WO2017212835A1 - Matériau de base renforcé pour élément en matériau composite, élément en matériau composite et son procédé de fabrication - Google Patents

Matériau de base renforcé pour élément en matériau composite, élément en matériau composite et son procédé de fabrication Download PDF

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Publication number
WO2017212835A1
WO2017212835A1 PCT/JP2017/017169 JP2017017169W WO2017212835A1 WO 2017212835 A1 WO2017212835 A1 WO 2017212835A1 JP 2017017169 W JP2017017169 W JP 2017017169W WO 2017212835 A1 WO2017212835 A1 WO 2017212835A1
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WO
WIPO (PCT)
Prior art keywords
knitted
reinforced
base material
composite material
reinforcing fiber
Prior art date
Application number
PCT/JP2017/017169
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English (en)
Japanese (ja)
Inventor
駿一 森島
敏生 小佐々
正剛 波多野
和昭 岸本
幸生 武内
仁史 小鹿
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三菱重工業株式会社
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Filing date
Publication date
Application filed by 三菱重工業株式会社 filed Critical 三菱重工業株式会社
Publication of WO2017212835A1 publication Critical patent/WO2017212835A1/fr

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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/246—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using polymer based synthetic fibres
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/241—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres
    • C08J5/244—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres using glass fibres
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/241—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres
    • C08J5/243—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres using carbon fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B1/22—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes specially adapted for knitting goods of particular configuration
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes

Definitions

  • the present invention relates to a reinforced base material for composite parts, composite parts, and methods for producing them.
  • Fiber reinforced plastic is a composite material that uses fibers as a reinforcing material and a thermoplastic resin or a thermosetting resin as a matrix. Since fiber reinforced plastic is lightweight and has high strength, it is widely used as a structural member for aircraft, automobiles, ships, etc. (Patent Document 1).
  • a paper pattern 11 is created in accordance with the shape of the molded product 10 (FIGS. 6A and 6B).
  • the sheet-like preform 12 is cut according to the pattern paper 11 (FIG. 6C).
  • the cut preform 12 ' is pressed against the mold 13 to create a three-dimensional shape (FIG. 6 (d)).
  • the preform 12 is made of a unidirectional fiber reinforcing material or a woven material.
  • the unidirectional fiber reinforcement is a composite material in which the fiber direction is aligned only in one direction.
  • the woven material is a composite material including a fiber woven fabric formed by crossing fiber threads.
  • Unidirectional fiber reinforcements and woven materials have the characteristics that they are difficult to adapt to complex curved surfaces and have poor flexibility and moldability. For this reason, if the sheet of the unidirectional fiber reinforcing material and the woven material is pressed against the complicated curved surface as it is, the fiber orientation is deviated or wrinkles occur. Therefore, when a structural member having a complicated curved surface is manufactured, parts are created by dividing, or a part of fibers difficult to be molded is cut and molded (see FIG. 6C). .
  • the present invention has been made in view of such circumstances, and a method of manufacturing a composite material part capable of improving moldability while suppressing manufacturing cost even for a composite material part having a complicated curved surface.
  • the purpose is to provide.
  • the following means are employed in the reinforced base material for composite material parts, the composite material parts and the manufacturing method thereof according to the present invention.
  • a first aspect of the present invention is a method for producing a reinforced base material used for a composite part made of a fiber reinforced composite material, wherein the contour of the composite part has a target shape, and the first reinforcing fiber yarn is used.
  • a continuous loop is formed, a knitted layer having a curved surface following the target shape is knitted by combining the continuous loops, and a second reinforcing fiber yarn is knitted into the knitted layer through the continuous loop.
  • the manufacturing method of the reinforced base material which forms is provided.
  • a step of laminating the reinforcing base material on a mold and shaping may be provided.
  • the second aspect of the present invention provides a method for manufacturing a composite part comprising a step of impregnating a matrix into the reinforced base material manufactured in the first aspect.
  • a knitted fabric layer having a curved surface following the target shape, the curved surface being knitted by combining continuous loops of the first reinforcing fiber yarn, and the second reinforcing fiber yarn are the above-mentioned
  • a reinforced base material for a composite part comprising a reinforced portion that is passed through a continuous loop and knitted into the knitted layer.
  • a knitted layer having a curved surface that follows the target shape, the curved surface being knitted by combining continuous loops of the first reinforcing fiber yarn, and the second reinforcing fiber yarn.
  • a composite part including a reinforced base material including a reinforcing part that is passed through the continuous loop and knitted into the knitted layer, and a matrix.
  • the knitted layer By knitting the knitted layer so as to have a curved surface that follows the contour of the composite material part, it is possible to suppress a fiber orientation shift or wrinkle of the reinforcing base material when it is pressed against a mold and shaped. Therefore, an operation for cutting the reinforcing base material for shaping is unnecessary, or the number of times can be greatly reduced. Since the knitted layer is composed of a combination of continuous loops, it has stretch performance. Thereby, it can be set as the knitted layer provided with the high softness
  • Knitting the second reinforcing fiber into the knitted layer makes it possible to realize a high-strength reinforcing substrate. As a result, the number of laminations of the reinforced base material can be reduced, so that the manufacturing cost can be suppressed.
  • a reinforced base material formed by a knitting technique even a composite material part having a complicated curved surface can be manufactured by improving the formability while suppressing the manufacturing cost. it can.
  • the composite part is made of fiber reinforced composite material.
  • the fiber reinforced composite material includes a matrix and a reinforced substrate.
  • the composite material component may have a configuration in which a plurality of reinforcing substrates are laminated.
  • the matrix is a thermosetting resin, a thermoplastic resin, or the like.
  • the thermosetting resin include unsaturated polyester and epoxy resin.
  • the thermoplastic resin is polyether ether ketone (PEEK), polyether ketone ketone (PEKK), polyphenylene sulfide (PPS), or the like.
  • the reinforced base material includes a knitted layer and a reinforced portion.
  • the reinforced substrate is formed by a knitting technique.
  • Fig. 1 shows a diagram illustrating the configuration of the knitted layer.
  • the knitted layer 1 is a layer knitted by combining continuous loops 3 of the first reinforcing fiber yarns 2.
  • the loop 3 may be bound in either the vertical direction (length direction L) or the horizontal direction (width direction W).
  • FIG. 1 illustrates the knitted material layer 1 when the loop 3 is bound in the vertical direction (weft knitting).
  • the knitted layer 1 has a stretching performance of stretching in at least two directions of the length direction L and the width direction W. Thereby, flexibility is generated in the length direction L and the width direction W.
  • FIG. 2 illustrates a state when the knitted layer 1 of FIG. 1 is pulled in the width direction W.
  • the shape of the loop 3 is deformed and extends in the width direction W.
  • the loop 3 can be deformed not only in the width direction W but also in other directions.
  • Knitting layer 1 has a single layer structure.
  • the knitted layer 1 is knitted to have a curved surface that follows the target shape.
  • the target shape is the contour of the composite material part.
  • the curved surface that follows the target shape may be any shape that is close to the contour of the composite material part when it is designed, and does not necessarily need to completely match the contour of the composite material part. “Near” means a difference that is within the range of the stretch performance of the knitted layer 1.
  • the first reinforcing fiber yarn 2 is made of a material that is flexible enough to knit the knitted layer 1 and can be bonded to the matrix material.
  • the material of the first reinforcing fiber yarn 2 is resin fiber, carbon fiber, glass fiber or the like.
  • Resin fibers include polyamide fibers.
  • the polyamide-based fiber is an aliphatic polyamide or aromatic polyamide fiber.
  • the aliphatic polyamide is, for example, nylon (registered trademark).
  • the aromatic polyamide is, for example, aramid.
  • the first reinforcing fiber yarn 2 has a thickness (diameter) that can withstand the knitting of the knitted layer 1.
  • the reinforcing part is formed by knitting the second reinforcing fiber yarn into the knitted layer 1 through the loop 3.
  • a plurality of second reinforcing fiber yarns are knitted in the knitted layer 1.
  • the plurality of second reinforcing fiber yarns knitted are oriented in one direction or two directions in the knitted layer 1.
  • the plurality of second reinforcing fiber yarns knitted may be oriented in a plurality of directions in the knitted layer 1.
  • FIG. 3 and FIG. 4 illustrate the orientation of the second reinforcing fiber yarn.
  • FIG. 3 is a diagram in which the second reinforcing fiber yarns 4 are oriented in the width direction W of the knitted knitted fabric layer 1.
  • FIG. 3 is a diagram in which the second reinforcing fiber yarns 4 are oriented in the width direction W of the knitted knitted fabric layer 1.
  • the second reinforcing fiber yarns 4 are oriented in the length direction L of the knitted knitted fabric layer 1. As shown in FIGS. 3 and 4, the knitting cycle of the second reinforcing fiber yarn 4 may be the same or different in the knitted layer. In addition to the length direction L and the width direction W, the second reinforcing fiber yarn 4 may be oriented in an oblique direction.
  • the material of the second reinforcing fiber yarn 4 is carbon fiber, glass fiber, resin fiber, or the like.
  • the second reinforcing fiber yarn 4 has a thickness (diameter) enough to be knitted into the loop 3 of the knitted layer 1.
  • the fiber bundle preferably has a thickness of 12000 or more and 30000 or less, but this is not restrictive.
  • a continuous loop 3 is formed with the first reinforcing fiber yarns 2 and the knitted layer 1 is knitted.
  • the knitted layer 1 can be knitted by weft knitting or warp knitting.
  • the weft knitting is a flat knitting, rubber knitting, pearl knitting, lace knitting or the like.
  • the warp knitting includes single / Denby and single / Bandike.
  • the knitting method may be appropriately changed according to the shape of the curved surface.
  • a three-dimensional structure that is partially stereoscopic can be provided by increasing or decreasing the stitches.
  • the target shape is the contour of the composite part to be manufactured.
  • the curved surface does not need to completely match the target shape, but is preferably a shape close to the target shape.
  • the second reinforcing fiber yarns 4 are knitted into the knitted layer 1 in parallel to form the reinforced substrate 5 or the knitted reinforced substrate 6.
  • the knitted layer 1 can be knitted by inlay knitting.
  • Inlay knitting is a knitting method in which a yarn is inlayed (inserted) into a base knitted fabric, and is realized by passing the yarn through a loop of the knitted fabric.
  • the second reinforcing fiber yarn 4 may be knitted in parallel with the knitted layer 1, or may be knitted after forming a part or all of the knitted layer 1.
  • the second reinforcing fiber yarns 4 are arranged in one direction or two directions.
  • the second reinforcing fiber yarns 4 are arranged in the length direction L as shown in FIG.
  • the second reinforcing fiber yarns 4 are arranged in the width direction W as shown in FIG.
  • the direction of some of the second reinforcing fiber yarns 4 may be aligned in the length direction L, and the direction of the remaining second reinforcing fiber yarns 4 may be aligned in the width direction W.
  • a reinforced substrate 5 having a curved surface following the target shape is laminated on a mold.
  • the contour of the mold is substantially the same as the contour of the composite part. Therefore, when the reinforced substrate 5 is laminated on the mold, alignment is performed so that the curved surface is aligned with the corresponding portion.
  • the reinforcing substrate 5 is pressed against the mold and shaped. Since the reinforced base material 5 already has a curved surface that follows the target shape, the reinforced base material 5 can be directly pressed against the mold without being cut or the like. Since the deformation amount of the reinforced base material 5 at the time of shaping is small, even if there is a curved surface portion that does not match the contour of the mold, the stretch performance of the knitted layer 1 can cope with it. For example, when the curved surface portion is smaller than the contour of the mold, the knitted layer 1 can be stretched to make the reinforced substrate 5 conform to the contour of the mold. Thereby, even if it is a composite material part which has a complicated curved surface, a moldability can be improved.
  • the reinforcing substrate 5 is laminated in a plurality of layers on the mold. The shaping is performed every time the layers are stacked or after a plurality of layers are stacked.
  • FIG. 5 shows an example of lamination.
  • FIG. 5A shows a molded product shape 8.
  • FIG. 5B shows the reinforced base materials 7A, 7B, and 7C before shaping.
  • the first reinforcing substrate 7A, the second reinforcing substrate 7B, and the third reinforcing substrate 7C have different orientations of the second reinforcing fiber yarns 4, respectively.
  • the second reinforcing fiber yarn 4 is oriented at 0 °.
  • the second reinforcing fiber yarns 4 are oriented at 90 °.
  • the third reinforcing substrate 7C the second reinforcing fiber yarn is oriented at + 45 °.
  • the first reinforcing base material 7A is laminated on a mold and then shaped
  • the second reinforcing base material 7B is laminated on the shaped first reinforcing base material 7A, and then the second reinforcing base material 7B is shaped.
  • the third reinforced substrate 7C is laminated on the shaped second reinforced substrate 7B, the third reinforced substrate 7C is shaped.
  • the strength of the composite material component can be improved with respect to loads from a plurality of directions.
  • intensively orienting the second reinforcing fiber yarn 4 in a predetermined direction it is possible to have a necessary strength in a particularly necessary direction.
  • the matrix is impregnated into the reinforced base material (in FIG. 5, the first reinforced base material 7A, the second reinforced base material 7B, and the third reinforced base material 7C are deposited).
  • the mold and the reinforced substrate can be covered with a bag, and the reinforced substrate can be impregnated with the matrix in a state where the inside of the bag is decompressed.
  • the reinforcing base material can be fitted into a molding die composed of an upper die and a lower die, and the inside of the molding die can be decompressed to be impregnated with the matrix.
  • the thicknesses of the first reinforced substrate 7A, the second reinforced substrate 7B, and the third reinforced substrate 7C impregnated with the matrix are, for example, about 0.1 mm to 0.5 mm, respectively, and the total thickness of the reinforced substrate. Is, for example, about 0.5 mm to 10 mm.
  • the matrix is cured.
  • the reinforced base material impregnated with the matrix is heated to a curing temperature (180 ° C. or higher) to be cured. Thereby, a composite material part can be obtained.
  • the matrix is impregnated after the reinforced base material is laminated on the mold, but the present invention is not limited to this.
  • the prepreg in which the reinforced base material is impregnated is formed, the prepreg is molded into the mold. It may be laminated and shaped.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Manufacturing & Machinery (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Textile Engineering (AREA)
  • Reinforced Plastic Materials (AREA)
  • Moulding By Coating Moulds (AREA)
  • Knitting Of Fabric (AREA)

Abstract

La présente invention concerne un matériau de base renforcé, un élément en matériau composite et son procédé de fabrication grâce auquel l'aptitude au formage peut être améliorée tout en supprimant les coûts de fabrication, même lorsqu'un élément en matériau composite présente des surfaces incurvées complexes. La présente invention concerne un procédé de fabrication d'un matériau de base renforcé (6) qui peut être utilisé dans un élément en matériau composite constitué d'un matériau composite renforcé par des fibres, le contour de l'élément en matériau composite prenant une forme cible ; une boucle continue (3) étant créée au moyen d'un premier fil de fibre de renfort (2) et des boucles continues (3) étant jointes pour former une couche tricotée ayant une surface incurvée suivant la forme cible ; une partie renforcée étant formée en faisant passer un second fil de fibre de renfort (4) dans la boucle continue (3) et en la combinant avec la couche tricotée.
PCT/JP2017/017169 2016-06-07 2017-05-01 Matériau de base renforcé pour élément en matériau composite, élément en matériau composite et son procédé de fabrication WO2017212835A1 (fr)

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JP2016-113532 2016-06-07
JP2016113532A JP2017218688A (ja) 2016-06-07 2016-06-07 複合材部品用の強化基材、複合材部品およびそれらの製造方法

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20190344477A1 (en) * 2018-05-09 2019-11-14 Fabdesigns, Inc. System and method for knitting composite panel structures
CN112481797A (zh) * 2020-12-18 2021-03-12 安踏（中国）有限公司 一种峰谷结构的经编鞋面织物工艺及其鞋面
CN113085052A (zh) * 2021-03-15 2021-07-09 江南大学 一种横编全成形头盔壳体预制件、制备方法及其头盔壳体
WO2022071455A1 (fr) * 2020-09-30 2022-04-07 日鉄ケミカル＆マテリアル株式会社 Matériau composite renforcé par des fibres du type maille, structure tricotée du type maille, matériau permettant de former un matériau composite renforcé par des fibres du type maille et corps formé en matériau composite renforcé par des fibres du type maille
WO2022071454A1 (fr) * 2020-09-30 2022-04-07 日鉄ケミカル＆マテリアル株式会社 Matériau composite renforcé par des fibres de type maille, corps structural tricoté de type maille, matériau pour mouler un matériau composite renforcé par des fibres de type maille, et corps moulé en matériau composite renforcé par des fibres de type maille

Citations (5)

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Publication number Priority date Publication date Assignee Title
JPH04131682U (ja) * 1991-05-20 1992-12-03 ユニチカ株式会社 立体構造編地
JP2008106391A (ja) * 2006-10-25 2008-05-08 Shindo Seni Kogyo Kk シート状炭素繊維編物およびその製造方法
JP2011202328A (ja) * 2010-03-26 2011-10-13 Shima Seiki Mfg Ltd マルチレイヤ編地の編成方法とその編地及び構造体
JP2014133960A (ja) * 2013-01-10 2014-07-24 Shima Seiki Mfg Ltd 編物基材の形成方法、および編物基材
JP2015017149A (ja) * 2013-07-09 2015-01-29 三菱電機株式会社 繊維強化プラスチック成形体用プリフォーム、その製造方法、繊維強化プラスチック成形体の製造方法及びエレベータ用アクティブローラーガイドカバーの製造方法

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH04131682U (ja) * 1991-05-20 1992-12-03 ユニチカ株式会社 立体構造編地
JP2008106391A (ja) * 2006-10-25 2008-05-08 Shindo Seni Kogyo Kk シート状炭素繊維編物およびその製造方法
JP2011202328A (ja) * 2010-03-26 2011-10-13 Shima Seiki Mfg Ltd マルチレイヤ編地の編成方法とその編地及び構造体
JP2014133960A (ja) * 2013-01-10 2014-07-24 Shima Seiki Mfg Ltd 編物基材の形成方法、および編物基材
JP2015017149A (ja) * 2013-07-09 2015-01-29 三菱電機株式会社 繊維強化プラスチック成形体用プリフォーム、その製造方法、繊維強化プラスチック成形体の製造方法及びエレベータ用アクティブローラーガイドカバーの製造方法

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20190344477A1 (en) * 2018-05-09 2019-11-14 Fabdesigns, Inc. System and method for knitting composite panel structures
WO2022071455A1 (fr) * 2020-09-30 2022-04-07 日鉄ケミカル＆マテリアル株式会社 Matériau composite renforcé par des fibres du type maille, structure tricotée du type maille, matériau permettant de former un matériau composite renforcé par des fibres du type maille et corps formé en matériau composite renforcé par des fibres du type maille
WO2022071454A1 (fr) * 2020-09-30 2022-04-07 日鉄ケミカル＆マテリアル株式会社 Matériau composite renforcé par des fibres de type maille, corps structural tricoté de type maille, matériau pour mouler un matériau composite renforcé par des fibres de type maille, et corps moulé en matériau composite renforcé par des fibres de type maille
CN112481797A (zh) * 2020-12-18 2021-03-12 安踏（中国）有限公司 一种峰谷结构的经编鞋面织物工艺及其鞋面
CN113085052A (zh) * 2021-03-15 2021-07-09 江南大学 一种横编全成形头盔壳体预制件、制备方法及其头盔壳体
CN113085052B (zh) * 2021-03-15 2022-07-22 江南大学 一种横编全成形头盔壳体预制件、制备方法及其头盔壳体

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