WO2017006754A1 - 繊維積層体、繊維積層体の製造方法、及び繊維強化複合材 - Google Patents

繊維積層体、繊維積層体の製造方法、及び繊維強化複合材 Download PDF

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Publication number
WO2017006754A1
WO2017006754A1 PCT/JP2016/068252 JP2016068252W WO2017006754A1 WO 2017006754 A1 WO2017006754 A1 WO 2017006754A1 JP 2016068252 W JP2016068252 W JP 2016068252W WO 2017006754 A1 WO2017006754 A1 WO 2017006754A1
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Prior art keywords
fiber
thickness
roller
web
laminate
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PCT/JP2016/068252
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English (en)
French (fr)
Inventor
元基 吉川
神谷　隆太
Original Assignee
株式会社 豊田自動織機
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Publication date
Application filed by 株式会社 豊田自動織機 filed Critical 株式会社 豊田自動織機
Priority to CN201680038471.9A priority Critical patent/CN107709645B/zh
Priority to US15/741,302 priority patent/US10357937B2/en
Priority to EP16821224.9A priority patent/EP3321404B1/en
Publication of WO2017006754A1 publication Critical patent/WO2017006754A1/ja

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    • B32B3/263—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer having non-uniform thickness
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    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
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Definitions

  • the present invention relates to a fiber laminate formed by stacking a plurality of fiber layers, a method for manufacturing the fiber laminate, and a fiber-reinforced composite material.
  • Fiber reinforced composite materials are widely used as lightweight structural materials. There exists a fiber laminated body as a reinforcement base material for fiber reinforced composite materials. The fiber reinforced composite material is formed by impregnating a fiber laminate with a matrix resin. Fiber reinforced composite materials are used as structural materials for rockets, aircraft, automobiles, ships and buildings. There is also a fiber reinforced composite material configured by changing the thickness according to the shape to be used.
  • the fiber laminate 80 disclosed in Patent Document 1 is configured by stacking a plurality of sheet-like reinforcing fibers 81.
  • the fiber laminate 80 includes a base 82, an intermediate portion 83, and a surface layer portion 84.
  • a plurality of sheet-like reinforcing fibers 81 are stacked and have a uniform thickness.
  • a plurality of sheet-like reinforcing fibers 81 are stacked with the end portions of the respective sheet-like reinforcing fibers 81 being shifted stepwise.
  • the surface layer portion 84 covers the entire surface of the base 82 and the intermediate portion 83. The thickness of the fiber laminate 80 is gradually changed by shifting the end portion of each sheet-like reinforcing fiber 81 at the intermediate portion 83.
  • Patent Document 2 discloses that short fibers (non-continuous fibers) are oriented in a predetermined direction in order to enhance the formability of the fiber laminate to a complicated structure such as a curved structure and to exert strength in a predetermined direction. Disclosed is a fiber laminate using the prepared fiber layer.
  • An object of the present invention is to provide a fiber laminate, a method for producing the fiber laminate, and a fiber reinforced composite material capable of suppressing variations in physical properties in a portion where the thickness continuously changes.
  • At least a part of the taper portion whose thickness continuously changes depending on a position in a predetermined direction is provided, and a plurality of fiber layers are stacked.
  • a fiber laminate is provided.
  • the fiber layer is made of discontinuous fibers and is configured with the orientation angles of the discontinuous fibers aligned in one direction.
  • the orientation angles of the non-continuous fibers of at least two of the plurality of fiber layers are different, and each of the plurality of fiber layers is continuous with the fiber density kept constant regardless of the position in a predetermined direction.
  • the tapered portion is configured by stacking a plurality of thickness changing portions, and the amount of change in thickness of each of the plurality of thickness changing portions is the same regardless of the position in a predetermined direction.
  • the tapered portion whose thickness continuously changes depending on the position in a predetermined direction
  • a plurality of fiber layers are stacked.
  • the fiber layer is made of discontinuous fibers and is configured with the orientation angles of the discontinuous fibers aligned in one direction.
  • the orientation angle of non-continuous fibers of at least two fiber layers of the plurality of fiber layers is different, and the fiber layer is formed by stretching a web made of non-continuous fibers by a web drafter having a roller portion made of a plurality of roller groups, Manufactured.
  • the draft magnification of the roller unit can be reduced by relatively varying the peripheral speeds of the plurality of roller groups so that the thickness continuously changes while the density is kept constant regardless of the position in the predetermined direction. Make it different.
  • a fiber reinforced composite material obtained by impregnating a fiber reinforced base material with a matrix resin.
  • the reinforcing substrate is the fiber laminate.
  • FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. (A) is a figure which shows a web drafter typically, (b) is a figure which shows a control member typically. The figure which shows the manufacturing apparatus of a 1st fiber layer typically. The figure which shows background art.
  • the fiber reinforced composite material M is formed by impregnating a fiber laminate W as a reinforcing base material with a matrix resin Ma.
  • the fiber laminate W is configured by stacking four fiber layers 11 to 14.
  • the fiber layer constituting the lowermost layer of the fiber laminate W is referred to as the first fiber layer 11, and the fiber layers stacked on the lowermost first fiber layer 11 are The second fiber layer 12 is used.
  • the fiber layer stacked on the second fiber layer 12 is referred to as a third fiber layer 13, and the fiber layer stacked on the third fiber layer 13 and constituting the uppermost layer of the fiber laminate W is a first fiber layer. 4 fiber layers 14.
  • the direction in which the first to fourth fiber layers 11 to 14 are stacked is defined as a stacking direction.
  • the stacking direction of the first to fourth fiber layers 11 to 14 is the thickness direction, and the dimension along the thickness direction is the thickness of each fiber layer 11 to 14.
  • the first to fourth fiber layers 11 to 14 have a rectangular surface in plan view.
  • a direction along the long side of the surface of the first to fourth fiber layers 11 to 14 is defined as a longitudinal direction
  • a direction along the short side is defined as a short direction.
  • the discontinuous fibers 10 are aligned in one direction so as to be uniaxially oriented.
  • a method of aligning the discontinuous fibers 10 any of a card method using a card machine, a paper making method using a paper machine, a gil method using a gil machine, and the like may be adopted.
  • the non-continuous fiber 10 is made of carbon fiber, for example.
  • the orientation angle of the discontinuous fibers 10 in the first fiber layer 11 is 90 degrees, and the discontinuous fibers 10 are aligned in a state extending in the short direction of the first fiber layer 11.
  • the orientation angle of the discontinuous fibers 10 in the second fiber layer 12 is 45 degrees, and the discontinuous fibers 10 are aligned in a state inclined by 45 degrees with respect to the longitudinal direction of the second fiber layer 12.
  • the orientation angle of the discontinuous fibers 10 in the third fiber layer 13 is ⁇ 45 degrees, and the discontinuous fibers 10 are aligned in a state inclined by ⁇ 45 degrees with respect to the longitudinal direction of the third fiber layer 13.
  • the orientation angle of the discontinuous fibers 10 in the fourth fiber layer 14 is 0 degree, and the discontinuous fibers 10 are aligned in the longitudinal direction of the fourth fiber layer 14. Therefore, based on the orientation angles of the discontinuous fibers 10 in the four directions in the first to fourth fiber layers 11 to 14, the fiber laminate W has pseudo-isotropic properties in the four directions.
  • the thicknesses of the first to fourth fiber layers 11 to 14 are the smallest at the first end 21 in the longitudinal direction and the largest at the second end 22 in the longitudinal direction.
  • Each of the first to fourth fiber layers 11 to 14 includes a first thickness non-change portion 24 a having a constant thickness from the first end portion 21 toward the second end portion 22.
  • the first to fourth fiber layers 11 to 14 include a thickness changing portion 23 that is continuous in the longitudinal direction with respect to the first thickness non-changing portion 24a and has a thickness that continuously changes.
  • each of the first to fourth fiber layers 11 to 14 includes a second thickness non-change portion 24b that is continuous in the longitudinal direction with respect to the thickness change portion 23 and has a constant thickness in the vicinity of the second end portion 22. .
  • the thickness of the first thickness non-change portion 24a is constant regardless of the position in the longitudinal direction.
  • the thickness of the second thickness non-change portion 24b is constant regardless of the position in the longitudinal direction, and is larger than the thickness of the first thickness non-change portion 24a.
  • the thickness changing portion 23 is a portion between the first thickness non-changing portion 24a and the second thickness non-changing portion 24b.
  • the thickness of the thickness changing portion 23 increases continuously from the first thickness non-changing portion 24a toward the second thickness non-changing portion 24b.
  • the density of the fibers of the first to fourth fiber layers 11 to 14 is the same at any position in the longitudinal direction. That is, the density of the fibers of the first to fourth fiber layers 11 to 14 is the first thickness non-change portion 24a, the thickness change portion 23, or the second thickness non-change portion 24b. Are the same.
  • the thickness of the first to fourth fiber layers 11 to 14 varies depending on the position in the longitudinal direction.
  • the density of the fibers of the first to fourth fiber layers 11 to 14 is the same at any position of the thickness changing portion 23. Therefore, the amount of change in thickness at the thickness changing portion 23 in the fiber laminate W is the same at any position in the longitudinal direction. This is because the web of the discontinuous fiber 10 is stretched by the web drafter 50 to change the thickness of the first to fourth fiber layers 11 to 14.
  • the thicknesses of the first to fourth fiber layers 11 to 14 are the same at any position of the thickness changing portion 23.
  • the thickness of the first to fourth fiber layers 11 to 14 is the same at any position of the first thickness non-change portion 24a, and the thickness of the first to fourth fiber layers 11 to 14 is the second thickness. The same is true at any position of the non-change portion 24b. Therefore, the physical properties of the first to fourth fiber layers 11 to 14 are the same at any position of the thickness changing portion 23, the first thickness non-changing portion 24a, and the second thickness non-changing portion 24b.
  • the fiber density is the same at any position in the longitudinal direction and the short direction of the fiber laminate W, and there is no difference in physical properties such as strength and shapeability of the fiber laminate W.
  • the fiber laminate W includes a tapered portion W1 in which the thickness changing portions 23 are stacked, and has a constant thickness at a position where the first thickness non-change portions 24a are stacked and a position where the second thickness non-change portions 24b are stacked. Part W2 is provided.
  • the fiber density is the same at any position in the longitudinal direction, which is the predetermined direction of the tapered portion W1, and there is no difference in physical properties such as strength and formability. Further, since the discontinuous fibers 10 are oriented every 45 degrees as viewed in the lamination direction, the fiber laminate W has pseudo-isotropic properties in four directions.
  • the thickness is constant and the fiber density is the same at any position in the longitudinal direction that is the predetermined direction of each constant thickness portion W2, and there is no difference in physical properties such as strength and formability. . Further, since the discontinuous fibers 10 are oriented every 45 degrees as viewed in the lamination direction, the fiber laminate W has pseudo-isotropic properties in four directions.
  • the fourth fiber layer 14 is formed by stretching a wide fiber bundle (hereinafter referred to as a web) made of discontinuous fibers with a web drafter 50.
  • the web drafter 50 includes a transport conveyor 55 that transports a fiber layer manufactured from the web 40, a roller section 51 that stretches (drafts) the web 40, and the web 40 that is stretched by the roller section 51.
  • a guide roller 53 that guides the web 40 and a regulating member 60 that regulates the width of the web 40 on the downstream side of the roller portion 51 are provided.
  • the web 40 passes through the roller portion 51, passes through the regulating member 60, and is then sent out to the transport conveyor 55 by the guide roller 53.
  • the flow direction of the web 40 in the web drafter 50 is defined as a distribution direction X.
  • the roller unit 51 has a plurality of roller groups 52.
  • Each roller group 52 includes three rollers 52a, 52b, and 52c.
  • the roller group 52 includes two upper rollers 52a and 52b and one lower roller 52c positioned between the rollers 52a and 52b.
  • the three rollers 52a, 52b, and 52c are driven at the same peripheral speed, thereby transferring the web 40 while being sandwiched between the lower roller 52c and the upper rollers 52a and 52b. Further, the peripheral speed of each roller group 52 can be changed.
  • a desired draft magnification is obtained by making the peripheral speed of the downstream roller group 52 faster than the peripheral speed of the upstream roller group 52.
  • the regulating member 60 of the web drafter 50 regulates the width of the web 40.
  • the regulating member 60 includes a pair of rectangular plate-like guides 61 positioned at both ends in the width direction of the web 40.
  • a first roller 62 and a second roller 63 are rotatably supported by the pair of guides 61.
  • Each guide 61 includes a guide groove 61a extending in the longitudinal direction.
  • the rotation shaft 62 a of the first roller 62 is inserted into the guide groove 61 a of the guide 61. Both ends of the rotation shaft 62a are rotatably supported by the support member 64.
  • the support member 64 can be moved in a direction in which the first roller 62 is brought into contact with and separated from the second roller 63 by a driving unit (not shown).
  • the rotation shaft 63 a of the second roller 63 is rotatably supported by the guide 61.
  • the second roller 63 is not movable in the longitudinal direction of the guide 61. Therefore, the distance between the first roller 62 and the second roller 63 can be adjusted by moving the first roller 62 in the longitudinal direction of the guide groove 61 a by the support member 64.
  • the distance between the first roller 62 and the second roller 63 can correspond to the thickness of the web 40 by bringing the first roller 62 into and out of contact with the second roller 63.
  • the discontinuous fibers 10 in the web 40 are aligned in one direction by an arbitrary method on the supply side of the web 40 (upstream in the flow direction X). Specifically, the discontinuous fibers 10 are aligned along the flow direction X.
  • each roller group 52 is driven to convey the web 40.
  • the peripheral speed of the uppermost roller group 52 is made constant, and the peripheral speed of the downstream roller group 52 is made faster than that of the uppermost roller group 52.
  • the thickness of the web 40 coming out of the most downstream roller group 52 is smaller than the thickness of the web 40 when it passes through the most upstream roller group 52. Therefore, as the peripheral speed of the downstream roller group 52 is made higher than the peripheral speed of the most upstream roller group 52, the thickness of the web 40 coming out of the most downstream roller group 52 can be reduced. Therefore, if the peripheral speed of the downstream roller group 52 is continuously increased, the thickness of the web 40 can be continuously reduced.
  • the number of fibers per unit area decreases as the thickness of the web 40 is reduced, and the density of the discontinuous fibers 10 is kept constant.
  • the width of the web 40 is then regulated by the pair of guides 61 of the regulating member 60. Therefore, in the web drafter 50, the width of the fiber layer obtained after passing through the regulating member 60 is regulated to a desired width.
  • the width of the web 40 is regulated, the thickness of the web 40 increases. Accordingly, the position of the first roller 62 with respect to the second roller 63 is controlled. As a result, the fiber density of the web 40 is kept constant regardless of the position in the longitudinal direction.
  • the web 40 is manufactured in a shape including the thickness changing portion 23 whose thickness changes depending on the position in the longitudinal direction, and the first and second thickness non-changing portions 24a and 24b whose thickness is constant.
  • the web drafter 70 for producing the first to third fiber layers 11 to 13 will be described.
  • the web drafter 70 includes a roller portion 51 including a plurality of first roller sets 71 and second roller sets 72 arranged in the longitudinal direction of the web 40.
  • the first roller set 71 manufactures the thickness changing portion 23 of the first fiber layer 11
  • the second roller set 72 manufactures the thickness non-changing portions 24 a and 24 b of the first fiber layer 11.
  • Each first roller set 71 includes a first support roller 66 that supports the web 40, and a different diameter roller 67 that sandwiches the web 40 together with the first support roller 66.
  • Each first support roller 66 is a roller having the same diameter regardless of the position of the rotation axis L1 in the axial direction.
  • the different diameter roller 67 is a roller whose diameter gradually changes depending on the position of the rotation axis L2 in the axial direction.
  • Each of the different diameter rollers 67 is arranged in a state where the diameter gradually increases from one end portion in the longitudinal direction of the web 40 toward the other end portion.
  • the plurality of different-diameter rollers 67 are arranged so that their peripheral surfaces are continuous in the longitudinal direction of the web 40.
  • Each second roller set 72 includes a second support roller 68 that supports the web 40 and a roller 69 that sandwiches the web 40 together with the second support roller 68.
  • Each of the second support roller 68 and the roller 69 is a roller having the same diameter regardless of the position in the axial direction of the rotation axis L1, L2.
  • the peripheral surface of each second support roller 68 is arranged so as to be continuous in the longitudinal direction of the web 40.
  • Each circumferential surface of each roller 69 is also arranged to be continuous in the longitudinal direction of the web 40.
  • the web 40 is supplied to the web drafter 70 in a state where the discontinuous fibers 10 extend along the surface of the first fiber layer 11 and in a direction orthogonal to the rotation axes L1 and L2. Then, each of the plurality of first roller sets 71 and second roller sets 72 is driven.
  • the peripheral speed of the first roller set 71 close to the first end 21 is relatively increased. That is, the draft magnification of the first roller set 71 close to the first end 21 is relatively increased.
  • the thickness of the web 40 gradually increases from the first roller set 71 close to the first end 21 toward the first roller set 71 close to the second end 22.
  • the thickness changing portion 23 of the first fiber layer 11 is manufactured.
  • the first thickness non-change portion 24 a is manufactured by the second roller set 72 close to the first end portion 21, and the second thickness non-change portion 24 b is manufactured by the second roller set 72 close to the second end portion 22. .
  • the second and third fiber layers 12 and 13 are also manufactured using a web drafter in which a roller set is divided in the width direction of the web 40, similarly to the web drafter 70.
  • the peripheral speed (draft magnification) of each of the divided roller sets is set so that the web 40 has a desired thickness in each divided area, and the second and third fiber layers 12, 13 are used. It changes according to the position of the longitudinal direction.
  • the manufactured first to fourth fiber layers 11 to 14 are stacked, and the fiber laminate W is manufactured. Thereafter, the fiber laminate W is impregnated with a thermosetting matrix resin Ma and cured. Impregnation and curing of the matrix resin Ma is performed by an RTM (resin transfer molding) method.
  • the fiber laminate W includes a tapered portion W1 whose thickness continuously changes depending on the position in the longitudinal direction.
  • the taper portion W1 is formed by stacking the thickness changing portions 23 of the first to fourth fiber layers 11-14.
  • the density of the fiber is the same and the change amount of the thickness is also the same. Therefore, although the thickness of the tapered portion W1 varies, the number of fiber layers and the fiber orientation are the same regardless of the position in the longitudinal direction. Therefore, in the taper part W1 of the fiber laminate W, variations in physical properties such as formability and strength can be suppressed.
  • the thickness of the taper portion W1 of the fiber laminate W is changed by changing the thickness of each of the first to fourth fiber layers 11-14. According to this configuration, the number of fiber layers is not changed in order to change the thickness of the fiber laminate W, and the end of the fiber layer does not exist in the tapered portion W1. For this reason, the resin-rich portion where only the matrix resin Ma exists in the vicinity of the end portion of the fiber layer is not formed in the tapered portion W1. Therefore, the strength of the fiber reinforced composite material M does not decrease due to the resin-rich portion.
  • the orientation angles of the discontinuous fibers 10 of each fiber layer were set to 0 degrees, 45 degrees, -45 degrees, and 90 degrees. For this reason, the fiber laminate W can have pseudo-isotropic properties in four directions in plan view.
  • the thickness of the web 40 can be varied by changing the draft magnification of the roller portion 51.
  • the thickness changing portion 23 whose thickness changes can be manufactured in the first to fourth fiber layers 11 to 14.
  • the first and second thickness non-change portions 24a and 24b can be manufactured in the first to fourth fiber layers 11 to 14. Therefore, if the web drafters 50 and 70 are used, the first to fourth fiber layers 11 to 14 having the thickness changing portion 23 and the thickness non-changing portions 24a and 24b can be easily manufactured.
  • the web drafters 50 and 70 include a regulating member 60 that regulates the extension of the web 40 in the width direction. For this reason, the width of the web 40 can be regulated to a predetermined dimension by the regulating member 60 while the web 40 is stretched by the web drafters 50 and 70.
  • the fiber laminate W is configured by stacking fiber layers having the thickness changing portion 23. Therefore, the intensity
  • the orientation angles of the discontinuous fibers 10 of the first to fourth fiber layers 11 to 14 are all different, but out of the four fiber layers, the discontinuous fibers 10 of two or three fiber layers are used. Only the orientation angle may be different.
  • the fiber laminate W has pseudo-isotropic properties in four directions, but may have pseudo-isotropic properties in three directions or six directions.
  • the fiber laminate W may not have pseudo-isotropic properties.
  • the thickness of the taper portion W1 is changed depending on the position in the longitudinal direction, and the thickness of the constant thickness portion W2 is made constant, but this is not limitative. That is, the entire longitudinal direction of the fiber laminate W may be the tapered portion W1 by continuously changing the thickness of the fiber laminate W over the entire longitudinal direction.
  • the predetermined direction of the fiber laminate W is the longitudinal direction, but the predetermined direction of the fiber laminate W may be the short direction.
  • the fiber laminate W is configured such that the thickness of the tapered portion W1 increases continuously from the first end portion 21 toward the second end portion 22, but the present invention is not limited thereto. That is, you may comprise the fiber laminated body W so that the thickness of the taper part W1 may become small continuously as it goes to the 2nd end part 22 from the 1st end part 21.
  • the number of roller groups 52 in the web drafters 50 and 70 may be changed as appropriate. You may manufacture the thickness change part 23 of the 1st-4th fiber layers 11-14 by methods other than the method of extending the web 40 with the web drafters 50 and 70.
  • FIG. For example, a base in which the thickness of the fiber layer is constant and a fiber sheet different from the base may be prepared and joined to continuously change the thickness of the fiber laminate. In this case, in the fiber sheet, the fiber density is constant regardless of the position in the longitudinal direction of the fiber layer.
  • the regulating member 60 may be omitted from the web drafters 50 and 70.
  • the fiber layers are laminated in a state where the widths of the first to fourth fiber layers 11 to 14 are uneven, and after the lamination, the end portions of the fiber layers are cut to provide the widths of the fiber layers. Also good.

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Abstract

繊維積層体Ｗは、第１～第４の繊維層を積み重ねて構成されている。繊維積層体は、長手方向の位置によって厚みが変化するテーパ部を備える。第１～第４の繊維層は、非連続繊維からなり、非連続繊維の配向角度を一方向に揃えて構成されている。第１～第４の繊維層の非連続繊維の配向角度はそれぞれ異なる。また、第１～第４の繊維層は、長手方向の位置によらず繊維の密度が一定に保たれたまま連続的に厚みが変化する厚み変化部を備える。テーパ部は、複数の厚み変化部が積み重なって構成されている。複数の厚み変化部のそれぞれの厚みの変化量は、長手方向の位置によらず同じである。

Description

繊維積層体、繊維積層体の製造方法、及び繊維強化複合材
　本発明は、複数の繊維層を積み重ねて構成された繊維積層体、繊維積層体の製造方法、及び繊維強化複合材に関する。
　繊維強化複合材は、軽量の構造材料として広く使用されている。繊維強化複合材用の強化基材として、繊維積層体がある。繊維強化複合材は、繊維積層体にマトリックス樹脂を含浸させて形成されている。繊維強化複合材は、ロケット、航空機、自動車、船舶及び建築物の構造材として用いられている。また、使用される形状に合わせて厚みを変化させて構成した繊維強化複合材もある。
　図７に示すように、特許文献１に開示の繊維積層体８０は、複数のシート状補強繊維８１を積み重ねて構成されている。繊維積層体８０は、ベース８２、中間部８３、及び表層部８４を有する。ベース８２では、複数のシート状補強繊維８１が積み重ねられて、一様な厚みを有している。中間部８３では、複数のシート状補強繊維８１が、各シート状補強繊維８１の端部を階段状にずらして積み重ねられている。表層部８４は、ベース８２及び中間部８３の表面全体を覆う。この繊維積層体８０の厚みは、中間部８３で各シート状補強繊維８１の端部をずらすことで、徐々に変化する。
　また、特許文献２は、繊維積層体の曲面構造等の複雑な構造への賦形性を高めかつ所定の方向への強度を発揮させるために短繊維（非連続繊維）を所定の方向に配向した繊維層を用いた繊維積層体を開示する。
　ところが、非連続繊維を所定の方向に配向させた繊維層を用いた繊維積層体において、特許文献１のように繊維積層体の厚みを連続的に変化させると、以下の問題が生じる。即ち、各繊維層の端部をずらして積層した場合、繊維積層体の厚みが連続的に変化する部分では、層方向の位置によって、繊維層の積層数も異なってしまう。よって、各繊維層の端部付近で繊維積層体の厚みが変化する毎に、非連続繊維の配向が変化し、繊維積層体の物性がばらついてしまう。
実開平４－５３０号公報 特開２０１３－２２１１１４号公報
　本発明の目的は、厚みが連続的に変化する部分において物性のばらつきを抑えることができる繊維積層体、繊維積層体の製造方法、及び繊維強化複合材を提供することにある。
　上記問題点を解決するため、本発明の第一の態様によれば、所定の方向の位置によって連続的に厚みが変化するテーパ部を少なくとも一部に備えるとともに、複数の繊維層を積み重ねて構成された繊維積層体が提供される。繊維層は、非連続繊維からなり、かつ非連続繊維の配向角度を一方向に揃えて構成されている。複数の繊維層のうちの少なくとも２つの繊維層の非連続繊維の配向角度が異なり、複数の繊維層のそれぞれは、所定の方向の位置によらず繊維の密度が一定に保たれたまま連続的に厚みが変化する厚み変化部を備える。テーパ部は、複数の厚み変化部が積み重なって構成されるとともに、複数の厚み変化部のそれぞれの厚みの変化量は、所定の方向の位置によらず同じである。
　上記問題点を解決するため、本発明の第二の態様によれば、所定の方向の位置によって連続的に厚みが変化するテーパ部を少なくとも一部に備えるとともに、複数の繊維層を積み重ねて構成された繊維積層体の製造方法が提供される。繊維層は、非連続繊維からなり、かつ非連続繊維の配向角度を一方向に揃えて構成されている。複数の繊維層のうちの少なくとも２つの繊維層の非連続繊維の配向角度が異なり、繊維層は、非連続繊維からなるウェブを、複数のローラ群からなるローラ部を有するウェブドラフタによって引き延ばして、製造される。また、所定の方向の位置によらず密度が一定に保たれたまま連続的に厚みが変化するように、複数のローラ群の周速度を相対的に異ならせることで、ローラ部のドラフト倍率を異ならせる。
　上記問題点を解決するため、本発明の第三の態様によれば、繊維製の強化基材にマトリックス樹脂を含浸させてなる繊維強化複合材が提供される。強化基材が上記の繊維積層体である。
本発明の一実施形態の繊維積層体及び繊維強化複合材を模式的に示す斜視図。 繊維積層体の分解斜視図。 繊維積層体を示す側面図。 図３の４－４線に沿った断面図。 （ａ）はウェブドラフタを模式的に示す図、（ｂ）は規制部材を模式的に示す図。 第１の繊維層の製造装置を模式的に示す図。 背景技術を示す図。
　以下、本発明の繊維積層体、繊維積層体の製造方法、及び繊維強化複合材を具体化した一実施形態を図１～図６にしたがって説明する。
　図１に示すように、繊維強化複合材Ｍは、強化基材としての繊維積層体Ｗにマトリックス樹脂Ｍａを含浸させて形成されている。繊維積層体Ｗは、４枚の繊維層１１～１４を積み重ねて構成されている。以下、４枚の繊維層１１～１４について、繊維積層体Ｗの最下層を構成する繊維層を第１の繊維層１１とし、最下層の第１の繊維層１１上に積み重ねられた繊維層を第２の繊維層１２とする。また、第２の繊維層１２の上に積み重ねられた繊維層を第３の繊維層１３とし、第３の繊維層１３上に積み重ねられかつ繊維積層体Ｗの最上層を構成する繊維層を第４の繊維層１４とする。
　繊維積層体Ｗにおいて、第１～第４の繊維層１１～１４が積み重ねられた方向を積層方向とする。また、第１～第４の繊維層１１～１４の積層方向を厚み方向とし、厚み方向に沿う寸法を各繊維層１１～１４の厚みとする。第１～第４の繊維層１１～１４は、平面視で、矩形状の表面を有する。また、第１～第４の繊維層１１～１４の表面の長辺に沿う方向を長手方向とし、短辺に沿う方向を短手方向とする。
　図２に示すように、第１～第４の繊維層１１～１４のそれぞれでは、非連続繊維１０が１軸配向となるように一方向に引き揃えられている。非連続繊維１０を引き揃える方法としては、カード機を用いたカード方式、抄紙機を用いた抄紙方式、ギル機を用いたギル方式等、いずれを採用してもよい。
　非連続繊維１０は、例えば、炭素繊維で構成されている。第１の繊維層１１における非連続繊維１０の配向角度は９０度であり、非連続繊維１０は第１の繊維層１１の短手方向に延びた状態に引き揃えられている。第２の繊維層１２における非連続繊維１０の配向角度は４５度であり、非連続繊維１０は第２の繊維層１２の長手方向に対し４５度傾いた状態に引き揃えられている。第３の繊維層１３における非連続繊維１０の配向角度は－４５度であり、非連続繊維１０は第３の繊維層１３の長手方向に対し－４５度傾いた状態に引き揃えられている。第４の繊維層１４における非連続繊維１０の配向角度は０度であり、非連続繊維１０は第４の繊維層１４の長手方向に引き揃えられている。よって、第１～第４の繊維層１１～１４における非連続繊維１０の４方向への配向角度に基づき、繊維積層体Ｗは４方向に擬似等方性を有する。
　図３又は図４に示すように、第１～第４の繊維層１１～１４の各厚みは、長手方向の第１端部２１で最も小さく、長手方向の第２端部２２で最も大きい。第１～第４の繊維層１１～１４は、第１端部２１から第２端部２２に向かうに従い厚みが一定である第１厚み非変化部２４ａを備える。また、第１～第４の繊維層１１～１４は、第１厚み非変化部２４ａに対して長手方向に連続しかつ厚みが連続的に変化する厚み変化部２３を備える。さらに、第１～第４の繊維層１１～１４は、厚み変化部２３に対して長手方向に連続しかつ厚みが一定である第２厚み非変化部２４ｂを、第２端部２２近傍に備える。
　第１厚み非変化部２４ａの厚みは、長手方向の位置によらず一定である。また、第２厚み非変化部２４ｂの厚みは、長手方向の位置によらず一定であるとともに、第１厚み非変化部２４ａの厚みに比べて大きい。
　厚み変化部２３は、第１厚み非変化部２４ａと第２厚み非変化部２４ｂとの間の部分である。厚み変化部２３の厚みは、第１厚み非変化部２４ａから第２厚み非変化部２４ｂに向かうに従い、連続的に大きくなる。
　第１～第４の繊維層１１～１４の繊維の密度は、長手方向のいずれの位置であっても、同じである。すなわち、第１厚み非変化部２４ａであっても、厚み変化部２３であっても、第２厚み非変化部２４ｂであっても、第１～第４の繊維層１１～１４の繊維の密度は、同じである。
　厚み変化部２３では、第１～第４の繊維層１１～１４の厚みが、長手方向の位置によって異なる。しかしながら、第１～第４の繊維層１１～１４の繊維の密度は、厚み変化部２３のいずれの位置でも、それぞれ同じである。したがって、繊維積層体Ｗにおいて厚み変化部２３での厚みの変化量は、長手方向のいずれの位置であっても、同じである。これは、非連続繊維１０のウェブをウェブドラフタ５０で引き延ばして第１～第４の繊維層１１～１４の厚みを変化させているからである。
　また、第１～第４の繊維層１１～１４の厚みは、厚み変化部２３のいずれの位置でも、同じである。第１～第４の繊維層１１～１４の厚みは、第１厚み非変化部２４ａのいずれの位置でも、同じであり、第１～第４の繊維層１１～１４の厚みは、第２厚み非変化部２４ｂのいずれの位置でも、同じである。よって、第１～第４の繊維層１１～１４の物性は、厚み変化部２３、第１厚み非変化部２４ａ、及び第２厚み非変化部２４ｂのいずれの位置でも、同じである。
　繊維積層体Ｗの長手方向及び短手方向のいずれの位置であっても、繊維の密度は同じであり、繊維積層体Ｗの強度、賦形性等の物性に差がない。また、繊維積層体Ｗは、厚み変化部２３が積み重なったテーパ部Ｗ１を備えるとともに、第１厚み非変化部２４ａが積み重なった位置と第２厚み非変化部２４ｂが積み重なった位置とにそれぞれ定厚部Ｗ２を備える。テーパ部Ｗ１の所定の方向である長手方向のいずれの位置であっても、繊維の密度は同じであり、強度、賦形性等の物性に差がない。また、積層方向に見て非連続繊維１０が４５度おきに配向されているため、繊維積層体Ｗは四方向に疑似等方性を有する。
　また、各定厚部Ｗ２の所定の方向である長手方向のいずれの位置であっても、厚みが一定であり、繊維の密度が同じであり、強度、賦形性等の物性に差がない。また、積層方向に見て非連続繊維１０が４５度おきに配向されているため、繊維積層体Ｗは四方向に疑似等方性を有する。
　次に、第１～第４の繊維層１１～１４の製造方法について説明する。
　まず、第４の繊維層１４の製造方法について説明する。図５（ａ）に示すように、第４の繊維層１４は、非連続繊維からなる幅広の繊維束（以下、ウェブと記載する）をウェブドラフタ５０で引き延ばして形成されている。ウェブドラフタ５０は、ウェブ４０から製造された繊維層を搬送する搬送コンベア５５と、ウェブ４０を引き延ばす（ドラフトする）ローラ部５１と、ローラ部５１で引き延ばされたウェブ４０を搬送コンベア５５に向けてガイドするガイドローラ５３と、ローラ部５１の下流側でウェブ４０の幅を規制する規制部材６０とを備える。ウェブ４０は、ローラ部５１を通過し、規制部材６０を通過した後、ガイドローラ５３によって搬送コンベア５５に送り出される。ウェブドラフタ５０においてウェブ４０の流れる方向を流通方向Ｘとする。
　ローラ部５１は、複数のローラ群５２を有する。各ローラ群５２は、３本のローラ５２ａ，５２ｂ，５２ｃからなる。ローラ群５２は、２本の上ローラ５２ａ，５２ｂと、ローラ５２ａ，５２ｂ間に位置する１本の下ローラ５２ｃとからなる。３本のローラ５２ａ，５２ｂ，５２ｃは、同一周速度で駆動されることで、ウェブ４０を下ローラ５２ｃと上ローラ５２ａ，５２ｂとにより挟みながら移送する。また、各ローラ群５２の周速度は変更可能である。上流側のローラ群５２の周速度より下流側のローラ群５２の周速度を速くすることで、所望のドラフト倍率を得る。
　ウェブドラフタ５０の規制部材６０は、ウェブ４０の幅を規制する。
　図５（ａ）又は図５（ｂ）に示すように、規制部材６０は、ウェブ４０の幅方向両端に位置する矩形板状の一対のガイド６１を備える。一対のガイド６１には、第１ローラ６２及び第２ローラ６３が回転可能に支持されている。各ガイド６１は、長手方向に延びるガイド溝６１ａを備える。
　第１ローラ６２の回転軸６２ａは、ガイド６１のガイド溝６１ａに挿入されている。回転軸６２ａの両端は、支持部材６４によって回転可能に支持されている。支持部材６４は、図示しない駆動部により、第１ローラ６２を第２ローラ６３に対し接離させる方向へ移動可能である。第２ローラ６３の回転軸６３ａは、ガイド６１に回転可能に支持されている。第２ローラ６３は、第１ローラ６２と異なり、ガイド６１の長手方向に移動不能である。よって、支持部材６４によって第１ローラ６２をガイド溝６１ａの長手方向に移動させることで、第１ローラ６２と第２ローラ６３の間隔の大きさが調節可能である。このように、第１ローラ６２を第２ローラ６３に対し接離させることで、第１ローラ６２と第２ローラ６３の間隔を、ウェブ４０の厚みに対応可能である。
　ウェブドラフタ５０によって第４の繊維層１４を製造する場合、まず、ウェブ４０の供給側（流通方向Ｘの上流）において、ウェブ４０中の非連続繊維１０を任意の方法で一方向に引き揃える。詳細には、非連続繊維１０を流通方向Ｘに沿って引き揃える。
　次に、各ローラ群５２を駆動させて、ウェブ４０を搬送する。このとき、最上流のローラ群５２の周速度を一定とし、下流側のローラ群５２の周速度を最上流のローラ群５２よりも速くする。これにより、最下流のローラ群５２から出てくるウェブ４０の厚みは、最上流のローラ群５２を通過する時点でのウェブ４０の厚みよりも、小さくなる。よって、下流側のローラ群５２の周速度を最上流のローラ群５２の周速度より速くするほど、最下流のローラ群５２から出てくるウェブ４０の厚みを小さくできる。したがって、下流側のローラ群５２の周速度を連続的に速くすれば、ウェブ４０の厚みを連続的に小さくできる。しかも、ウェブ４０を圧縮して薄くする方法とは異なり、ウェブ４０の厚みを小さくするのに従って単位面積当たりの繊維の数が減少し、非連続繊維１０の密度は一定に保たれる。
　各ローラ群５２の周速度の変更によりウェブ４０の厚みが連続的に変化させられると、次に、ウェブ４０の幅が規制部材６０の一対のガイド６１によって規制される。したがって、ウェブドラフタ５０では、規制部材６０を通過した後に得られる繊維層の幅が、所望の幅に規制される。ウェブ４０の幅が規制されると、ウェブ４０の厚みが大きくなる。これに応じて、第２ローラ６３に対する第１ローラ６２の位置が制御される。その結果、ウェブ４０の繊維の密度は、長手方向の位置によらず一定に保たれる。一方で、ウェブ４０は、長手方向の位置によって厚みが変化する厚み変化部２３と、厚みが一定である第１及び第２厚み非変化部２４ａ，２４ｂとを備える形状に、製造される。
　次に、第１～第３の繊維層１１～１３を製造するウェブドラフタ７０について説明する。
　図６に示すように、ウェブドラフタ７０は、ウェブ４０の長手方向に配置される第１ローラ組７１と第２ローラ組７２とをそれぞれ複数組備えたローラ部５１を有する。第１ローラ組７１は、第１の繊維層１１の厚み変化部２３を製造し、第２ローラ組７２は、第１の繊維層１１の厚み非変化部２４ａ，２４ｂを製造する。
　各第１ローラ組７１は、ウェブ４０を支持する第１支持ローラ６６と、第１支持ローラ６６と共にウェブ４０を挟む異径ローラ６７とを備える。各第１支持ローラ６６は、回転軸線Ｌ１の軸線方向の位置によらず同径であるローラである。一方、異径ローラ６７は、回転軸線Ｌ２の軸線方向の位置によって直径が徐々に変化するローラである。各異径ローラ６７は、ウェブ４０の長手方向の一方の端部から他方の端部に向けて直径が徐々に大きくなる状態で配置されている。複数の異径ローラ６７は、それらの周面をウェブ４０の長手方向に連続させるように配置されている。
　各第２ローラ組７２は、ウェブ４０を支持する第２支持ローラ６８と、第２支持ローラ６８と共にウェブ４０を挟むローラ６９とを備える。各第２支持ローラ６８及びローラ６９は、回転軸線Ｌ１，Ｌ２の軸方向の位置によらず同径であるローラである。各第２支持ローラ６８の周面は、ウェブ４０の長手方向に連続するように配置されている。各ローラ６９の各周面も、ウェブ４０の長手方向に連続するように配置されている。
　第１の繊維層１１を製造する場合、複数のローラ組７１の第１支持ローラ６６と異径ローラ６７との間に、ウェブ４０において厚み変化部２３となる部位を配置する。また、複数の第２ローラ組７２の第２支持ローラ６８とローラ６９との間に、ウェブ４０において厚み非変化部２４ａ，２４ｂとなる部位を配置する。このとき、非連続繊維１０が第１の繊維層１１の表面に沿ってかつ各回転軸線Ｌ１，Ｌ２と直交する方向に延びる状態で、ウェブ４０がウェブドラフタ７０に供給される。そして、複数の第１ローラ組７１及び第２ローラ組７２をそれぞれ駆動させる。
　複数の第１ローラ組７１間では、第１端部２１に近い第１ローラ組７１の周速度を相対的に速くする。すなわち、第１端部２１に近い第１ローラ組７１のドラフト倍率を相対的に高くする。すると、第１端部２１に近い第１ローラ組７１から第２端部２２に近い第１ローラ組７１に向かうほど、ウェブ４０の厚みが徐々に大きくなる。こうして、第１の繊維層１１の厚み変化部２３が製造される。また、第１端部２１に近い第２ローラ組７２によって第１厚み非変化部２４ａが製造され、第２端部２２に近い第２ローラ組７２によって第２厚み非変化部２４ｂが製造される。
　第２及び第３の繊維層１２，１３も、ウェブドラフタ７０と同様に、ローラ組がウェブ４０の幅方向に分割されたウェブドラフタを用いて、製造される。ただし、ウェブドラフタ７０とは異なり、各分割区域においてウェブ４０が所望の厚みとなるように、分割された各ローラ組の周速度（ドラフト倍率）を、第２及び第３の繊維層１２，１３の長手方向の位置に応じて変更する。
　製造された第１～第４の繊維層１１～１４が積み重ねられ、繊維積層体Ｗが製造される。その後、繊維積層体Ｗに、熱硬化性のマトリックス樹脂Ｍａを含浸し、硬化させる。マトリックス樹脂Ｍａの含浸硬化は、ＲＴＭ（レジン・トランスファー・モールディング）法で行われる。
　上記実施形態によれば、以下のような効果を得ることができる。
　（１）繊維積層体Ｗは、長手方向の位置によって厚みが連続的に変化するテーパ部Ｗ１を備える。テーパ部Ｗ１は、第１～第４の繊維層１１～１４の厚み変化部２３が積み重なって形成されている。各厚み変化部２３では、厚みが連続的に変化しながらも、繊維の密度が同じであり、厚みの変化量も同じである。したがって、テーパ部Ｗ１では、厚みが変化するものの、長手方向の位置によらず、繊維層の積層数も、繊維配向も同じである。よって、繊維積層体Ｗのテーパ部Ｗ１では賦形性や強度といった物性のばらつきを抑えることができる。
　（２）第１～第４の繊維層１１～１４それぞれの厚みを変えることで、繊維積層体Ｗのテーパ部Ｗ１の厚みを変化させている。この構成によれば、繊維積層体Ｗの厚みを変化させるために繊維層の積層数を変えておらず、テーパ部Ｗ１に繊維層の端部が存在していない。このため、繊維層の端部付近にマトリックス樹脂Ｍａのみが存在する樹脂リッチな部分が、テーパ部Ｗ１に形成されない。よって、樹脂リッチな部分によって繊維強化複合材Ｍの強度が低下することがない。
　（３）第１～第４の繊維層１１～１４間で、各繊維層の非連続繊維１０の配向角度を、０度、４５度、－４５度、９０度とした。このため、繊維積層体Ｗは、平面視で、四方向に疑似等方性を有することができる。
　（４）ウェブドラフタ５０，７０において、ローラ部５１のドラフト倍率を変化させることで、ウェブ４０の厚みを異ならせることができる。その結果、第１～第４の繊維層１１～１４に、厚みが変化する厚み変化部２３を製造することができる。また、ローラ部５１のドラフト倍率を同じにすることで、第１～第４の繊維層１１～１４に、第１及び第２厚み非変化部２４ａ，２４ｂを製造することができる。よって、ウェブドラフタ５０，７０を使用すれば、厚み変化部２３及び各厚み非変化部２４ａ，２４ｂを有する第１～第４の繊維層１１～１４を容易に製造することができる。
　（５）ウェブドラフタ５０，７０は、ウェブ４０の幅方向への延びを規制する規制部材６０を備える。このため、ウェブドラフタ５０，７０によってウェブ４０を引き延ばしつつも、規制部材６０によってウェブ４０の幅を所定寸法に規制することができる。
　（６）繊維積層体Ｗは、厚み変化部２３を有する繊維層を積み重ねて構成されている。よって、繊維層の積層数を調整することで、得られる繊維積層体Ｗの強度を調節することができる。よって、厚みが連続的に変化するテーパ部Ｗ１を有する繊維積層体Ｗにおいて、テーパ部Ｗ１での物性のばらつきを抑えつつ、強度も調節することができる。
　上記実施形態は、以下のように変更してもよい。
　上記実施形態では、第１～第４の繊維層１１～１４の非連続繊維１０の配向角度を全て異ならせたが、４枚の繊維層うち、２又は３枚の繊維層の非連続繊維１０の配向角度のみを異ならせてもよい。
　繊維積層体Ｗは、四方向に疑似等方性を有していたが、三方向や六方向に疑似当方性を有していてもよい。
　繊維積層体Ｗは、疑似等方性を有していなくてもよい。
　繊維積層体Ｗでは、長手方向の位置によってテーパ部Ｗ１の厚みを変化させ、定厚部Ｗ２の厚みを一定としたが、これに限らない。つまり、繊維積層体Ｗの厚みを長手方向全体に亘って連続的に変化させることで、繊維積層体Ｗの長手方向全体をテーパ部Ｗ１としてもよい。
　実施形態では、繊維積層体Ｗの所定方向を長手方向としたが、繊維積層体Ｗの所定方向を短手方向としてもよい。
　実施形態では、第１端部２１から第２端部２２に向かうに従いテーパ部Ｗ１の厚みが連続的に大きくなるように、繊維積層体Ｗを構成したが、これに限らない。つまり、第１端部２１から第２端部２２に向かうに従いテーパ部Ｗ１の厚みが連続的に小さくなるように、繊維積層体Ｗを構成してもよい。
　ウェブドラフタ５０，７０におけるローラ群５２の数は、適宜変更してもよい。
　第１～第４の繊維層１１～１４の厚み変化部２３を、ウェブドラフタ５０，７０によりウェブ４０を引き延ばす方法以外の方法によって、製造してもよい。例えば、繊維層の厚みが一定であるベースと、ベースとは別の繊維シートとを準備し、それらを接合して、繊維積層体の厚みを連続的に変化させてもよい。この場合、繊維シートでは、繊維層の長手方向の位置によらず、繊維の密度が一定である。
　ウェブドラフタ５０，７０から規制部材６０を省略してもよい。この場合、第１～第４の繊維層１１～１４の幅が不揃いな状態で各繊維層を積層し、積層後に、各繊維層の端部をカットして、各繊維層の幅を備えてもよい。

Claims (5)

  1. 所定の方向の位置によって連続的に厚みが変化するテーパ部を少なくとも一部に備えるとともに、複数の繊維層を積み重ねて構成された繊維積層体であって、
    　前記繊維層は、非連続繊維からなり、かつ前記非連続繊維の配向角度を一方向に揃えて構成され、
    　前記複数の繊維層のうちの少なくとも２つの繊維層の前記非連続繊維の配向角度が異なり、
    　前記複数の繊維層のそれぞれは、前記所定の方向の位置によらず繊維の密度が一定に保たれたまま連続的に厚みが変化する厚み変化部を備え、
    　前記テーパ部は、複数の厚み変化部が積み重なって構成されるとともに、前記複数の厚み変化部のそれぞれの厚みの変化量は、前記所定の方向の位置によらず同じである、繊維積層体。
  2. 請求項１に記載の繊維積層体は、更に、
    　前記所定の方向の位置によらず前記繊維層の厚みが変化しない定厚部を備える、繊維積層体。
  3. 所定の方向の位置によって連続的に厚みが変化するテーパ部を少なくとも一部に備えるとともに、複数の繊維層を積み重ねて構成された繊維積層体の製造方法であって、
    　前記繊維層は、非連続繊維からなり、かつ前記非連続繊維の配向角度を一方向に揃えて構成され、
    　前記複数の繊維層のうちの少なくとも２つの繊維層の前記非連続繊維の配向角度が異なり、
    　前記繊維層は、前記非連続繊維からなるウェブを、複数のローラ群からなるローラ部を有するウェブドラフタによって引き延ばして、製造され、
    　前記所定の方向の位置によらず密度が一定に保たれたまま連続的に厚みが変化するように、前記複数のローラ群の周速度を相対的に異ならせることで、前記ローラ部のドラフト倍率を異ならせる、繊維積層体の製造方法。
  4. 請求項３に記載の繊維積層体の製造方法において、
    　前記ローラ部の下流側で、前記ウェブの幅を規制部材で規制する、繊維積層体の製造方法。
  5. 繊維製の強化基材にマトリックス樹脂を含浸させてなる繊維強化複合材であって、
    　前記強化基材が請求項１に記載の繊維積層体である、繊維強化複合材。
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