WO2018179878A1 - 繊維構造体及び繊維強化複合材 - Google Patents

繊維構造体及び繊維強化複合材 Download PDF

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Publication number
WO2018179878A1
WO2018179878A1 PCT/JP2018/004260 JP2018004260W WO2018179878A1 WO 2018179878 A1 WO2018179878 A1 WO 2018179878A1 JP 2018004260 W JP2018004260 W JP 2018004260W WO 2018179878 A1 WO2018179878 A1 WO 2018179878A1
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Prior art keywords
weft
warp
thickness
fiber
fiber structure
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PCT/JP2018/004260
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English (en)
French (fr)
Inventor
武井裕之
Original Assignee
株式会社豊田自動織機
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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 CN201880021156.4A priority Critical patent/CN110475921A/zh
Priority to EP18776597.9A priority patent/EP3604649A4/en
Priority to US16/497,533 priority patent/US20200109493A1/en
Publication of WO2018179878A1 publication Critical patent/WO2018179878A1/ja

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    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D11/00—Double or multi-ply fabrics not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
    • B29C70/222—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure the structure being shaped to form a three dimensional configuration
    • 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
    • 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
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/242—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads inorganic, e.g. basalt
    • D03D15/275—Carbon fibres
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
    • D03D15/43—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads with differing diameters
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
    • D03D15/44—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads with specific cross-section or surface shape
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/573—Tensile strength
    • 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
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/55—Epoxy resins
    • 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
    • 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
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D13/00—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
    • D03D13/008—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft characterised by weave density or surface weight
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D25/00—Woven fabrics not otherwise provided for
    • D03D25/005—Three-dimensional woven fabrics
    • 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
    • D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
    • D06M2101/40—Fibres of carbon
    • 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
    • D10B2101/00—Inorganic fibres
    • D10B2101/10—Inorganic fibres based on non-oxides other than metals
    • D10B2101/12—Carbon; Pitch
    • 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
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • 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
    • 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
    • D10B2505/12—Vehicles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3179—Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
    • Y10T442/3301—Coated, impregnated, or autogenous bonded

Definitions

  • the present invention relates to a fiber structure made of a multilayer fabric having a warp layer and a weft layer, and a fiber reinforced composite material using the fiber structure as a reinforced base material.
  • Fiber reinforced composite materials are widely used as lightweight structural materials. BACKGROUND ART Fiber reinforced composite materials obtained by impregnating a matrix resin into a reinforced base material for fiber reinforced composite materials are used as structural materials for rockets, aircraft, automobiles, ships, and buildings. In some fiber reinforced composite materials, the thickness is changed in accordance with the shape to be used.
  • Patent Document 1 discloses a fiber structure for a fiber-reinforced composite material having a changed thickness.
  • the three-dimensional fabric 80 disclosed in Patent Document 1 includes a warp yarn 81 grouped into a plurality of groups, a weft yarn 82 divided into a plurality of layers, and an entanglement yarn 83 that restrains the weft yarn 82 of the outer layer. And is woven.
  • the three-dimensional fabric 80 includes tapered portions 84 having different thicknesses in the weaving direction.
  • the tapered portion 84 is formed by sequentially dividing a plurality of groups of warp yarns 81 into groups and inserting a new weft yarn 82 between the divided warp yarns 81.
  • the taper portion 84 is increased in thickness in a tapered shape by sequentially increasing the number of layers of the fabric from the thin portion 85 to the thick portion 86 side.
  • the three-dimensional woven fabric 80 of Patent Document 1 is manufactured by dividing the warp 81 collected into a plurality of groups or inserting the weft 82 between the divided warps 81 in order to produce the tapered portion 84. Is very cumbersome. Further, in the three-dimensional fabric 80, in order to manufacture the tapered portion 84 and the thick portion 86, the warp 81 collected in a plurality of groups is required in the thin portion 85, and in addition, the tapered portion 84 and the thick portion 86 are used. It is necessary to gradually increase the number of weft yarns 82 in order to manufacture the yarn, and the production is very complicated.
  • An object of the present invention is to provide a fiber structure and a fiber-reinforced composite material that can be easily woven even if they have portions with different thicknesses.
  • a fiber structure for solving the above problems is a fiber reinforced composite material reinforced base material, a fiber structure comprising a multi-layer fabric having a warp layer and a weft layer, in the warp layer or the weft layer.
  • the warp or the weft has a first portion and a second portion that are continuous along the one direction.
  • / or the second portion of the weft is thicker than the first portion of the weft, and the distance between the yarn main axes of the yarns adjacent in the one direction is the pitch.
  • the gist is that the pitch of the portion is narrower than the pitch of the first portion.
  • the width of the yarn (the dimension in the direction perpendicular to the thickness) changes between the first part and the second part
  • the thickness of the yarn changes with the change.
  • the thickness of the second portion can be changed with respect to the thickness of the first portion. Further, as compared with the case where the thickness is changed by changing the number of yarns in the thickness direction of the multilayer fabric, weaving by a loom is easy and the manufacturing cost can be suppressed.
  • the fiber layers laminated in the thickness direction of the multilayer fabric are integrated in the thickness direction by a binding yarn, and the binding yarn has the one direction within the thickness of the multilayer fabric. If the distance between adjacent parts is the inter-yarn distance, the inter-yarn distance differs between the second part and the first part.
  • the binding yarn penetrates the thickness of the multilayer fabric along the warp or weft overlapping in the thickness direction. For this reason, when the first portion and the second portion have different warp or weft pitches that are arranged in one direction, the inter-yarn distances of the bundled yarns also differ. Therefore, even the first portion and the second portion having different pitches and different thicknesses can be bound in the thickness direction by the binding yarn.
  • a fiber reinforced composite material for solving the above problems is a fiber reinforced composite material obtained by impregnating a matrix resin into a reinforced base material made of a fiber structure, and the fiber structure according to claim 1 or claim 2.
  • the gist of the fiber structure is as described.
  • the thickness of the first part can be changed with respect to the second part by making the pitch of the yarns arranged in one direction different between the first part and the second part. .
  • the fiber reinforced composite material it is easy to weave the reinforcing base material made of the fiber structure by the loom, and the manufacturing cost can be suppressed.
  • Sectional drawing which shows the fiber reinforced composite material of embodiment.
  • the expanded sectional view which shows the general part and reinforcement part of a fiber structure made from a multilayer fabric.
  • the figure which shows a loom typically.
  • (A) is a partial cross-sectional view showing a state before striking
  • (b) is a partial cross-sectional view showing a state of striking to form a general part
  • (c) is a movement amount for forming a reinforcing part.
  • (D) is a fragmentary sectional view which shows the state beaten in order to form a reinforcement part.
  • the expanded sectional view which shows the general part and reinforcement part of a fiber structure made from a single layer fabric.
  • the fiber reinforced composite material 10 is configured by combining a fiber structure 11 made of a multilayer fabric with a matrix resin 12.
  • a matrix resin for example, a thermosetting epoxy resin is used.
  • the fiber structure 11 includes a weft 13 made of reinforcing fibers and a warp 14 made of reinforcing fibers.
  • the weft 13 and the warp 14 extend in directions orthogonal to each other.
  • carbon fiber is used as the reinforcing fiber.
  • All the warp yarns 14 are yarns having the same fineness, and all the weft yarns 13 are yarns having the same fineness. The fineness is the weight per unit length. Further, the weft 13 and the warp 14 are continuous yarns in which carbon fibers are bundled.
  • the fiber structure 11 includes a first weft layer 21 in which a plurality of wefts 13 are arranged in parallel to each other, a second weft layer 22 disposed below the first weft layer 21, and a lower side than the second weft layer 22. And a third weft layer 23 disposed on the surface.
  • the first to third weft layers 21, 22, and 23 are fiber layers that constitute a multilayer fabric.
  • the fiber structure 11 includes a first warp layer 31 in which a plurality of warps 14 are arranged in parallel to each other, and a second warp layer 32 disposed below the first warp layer 31.
  • the first warp layer 31 and the second warp layer 32 are fiber layers that constitute a multilayer fabric.
  • the fiber structure 11 is laminated from the top to the bottom in the order of the first weft layer 21, the first warp layer 31, the second weft layer 22, the second warp layer 32, and the third weft layer 23.
  • the first weft layer 21, the first warp layer 31, the second weft layer 22, the second warp layer 32, and the third weft layer 23 are bound by a binding yarn 15 constituting a part of the warp.
  • the binding yarn 15 is for maintaining the shape of the fiber structure 11 and is composed of non-reinforced fibers.
  • the binding yarn 15 is arranged in parallel with each warp 14 and the outer surface of the weft 13 of the first weft layer 21 at a position above the uppermost warp 14 (first warp layer 31) constituting the fiber structure 11.
  • the binding yarn 15 is arranged so as to be folded back through the outer surface of the weft 13 of the third weft layer 23 at a position below the lowermost warp 14 (second warp layer 32).
  • the binding yarn 15 constitutes a part of the warp of the multilayer fabric.
  • the fiber structure 11 configured as described above is formed of a multi-layer weave in which wefts 13 are inserted in a state where a necessary number of warps 14 and a necessary number of binding yarns 15 are arranged.
  • the fiber structure 11 made of a multilayer fabric configured as described above is impregnated and cured with a matrix resin to form a fiber-reinforced composite material 10. Therefore, the fiber reinforced composite material 10 is formed by impregnating a matrix resin into a reinforced base material made of the fiber structure 11.
  • the matrix resin is impregnated and cured by, for example, an RTM (resin transfer molding) method.
  • the matrix resin 12 is impregnated and cured in the fiber structure 11, whereby the weft 13 and the warp 14 of the fiber structure 11 are combined with the matrix resin to form the fiber reinforced composite material 10.
  • the fiber reinforced composite material 10 is used as an outer plate of a moving body such as an aircraft or a passenger car.
  • the direction in which the plurality of wefts 13 are arranged is the longitudinal direction Y1, and the first weft layer 21, the first warp layer 31, the second weft layer 22, the second warp layer 32, and the third weft
  • the direction in which the layers 23 are stacked is defined as the thickness direction Y2.
  • the longitudinal direction Y1 is also a direction in which the main spindle of the warp 14 extends.
  • the fiber structure 11 includes a general portion 41 as a first portion in a part along the longitudinal direction Y1, and a reinforcing portion 51 as a second portion in a portion other than the general portion 41.
  • the general part 41 and the reinforcing part 51 are formed continuously in the longitudinal direction Y1, and it can be said that the general part 41 and the reinforcing part 51 are continuous in one direction.
  • the one direction is a direction in which the wefts 13 are adjacent to each other in the first to third weft layers 21 to 23.
  • the thickness of the general part 41 is constant along the longitudinal direction Y1.
  • the thickness of the reinforcing portion 51 is constant along the longitudinal direction Y1 and is thicker than the thickness of the general portion 41.
  • the weft 13 constituting the general portion 41 is defined as a general portion weft 13a.
  • the cross-sectional view orthogonal to the yarn main axis R is horizontally long and flat.
  • the maximum dimension is defined as the width W1.
  • the maximum dimension is the thickness H1.
  • the distance between the main spindles R of the general part wefts 13a adjacent in the longitudinal direction Y1 is defined as a general part pitch P1.
  • the weft yarn 13 constituting the reinforcing portion 51 is the reinforcing portion weft yarn 13b.
  • the general portion weft 13a and the reinforcing portion weft 13b are the wefts 13 having the same fineness, and are different only in cross-sectional shape.
  • the reinforcing part weft 13b has a horizontally long flat shape in a cross-sectional view perpendicular to the yarn main axis R, but is narrower than the general part weft 13a.
  • the maximum dimension is the width W2.
  • the maximum dimension is the thickness H2.
  • the reinforcing portion pitch P2 (the pitch of the second portion) is the general portion. Narrower than the pitch P1 (pitch of the first portion).
  • the width W2 of the reinforcing portion weft 13b is narrower than the width W1 of the general portion weft 13a
  • the thickness H2 of the reinforcing portion weft 13b in the reinforcing portion 51 is the thickness of the general portion weft 13a in the general portion 41. Thicker than H1.
  • the thickness of the reinforcing portion weft 13b arranged in the longitudinal direction Y1 is larger in the general portion 41 than the thickness of the general portion weft 13a arranged in the longitudinal direction Y1. Therefore, in the general part 41 and the reinforcing part 51, the thickness T1 of the general part 41 including the general part weft 13a is smaller than the thickness T2 of the reinforcing part 51 including the reinforcing part weft 13b. In other words, the reinforcing part 51 is thicker than the general part 41.
  • the amount of the weft 13 present per unit length in the longitudinal direction Y1 is larger in the reinforcing portion 51 than in the general portion 41, and the yarn density in the reinforcing portion 51 is higher than the yarn density in the general portion 41.
  • the portion extending in the thickness direction Y2 of the fiber structure 11 is a straight portion 15a, and the outer surface of the weft 13 is formed at both ends of the fiber structure 11 in the thickness direction Y2.
  • a portion that is folded back through is referred to as a return portion 15b.
  • the distance between the linear portions 15a adjacent to each other in the direction in which the binding yarn 15 advances, that is, the longitudinal direction Y1 is defined as an inter-yarn distance K3.
  • the inter-yarn distance K3 at the general part 41 is larger than the inter-yarn distance K3 at the reinforcing part 51.
  • the manufacturing method of the fiber structure 11 is demonstrated.
  • the sent warp 14 is guided to the ridges 61 and 62.
  • the wefts 13 that have been inserted are beaten by a reed 62, and the woven fabric T is taken up by a take-up roller 63.
  • the weft 13 is wefted and beaten by the scissors 62.
  • all the wefts 13 to be inserted have a horizontally long flat shape having the same width W1 as the general part wefts 13a.
  • the striking place P is a position indicated by a two-dot chain line L1 in FIG. 4A and is always the same position. Then, the weft 13 is weft-inserted on the side farther from the woven fabric T than the hammering place P, that is, the two-dot chain line L1.
  • the woven fabric T that has already been woven is wound up by the winding roller 63, and the leading end G of the woven fabric T moves from the punching place P to the winding roller 63 side.
  • the movement amount of the woven fabric T when manufacturing the general part 41 is defined as a first movement amount K1.
  • the first movement amount K1 is the same as the width W1 of the general portion weft 13a.
  • the moving amount of the woven fabric T can be changed by adjusting the winding speed of the winding roller 63. For example, when the winding speed of the winding roller 63 is increased, the moving amount of the woven cloth T per fixed time increases, and when the winding speed of the winding roller 63 is decreased, the moving amount of the woven cloth T per fixed time. Less.
  • the weft thread 13 that has been inserted is beaten at the beating place P, but the weft thread 13 that has been inserted does not jump out of the beating place P. Therefore, the weft 13 is not crushed and remains in the width W1. As a result, a part of the general part 41 is formed by the general part weft 13a.
  • the reinforcing part 51 is manufactured.
  • the moving amount of the woven fabric T is made smaller than the first moving amount K ⁇ b> 1 when the general portion 41 is manufactured by the winding roller 63.
  • a movement amount of the woven fabric T for manufacturing the reinforcing portion 51 is set as a second movement amount K2.
  • the second moving amount K2 is shorter than the width W1 of the general portion weft 13a and is the same as the width W2 of the reinforcing portion weft 13b.
  • the cross-sectional shape of the reinforcing portion weft 13 b that forms the reinforcing portion 51 of the reinforcing portion 51 that is desired to increase strength is a flat shape that is vertically longer than the general portion weft 13 a that forms the general portion 41. .
  • the cross-sectional shape of the general portion weft 13a is a horizontally long flat shape. For this reason, the thickness of the reinforcement part 51 is thicker than the thickness of the general part 41, and the intensity
  • the reinforcing portion 51 and the general portion 41 are formed so that the reinforcing portion pitch P2 is narrower than the general portion pitch P1. Therefore, the thickness H2 of the reinforcing portion weft 13b can be made larger than the thickness H1 of the general portion weft 13a. Therefore, the thickness of the reinforcement part 51 can be made thicker than the thickness of the general part 41. And since the general part 41 and the reinforcement part 51 are the same weaving method using the weft 13 and the warp 14, compared with the case where the weave is different and the thickness of the reinforcement part 51 is different from the general part 41. The weaving by the loom 60 is easy without changing the way of moving the reed 61.
  • the general part 41 and the reinforcement part 51 use the thread
  • the reinforcing portion 51 is increased in thickness by increasing the yarn density of the weft yarn 13 from the general portion 41 to increase the strength. For this reason, compared with the case where the reinforcement fabric etc. different from the fiber structure 11 are joined to the part which wants to raise intensity
  • the reinforcing portion 51 is manufactured by adjusting the winding speed of the woven fabric T by the winding roller 63 during weaving by the loom 60, so that the weft 13 can be inserted into a position where the weft 13 is crushed when beaten. It is feasible. Therefore, the reinforcing part 51 can be manufactured without changing the weaving method.
  • the binding yarn 15 penetrates the general portion 41 and the reinforcing portion 51 along the weft 13 that overlaps in the thickness direction. For this reason, when the pitch of the weft 13 is different between the general portion 41 and the reinforcing portion 51, the inter-yarn distance K3 of the binding yarn 15 is also different. Therefore, even the general portion 41 and the reinforcing portion 51 having different pitches and different thicknesses can be bound in the thickness direction by the binding yarn 15.
  • the fiber structure 11 is formed by the wefts 13 and the warps 14 having the same fineness, and other types of yarns are not added to increase the thickness. For this reason, in the fiber reinforced composite material 10 using the fiber structure 11 as a reinforcing base material, weaving by the loom 60 is more effective than when the thickness is changed by changing the number of wefts 13 to be inserted into the fiber structure 11. It is easy and the manufacturing cost can be reduced.
  • the thickness of the reinforcing portion wefts 13b forming the reinforcing portion 51 may be varied, and the thickness of the reinforcing portion 51 may be varied in the longitudinal direction Y1.
  • the inter-yarn distance K3 between the straight portions 15a in the binding yarn 15 passing through the reinforcing portion 51 also varies depending on the thickness of the reinforcing portion weft 13b.
  • the direction in which the wefts 13 are adjacent to each other in the first to third weft layers 21 to 23 is the one direction (longitudinal direction Y1), and the pitch of the wefts 13 is made different so that the general part 41 and the reinforcing part 51 are Although formed, it is not restricted to this.
  • the direction in which the warps 14 are adjacent to each other is defined as one direction, and the general portion 41 and the reinforcing portion 51 are continuously formed in the direction in which the warps 14 are adjacent to each other. 11 is formed.
  • the thickness of the warp 14 in the reinforcing part 51 may be thicker than the thickness of the warp 14 in the general part 41, and the pitch of the warp 14 may be different between the general part 41 and the reinforcing part 51.
  • the pitch of the warp 14 is adjusted by adjusting the density of the wrinkles.
  • the general part 41 and the reinforcing part 51 are formed in the direction in which the wefts 13 are adjacent, and the weft 13 in the reinforcing part 51 is formed.
  • the thickness of the wefts 14 and the warps 14 may be made thicker than the thickness of the wefts 13 and the warps 14 in the general part 41, and the pitches of the wefts 13 and the warps 14 may be made different between the general part 41 and the reinforcing part 51.
  • the general portion 41 and the reinforcement portion 51 are formed in the direction in which the warps 14 are adjacent to each other.
  • the thickness of the weft 13 and the warp 14 is made thicker than the thickness of the weft 13 and the warp 14 in the general portion 41.
  • the pitch of the weft 13 and the warp 14 may be made different between the general part 41 and the reinforcing part 51.
  • the weft 13 is crushed by adjusting the amount of protrusion of the weft 13 from the scissoring place P by adjusting the moving speed of the woven fabric T by the winding roller 63. May change.
  • the amount of crushing the weft 13 may be adjusted by changing the striking stroke.
  • the general part weft 13a of the general part 41 is not crushed at the time of hammering, but the general part weft 13a of the general part 41 may be crushed to adjust the thickness.
  • the number of weft layers and warp layers to be laminated and the order of the weft layers and warp layers to be laminated may be appropriately changed.
  • the fiber structure 11 is used as a reinforcing base material for the fiber reinforced composite material 10
  • the fiber bundle constituting the weft 13 and the warp 14 has high strength such as aramid fiber, poly-p-phenylenebenzobisoxazole fiber, ultrahigh molecular weight polyethylene fiber, etc., corresponding to the physical properties required for the fiber reinforced composite material 10
  • Inorganic fibers such as organic fibers, glass fibers, and ceramic fibers may be used.
  • the weft 13 and the warp 14 may be spun yarns instead of continuous yarns. O
  • the weft 13 and the warp 14 do not need to have the same fineness, and may have different fineness.
  • the weft 13 to be inserted is not limited to a horizontally long flat shape.
  • the weft 13 may be flat, circular, or vertically long.
  • the binding yarn 15 may be composed of reinforcing fibers.
  • the binding yarn 15 may be a weft yarn. O Folding by the binding yarn 15 may not be folded at the outermost layers at both ends in the thickness direction of the multilayer fabric, and may be folded halfway.

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Abstract

繊維構造体は長手方向に沿って連続する一般部と補強部と、を有する。補強部の補強部用緯糸の厚みは、一般部の一般部用緯糸の厚みより厚い。また、補強部での補強部ピッチは、一般部での一般部ピッチより狭い。

Description

繊維構造体及び繊維強化複合材
　本発明は、経糸層及び緯糸層を有する多層織物製の繊維構造体、及び該繊維構造体を強化基材とした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にマトリックス樹脂を含浸させた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、繊維強化複合材では、使用される形状に合わせて厚みを変化させたものがある。
　厚みを変化させた繊維強化複合材用の繊維構造体としては、例えば、特許文献１に開示されている。図５に示すように、特許文献１に開示された三次元織物８０は、複数群に纏められた経糸８１と、複数層に分けられた緯糸８２と、外層の緯糸８２を拘束する絡み糸８３とで織製されている。三次元織物８０は、織り方向に厚さの異なるテーパ部８４を備える。テーパ部８４は、纏められた複数群からなる経糸８１を、群毎に順次分割してその分割された経糸８１の間に新たに緯糸８２を挿通して形成されている。テーパ部８４は、薄肉部８５から厚肉部８６側へと織物の層数が順次増加させることで厚みがテーパ状に増加している。
特開平０９－１５７９９３号公報
　しかし、特許文献１の三次元織物８０は、テーパ部８４を製造するために、複数群に纏められた経糸８１を分割したり、分割された経糸８１の間に緯糸８２を挿通したりと製造が非常に煩雑である。また、三次元織物８０では、テーパ部８４及び厚肉部８６を製造するために、複数群に纏められた経糸８１が薄肉部８５で必要となるのに加え、テーパ部８４及び厚肉部８６を製造するために緯糸８２の本数を徐々に増やす必要があり、製造が非常に煩雑である。
　本発明の目的は、厚みの異なる部分を有していても簡単に製織できる繊維構造体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の繊維構造体は、繊維強化複合材の強化基材であり、経糸層及び緯糸層を有する多層織物よりなる繊維構造体であって、前記経糸層又は前記緯糸層において経糸又は緯糸が隣り合う方向を一方向とすると、前記一方向に沿って連続する第１の部分と第２の部分とを有し、前記第２の部分の経糸は第１の部分の経糸より糸の厚みが厚く、及び／又は前記第２の部分の緯糸は第１の部分の緯糸より糸の厚みが厚く、前記一方向に隣り合う糸の糸主軸同士の距離をピッチとすると、前記第２の部分の前記ピッチは前記第１の部分の前記ピッチより狭いことを要旨とする。
　これによれば、第１の部分と第２の部分とでピッチを異ならせることにより、第１の部分と第２の部分とで糸の幅（厚みに直交する方向の寸法）が変化し、その変化に伴って糸の厚みが変化する。この糸の厚みの変化により、第１の部分の厚みに対し第２の部分の厚みを変化させることができる。また、多層織物の厚さ方向における糸の本数を異ならせて厚みを変化させる場合と比べると、織機による織製が容易であるとともに、製造コストを抑えることができる。
　また、繊維構造体について、前記多層織物の厚み方向に積層された繊維層同士は、結束糸により前記厚み方向に一体化されており、前記結束糸において、前記多層織物の厚み内で前記一方向に隣り合う部分同士間の距離を糸間距離とすると、前記第２の部分と前記第１の部分とで前記糸間距離が異なる。
　これによれば、結束糸は、厚み方向に重なる経糸又は緯糸に沿って多層織物の厚みを貫通する。このため、第１の部分と第２の部分とで一方向に配列された糸となる経糸又は緯糸のピッチが異なる場合には、結束糸の糸間距離も異なることになる。よって、ピッチが異なり、厚みが異なる第１の部分と第２の部分であっても、結束糸により厚み方向に結束できる。
　上記問題点を解決するための繊維強化複合材は、繊維構造体製の強化基材にマトリックス樹脂を含浸させた繊維強化複合材であって、前記繊維構造体が請求項１又は請求項２に記載の繊維構造体であることを要旨とする。
　これによれば、第１の部分と第２の部分とで、一方向に配列された糸のピッチを異ならせることで、第１の部分の厚みを第２の部分に対し変化させることができる。このため、繊維強化複合材において、繊維構造体製の強化基材の織機による織製が容易であるとともに、製造コストを抑えることができる。
　本発明によれば、厚みの異なる部分を有していても簡単に製織できる。
実施形態の繊維強化複合材を示す断面図。 多層織物製の繊維構造体の一般部及び補強部を示す拡大断面図。 織機を模式的に示す図。 （ａ）は筬打ちする前の状態を示す部分断面図、（ｂ）は一般部を形成するために筬打ちした状態を示す部分断面図、（ｃ）は補強部を形成するための移動量を示す部分断面図、（ｄ）は補強部を形成するために筬打ちした状態を示す部分断面図。 単層織物製の繊維構造体の一般部及び補強部を示す拡大断面図。
　以下、繊維構造体及び繊維強化複合材を具体化した一実施形態を図１～図４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１０は、多層織物製の繊維構造体１１がマトリックス樹脂１２に複合化されて構成されている。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。繊維構造体１１は、強化繊維からなる緯糸１３と、強化繊維からなる経糸１４とで構成されている。緯糸１３及び経糸１４は互いに直交する方向に延びている。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。全ての経糸１４は同じ繊度の糸であり、全ての緯糸１３は同じ繊度の糸である。なお、繊度とは、単位長さ当たりの重量のことである。また、緯糸１３及び経糸１４は炭素繊維を繊維束とした連続糸である。
　繊維構造体１１は、複数本の緯糸１３が互いに平行に配列された第１緯糸層２１と、第１緯糸層２１より下方に配置された第２緯糸層２２と、第２緯糸層２２より下方に配置された第３緯糸層２３とを有する。第１～第３緯糸層２１，２２，２３は、多層織物を構成する繊維層である。また、繊維構造体１１は、複数本の経糸１４が互いに平行に配列された第１経糸層３１と、第１経糸層３１より下方に配置された第２経糸層３２とを有する。第１経糸層３１及び第２経糸層３２は、多層織物を構成する繊維層である。
　繊維構造体１１は、上から下へ第１緯糸層２１、第１経糸層３１、第２緯糸層２２、第２経糸層３２、第３緯糸層２３の順番で積層されている。これら第１緯糸層２１、第１経糸層３１、第２緯糸層２２、第２経糸層３２、及び第３緯糸層２３は、経糸の一部を構成する結束糸１５で結束されている。結束糸１５は、繊維構造体１１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１５は、各経糸１４と平行に配列されるとともに、繊維構造体１１を構成する最上層の経糸１４（第１経糸層３１）より上の位置で第１緯糸層２１の緯糸１３の外面を通って折り返すように配置されている。また、結束糸１５は、最下層の経糸１４（第２経糸層３２）より下の位置で第３緯糸層２３の緯糸１３の外面を通って折り返すように配置されている。結束糸１５は多層織物の経糸の一部を構成している。
　前記のように構成された繊維構造体１１は、必要な本数の経糸１４と、必要な本数の結束糸１５を配列した状態で、緯糸１３を緯入れする多層織りで形成される。前記のように構成された多層織物製の繊維構造体１１は、マトリックス樹脂を含浸硬化させて、繊維強化複合材１０となる。よって、繊維強化複合材１０は繊維構造体１１製の強化基材にマトリックス樹脂を含浸させて形成されている。なお、マトリックス樹脂の含浸硬化は、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。
　繊維構造体１１にマトリックス樹脂１２が含浸硬化されることにより、繊維構造体１１の緯糸１３及び経糸１４は、マトリックス樹脂と複合化して繊維強化複合材１０となる。そして、繊維強化複合材１０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。
　繊維構造体１１において、複数本の緯糸１３が配列された方向を長手方向Ｙ１とし、第１緯糸層２１、第１経糸層３１、第２緯糸層２２、第２経糸層３２、及び第３緯糸層２３が積み重なった方向を厚み方向Ｙ２とする。なお、長手方向Ｙ１は、経糸１４の糸主軸が延びる方向でもある。また、繊維構造体１１において、厚み方向Ｙ２への寸法を厚みとする。繊維構造体１１は、長手方向Ｙ１に沿う一部に第１の部分としての一般部４１を備えるとともに、一般部４１以外の部分に第２の部分としての補強部５１を備える。
　一般部４１と補強部５１は、長手方向Ｙ１に連続して形成されており、一般部４１と補強部５１は、一方向に連続しているといえる。本実施形態において、一方向とは、第１～第３緯糸層２１～２３において緯糸１３が隣り合う方向である。一般部４１の厚みは、長手方向Ｙ１に沿って一定である。補強部５１の厚みは、長手方向Ｙ１に沿って一定であるとともに、一般部４１の厚みより厚い。
　図２に示すように、一般部４１を構成する緯糸１３を一般部用緯糸１３ａとする。一般部用緯糸１３ａについて、糸主軸Ｒに直交する断面視は横長扁平状である。長手方向Ｙ１に沿った一般部用緯糸１３ａの寸法のうち、最大寸法を幅Ｗ１とする。厚み方向Ｙ２に沿った一般部用緯糸１３ａの寸法のうち、最大寸法を厚みＨ１とする。また、一般部４１において、長手方向Ｙ１に隣り合う一般部用緯糸１３ａの糸主軸Ｒ同士間の距離を一般部ピッチＰ１とする。
　補強部５１を構成する緯糸１３を補強部用緯糸１３ｂとする。なお、一般部用緯糸１３ａと補強部用緯糸１３ｂとは、同じ繊度の緯糸１３であり、断面形状が異なるだけである。補強部用緯糸１３ｂについて、糸主軸Ｒに直交する断面視は横長扁平状であるが、一般部用緯糸１３ａよりも幅狭な扁平状である。長手方向Ｙ１に沿った補強部用緯糸１３ｂの寸法のうち、最大寸法を幅Ｗ２とする。また、厚み方向Ｙ２に沿った補強部用緯糸１３ｂの寸法のうち、最大寸法を厚みＨ２とする。
　また、補強部５１において、長手方向Ｙ１に隣り合う補強部用緯糸１３ｂの糸主軸Ｒ同士間の距離を補強部ピッチＰ２とすると、補強部ピッチＰ２（第２の部分のピッチ）は、一般部ピッチＰ１（第１の部分のピッチ）より狭い。その結果として、補強部用緯糸１３ｂの幅Ｗ２は、一般部用緯糸１３ａの幅Ｗ１より狭く、補強部５１における補強部用緯糸１３ｂの厚みＨ２は、一般部４１における一般部用緯糸１３ａの厚みＨ１より厚い。言い換えると、補強部５１において、長手方向Ｙ１に配列された補強部用緯糸１３ｂの厚みは、一般部４１において、長手方向Ｙ１に配列された一般部用緯糸１３ａの厚みより厚い。したがって、一般部４１と補強部５１とでは、一般部用緯糸１３ａを備えた一般部４１の厚みＴ１は、補強部用緯糸１３ｂを備えた補強部５１の厚みＴ２より薄い。言い換えると、補強部５１は一般部４１より厚い。
　よって、長手方向Ｙ１における単位長さ当たりに存在する緯糸１３の量は、補強部５１の方が一般部４１よりも多く、補強部５１における糸密度は、一般部４１における糸密度より高い。
　また、長手方向Ｙ１に何度も折り返された結束糸１５において、繊維構造体１１の厚み方向Ｙ２に延びる部分を直線部１５ａとし、繊維構造体１１の厚み方向Ｙ２の両端で緯糸１３の外面を通って折り返された部分を返し部１５ｂとする。この場合、結束糸１５が織り進む方向、すなわち長手方向Ｙ１に隣り合う直線部１５ａ同士間の距離を糸間距離Ｋ３とする。一般部４１の一般部用緯糸１３ａは、補強部５１の補強部用緯糸１３ｂより幅広であるため、一般部４１での糸間距離Ｋ３は、補強部５１での糸間距離Ｋ３より広い。
　次に、繊維構造体１１の製造方法について説明する。
　図３に示すように、織機６０において、送り出された経糸１４は、綜絖６１、筬６２へ案内される。緯入れされた緯糸１３は、筬６２によって筬打ちされ、製織された織布Ｔは、巻取りローラ６３に巻き取られる。
　織機６０によって繊維構造体１１を製造する際、緯糸１３が緯入れされ、筬６２によって筬打ちされる。なお、以下の説明において、緯入れされる緯糸１３は、全て一般部用緯糸１３ａと同じ幅Ｗ１の横長扁平状である。また、筬打ち場所Ｐは、図４（ａ）の２点鎖線Ｌ１に示す位置であり、常に同じ位置である。そして、緯糸１３は、筬打ち場所Ｐ、すなわち２点鎖線Ｌ１よりも織布Ｔから離れる側に緯入れされる。
　一般部４１の製造では、まず、巻取りローラ６３により、既に織製された織布Ｔが巻き取られ、織布Ｔの先端Ｇが筬打ち場所Ｐから巻取りローラ６３側へ移動する。一般部４１を製造するときの織布Ｔの移動量を第１移動量Ｋ１とする。この第１移動量Ｋ１は、一般部用緯糸１３ａの幅Ｗ１と同じである。
　なお、織布Ｔの移動量は、巻取りローラ６３の巻取り速度を調節することで変化させることができる。例えば、巻取りローラ６３の巻取り速度を速めると、一定時間当たりの織布Ｔの移動量が多くなり、巻取りローラ６３の巻取り速度を遅くすると、一定時間当たりの織布Ｔの移動量が少なくなる。
　そして、図４（ｂ）に示すように、緯入れされた緯糸１３が筬打ち場所Ｐで筬打ちされるが、緯入れされた緯糸１３は筬打ち場所Ｐから飛び出さない状態となる。よって、緯糸１３は押し潰されず、幅Ｗ１のままとなる。その結果、一般部用緯糸１３ａによって一般部４１の一部が形成される。
　次に、補強部５１が製造される。図４（ｃ）に示すように、補強部５１の製造では、巻取りローラ６３により、織布Ｔの移動量を、一般部４１製造時の第１移動量Ｋ１より少なくする。補強部５１を製造するための織布Ｔの移動量を、第２移動量Ｋ２とする。第２移動量Ｋ２は、一般部用緯糸１３ａの幅Ｗ１より短く、補強部用緯糸１３ｂの幅Ｗ２と同じである。そして、織布Ｔが巻き取られると、織布Ｔの先端Ｇと筬打ち場所Ｐとの間には、幅Ｗ２に相当する隙間Ｓ１が形成される。
　そして、図４（ｄ）に示すように、緯入れされた緯糸１３が筬打ち場所Ｐで筬６２によって筬打ちされると、図４（ｄ）の２点鎖線に示すように、筬打ち場所Ｐから飛び出した緯糸１３が、筬６２によって押し潰される。その結果、補強部用緯糸１３ｂが形成されるとともに、補強部用緯糸１３ｂの幅Ｗ２となる。補強部５１を形成する本数の補強部用緯糸１３ｂが形成されると、補強部５１の一部が形成される。
　次に、繊維構造体１１の作用を記載する。
　繊維構造体１１において、強度を高めたい補強部５１について、補強部５１を形成する補強部用緯糸１３ｂの断面形状は、一般部４１を形成する一般部用緯糸１３ａよりも縦長の扁平状である。補強部用緯糸１３ｂと同じ繊度の一般部用緯糸１３ａで形成された一般部４１において、一般部用緯糸１３ａの断面形状は横長扁平状である。このため、補強部５１の厚みは、一般部４１の厚みより厚く、一般部４１より強度が高められている。
　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）繊維構造体１１において、補強部ピッチＰ２が一般部ピッチＰ１より狭くなるように補強部５１及び一般部４１を形成した。このため、補強部用緯糸１３ｂの厚みＨ２を一般部用緯糸１３ａの厚みＨ１より厚くできる。よって、補強部５１の厚みを一般部４１の厚みより厚くできる。そして、一般部４１と補強部５１が、緯糸１３と経糸１４を使った同じ織り方であることから、織り方を異ならせて、補強部５１の厚みを一般部４１と異ならせる場合と比べると、綜絖６１の動かし方を変える必要もなく織機６０による織製が容易である。また、一般部４１と補強部５１とで、同じ繊度の糸を使い、厚み方向Ｙ２について同じ本数である。このため、繊度の異なる糸で厚みを異ならせたり、緯入れする緯糸１３の本数を異ならせて厚みを変化させる場合と比べると、織機６０による織製が容易であるとともに、製造コストを抑えることができる。
　（２）補強部５１は、緯糸１３の糸密度を一般部４１より増やすことで厚みを厚くし、強度を高めている。このため、強度を高めたい部分に、繊維構造体１１とは別の補強織物等を接合する場合と比べて、補強織物の追加分、補強織物を接合するための手間を省くことができる。
　（３）補強部５１の製造は、織機６０による織製時、巻取りローラ６３による織布Ｔの巻取り速度を調節し、筬打ち時に緯糸１３が押し潰される位置に緯入れ可能とすることで実現可能である。よって、織り方を変えることなく、補強部５１を製造できる。
　（４）結束糸１５は、厚み方向に重なる緯糸１３に沿って一般部４１及び補強部５１を貫通する。このため、一般部４１と補強部５１とで緯糸１３のピッチが異なる場合には、結束糸１５の糸間距離Ｋ３も異なることになる。よって、ピッチが異なり、厚みが異なる一般部４１と補強部５１とであっても、結束糸１５により厚み方向に結束できる。
　（５）繊維構造体１１は、繊度が同じ緯糸１３及び経糸１４によって形成され、厚み増加のために他の種類の糸を追加することがない。このため、繊維構造体１１を強化基材とした繊維強化複合材１０において、繊維構造体１１の緯入れする緯糸１３の本数を異ならせて厚みを変化させる場合と比べると、織機６０による製織が容易であるとともに、製造コストを抑えることができる。
　なお、上記実施形態は以下のように変更してもよい。
　○ 補強部５１を形成する補強部用緯糸１３ｂ同士で厚みを異ならせ、長手方向Ｙ１に補強部５１の厚みを異ならせてもよい。この場合、補強部５１を通る結束糸１５における直線部１５ａ同士の糸間距離Ｋ３も補強部用緯糸１３ｂの厚みに応じて異なる。
　○ 実施形態では、第１～第３緯糸層２１～２３において緯糸１３が隣り合う方向を（長手方向Ｙ１）を一方向とし、その緯糸１３のピッチを異ならせて一般部４１と補強部５１を形成したが、これに限らない。第１経糸層３１及び第２経糸層３２において、経糸１４が隣り合う方向を一方向とするとともに、経糸１４が隣り合う方向に一般部４１と補強部５１を連続して形成して繊維構造体１１を形成する。そして、補強部５１における経糸１４の厚みを、一般部４１における経糸１４の厚みより厚くし、それら経糸１４のピッチを一般部４１と補強部５１とで異ならせてもよい。なお、経糸１４のピッチの調節は、筬密度を調節して行われる。
　又は、第１～第３緯糸層２１～２３において緯糸１３が隣り合う方向を一方向とした場合、緯糸１３が隣り合う方向に一般部４１と補強部５１を形成し、補強部５１における緯糸１３及び経糸１４の厚みを、一般部４１における緯糸１３及び経糸１４の厚みより厚くし、それら緯糸１３及び経糸１４のピッチを一般部４１と補強部５１で異ならせてもよい。
　若しくは、第１経糸層３１及び第２経糸層３２において、経糸１４が隣り合う方向を一方向とした場合、経糸１４が隣り合う方向に一般部４１と補強部５１を形成し、補強部５１における緯糸１３及び経糸１４の厚みを、一般部４１における緯糸１３及び経糸１４の厚みより厚くする。そして、それら緯糸１３及び経糸１４のピッチを一般部４１と補強部５１で異ならせてもよい。
　○ 実施形態では、巻取りローラ６３による織布Ｔの移動速度を調節することで、筬打ち場所Ｐからの緯糸１３の突出量を調節して緯糸１３を押し潰すようにしたが、押し潰す方法は変えてもよい。例えば、筬打ちストロークを変えて緯糸１３を押し潰す量を調節してもよい。
　○ 実施形態では、一般部４１の一般部用緯糸１３ａは、筬打ち時に押し潰されなかったが、一般部４１の一般部用緯糸１３ａを押し潰して厚み調整してもよい。
　○ 多層織物製の繊維構造体１１において、積層する緯糸層及び経糸層の数や積層する緯糸層及び経糸層の順番は適宜変更してもよい。
　○ 繊維構造体１１を繊維強化複合材１０の強化基材として使用する場合、マトリックス樹脂の種類や繊維強化複合材１０の製造方法に、特に規制はない。
　○ 緯糸１３及び経糸１４を構成する繊維束は、繊維強化複合材１０に要求される物性に対応して、アラミド繊維、ポリ－ｐ－フェニレンベンゾビスオキサゾール繊維、超高分子量ポリエチレン繊維等の高強度の有機繊維、ガラス繊維やセラミック繊維等の無機繊維を使用してもよい。
　○ 緯糸１３及び経糸１４は、連続糸ではなく紡績糸であってもよい。
　○ 緯糸１３及び経糸１４は、同じ繊度の糸でなくてもよく、繊度の異なる糸であってもよい。
　○ 緯入れされる緯糸１３は横長扁平状に限らない。例えば、緯糸１３は扁平形状や円形状、縦長扁平状であってもよい。
　○ 結束糸１５は強化繊維で構成されていてもよい。
　○ 結束糸１５は緯方向の糸であってもよい。
　○ 結束糸１５による折り返しは、多層織物の厚み方向両端の最外層で折り返されていなくてもよく、途中で折り返されていてもよい。
　次に、上記実施形態及び別例から把握できる技術的思想について以下に追記する。
　（１）前記第１の部分と前記第２の部分とで糸の断面形状が異なる繊維構造体。
　（２）前記第１の部分と前記第２の部分とで糸密度が異なる繊維構造体。
　Ｐ１　　一般部ピッチ
　Ｐ２　　補強部ピッチ
　Ｒ　　糸主軸　
　Ｋ３　　糸間距離　
　Ｙ１　　一方向としての長手方向　
　１０　　繊維強化複合材
　１１　　繊維構造体
　１２　　マトリックス樹脂
　１３　　緯糸
　１４　　経糸
　１５　　結束糸
　２１～２３　　第１～第３緯糸層
　３１～３２　　第１～第２経糸層
　４１　　第１の部分としての一般部
　５１　　第２の部分としての補強部
　６０　　織機

Claims (5)

  1. 　繊維強化複合材の強化基材であり、経糸層及び緯糸層を有する多層織物よりなる繊維構造体であって、
    　前記経糸層又は前記緯糸層において経糸又は緯糸が隣り合う方向を一方向とすると、
    　前記一方向に沿って連続する第１の部分と第２の部分とを有し、
    　前記第２の部分の経糸は第１の部分の経糸より糸の厚みが厚く、
    　及び／又は
    　前記第２の部分の緯糸は第１の部分の緯糸より糸の厚みが厚く、
    　前記一方向に隣り合う糸の糸主軸同士の距離をピッチとすると、
    　前記第２の部分の前記ピッチは前記第１の部分の前記ピッチより狭いことを特徴とする繊維構造体。
  2. 　前記多層織物の厚み方向に積層された繊維層同士は、結束糸により前記厚み方向に一体化されており、前記結束糸において、前記多層織物の厚み内で前記一方向に隣り合う部分同士間の距離を糸間距離とすると、前記第２の部分と前記第１の部分とで前記糸間距離が異なる請求項１に記載の繊維構造体。
  3. 　前記第１の部分と前記第２の部分とで糸の断面形状が異なる請求項１又は請求項２に記載の繊維構造体。
  4. 　前記第１の部分と前記第２の部分とで糸密度が異なる請求項１～請求項３のうちいずれか一項に記載の繊維構造体。
  5. 　繊維構造体製の強化基材にマトリックス樹脂を含浸させた繊維強化複合材であって、前記繊維構造体が請求項１～請求項４のうちいずれか一項に記載の繊維構造体であることを特徴とする繊維強化複合材。
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