabric edge 13 , a plurality of the fabric-style fixing portions 14 may be disposed along the second direction Y by needle punching on the warps 21 which are located more inside than the outermost warp 22 in the second direction Y.
  • the fabric-style fixing portions 14 may be disposed only in the ends 21 a of the warps 21 which are located more outside than the outermost weft 32 in the first direction X.
  • the fabric-style fixing portions 14 may be disposed in the ends 21 a of the warps 21 that are located closer to the ends than the outermost weft 32 in the yarn main axis direction of the warps 21 corresponding to the one of the two types of yarns (in the first direction X).
  • the fabric-style fixing portions 14 may be disposed only in the ends 31 a of the wefts 31 which are located more outside than the outermost warp 22 in the second direction Y.
  • the fabric-style fixing portions 14 may be disposed in the ends 31 a of the wefts 31 that are located closer to the ends than the outermost warp 22 in the yarn main axis direction of the wefts 31 corresponding to the one of the two types of yarns (in the second direction Y).
  • the discontinuous fibers 11 a are entangled between the warps 21 overlapped in the lamination direction in the ends 21 a closer to the ends in the yarn main axis direction of the warps 21 than the outermost weft 32 , so that the outermost weft 32 is prevented from being pulling out over the ends 21 a of the warps 21 .
  • the discontinuous fibers 11 a are entangled between the wefts 31 overlapped in the lamination direction in the ends 31 a closer to the ends in the yarn main axis direction of the wefts 31 than the outermost warp 22 , so that the outermost warp 22 is prevented from being pulling out over the end 31 a of the wefts 31 .
  • forming the fabric-style fixing portions 14 prevent the fraying in the fabric edge 12 , 13 .
  • the fabric-style fixing portions 14 are formed such that the discontinuous fibers 11 a are entangled between the warps 21 overlapped in the lamination direction, and between the wefts 31 overlapped in the lamination direction. Therefore, no separate members are needed to prevent the fraying in the fabric edge 12 , 13 .
  • the fabric-style fixing portions 14 may be added by needle punching on the outermost weft 32 in each first fabric edge 12 and on the outermost warp 22 in each second fabric edge 13 . Owing to this addition, both the fabric-style fixing portions 14 which are located on the outermost weft 32 and the fabric-style fixing portions 14 which are located on the ends 21 a of the warps 21 cooperate to effectively prevent the fraying in the first fabric edge 12 . Similar to the first fabric edge 12 , both the fabric-style fixing portions 14 which are located on the outermost warp 22 and the fabric-style fixing portions 14 which are located on each end 31 a of the wefts 31 cooperate to effectively prevent the fraying in the second fabric edge 13 .
  • the fabric-style fixing portions 14 may be disposed in only either the first fabric edges 12 and the second fabric edges 13 in the fiber structure 11 , and in only either the first fabric edges 51 and the second fabric edges in the fiber structure 40 . In this case, the opposite edges on the upstream and downstream sides in the weaving direction of the fiber structures 11 , 40 are cut after the fiber structures 11 , 40 are completed. Therefore, the fabric-style fixing portions 14 may be disposed only in the cut edges and may not be disposed in the opposite sides in the weaving width direction.
  • tufting may be applied. Besides needle punching and tufting, any method may be applied if the reinforcing fibers (the discontinuous fibers 11 a ) are entangled with each other between adjacent layers.
  • the fabrics 20 are formed by plain weave in the above embodiment, the fabrics 20 may be formed by satin weave or twill weave.
  • the number of laminated weft layers and warp layers may be changed as required in the fiber structure 40 .
  • the type of matrix resin and the method for manufacturing the fiber-reinforced composite material 10 are not limited to any particular resin or method.
  • the fabric-style fixing portions are formed by needle punching.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Woven Fabrics (AREA)
  • Reinforced Plastic Materials (AREA)
  • Knitting Of Fabric (AREA)
US16/484,230 2017-02-08 2018-01-23 Fiber structure and fiber reinforced composite material Abandoned US20200032433A1 (en)

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JP2017021130A JP6620771B2 (ja) 2017-02-08 2017-02-08 繊維構造体及び繊維強化複合材
JP2017-021130 2017-02-08
PCT/JP2018/001963 WO2018147072A1 (ja) 2017-02-08 2018-01-23 繊維構造体及び繊維強化複合材

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FR2669940B1 (fr) * 1990-12-03 1994-10-21 Europ Propulsion Fil forme a partir de fibres refractaires ou de leurs precurseurs et son application a la fabrication de pieces en materiau composite.
JP2002249957A (ja) 2001-02-20 2002-09-06 Hiroharu Oishibashi 拡繊糸織物の製造装置
JP2007182661A (ja) * 2005-12-09 2007-07-19 Toray Ind Inc 多軸成形材料、プリフォーム、ｆｒｐおよびそれらの製造方法
US20090209155A1 (en) * 2008-02-15 2009-08-20 Chapman Thermal Products, Inc. Layered thermally-insulating fabric with thin heat reflective and heat distributing core
JP2011202304A (ja) * 2010-03-25 2011-10-13 Toray Ind Inc 繊維構造体およびその製造方法、ならびにプリフォーム
JP2013011027A (ja) * 2011-06-28 2013-01-17 Toray Ind Inc 補強用織物およびその製造方法
US20140206248A1 (en) * 2011-12-20 2014-07-24 Matscitechno Licensing Company Impact dissipating fabric
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EP3581690A1 (en) 2019-12-18
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