WO2018020945A1 - サンドイッチ構造用の多層織物及びサンドイッチ構造繊維強化複合材 - Google Patents

サンドイッチ構造用の多層織物及びサンドイッチ構造繊維強化複合材 Download PDF

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Publication number
WO2018020945A1
WO2018020945A1 PCT/JP2017/023843 JP2017023843W WO2018020945A1 WO 2018020945 A1 WO2018020945 A1 WO 2018020945A1 JP 2017023843 W JP2017023843 W JP 2017023843W WO 2018020945 A1 WO2018020945 A1 WO 2018020945A1
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Prior art keywords
skin
sandwich structure
core
fiber
warp
Prior art date
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PCT/JP2017/023843
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English (en)
French (fr)
Inventor
元基 吉川
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 EP17833954.5A priority Critical patent/EP3492639A1/en
Priority to US16/319,568 priority patent/US20210277546A1/en
Priority to CN201780045726.9A priority patent/CN109642360A/zh
Publication of WO2018020945A1 publication Critical patent/WO2018020945A1/ja

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Definitions

  • the present invention relates to a multilayer fabric for sandwich structure and a sandwich structure fiber reinforced composite material.
  • this type of composite material structure 81 has a sandwich structure in which a core material 82 is sandwiched between skin materials 83.
  • the core material 82 is made of a synthetic resin foam.
  • the skin material 83 is composed of a plain weave cloth formed of carbon fiber.
  • the skin material 83 and the core material 82 are joined by fibers 84 that penetrate both of them and are folded back outside the skin material 83.
  • the skin material 83 is made into FRP by impregnating and curing the skin material 83 of the composite material structure 81.
  • An object of the present invention is to provide a multi-layer woven fabric for sandwich structure or a sandwich structure fiber reinforced composite material, which requires less labor to manufacture than a case where a skin and a core are separately formed and then integrated.
  • a multilayer fabric for a sandwich structure including a skin made of fiber reinforced resin and a core sandwiched between the skins.
  • the skin portion serving as a skin is composed of warp and weft yarns made of reinforcing fibers.
  • the core portion that is the core is composed of warp and weft yarns made of fibers that are insoluble in the matrix resin of the skin and have a specific gravity smaller than the reinforcing fibers.
  • the skin portion and the core portion are integrated by a binding yarn insoluble in the skin matrix resin.
  • the “multilayer fabric” means a fabric formed from a weft layer and a warp layer, and a plurality of layers are integrated by a bundled yarn.
  • the “non-reinforcing fiber” means a fiber that does not need to play the reinforcing function of the matrix resin even if it is combined with the matrix resin, and at least plays the role of maintaining the shape.
  • a sandwich structure fiber reinforced composite material formed by combining the multilayer fabric for sandwich structure with a matrix resin.
  • a multilayer fabric for sandwich structure (hereinafter referred to as a multilayer fabric) 10 includes a skin portion 30 and a core portion 20 sandwiched between the skin portions 30.
  • the core part 20 and the skin part 30 are impregnated with a matrix resin so that the core 51 and the skin 52 of the sandwich structure fiber reinforced composite material (hereinafter referred to as composite material) 50 shown in FIG. Become.
  • a matrix resin for example, a thermosetting epoxy resin is used.
  • the skin portion 30 and the core portion 20 are integrated by the binding yarn Z.
  • the skin portion 30 is composed of a weft Yb and a warp Xb. Both the weft Yb and the warp Xb weft Yb are made of reinforcing fibers. Both the weft Yb and the warp Xb extend straight and are orthogonal to each other. In this embodiment, carbon fiber is used as the reinforcing fiber.
  • the core part 20 is composed of a weft Ya and a warp Xa. Both the weft Ya and the warp Xa are made of fibers that are insoluble in the matrix resin and have a lower specific gravity than the reinforcing fibers.
  • the weft Ya and the warp Xa extend straight and are orthogonal to each other.
  • Organic fibers are used as fibers that are insoluble in the matrix resin and have a lower specific gravity than the reinforcing fibers. Examples of the organic fiber include PA (nylon), polyester, PP (polypropylene), PPS (polyphenylene sulfide), PBT (polybutylene terephthalate), PC (polycarbonate), and PEEK (polyether ether ketone).
  • nylon is used as the organic fiber.
  • Nylon has a small specific gravity and good adhesion to an epoxy resin as a matrix resin.
  • nylon is preferred as a fiber that is insoluble in the matrix resin and has a lower specific gravity than the reinforcing fiber. That is, even if the warp yarn Xa and the weft yarn Ya are integrated with the epoxy resin as the matrix resin, the warp yarn Xa and the weft yarn Ya do not play the role of the matrix resin, but are composed of nylon as the non-reinforcing fiber that only plays the role of maintaining the shape. Yes.
  • Bundled yarn Z is for maintaining the shape of the multilayer fabric 10 and is made of non-reinforced fibers.
  • the binding yarn Z penetrates both the skin portions 30 and the core portion 20 and is folded back outside the skin portions 30.
  • the binding yarn Z may be either a reinforcing fiber or a non-reinforcing fiber, but in this embodiment, it is made of nylon.
  • the multilayer fabric 10 is a state in which the number of warps Xa necessary for constituting the core portion 20, the number of warps Xb necessary for constituting both the skin portions 30, and the required number of binding yarns Z are arranged. Thus, it is formed by multi-layer weaving in which wefts Ya and Yb are inserted. At this time, the binding yarn Z is arranged in parallel with the warp yarns Xa and Xb. Then, the binding yarn Z is opened so that the binding yarn Z moves between the uppermost warp Xb and the lowermost warp Xb of the skin portion 30 by the heald. Thereby, the binding yarn Z constitutes a part of the warp of the multi-layer fabric, and is arranged so as to pass through both the skin portions 30 and the core portion 20 and be folded outside the both skin portions 30.
  • the multilayer fabric 10 becomes a composite material 50 by impregnating the matrix fabric itself with a matrix resin and curing it.
  • the resin is impregnated and cured by an RTM (resin transfer molding) method.
  • RTM resin transfer molding
  • a composite material 50 formed by impregnating a matrix resin into a multilayer fabric 10 and curing it has a structure in which a core 51 is sandwiched between skins 52.
  • the composite material 50 is used as an outer plate of a moving body such as an aircraft or a passenger car.
  • the multilayer fabric 10 is a multilayer fabric for a sandwich structure in which a core 51 is sandwiched between skins 52 made of fiber reinforced resin.
  • the skin portion 30 serving as the skin 52 is composed of warps Xb and wefts Yb made of reinforcing fibers.
  • the core portion 20 that becomes the core 51 is composed of warp yarns Xa and weft yarns Ya made of fibers that are insoluble in the matrix resin of the skin 52 and have a specific gravity smaller than that of the reinforcing fibers.
  • the skin portion 30 and the core portion 20 are integrated by a binding yarn Z that is insoluble in the matrix resin of the skin 52.
  • the binding yarn Z passes through the skin portion 30 and the core portion 20 and is folded back outside the skin portion 30. All of the warps Xa, Xb, the wefts Ya, Yb, and the binding yarn Z can be combined with the matrix resin constituting the fiber-reinforced composite material.
  • the multilayer fabric 10 is manufactured by a multilayer weaving in which the skin portion 30 that becomes the skin 52 and the core portion 20 that becomes the core 51 are integrated by the binding yarn Z. Therefore, a sandwich structure can be obtained only by impregnating the multilayer fabric 10 with a matrix resin and curing it. For this reason, it takes less time than the manufacturing method in which the skin and the core are separately formed and then integrated.
  • the binding yarn Z is composed of non-reinforced fibers.
  • the binding yarn Z is not limited to non-reinforcing fibers, and may be composed of reinforcing fibers.
  • the binding yarn Z can be held in a state where the skin portion 30 and the core portion 20 of the multilayer fabric 10 are integrated until the composite material 50 is formed by impregnating the matrix fabric 10 with the matrix resin and curing it. Good. For this reason, it is not always necessary to use reinforcing fibers for the binding yarn Z. That is, if it is a non-reinforced fiber, it is easy to select a thread thinner than the reinforced fiber. For this reason, the reinforcing fiber content rate of a composite material can be raised.
  • non-reinforcing fibers having a specific gravity smaller than that of reinforcing fibers it is easy to obtain non-reinforcing fibers having a specific gravity smaller than that of reinforcing fibers. For this reason, the use of non-reinforcing fibers is preferable for weight reduction compared to the case of using reinforcing fibers.
  • the composite material 50 is formed by combining the multilayer fabric 10 with a matrix resin.
  • the composite material 50 is formed by placing the multilayer fabric 10 in a mold, impregnating the multilayer fabric 10 with the matrix resin, and curing it.
  • the reinforcing fibers of the skin portion 30 are combined with the matrix resin to form the skin 52, and the fibers of the core portion 20 are combined with the matrix resin to form the core 51. Therefore, it takes less time than the manufacturing method in which the skin and the core are separately formed and then integrated.
  • FIG. 2A schematically shows the composite material 50.
  • interval of the rib 53 differ from the number and space
  • the skin portion 30 and the core portion 20 sandwiched between the skin portions 30 are integrated by the binding yarn Z.
  • the multilayer fabric 10 has a rib constituting part 25 in a part of the core part 20.
  • the rib constituting portion 25 constitutes the rib 53 of the composite material 50.
  • the rib constituting portion 25 is arranged in the core portion 20 adjacent to a part of the warp Xb made of the reinforcing fiber constituting the skin portion 30 and a part of the warp Xb. And the weft Yb made of reinforcing fibers.
  • the rib constituting portion 25 extends in the direction in which the wefts Yb are arranged, that is, in the same direction as the wefts Yb.
  • the warp Xb made of reinforcing fibers constituting the skin part 30 and facing the core part 20 enters the core part 20 on the way and is folded back by the other skin part 30. For this reason, the warp Xb has a portion Xbc extending in the thickness direction of the multilayer fabric 10.
  • the portion Xbc that enters the core portion 20 from the lower skin portion 30 of the warp yarn Xb that constitutes the rib constituting portion 25 becomes the weft Yb made of reinforcing fibers. It is sandwiched. Further, the portion Xbc entering the core portion 20 from the upper skin portion 30 is sandwiched between weft yarns Yb made of reinforcing fibers and weft yarns Ya (not shown) made of non-reinforcing fibers.
  • the warp Xb made of the reinforcing fiber constituting the rib constituting portion 25 enters the core portion 20 from the upper skin portion 30 and then enters the core portion 20 from the lower skin portion 30.
  • the interval until entering is wider than the interval from entering the core portion 20 from the lower skin portion 30 to entering the core portion 20 from the upper skin portion 30 side.
  • the warp yarn Xa and the weft yarn Ya made of non-reinforcing fibers, the weft yarn Yb made of reinforcing fibers outside the skin portion 30, and the binding yarn Z are omitted. ing.
  • the multilayer fabric 10 of this embodiment is formed by multilayer weaving. Specifically, the warp Xb at the position facing the core portion 20 of the warp yarns Xb of the both skin portions 30 is placed between the upper part of the uppermost layer of the core part 20 and the lower part of the lowermost part of the weft Ya of the core part 20 by heald. The opening operation of the warp Xb is performed so as to be folded back at a predetermined interval.
  • the core part 20 of the multilayer fabric 10 has the rib structure part 25 which consists of a reinforced fiber. According to this configuration, when the composite material 50 is manufactured by impregnating the multilayer fabric 10 with the matrix resin and curing, the rib constituting portion 25 constitutes the rib 53 of the composite material 50. Therefore, the bending strength of the composite material 50 is higher than that of the composite material 50 of the first embodiment in which the ribs 53 are not present.
  • the number of portions Xbc of the warp Xb made of reinforcing fibers constituting one rib constituting portion 25 of the multilayer fabric 10 may be 3 or more, for example, 4.
  • the number of parts Xbc of the warp Xb is set according to the required performance for the composite material 50.
  • FIG. 4 also omits the warp yarn Xa and the weft yarn Ya made of non-reinforcing fibers, the weft yarn Yb made of the reinforcing fibers outside the skin portion 30, and the binding yarn Z. .
  • a layer made of reinforcing fibers may exist in the core part 20 made of non-reinforcing fibers sandwiched between the skin parts 30.
  • the warp yarns Xa, Xb and the weft yarns Ya, Yb are not limited to the same thickness but may have different thicknesses.
  • a plurality of warp yarns Xa having different thicknesses may be mixed, or a plurality of warp yarns Xb having different thicknesses may be mixed.
  • a plurality of wefts Ya having different thicknesses may be mixed, and a plurality of wefts Yb having different thicknesses may be mixed.
  • the multilayer fabric 10 may be a three-dimensional fabric.
  • the three-dimensional woven fabric is formed by binding a plurality of fiber layers composed of warps and wefts with a binding yarn.
  • a sandwich structure can be obtained by simply impregnating a matrix resin into a three-dimensional fabric for sandwich structure and curing it.
  • the binding yarn does not have to be inserted between all adjacent wefts.
  • the interval between the binding yarns may be changed as appropriate.
  • the non-reinforcing fiber of the core part 20 only needs to have a specific gravity smaller than that of the reinforcing fiber of the skin part 30, and is not limited to organic fiber.
  • the weft Yb and the warp Xb made of the reinforcing fibers of the skin part 30 are not limited to carbon fibers, and may be glass fibers or ceramic fibers, for example.
  • the matrix resin used to manufacture the composite material 50 from the multilayer fabric 10 is not limited to an epoxy resin, and may be other thermosetting resins such as an unsaturated polyester resin and a vinyl ester resin. Further, the matrix resin is not limited to a thermosetting resin, and may be a thermoplastic resin.
  • Reinforcing fibers may be used for the binding yarn Z. Further, only some of the plurality of binding yarns Z may be reinforced fibers, and the rest may be non-reinforced fibers.
  • the number of rib constituent portions 25 of the multilayer fabric 10 and the number of ribs 53 of the composite material 50 are appropriately set depending on the performance required for the composite material 50.
  • the warp yarn Xb may be the outermost layer.
  • the weft Yb may be the outermost layer in one of the skin portions 30, and the warp Xb may be the outermost layer in the other skin portion 30.
  • the weft Ya and the warp Xa may be interchanged, and the weft Yb and the warp Xb may be interchanged.
  • the binding yarn Z is not limited to one that penetrates the skin portion 30 and the core portion 20 and is folded back outside the skin portion 30. That is, the inner binding yarn that integrates the layers constituting the skin portion 30 and the core portion 20 may be divided from the outer binding yarn that integrates the skin portion 30 and the core portion 20.

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Abstract

サンドイッチ構造用の多層織物は、繊維強化樹脂からなるスキンと、スキンで挟まれたコアとを含む。スキン部は、強化繊維からなる経糸及び緯糸から構成されている。コア部は、スキンのマトリックス樹脂に不溶で強化繊維より比重が小さい繊維からなる経糸及び緯糸から構成されている。スキン部及びコア部は、スキンのマトリックス樹脂に不溶の結束糸で一体化されている。

Description

サンドイッチ構造用の多層織物及びサンドイッチ構造繊維強化複合材
　本発明は、サンドイッチ構造用の多層織物及びサンドイッチ構造繊維強化複合材に関する。
　ＦＲＰの剛性不足を補うために、表面にＦＲＰ材、芯材にプラスチックフォームを用いたサンドイッチ構造がある。一般的にサンドイッチ構造の製作方法に、ウェットレイアップやプリプレグが用いられる。
　また、軽量のコア材をスキン材で挟んだサンドイッチ構造の複合材料構造体が提案されている（特許文献１参照）。図５に示すように、この種の複合材料構造体８１は、コア材８２をスキン材８３で挟んだサンドイッチ構造を有する。コア材８２は、合成樹脂製の発泡体で構成されている。スキン材８３は、炭素繊維で形成された平織りの布で構成されている。スキン材８３とコア材８２とは、両者を貫通するとともにスキン材８３の外側で折り返される繊維８４によって結合されている。複合材料構造体８１のスキン材８３に樹脂を含浸し硬化させることで、スキン材８３がＦＲＰ化されている。
　ウェットレイアップは、ＦＲＰ物性が低く、生産に人手がかかる。プリプレグは、ＦＲＰ物性が高いが、生産に高額な投資が必要になる。特許文献１の複合材料構造体は、高いＦＲＰ物性を有する。しかしながら、炭素繊維で形成された平織りの布にマトリックス樹脂を含浸し硬化させて強化材（スキン材）を製造した後、芯材（コア材）と芯材を挟んだ強化材とを繊維により結合（一体化）するのに手間がかかる。
特開２００１－２４６６８６号公報
　本発明の目的は、スキンとコアとを別々に形成した後で一体化する場合に比べて製造に手間がかからないサンドイッチ構造用の多層織物あるいはサンドイッチ構造繊維強化複合材を提供することにある。
　上記課題を解決するため、本発明の第一の態様によれば、繊維強化樹脂からなるスキンと、スキンで挟まれたコアとを含むサンドイッチ構造用の多層織物が提供される。スキンとなるスキン部は、強化繊維からなる経糸及び緯糸から構成されている。コアとなるコア部は、スキンのマトリックス樹脂に不溶で強化繊維より比重が小さい繊維からなる経糸及び緯糸から構成されている。スキン部及びコア部は、スキンのマトリックス樹脂に不溶の結束糸により一体化されている。
　ここで、「多層織物」とは、緯糸の層と経糸の層とから形成され、複数の層が結束糸で一体化されたものを意味する。「非強化繊維」とは、マトリックス樹脂と複合化しても、マトリックス樹脂の強化機能の役割を果たす必要はなく、少なくとも形状保持の役割を果たせばよい繊維を意味する。
　上記課題を解決するため、本発明の第二の態様によれば、上記のサンドイッチ構造用の多層織物がマトリックス樹脂と複合化して形成されたサンドイッチ構造繊維強化複合材が提供される。
（ａ）は第１の実施形態のサンドイッチ構造用の多層織物の模式断面図、（ｂ）はサンドイッチ構造繊維強化複合材の模式斜視図。 （ａ）は第２の実施形態のサンドイッチ構造繊維強化複合材の模式斜視図、（ｂ）はサンドイッチ構造用の多層織物の模式断面図。 （ａ），（ｂ），（ｃ）は第２の実施形態のサンドイッチ構造用の多層織物のリブ構成部を構成する強化繊維の配列を示す模式断面図。 別の実施形態のリブ構成部を有するサンドイッチ構造用の多層織物のリブ構成部を構成する強化繊維の配列を示す模式断面図。 従来技術の複合材料構造体の模式斜視図。
　（第１の実施形態）
　以下、本発明を具体化した第１の実施形態を図１にしたがって説明する。
　図１（ａ）に示すように、サンドイッチ構造用の多層織物（以下、多層織物と称す）１０は、スキン部３０と、スキン部３０で挟まれたコア部２０とを有する。コア部２０及びスキン部３０は、それらにマトリックス樹脂が含浸されることで、図１（ｂ）に示すサンドイッチ構造繊維強化複合材（以下、複合材と称す）５０のコア５１及びスキン５２にそれぞれなる。マトリックス樹脂としては、例えば、熱硬化性樹脂のエポキシ樹脂が使用される。多層織物１０では、スキン部３０とコア部２０とが結束糸Ｚによって一体化されている。
　スキン部３０は、緯糸Ｙｂと経糸Ｘｂとで構成されている。緯糸Ｙｂ及び経糸Ｘｂ緯糸Ｙｂはいずれも、強化繊維からなる。緯糸Ｙｂ及び経糸Ｘｂはいずれも真っ直ぐに延び、互いに直交している。この実施形態では、強化繊維として、炭素繊維が使用されている。
　コア部２０は、緯糸Ｙａと経糸Ｘａとで構成されている。緯糸Ｙａ及び経糸Ｘａはいずれも、マトリックス樹脂に不溶で強化繊維より比重が小さい繊維からなる。緯糸Ｙａ及び経糸Ｘａは真っ直ぐ延び、互いに直交している。マトリックス樹脂に不溶で強化繊維より比重が小さい繊維として、有機繊維が使用されている。有機繊維としては、例えば、ＰＡ（ナイロン）、ポリエステル、ＰＰ（ポリプロピレン）、ＰＰＳ（ポリフェニレンサルファイド）、ＰＢＴ（ポリブチレンテレフタレート）、ＰＣ（ポリカーボネート）、ＰＥＥＫ（ポリエーテルエーテルケトン）が挙げられる。この実施形態では、有機繊維として、ナイロンが使用されている。ナイロンは、比重が小さく、マトリックス樹脂としてのエポキシ樹脂との接着性が良い。このため、ナイロンは、マトリックス樹脂に不溶で強化繊維より比重が小さい繊維として好ましい。即ち、経糸Ｘａ及び緯糸Ｙａは、マトリックス樹脂としてのエポキシ樹脂と一体化されても、マトリックス樹脂の強化機能の役割は果たさず、形状保持の役割のみを果たす非強化繊維としてのナイロンから構成されている。
　結束糸Ｚは、多層織物１０の形状保持用であって、非強化繊維で構成されている。結束糸Ｚは、両スキン部３０及びコア部２０を貫通するとともに、両スキン部３０の外側で折り返されている。結束糸Ｚは、強化繊維及び非強化繊維のいずれであってもよいが、この実施形態では、ナイロンから構成されている。
　多層織物１０は、コア部２０を構成するのに必要な数の経糸Ｘａと、両スキン部３０を構成するのに必要な数の経糸Ｘｂと、必要な数の結束糸Ｚとを配列した状態で、緯糸Ｙａ，Ｙｂを緯入れする多層織りによって形成される。このとき、結束糸Ｚは、経糸Ｘａ，Ｘｂと平行に配列される。そして、結束糸Ｚがヘルドによってスキン部３０の最上層の経糸Ｘｂより上方と最下層の経糸Ｘｂより下方との間を移動するように、結束糸Ｚの開口動作が行われる。これにより、結束糸Ｚは、多層織物の経糸の一部を構成すると共に、両スキン部３０及びコア部２０を貫通して両スキン部３０の外側で折り返されるように配置される。
　多層織物１０は、それ自体にマトリックス樹脂を含浸し硬化させることで、複合材５０となる。樹脂の含浸硬化は、例えば、ＲＴＭ（レジン・トランスファー・モールディング）法で行なわれる。また、多層織物１０にマトリックス樹脂を含浸し硬化させると、コア部２０の緯糸Ｙａ及び経糸Ｘａはマトリックス樹脂と複合化してコア５１となり、スキン部３０の緯糸Ｙｂ及び経糸Ｘｂはマトリックス樹脂と複合化してスキン５２となる。
　図１（ｂ）に示すように、多層織物１０にマトリックス樹脂を含浸し硬化させて形成された複合材５０は、コア５１がスキン５２で挟まれた構造を有している。複合材５０は、例えば、航空機や乗用車等の移動体の外板として使用される。
　この実施形態によれば、以下に示す効果を得ることができる。
　（１）多層織物１０は、繊維強化樹脂からなるスキン５２でコア５１が挟まれたサンドイッチ構造用の多層織物である。スキン５２となるスキン部３０は、強化繊維からなる経糸Ｘｂ及び緯糸Ｙｂから構成されている。コア５１となるコア部２０は、スキン５２のマトリックス樹脂に不溶で強化繊維より比重が小さい繊維からなる経糸Ｘａ及び緯糸Ｙａから構成されている。スキン部３０及びコア部２０は、スキン５２のマトリックス樹脂に不溶の結束糸Ｚにより一体化されている。結束糸Ｚは、スキン部３０及びコア部２０を貫通するとともにスキン部３０の外側で折り返されている。経糸Ｘａ，Ｘｂ、緯糸Ｙａ，Ｙｂ及び結束糸Ｚはいずれも、繊維強化複合材を構成するマトリックス樹脂と複合化可能である。
　この構成によれば、多層織物１０は、スキン５２となるスキン部３０とコア５１となるコア部２０とを結束糸Ｚにより一体化する多層織りによって製造される。したがって、多層織物１０にマトリックス樹脂を含浸し硬化させるだけで、サンドイッチ構造が得られる。このため、スキンとコアとを別々に形成した後で一体化する製法に比べて手間がかからない。
　（２）結束糸Ｚは、非強化繊維で構成されている。結束糸Ｚは、非強化繊維に限らず、強化繊維で構成されてもよい。しかし、結束糸Ｚは、多層織物１０にマトリックス樹脂を含浸し硬化させて複合材５０が形成されるまでの間、多層織物１０のスキン部３０とコア部２０とを一体化した状態に保持できればよい。このため、結束糸Ｚには、必ずしも強化繊維を使用する必要はない。つまり、非強化繊維であれば、強化繊維よりも細い糸を選択することも容易である。このため、複合材の強化繊維含有率を高めることができる。また、非強化繊維は、強化繊維に比べて比重が小さなものを得ることも容易である。このため、非強化繊維を使用した方が、強化繊維を使用する場合に比べて、軽量化には好ましい。
　（３）スキン５２のマトリックス樹脂に不溶で強化繊維より比重が小さい繊維として、有機繊維を使用する必要はない。しかしながら、有機繊維は、マトリックス樹脂との親和性が高い。このため、有機繊維を使用すれば、多層織物１０にマトリックス樹脂を含浸し硬化させて複合材５０を製造した場合、複合材５０の物性が高くなり易い。
　（４）複合材５０は、多層織物１０がマトリックス樹脂と複合化することで形成されている。この構成によれば、複合材５０は、多層織物１０を型内に入れて、多層織物１０にマトリックス樹脂を含浸し硬化させることにより形成される。そして、スキン部３０の強化繊維がマトリックス樹脂と複合化してスキン５２となり、コア部２０の繊維がマトリックス樹脂と複合化してコア５１となる。したがって、スキンとコアとを別々に形成した後で一体化する製法に比べて、手間がかからない。
　（第２の実施形態）
　次に、第２の実施形態を図２にしたがって説明する。
　図２（ａ）に示すように、この実施形態の複合材５０は、コア５１の両側に位置するスキン５２の間に複数のリブ５３が設けられている点で、第１の実施形態と大きく異なっている。第１の実施形態と同一部分は、同一符号を付して、その詳しい説明を省略する。図２（ａ）は、複合材５０を模式的に示す。このため、図２（ａ）では、リブ５３の数や間隔が、図２（ｂ）に示す多層織物１０のリブ構成部２５の数や間隔とは異なっている。
　図２（ｂ）に示すように、多層織物１０では、スキン部３０と、スキン部３０に挟まれたコア部２０とが結束糸Ｚによって一体化されている。多層織物１０は、コア部２０の一部に、リブ構成部２５を有する。多層織物１０にマトリックス樹脂を含浸し硬化させて複合材５０を製造した場合、リブ構成部２５は、複合材５０のリブ５３を構成する。
　図２（ｂ）に示すように、リブ構成部２５は、スキン部３０を構成する強化繊維からなる経糸Ｘｂの一部と、その経糸Ｘｂの一部に隣接してコア部２０内に配列された強化繊維からなる緯糸Ｙｂとで構成されている。リブ構成部２５は、緯糸Ｙｂの配列方向、即ち、緯糸Ｙｂと同方向に延びている。
　詳述すると、スキン部３０を構成しかつコア部２０と対向する位置の強化繊維からなる経糸Ｘｂは、途中でコア部２０内に進入してから他方のスキン部３０で折り返されている。このため、経糸Ｘｂは、多層織物１０の厚さ方向に延びる部分Ｘｂｃを有する。
　図３（ａ），（ｂ）に示すように、リブ構成部２５を構成する経糸Ｘｂのうち、下側のスキン部３０からコア部２０に進入する部分Ｘｂｃは、強化繊維からなる緯糸Ｙｂに挟まれている。また、上側のスキン部３０からコア部２０に進入する部分Ｘｂｃは、強化繊維からなる緯糸Ｙｂと非強化繊維からなる緯糸Ｙａ（図示せず）とに挟まれている。
　図３（ｃ）に示すように、リブ構成部２５を構成する強化繊維からなる経糸Ｘｂは、上側のスキン部３０よりコア部２０に進入してから下側のスキン部３０よりコア部２０に進入するまでの間隔が、下側のスキン部３０よりコア部２０に進入してから上側のスキン部３０側よりコア部２０に進入するまでの間隔よりも広い。図３（ａ），（ｂ），（ｃ）では、非強化繊維で構成された経糸Ｘａ及び緯糸Ｙａと、スキン部３０の外側の強化繊維からなる緯糸Ｙｂと、結束糸Ｚとが省略されている。
　この実施形態の多層織物１０は、多層織りによって形成されている。詳しくは、両スキン部３０の経糸Ｘｂのうちコア部２０と対向する位置の経糸Ｘｂを、ヘルドによって、コア部２０の最上層の緯糸Ｙａより上方と最下層の緯糸Ｙａより下方との間を予め設定された間隔で折り返すように、経糸Ｘｂの開口動作が行われる。
　第２の実施形態によれば、第１の実施形態における（１）～（４）と同様な効果に加えて、以下の効果を得ることができる。
　（５）多層織物１０のコア部２０は、強化繊維からなるリブ構成部２５を有している。この構成によれば、多層織物１０にマトリックス樹脂を含浸し硬化させて複合材５０を製造した場合、リブ構成部２５が複合材５０のリブ５３を構成する。そのため、リブ５３が存在しない第１の実施形態の複合材５０に比べて、複合材５０の曲げ強度が高くなる。
　上記各実施形態は、次のように変更してもよい。
　図４に示すように、多層織物１０の一つのリブ構成部２５を構成する強化繊維からなる経糸Ｘｂの部分Ｘｂｃの数は、３以上、例えば、４であってもよい。経糸Ｘｂの部分Ｘｂｃの数は、複合材５０に対する要求性能によって設定される。図４も、図３（ｃ）と同様に、非強化繊維で構成された経糸Ｘａ及び緯糸Ｙａと、スキン部３０の外側の強化繊維からなる緯糸Ｙｂと、結束糸Ｚとが省略されている。
　サンドイッチ構造とは、強化繊維からなる対向するスキン部３０が少なくとも一対存在すればよい。例えば、スキン部３０で挟まれた非強化繊維からなるコア部２０に、強化繊維からなる層が存在してもよい。
　経糸Ｘａ，Ｘｂ及び緯糸Ｙａ，Ｙｂは、同じ太さに限らず、異なる太さであってもよい。
　太さの異なる複数の経糸Ｘａが混在してもよく、太さの異なる複数の経糸Ｘｂが混在してもよい。
　太さの異なる複数の緯糸Ｙａが混在し、太さの異なる複数の緯糸Ｙｂが混在してもよい。
　多層織物１０は、三次元織物であってもよい。三次元織物とは、経糸及び緯糸からなる複数の繊維層を積層した状態で結束糸により結合して形成したものである。この場合も、サンドイッチ構造用の三次元織物にマトリックス樹脂を含浸し硬化させるだけで、サンドイッチ構造が得られる。
　多層織物及び三次元織物の場合、結束糸は、全ての隣り合う緯糸間に挿入されなくてもよい。多層織物及び三次元織物に対する要求性能によって、結束糸の挿入間隔を、適宜変更してもよい。
　コア部２０の非強化繊維は、スキン部３０の強化繊維より比重が小さければよく、有機繊維に限らない。
　スキン部３０の強化繊維からなる緯糸Ｙｂ及び経糸Ｘｂは、炭素繊維に限らず、例えば、ガラス繊維やセラミック繊維であってもよい。
　多層織物１０から複合材５０を製造するのに使用されるマトリックス樹脂は、エポキシ樹脂に限らず、例えば、不飽和ポリエステル樹脂、ビニルエステル樹脂等の他の熱硬化性樹脂であってもよい。また、マトリックス樹脂は、熱硬化性樹脂に限らず、熱可塑性樹脂であってもよい。
　結束糸Ｚに、強化繊維を使用してもよい。また、複数の結束糸Ｚの一部だけを強化繊維とし、残りを非強化繊維としてもよい。
　多層織物１０のリブ構成部２５の数及び複合材５０のリブ５３の数は、複合材５０に要求される性能によって、適宜設定される。
　両スキン部３０を構成する緯糸Ｙｂと経糸Ｘｂの配列構造では、緯糸Ｙｂが最外層になる構成に代えて、経糸Ｘｂが最外層になる構成としてもよい。また、両スキン部３０のうちの一方のスキン部３０では、緯糸Ｙｂが最外層になる構成とし、他方のスキン部３０では、経糸Ｘｂが最外層になる構成としてもよい。
　多層織物１０において、緯糸Ｙａと経糸Ｘａとを入れ替え、緯糸Ｙｂと経糸Ｘｂとを入れ替えてもよい。
　結束糸Ｚは、スキン部３０及びコア部２０を貫通するとともにスキン部３０の外側で折り返されるものに限られない。即ち、スキン部３０及びコア部２０を構成する各層を一体化する内部結合糸と、スキン部３０とコア部２０とを一体化する外部結合糸とを分けてもよい。

Claims (5)

  1. 　繊維強化樹脂からなるスキンと、前記スキンで挟まれたコアとを含むサンドイッチ構造用の多層織物であって、
    　前記スキンとなるスキン部は、強化繊維からなる経糸及び緯糸から構成され、
    　前記コアとなるコア部は、前記スキンのマトリックス樹脂に不溶で前記強化繊維より比重が小さい繊維からなる経糸及び緯糸から構成され、
    　前記スキン部及び前記コア部は、前記スキンのマトリックス樹脂に不溶の結束糸により一体化されている、サンドイッチ構造用の多層織物。
  2. 　前記結束糸は、非強化繊維で構成されている、請求項１に記載のサンドイッチ構造用の多層織物。
  3. 　前記コア部は、強化繊維からなるリブ構成部を有している、請求項１又は２に記載のサンドイッチ構造用の多層織物。
  4. 　前記繊維強化樹脂のマトリックス樹脂に不溶で前記強化繊維より比重が小さい繊維は、有機繊維である、請求項１～３のいずれか一項に記載のサンドイッチ構造用の多層織物。
  5. 　請求項１～４のいずれか一項に記載のサンドイッチ構造用の多層織物がマトリックス樹脂と複合化して形成されたサンドイッチ構造繊維強化複合材。
PCT/JP2017/023843 2016-07-29 2017-06-29 サンドイッチ構造用の多層織物及びサンドイッチ構造繊維強化複合材 WO2018020945A1 (ja)

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