WO2020111215A1 - シート状強化繊維基材およびその製造方法 - Google Patents
シート状強化繊維基材およびその製造方法 Download PDFInfo
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- WO2020111215A1 WO2020111215A1 PCT/JP2019/046706 JP2019046706W WO2020111215A1 WO 2020111215 A1 WO2020111215 A1 WO 2020111215A1 JP 2019046706 W JP2019046706 W JP 2019046706W WO 2020111215 A1 WO2020111215 A1 WO 2020111215A1
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- 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
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J5/047—Reinforcing macromolecular compounds with loose or coherent fibrous material with mixed fibrous material
- C08J5/048—Macromolecular compound to be reinforced also in fibrous form
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- 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
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- 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
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
-
- 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
- B32B5/12—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 the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
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- 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
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/08—Interconnection of layers by mechanical means
- B32B7/09—Interconnection of layers by mechanical means by stitching, needling or sewing
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- 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
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/002—Inorganic yarns or filaments
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
- D04H3/04—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2307/00—Use of elements other than metals as reinforcement
- B29K2307/04—Carbon
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/021—Fibrous or filamentary layer
- B32B2260/023—Two or more layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/106—Carbon fibres, e.g. graphite fibres
Definitions
- the present invention relates to a sheet-shaped reinforcing fiber base material obtained by arranging a plurality of reinforcing fiber bundles, and a method for manufacturing the sheet-shaped reinforcing fiber base material.
- RTM Resin Transfer Molding
- a laminated body composed of a sheet-shaped reinforcing fiber base material is placed in a shaping mold and shaped into a three-dimensional shape substantially the same as a fiber-reinforced resin molded product, and a preform is formed. To generate. Next, after placing this preform in a molding die, a matrix resin such as an epoxy resin is injected into the molding die to impregnate the preform with the matrix resin and cure it. As a result, a fiber-reinforced resin molded product can be obtained.
- a sheet-like reinforcing fiber base material used in the RTM method generally, a woven fabric base material in which a warp yarn and a weft yarn of a reinforcing fiber bundle are woven to obtain a fabric form, or a reinforcing fiber bundle arranged in parallel is used.
- a non-crimp base material obtained by joining by a method such as suturing using an auxiliary thread.
- the woven fabric base material does not have each reinforcing fiber bundle joined to another reinforcing fiber bundle, but maintains the sheet form only by the friction of the three-dimensionally intersecting directly overlapping portions. Therefore, the warp yarns and the weft yarns of the woven fabric base material can freely move with each other when subjected to an external force, and are easily sheared and deformed in a plane.
- the respective reinforcing fiber bundles are not three-dimensionally intersected with each other, and the reinforcing fiber bundles are joined to each other by the auxiliary yarns, and the reinforcing fiber bundles are bound to each other.
- the reinforcing fiber bundle cannot move freely in the vicinity of the joint portion and is deformed in a twisted state. Hard to be sheared inside.
- a fabric base material that is easily sheared is suitable for a complex three-dimensional preform.
- the textile base material and the non-crimp base material are continuously manufactured with a constant width, when the preform is produced, these base materials are cut according to the product shape, and the end materials remaining after cutting are Does not contribute to the product. Therefore, in the production of the fiber-reinforced resin molded product using the woven fabric base material or the non-crimp base material, there is a problem that the yield of the reinforcing fiber is poor and the production cost is high.
- a reinforcing fiber bundle is arranged only in a necessary place from the beginning according to the product shape.
- the Mento method is drawing attention.
- Patent Document 1 discloses a device using this fiber placement method.
- the reinforcing fiber bundle wound on the bobbin is pulled out to the head arranged on the plane, then arranged in one direction on the plane, and cut into a desired length.
- the reinforced fiber bundle is arranged so as to be adjacent to the reinforced fiber bundle arranged and the cutting is repeated at a desired length, and as a result, one having a desired outer peripheral shape composed of the reinforced fiber bundle is formed. Layers are formed.
- the reinforcing fiber bundles are sequentially placed in the same direction as the above in a direction different from the longitudinal direction of the reinforcing fiber bundles forming the above layers, and these layers are joined to each other. In this way, finally, a sheet-shaped reinforcing fiber base material can be obtained.
- the sheet-shaped reinforcing fiber base formed by this method is not a form in which the reinforcing fiber bundles are three-dimensionally intersected with each other and the sheet shape is maintained by friction, unlike a woven base material, the reinforcing fiber base is particularly preferable.
- the bundle is dry, it is necessary to bond the layers composed of the reinforcing fiber bundle to each other using a resin binder or auxiliary yarn over the entire surface. Therefore, the sheet-like reinforcing fiber base material formed by this method is inferior in easiness of shear deformation in a plane when it is subjected to an external force, like a non-crimp base material, to a fabric base material.
- Patent Document 2 in order to secure the ease of shear deformation as a sheet-like reinforcing fiber base material, layers composed of reinforcing fiber bundles are not joined over the entire surface, but partially.
- a method is disclosed for a non-crimp fabric (substrate) that is bonded only to the.
- the reinforcing fiber bundles are not three-dimensionally intersected with each other like the textile substrate, when the reinforcing fiber bundles are largely shaped into a three-dimensional shape in the subsequent step, the reinforcing fiber bundles are not The supporting force is too small to control the position of the reinforcing fiber bundle as intended, and it is difficult to develop stable physical properties as a reinforcing fiber resin molded product.
- Patent Document 3 discloses a method in which a reinforcing fiber bundle is continuously wound around a mandrel and then cut into a desired shape to form a sheet-like reinforcing fiber base material.
- this method it is possible to obtain a form (hereinafter, this form is referred to as “pseudo-woven fabric”) that is quite close to a woven fabric base material in which reinforcing fiber bundles are three-dimensionally intersected, but it is still composed of reinforcing fiber bundles.
- the layers to be formed are joined to each other by tackifier over the entire surface, and it is not possible to expect the ease of shear deformation in a plane when an external force is applied.
- the reinforcing fiber bundle is wound around the mandrel to form a cylindrical sheet-like reinforcing fiber base, and the end remaining after being cut into a desired shape is the same as a usual woven base or non-crimp base.
- the wood still does not contribute to the product. Therefore, improvement in the yield of reinforcing fibers cannot be expected.
- An object of the present invention is to improve sheet yield, which has shear deformability, can follow a three-dimensional shape, and can significantly improve the yield of reinforcing fibers by suppressing the generation of mill ends and reduce the manufacturing cost.
- a fiber base material hereinafter, sometimes referred to as a pseudo woven fabric, the sheet-shaped reinforcing fiber base material and the pseudo woven fabric have exactly the same concept
- a method for producing the same a fiber reinforced resin molded article is provided. To improve productivity.
- the present invention has the following configurations [1] to [13] in order to solve the problems. That is, [1] A sheet-like reinforcing fiber base material having a laminated structure of N layers (N is an integer of 3 or more) obtained by arranging a plurality of reinforcing fiber bundles having an arbitrary length, and comprising the following (1 ) To (5), a sheet-like reinforcing fiber base material that satisfies the respective conditions.
- the adjacent reinforcing fiber bundles are arranged in parallel with each other, and the clearance between the adjacent reinforcing fiber bundles is equal to or more than the width of the reinforcing fiber bundle
- Layers contacting each other vertically (3) Arranged in different directions in the reinforcing fiber bundles constituting (3) the longitudinal direction of the reinforcing fiber bundles constituting the odd-numbered layer which is an arbitrary no-th layer (no is an odd number of 3 or more and N or less), and ( no-2)
- the longitudinal directions of the reinforcing fiber bundles forming the second layer are parallel to each other, and the reinforcing fiber bundles forming the respective layers do not overlap each other (4)
- N is 4 or more
- Longitudinal direction of the reinforcing fiber bundles forming the even layer which is an optional ne layer (ne is an even number of 4 or more and N or less)
- the longitudinal direction of the reinforcing fiber bundles constituting the (ne-2)th layer Are parallel to each other,
- N layers (N is an integer of 4 or more) obtained by arranging a plurality of reinforcing fiber bundles having an arbitrary length in which intersecting reinforcing fiber bundles are joined to each other in at least a part of the intersecting region [2]
- the adjacent reinforcing fiber bundles are arranged in parallel with each other, and the clearance between the adjacent reinforcing fiber bundles is not less than the width of the reinforcing fiber bundle.
- adjacent reinforcing fiber bundles are parallel to each other in a direction different from the longitudinal direction of the reinforcing fiber bundle forming the first layer.
- a clearance between the adjacent reinforcing fiber bundles is not less than the width of the reinforcing fiber bundle, and a (n ⁇ 2)th layer (n is 4 or more and N or less).
- n is 4 or more and N or less.
- a reinforcing fiber bundle that does not overlap with any of the odd-numbered layers does not overlap with each other, and the adjacent reinforcing fiber bundles are arranged in parallel with each other, and the clearance between the adjacent reinforcing fiber bundles is not less than the width of the reinforcing fiber bundle.
- the reinforcing fiber bundles that are adjacent to each other do not overlap any of the reinforcing fiber bundles constituting the even-numbered layers from the second layer to the (n ⁇ 2)th layer, and the adjacent reinforcing fiber bundles are arranged in parallel with each other and are adjacent to each other.
- the clearance between the reinforcing fiber bundles is The n-th layer having a width or more is repeatedly placed up to the N-th layer, and the reinforcing fiber bundle forming the first layer and the reinforcing fiber bundle forming the N-th layer are The sheet-shaped reinforcing fiber base material according to the above [1], wherein the intersecting reinforcing fiber bundles are joined to each other in at least a part of the intersecting region which is a directly overlapping portion.
- the N is an odd number of 3 or more, and the reinforcing fiber bundles constituting the first layer and any even layer from the second layer to the N-1th layer (Ne 1 ).
- the reinforcing fiber bundles that cross each other are joined to each other in at least a part of the intersecting region of the reinforcing fiber bundles that form the (layer), and the reinforcing fiber bundle that forms the Nth layer and the second to N-1th layers.
- the intersecting reinforcing fiber bundles are joined to each other in at least a part of the intersecting region of the reinforcing fiber bundles forming any of the even-numbered layers up to the layer (Ne Nth layer), [1]
- the sheet-shaped reinforcing fiber substrate according to.
- the sheet-shaped reinforcing fiber base material according to any one of the above [1] to [4], wherein the reinforcing fiber bundles are bonded to each other in at least a part of a crossing region with.
- the length of each reinforcing fiber bundle in the longitudinal direction is determined such that the outer peripheral shape is the same as the shape of the fiber-reinforced resin molded product, according to any one of the above [1] to [5].
- Sheet-shaped reinforcing fiber base material [7] The above [1] to [1], wherein the angle between the longitudinal direction of the reinforcing fiber bundles forming the odd layer and the longitudinal direction of the reinforcing fiber bundles forming the even layer is 45° to 90°.
- the sheet-shaped reinforcing fiber base material according to any one of [1] to [10], wherein the reinforcing fiber bundle is a carbon fiber.
- a plurality of reinforcing fiber bundles having a clearance between the reinforcing fiber bundles in a direction different from the longitudinal direction of the reinforcing fiber bundles forming the odd layer of the first layer is equal to or larger than the width of the reinforcing fiber bundles on the odd layer.
- the clearance between the reinforcing fiber bundles is such that the clearance between the reinforcing fiber bundles is parallel to the longitudinal direction of the reinforcing fiber bundles forming the previous even layer so as not to overlap any of the reinforcing fiber bundles forming all the even layers laminated up to that time.
- a plurality of reinforcing fiber bundles are arranged in parallel at a width equal to or larger than, and an even layer of a ne-th layer (ne is an even number of 4 or more and N or less) is formed. (e) When N is 5 or more, no or Step (c) and step (d) are alternately repeated until ne reaches a predetermined value of n.
- the sheet-shaped reinforcing fiber base material (pseudo-woven fabric) of the present invention has shear deformability, can follow a three-dimensional shape, and significantly improves the yield of reinforcing fibers by suppressing the generation of end material.
- the manufacturing cost can be reduced. Therefore, the fiber-reinforced resin molded product can be manufactured with high productivity.
- FIG. 1 is a plan view showing a sheet-shaped reinforcing fiber base material (pseudo-woven fabric) 10 according to an embodiment of the present invention.
- 1 is a perspective view showing a structure of each layer composed of reinforcing fiber bundles 11 to 14 in a sheet-like reinforcing fiber base material (pseudo-woven fabric) 10.
- FIG. 3 is a plan view showing clearances 11C to 14C of reinforcing fiber bundles 11 to 14 constituting each layer in a sheet-like reinforcing fiber base material (pseudo-woven fabric) 10.
- FIG. 2 is a plan view showing constituent elements of a sheet-shaped reinforcing fiber base material (pseudo-woven fabric) 10.
- FIG. 3 is a plan view showing a state where the sheet-shaped reinforcing fiber base material (pseudo-woven fabric) 10 is subjected to external force and is sheared and deformed in a plane.
- FIG. 3 is a plan view showing a state where the sheet-shaped reinforcing fiber base material (pseudo-woven fabric) 10 is subjected to external force and is sheared and deformed in a plane.
- the reinforcing fiber bundles 12' and 13' are joined to each other at the joining portion 1E' that directly overlaps the reinforcing fiber bundles 13 and 12, respectively. It is a top view shown.
- FIG. 3 is a plan view showing a sheet-shaped reinforcing fiber base material (pseudo-woven fabric) 20 whose outer peripheral shape is determined according to the shape of a fiber-reinforced resin molded product.
- FIG. 3 is a plan view showing a sheet-shaped reinforcing fiber base material (pseudo-woven fabric) 30 in which reinforcing fiber bundles 31 to 34 are randomly arranged and arranged.
- the top view which shows the sheet-like reinforcing fiber base material (pseudo-woven fabric) 40 whose angle between the longitudinal direction of the reinforcing fiber bundles 41 and 43 of an odd number layer and the longitudinal direction of the reinforcing fiber bundles 42 and 44 of an even number layer is 45 degrees. Is. FIG.
- FIG. 5 is a plan view showing a sheet-like reinforcing fiber base material (pseudo-woven fabric) 50, which is composed of reinforcing fiber bundles 51 to 56 and has a layer number N of 6;
- FIG. 7 is a plan view showing a sheet-like reinforcing fiber base material (pseudo-woven fabric) 60 having a number N of layers of 8 and composed of reinforcing fiber bundles 61 to 68.
- a procedure for manufacturing the sheet-shaped reinforcing fiber base material (pseudo-woven fabric) 20 will be described.
- FIG. 1 shows a sheet-shaped reinforcing fiber substrate (pseudo-woven fabric) 10 according to one embodiment of the present invention
- FIGS. 2a to 2c show the sheet-shaped reinforcing fiber substrate (pseudo-woven fabric) 10 of FIG.
- the configuration is shown in more detail.
- the value of the number N of layers composed of reinforcing fiber bundles is 4.
- the value of N is 4 in the example shown in FIGS. 1 to 2c, it may have a laminated structure of N layers in which N is an integer of 3 or more.
- the reinforcing fiber bundle 11 (first layer) is provided on the reinforcing fiber bundle 12 (second layer), and the reinforcing fiber bundle 13 (third layer) is provided on top of the reinforcing fiber bundle 12 (second layer). Further, a reinforcing fiber bundle 14 (fourth layer) is placed on the upper part thereof, and the reinforcing fiber bundles constituting the vertically contacting layers are arranged in different directions.
- Reinforcing fiber bundles of odd-numbered layers (first layer and third layer) and reinforcing fiber bundles of even-numbered layers (second layer and fourth layer) are respectively In each layer so that it does not overlap with the reinforcing fiber bundle of any layer, the adjacent reinforcing fiber bundles are arranged in parallel with each other, and the clearance between the adjacent reinforcing fiber bundles is not less than the width of the reinforcing fiber bundle. Is. Then, the directly overlapping portions of the first layer composed of the reinforcing fiber bundle 11 and the fourth layer composed of the reinforcing fiber bundle 14 are bonded to each other at a bonding site 1E by a resin binder. ing.
- the intersecting reinforcing fiber bundles are joined to each other by a sheet. While maintaining the shape as described above, when the fiber is made to follow a curved surface shape, it is possible to follow the shape without causing wrinkles by appropriately shifting the fibers.
- the reinforcing fiber bundles 11 to 14 have the same length in the longitudinal direction. This is because in the embodiment shown in FIG. 1, since the sheet-shaped reinforcing fiber base material (pseudo-woven fabric) 10 has a substantially square shape, the reinforcing fiber bundles 11 to 14 have the same length in the longitudinal direction. This is because When applied to actual molding, by arranging a plurality of reinforcing fiber bundles of an arbitrary length, a sheet-like reinforcing fiber base material according to the target shape as shown in other figures described later. (Pseudo-woven fabric) can be obtained.
- the clearances 11C to 14C which are the clearances between the adjacent reinforcing fiber bundles of the reinforcing fiber bundles 11 to 14 constituting each layer, are adjusted to be not less than the widths of the reinforcing fiber bundles 11 to 14, respectively. ing. That is, in each layer, the clearance between the adjacent reinforcing fiber bundles is not less than the width of the reinforcing fiber bundles.
- the angle between the longitudinal direction of the reinforcing fiber bundles of the odd layers and the longitudinal direction of the reinforcing fiber bundles of the even layers is 90°, but the reinforcing fiber bundles constituting the layers in contact with each other are different. If arranged in the direction, as will be described later, at least a part of the intersecting region where the reinforcing fiber bundles forming the odd layers and the reinforcing fiber bundles forming the even layers directly overlap each other, the reinforcing fiber bundles intersecting each other. Can be bonded to each other and can be handled as a sheet-like reinforcing fiber base material.
- the reinforcing fiber bundle 11 and the reinforcing fiber bundle 13 forming the odd layer and the reinforcing fiber bundle 12 and the reinforcing fiber bundle 14 forming the even layer are parallel (however, a deviation of ⁇ 2° or less is included in parallel). is there. That is, the longitudinal direction of the reinforcing fiber bundle that constitutes the third layer is parallel to the longitudinal direction of the reinforcing fiber bundle that constitutes the first layer, and the reinforcing direction that constitutes the fourth layer. The longitudinal direction of the fiber bundle is parallel to the longitudinal direction of the reinforcing fiber bundle constituting the second layer.
- the value of N is 4, but when the number of layers is more than that, the above relationship constitutes an odd-numbered layer which is any no-th layer (no is an odd number of 3 or more and N or less).
- the longitudinal direction of the reinforcing fiber bundle is parallel to the longitudinal direction of the reinforcing fiber bundle constituting the (no-2)th layer, and at any ne-th layer (ne is an even number of 4 or more and N or less). It suffices that the longitudinal direction of the reinforcing fiber bundle constituting the even-numbered layer and the longitudinal direction of the reinforcing fiber bundle constituting the (ne-2)th layer are parallel.
- the reinforcing fiber bundle forming the third layer and the reinforcing fiber bundle forming the first layer do not overlap each other
- the reinforcing fiber bundle forming the fourth layer and the The reinforcing fiber bundles constituting the second layer are arranged so as not to overlap each other.
- the value of N is 4, but when the number of layers is more than that, the above relationship constitutes an odd-numbered layer which is any no-th layer (no is an odd number of 3 or more and N or less).
- the reinforcing fiber bundle and the reinforcing fiber bundle forming the (no-2)th layer are arranged so as not to overlap with each other, and are any ne layer (ne is an even number of 4 or more and N or less). It is sufficient that the reinforcing fiber bundles forming the even-numbered layers and the reinforcing fiber bundles forming the (ne-2)th layer do not overlap with each other.
- FIG. 2c shows a reinforcing fiber that intersects in a crossing region where a reinforcing fiber bundle 11 forming an odd layer and a reinforcing fiber bundle 14 forming an even layer directly overlap each other in a sheet-like reinforcing fiber base material (pseudo-woven fabric) 10.
- the minimum unit of the part where the bundles are joined to each other is shown.
- the minimum unit refers to the smallest range in which the sheet-like reinforcing fiber base material (pseudo-woven fabric) 10 is repeated two-dimensionally.
- the reinforcing fiber bundle constituting the first layer that is, the lowermost layer in the sheet-shaped reinforcing fiber base material (pseudo-woven fabric) 10) as described above.
- 11 and a crossing region of the reinforcing fiber bundle 14 constituting the fourth layer that is, the uppermost layer in the sheet-like reinforcing fiber base material (pseudo-woven fabric) 10) are joined to each other at the joining portion 1E.
- the joint location is not necessarily limited to this.
- the reinforcing fiber bundle 11 is one of the reinforcing fiber bundles 12 constituting the second layer (that is, the layer one layer above the lowermost layer in the sheet-like reinforcing fiber base material (pseudo-woven fabric) 10), and
- the reinforcing fiber bundle 14 is bonded to any one of the reinforcing fiber bundles 13 constituting the third layer (that is, the layer immediately below the uppermost layer in the sheet-like reinforcing fiber base material (pseudo-woven fabric) 10).
- the reinforcing fiber bundle 12 may be joined to any one of the reinforcing fiber bundles 13, respectively.
- the form of the sheet can be maintained. Even when the value of N is 4 or more, the form of the sheet can be maintained by the same idea as long as it is selectively joined in at least a part of the intersection region.
- the sheet-shaped reinforcing fiber base material it is desirable for the sheet-shaped reinforcing fiber base material to maintain the sheet shape by the friction of the portion where the reinforcing fiber bundles directly overlap each other. For this reason, when the crossing region of the first layer composed of the reinforcing fiber bundle 11 and the crossing region of the fourth layer composed of the reinforcing fiber bundle 14 are joined to each other, the reinforcing fiber bundle therebetween is in between. Since 12 and 13 are all bound to each other by friction, they are preferable as the form of the sheet-like reinforcing fiber base material.
- the sheet-shaped reinforcing fiber base material (pseudo-woven fabric) 10 has a N value of 4, that is, N is an even number, but when N is an odd number, the first layer Further, in at least a part of the intersecting region of the reinforcing fiber bundle that constitutes the above and the reinforcing fiber bundle that constitutes the even-numbered layer (Ne 1-th layer) from any of the second layer to the N-1th layer, In the intersecting region of the reinforcing fiber bundles forming the Nth layer and the reinforcing fiber bundles forming any of the even-numbered layers (Ne Nth layer) from the second layer to the N-1th layer.
- FIG. 3 shows that the reinforcing fiber bundle 12 ′ is present adjacent to only one side of the reinforcing fiber bundle 14 with respect to any of the reinforcing fiber bundles 14 and the reinforcing fiber bundle 11 is included in any of the reinforcing fiber bundles 11.
- (Pseudo woven fabric) 10' is shown.
- the sheet-shaped reinforcing fiber base material (pseudo-woven fabric) 10′ has basically the same conditions as the sheet-like reinforcing fiber base material (pseudo-woven fabric) 10 except that it has a joint portion 1E′ in addition to the joint portion 1E.
- the sheet-shaped reinforcing fiber base material (pseudo-woven fabric) 10′ the reinforcing fiber bundles 12′ and 13′ are joined to each other at the joining portion 1E′, so that the falling-off is prevented. be able to. Therefore, the sheet-shaped reinforcing fiber substrate (pseudo-woven fabric) 10 ′ is more preferable than the sheet-shaped reinforcing fiber substrate (pseudo-woven fabric) 10 as the form of the sheet-shaped reinforcing fiber substrate (pseudo-woven fabric).
- the reinforcing fiber bundle 12′ is 13, and the reinforcing fiber bundle 13′ is 12, and the joint portions 1E′ are all in the respective intersecting regions.
- the joining location is not necessarily limited to this.
- the reinforcing fiber bundle 12' may be joined to 11, and the reinforcing fiber bundle 13' may be joined to 14 at respective intersecting regions. That is, the reinforcing fiber bundles 12' and 13' do not fall out independently if the reinforcing fiber bundles are joined to each other in at least a part of the intersecting region with any of the intersecting reinforcing fiber bundles.
- the reinforcing fiber bundles 11 to 14 constituting each layer have the same length in the longitudinal direction, and the outer peripheral shape thereof is rectangular, but not necessarily the same.
- the length is not limited, and the length may be determined depending on the shape of the target fiber-reinforced resin molded product.
- FIG. 4 shows a sheet-shaped reinforced fiber base material (pseudo-woven fabric) 20 when the target fiber-reinforced resin molded product has a shape such as an automobile hood.
- the minimum unit of the sheet-shaped reinforcing fiber base material (pseudo-woven fabric) 20 is the same as that of the sheet-like reinforcing fiber base material (pseudo-woven fabric) 10 shown in FIG. 2c, and a plurality of reinforcing fiber bundles constituting all even-numbered layers.
- the sheet-like reinforcing fiber base material (pseudo-woven fabric) 10' is basically used for an automobile hood that is an actual molded article. It has been applied.
- the outer peripheral shape of the sheet-shaped reinforcing fiber base material can be determined according to the shape of the target fiber-reinforced resin molded product, but in principle, the outer peripheral shape is the fiber-reinforced resin.
- the three-dimensional shape of the molded product is a shape developed on a plane. However, considering the behavior of each part when shaping the sheet-shaped reinforcing fiber base material (pseudo-woven fabric) into a three-dimensional shape, it is necessary to make the outer shape that is finely modified appropriately in order to improve product quality and material yield. Desirable from a point of view.
- the sheet-like reinforcing fiber base material (pseudo-woven fabric) 10 or 10 ′ is basically composed of an odd layer reinforcing fiber bundle 11 and a reinforcing fiber bundle 13, and an even layer reinforcing fiber bundle 12 and a reinforcing fiber bundle 14, respectively. It is parallel, but it does not exclude that there is a part that is out of parallel depending on the shape of the target fiber-reinforced resin molded product. That is, the reinforcing fiber bundles of the odd layer, and, and the reinforcing fiber bundles of the even layer, in the range that does not overlap with the reinforcing fiber bundle of any of the layers, the portion where the orientation angle of each reinforcing fiber bundle is arbitrarily set Can have.
- FIG. 5 is a sheet-shaped reinforcing fiber base material in which the reinforcing fiber bundles 31 to 34 are randomly arranged and arranged as an example of a portion having an orientation angle exceeding the above-mentioned parallel range ( ⁇ 2°).
- (Pseudo woven fabric) 30 is shown.
- the sheet-shaped reinforcing fiber base material (pseudo-woven fabric) 30 is different in that the reinforcing fiber bundle 31 and the reinforcing fiber bundle 33 forming the odd layer are not parallel to each other, and the reinforcing fiber bundle 32 and the reinforcing fiber bundle 34 forming the even layer are not parallel to each other.
- the sheet-shaped reinforcing fiber substrate (pseudo-woven fabric) 10 ′ has the same configuration.
- FIG. 6 shows that the reinforcing fiber bundle 41 and the reinforcing fiber bundle 43 forming the odd layer and the reinforcing fiber bundle 42 and the reinforcing fiber bundle 44 forming the even layer are parallel to each other.
- the sheet-shaped reinforcing fiber base material (pseudo-woven fabric) 40 has an angle between the longitudinal direction of the reinforcing fiber bundle of the odd layer and the longitudinal direction of the reinforcing fiber bundle of the even layer of 45°, and the reinforcing fiber bundle of the odd layer.
- the number of reinforcing fiber bundles forming an even number layer is different, and the lengths of the reinforcing fiber bundles forming each layer in the longitudinal direction are not necessarily the same, basically as a sheet-like reinforcing fiber base material (pseudo-woven fabric) 10′. It has the same structure.
- the orientation angle of each reinforcing fiber bundle can be arbitrarily set.
- the angle between the longitudinal direction of the reinforcing fiber bundle of the odd layer and the longitudinal direction of the reinforcing fiber bundle of the even layer can be arbitrarily set in the range of 45° to 90°, for example, a sheet-shaped reinforcing fiber base is used.
- the material (pseudo woven fabric) 40 receives an external force and undergoes shear deformation in the plane, the deformation margin may be small depending on the direction of deformation because the angle is 45°.
- the angle is 90°, it is possible to secure a uniform deformation allowance regardless of the direction of deformation. Therefore, it is more preferable that the angle is 90° as the form of the sheet-like reinforcing fiber base material (pseudo-woven fabric).
- the value of the number N of layers composed of reinforcing fiber bundles is 4, but not necessarily limited to 4. ..
- the value of the number N of layers can be set to 6 or 8, for example.
- the sheet shape cannot be maintained due to friction in the portion where the reinforcing fiber bundles directly overlap each other, so that the reinforcing fiber bundles may be bonded to each other at all the overlapping portions. Will be needed. For this reason, similar to the sheet-like reinforcing fiber substrate formed by the fiber placement method, it is not possible to obtain shear deformation in a plane like a woven substrate, and thus it is composed of a reinforcing fiber bundle.
- the value of the number N of layers to be used must be an integer of 3 or more.
- FIG. 7 shows a sheet-like reinforcing fiber base material (pseudo-woven fabric) 50 having a number N of layers of 6 composed of reinforcing fiber bundles 51 to 56
- FIG. Shows a sheet-like reinforcing fiber base material (pseudo-woven fabric) 60 composed of reinforcing fiber bundles 61 to 68 and having a layer number N of 8.
- the sheet-like reinforcing fiber base material (pseudo-woven fabric) 50 or 60 has the number of layers composed of the reinforcing fiber bundles 51 to 56 and the reinforcing fiber bundles 61 to 68, the number of each reinforcing fiber bundle, and the length in the longitudinal direction.
- the sheet-shaped reinforcing fiber base material (pseudo-woven fabric) 10' is basically configured in the same way of thinking.
- the value of the number N of layers can be arbitrarily set within an integer range of 3 or more.
- a general woven fabric can be obtained by setting the value of the number N of layers composed of the reinforcing fiber bundle to 6 or 8.
- a design property different from that of the base material for example, plain weave base material
- the value of the number N of layers can be arbitrarily set within an integer range of 3 or more, such as 6 or 8, for example, the reinforcing fibers constituting the sheet-like reinforcing fiber base material (pseudo-woven fabric) 50 or 60. Since the bundles 52 to 55 or the reinforcing fiber bundles 62 to 67 cross three-dimensionally with other reinforcing fiber bundles while straddling two or more reinforcing fiber bundles, respectively, the sheet-like reinforcing fiber base material (pseudo-woven fabric) 50 or When 60 receives an external force and undergoes shear deformation in a plane, its deformability may become slightly uneven.
- the value of the number N of layers is 4, that is, in the case of the sheet-like reinforcing fiber base material (pseudo-woven fabric) 10 to 40, the respective reinforcing fiber bundles constituting the second layer and the third layer are In any case, since the reinforcing fiber bundle always crosses over one reinforcing fiber bundle and intersects three-dimensionally with other reinforcing fiber bundles, the above deformability is substantially uniform. Therefore, it is more preferable that the number N of layers is 4 as the form of the sheet-like reinforcing fiber base material (pseudo-woven fabric).
- the sheet-like reinforcing fiber base material (pseudo-woven fabric) 10 or 10′ and 20 to 60 have joint portions 1E to 6E and 1E′ to 6E′, respectively.
- Adhesion by can be used.
- Adhesive force can be obtained by applying heat to the resin binders existing in the joining portions 1E to 6E and 1E' to 6E' to soften them, but the method of applying heat to the resin binder is not limited at all. Instead of electric heater heating, electric heating, ultrasonic heating, dielectric heating, etc. can be used.
- auxiliary yarn is not limited at all, but glass fiber, polyester fiber, nylon fiber and the like are preferable.
- the first layer and the N-th layer (that is, the uppermost layer) composed of the reinforcing fiber bundles are mutually connected at the joining portions 1E to 6E and 1E' to 6E', respectively.
- the binding method, the type of the resin binder, the type of the auxiliary thread, and the like are not limited as long as they can be restrained. If necessary, the resin binder and the auxiliary yarn may be combined and joined together.
- the binding force at the joining portions 1E to 6E and 1E' to 6E' is too weak, the handleability is deteriorated. On the contrary, if it is too strong, the joining portions 1E to 6E and 1E at the time of shaping are formed. When it is' ⁇ 6E', shear deformation becomes difficult. For this reason, it is desirable to select the restraint form and conditions so that the restraint force becomes appropriate.
- the reinforcing fiber bundle used for the sheet-like reinforcing fiber base material (pseudo-woven fabric) according to the present invention is not limited as long as it can be used as the reinforcing fiber of the fiber-reinforced resin.
- carbon fiber or glass fiber can be used.
- carbon fiber is suitable because it is possible to obtain a fiber-reinforced resin molded product that is lightweight and has excellent mechanical properties. It is also possible to combine a plurality of types of reinforcing fiber bundles having different materials and types.
- the reinforcing fiber bundle it is preferable to use a so-called dry reinforcing fiber bundle that is not impregnated with a resin for RTM, because it behaves exactly as a sheet-like reinforcing fiber base material (pseudo-woven fabric).
- the present invention is not limited to this, and even when a tape-shaped prepreg obtained by impregnating a reinforcing fiber bundle with a resin is used, the effect can be sufficiently exhibited.
- the type of prepreg that has the least tackiness (adhesiveness) on the surface is used because it is slippery when shaped into a three-dimensional shape and shears as a sheet-like reinforcing fiber base material (pseudo-woven fabric). It is preferable because it can exhibit deformability.
- thermoplastic resin powder or non-woven fabric which is solid at room temperature, is selectively applied to the surface, and a process for producing a sheet-like reinforcing fiber base material (pseudo-woven fabric). It is particularly preferable because the handling property can be improved in general.
- a plurality of reinforcing fiber bundles having a clearance between the reinforcing fiber bundles in a direction different from the longitudinal direction of the reinforcing fiber bundles forming the odd layer of the first layer is equal to or larger than the width of the reinforcing fiber bundles on the odd layer.
- the clearance between the reinforcing fiber bundles is such that the clearance between the reinforcing fiber bundles is parallel to the longitudinal direction of the reinforcing fiber bundles forming the previous even layer so that it does not overlap any of the reinforcing fiber bundles forming all the even layers laminated up to that time.
- a plurality of reinforcing fiber bundles are arranged in parallel at a width equal to or larger than, and an even layer of a ne-th layer (ne is an even number of 4 or more and N or less) is formed. (e) When N is 5 or more, no or Step (c) and step (d) are alternately repeated until ne reaches a predetermined value of N.
- Step (f) Intersection of the reinforcing fiber bundles forming the odd layer and the reinforcing fiber bundles forming the even layer. Step of Joining Reinforcing Fiber Bundles to Each Other in at least Part of Region
- FIG. 9 shows an example of a manufacturing procedure of the sheet-shaped reinforcing fiber base material 20 shown in FIG.
- the reinforcing fiber bundles 21 are sequentially arranged in parallel so as to have the shape of the fiber-reinforced resin molded product, and the first layer is formed. At this time, the clearance between the adjacent reinforcing fiber bundles 21 is adjusted to be equal to or larger than the width of the reinforcing fiber bundles 21 ( step 1 in FIG. 9).
- the reinforcing fiber bundles 22 are sequentially arranged in parallel on the upper part of the first layer composed of the reinforcing fiber bundles 21 so as to form 90° with the longitudinal direction of the reinforcing fiber bundles 21, A second layer is formed. At this time, the clearance between the reinforcing fiber bundle 22 adjacent is adjusted to be wider than the reinforcing fiber bundle 22 (step2 in Figure 9).
- the upper part of the second layer composed of the reinforcing fiber bundle 22 is reinforced so as to be parallel to the longitudinal direction of the reinforcing fiber bundle 21 and not to overlap with the reinforcing fiber bundle 21.
- the fiber bundles 23 are sequentially arranged in parallel to form a third layer ( Step 3 in FIG. 9).
- the method of arranging the reinforcing fiber bundles 21 to 24 is not limited at all, but they can be arranged by using the fiber placement method, for example.
- the mechanism for arranging the reinforcing fiber bundles 21 to 24 by moving and rotating the arrangement surface 7S in a necessary direction only needs to reciprocate in one direction, and thus the reinforcing fiber bundle 21 ⁇ 24 can be arranged at high speed.
- the positions of the reinforcing fiber bundles 21 to 24 should be maintained in their respective arranged positions.
- an electric heater or a laser is used at a place on the arrangement surface 7S where the reinforcing fiber bundles 21 to 24 are arranged, or a portion immediately before the arrangement of the reinforcing fiber bundles 21 to 24. For example, it may be appropriately heated in advance.
- the reinforcing fiber bundles 21 to 24 are dry reinforcing fiber bundles having no tackiness
- a means for holding the reinforcing fiber bundles 21 to 24 on the arrangement surface 7S is required.
- the means is not particularly limited, and examples thereof include adsorption by electrostatic force and adsorption by vacuum.
- a warm-sensitive adhesive sheet can also be used.
- the present disclosure is not limited to the above embodiments, and can be realized in various configurations without departing from the spirit of the present disclosure.
- the embodiments corresponding to the technical features in each of the modes described in the summary of the invention can be appropriately replaced or combined. .. If the technical features are not described as essential in this specification, they can be deleted as appropriate.
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Abstract
Description
[1]任意の長さの強化繊維束を複数配設して得られる、N層(Nは3以上の整数)の積層構造を有する、シート状強化繊維基材であって、以下の(1)~(5)の各条件を満たす、シート状強化繊維基材。
(1)各層の層内において、隣接する前記強化繊維束同士が平行に配列されるとともに、隣接する前記強化繊維束間のクリアランスが前記強化繊維束の幅以上である
(2)上下に接する層を構成する強化繊維束はそれぞれ異なる方向に配列される
(3)任意の第no層目(noは3以上N以下の奇数)である奇数層を構成する強化繊維束の長手方向と、第(no-2)層目の層を構成する強化繊維束の長手方向とが平行であり、かつ、それぞれの層を構成する強化繊維束は相互に重ならない
(4)前記Nが4以上の場合、任意の第ne層目(neは4以上N以下の偶数)である偶数層を構成する強化繊維束の長手方向と、第(ne-2)層目の層を構成する強化繊維束の長手方向とが平行であり、かつ、それぞれの層を構成する強化繊維束は相互に重ならない
(5)前記奇数層を構成する強化繊維束と前記偶数層を構成する強化繊維束が直接重なる部分である交差領域の少なくとも一部において、交差する強化繊維束同士が互いに接合されている
[2]任意の長さの強化繊維束を複数配設して得られる、N層(Nは4以上の整数)の積層構造を有する、シート状強化繊維基材であって、隣接する前記強化繊維束同士が平行に配列されるとともに、隣接する前記強化繊維束間のクリアランスが前記強化繊維束の幅以上である第1層目の層と、前記第1層目の層の上部に、前記第1層目の層を構成する強化繊維束の長手方向とは異なる方向に、隣接する前記強化繊維束同士が平行に配列されるとともに、隣接する前記強化繊維束間のクリアランスが前記強化繊維束の幅以上である第2層目の層と、第(n-2)層目の層(nは4以上N以下の偶数)の上部に、第(n-3)層目の層を構成する強化繊維束の長手方向と平行に、前記第1層目の層ないし第(n-3)層目の層までの奇数層を構成する強化繊維束のいずれとも重ならず、隣接する前記強化繊維束同士が平行に配列されるとともに、隣接する前記強化繊維束間のクリアランスが前記強化繊維束の幅以上である第(n-1)層目の層と、前記第(n-1)層目の層の上部に、第(n-2)層目の層を構成する強化繊維束の長手方向と平行に、前記第2層目の層ないし第(n-2)層目の層までの偶数層を構成する強化繊維束のいずれとも重ならず、隣接する前記強化繊維束同士が平行に配列されるとともに、隣接する前記強化繊維束間のクリアランスが前記強化繊維束の幅以上である第n層目の層が、第N層目まで繰り返し載置され、前記第1層目の層を構成する強化繊維束と前記第N層目の層を構成する強化繊維束が直接重なる部分である交差領域の少なくとも一部において、交差する強化繊維束同士が互いに接合されている、前記[1]に記載のシート状強化繊維基材。
[3]前記Nは3以上の奇数であり、第1層目の層を構成する強化繊維束と第2層目からN-1層目までのいずれかの偶数層目の層(第Ne1層)を構成する強化繊維束の交差領域の少なくとも一部において、交差する強化繊維束同士が互いに接合され、第N層目の層を構成する強化繊維束と第2層目から第N-1層目までのいずれかの偶数層目の層(第NeN層)を構成する強化繊維束の交差領域の少なくとも一部において、交差する強化繊維束同士が互いに接合されている、前記[1]に記載のシート状強化繊維基材。
[4]前記の強化繊維束の交差領域のすべての箇所において、交差する強化繊維束同士が互いに接合されている、前記[2]または[3]に記載のシート状強化繊維基材。
[5]すべての偶数層の層を構成する複数の強化繊維束のうち、偶数層を構成するいずれの強化繊維束に対しても片側のみ隣接して存在する強化繊維束、および、すべての奇数層の層を構成する複数の強化繊維束のうち、奇数層を構成するいずれの強化繊維束に対しても片側のみ隣接して存在する強化繊維束が、それぞれ、交差するいずれかの強化繊維束との交差領域の少なくとも一部において、強化繊維束同士が互いに接合されている、前記[1]~[4]のいずれかに記載のシート状強化繊維基材。
[6]外周形状が、繊維強化樹脂成形品の形状と同一となるように、各強化繊維束の長手方向の長さが決定された、前記[1]~[5]のいずれかに記載のシート状強化繊維基材。
[7]前記奇数層を構成する強化繊維束の長手方向と前記偶数層を構成する強化繊維束の長手方向の間の角度が45°~90°のいずれかである、前記[1]~[6]のいずれかに記載のシート状強化繊維基材。
[8]前記Nの値が4である、前記[1]~[7]のいずれかに記載のシート状強化繊維基材。
[9]前記強化繊維束同士が、樹脂バインダによって互いに接合されている、前記[1]~[8]のいずれかに記載のシート状強化繊維基材。
[10]前記強化繊維束同士が、補助糸での縫合によって互いに接合されている、前記[1]~[8]のいずれかに記載のシート状強化繊維基材。
[11]前記強化繊維束が炭素繊維である、前記[1]~[10]のいずれかに記載のシート状強化繊維基材。
[12]任意の長さの強化繊維束を複数配設して得られる、N層(Nは3以上整数)の積層構造を有する、シート状強化繊維基材の製造方法であって、次の(a)~(f)の工程を含むことを特徴とする、シート状強化繊維基材の製造方法。
(a)強化繊維束間のクリアランスが前記強化繊維束の幅以上で、複数の強化繊維束を平行に配列し、第1層目の奇数層を形成する工程
(b)前記第1層目の奇数層の上部に、前記第1層目の奇数層を構成する強化繊維束の長手方向とは異なる方向に、強化繊維束間のクリアランスが前記強化繊維束の幅以上で、複数の強化繊維束を平行に配列し、第1層目の偶数層である第2層目の層を形成する工程
(c)1層前の偶数層の上部に、2層前の奇数層を構成する強化繊維束の長手方向と平行に、それまでに積層したすべての奇数層を構成する強化繊維束のいずれとも重ならないよう、強化繊維束間のクリアランスが前記強化繊維束の幅以上で、複数の強化繊維束を平行に配列し、第no層目(noは3以上N以下の奇数)の奇数層を形成する工程
(d)前記Nが4以上の場合、1層前の奇数層の上部に、2層前の偶数層を構成する強化繊維束の長手方向と平行に、それまでに積層したすべての偶数層を構成する強化繊維束のいずれとも重ならないよう、強化繊維束間のクリアランスが前記強化繊維束の幅以上で、複数の強化繊維束を平行に配列し、第ne層目(neは4以上N以下の偶数)の偶数層を形成する工程
(e)前記Nが5以上の場合、noまたはneが所定のnの値に達するまで、(c)工程および(d)工程を交互に繰り返し行う工程
(f)前記奇数層を構成する強化繊維束と前記偶数層を構成する強化繊維束の交差領域の少なくとも一部において、交差する強化繊維束同士を互いに接合する工程
[13]上記(a)~(e)の工程において、強化繊維束の配列を、ファイバープレイスメント法により行うことを特徴とする、前記[12]に記載のシート状強化繊維基材の製造方法。
図1は、本発明の一実施態様に係る、シート状強化繊維基材(擬似織物)10を示しており、図2a~図2cは図1のシート状強化繊維基材(擬似織物)10の構成をさらに詳細に示している。シート状強化繊維基材(擬似織物)10は、強化繊維束から構成される層の数Nの値が4である。なお、図1~図2cに示す例では、Nの値が4であるが、Nが3以上の整数であるN層の積層構造を有すればよい。図2aに示すとおり、強化繊維束11(第1層目の層)の上部に強化繊維束12(第2層目の層)、その上部に強化繊維束13(第3層目の層)、さらにその上部に強化繊維束14(第4層目の層)が載置されており、上下に接する層を構成する強化繊維束はそれぞれ異なる方向に配されている。奇数層(第1層目の層および第3層目の層)の強化繊維束同士、ならびに、偶数層(第2層目の層および第4層目の層)の強化繊維束同士が、それぞれいずれの層の強化繊維束とも重ならないように各層の層内において、隣接する前記強化繊維束同士が平行に配列されるとともに、隣接する前記強化繊維束間のクリアランスが前記強化繊維束の幅以上である。そして、強化繊維束11から構成される第1層目の層と、強化繊維束14から構成される第4層目の層の直接重なる部分が、それぞれ接合部位1Eで、樹脂バインダによって互いに接合されている。このように、奇数層を構成する強化繊維束と数層を構成する強化繊維束が直接重なる部分である交差領域の少なくとも一部において、交差する強化繊維束同士が互いに接合されていることでシートとしての形態を保持しつつ、曲面形状へ沿わせる場合など、適度に繊維がずれることにより、しわを生じることなく形状に沿わせることができる。
本発明の任意の長さの強化繊維束を複数配設して得られる、N層(Nは3以上の整数)の積層構造を有するシート状強化繊維基材(擬似織物)の製造方法は、次の(a)~(f)の工程を含む。
(a)強化繊維束間のクリアランスが前記強化繊維束の幅以上で、複数の強化繊維束を平行に配列し、第1層目の奇数層を形成する工程
(b)前記第1層目の奇数層の上部に、前記第1層目の奇数層を構成する強化繊維束の長手方向とは異なる方向に、強化繊維束間のクリアランスが前記強化繊維束の幅以上で、複数の強化繊維束を平行に配列した、第1層目の偶数層である第2層目の層を形成する工程
(c)1層前の偶数層の上部に、2層前の奇数層を構成する強化繊維束の長手方向と平行に、それまでに積層したすべての奇数層を構成する強化繊維束のいずれとも重ならないよう、強化繊維束間のクリアランスが前記強化繊維束の幅以上で、複数の強化繊維束を平行に配列し、第no層目(noは3以上N以下の奇数)の奇数層を形成する工程
(d)前記Nが4以上の場合、1層前の奇数層の上部に、2層前の偶数層を構成する強化繊維束の長手方向と平行に、それまでに積層したすべての偶数層を構成する強化繊維束のいずれとも重ならないよう、強化繊維束間のクリアランスが前記強化繊維束の幅以上で、複数の強化繊維束を平行に配列し、第ne層目(neは4以上N以下の偶数)の偶数層を形成する工程
(e)前記Nが5以上の場合、noまたはneが所定のNの値に達するまで、(c)工程および(d)工程を交互に繰り返し行う工程
(f)前記奇数層を構成する強化繊維束と前記偶数層を構成する強化繊維束の交差領域の少なくとも一部において、交差する強化繊維束同士を互いに接合する工程
本発明のシート状強化繊維基材(擬似織物)の製造方法を、図9を用いて具体的に説明する。図9は、図4に示すシート状強化繊維基材20の製造手順の一例を示している。
11,12,13,14,12’,13’:強化繊維束
1E,1E’:接合部位
11C,12C,13C,14C:強化繊維束間のクリアランス
20:シート状強化繊維基材(擬似織物)
21,22,23,24,22’,23’:強化繊維束
2E,2E’:接合部位
2S:繊維強化樹脂成形品の外周形状
30:シート状強化繊維基材(擬似織物)
31,32,33,34:強化繊維束
3E,3E’:接合部位
40:シート状強化繊維基材(擬似織物)
41,42,43,44:強化繊維束
4E,4E’:接合部位
50:シート状強化繊維基材(擬似織物)
51,52,53,54,55,56:強化繊維束
5E,5E’:接合部位
60:シート状強化繊維基材(擬似織物)
61,62,63,64,65,66,67,68:強化繊維束
6E,6E’:接合部位
7S:配置面
Claims (13)
- 任意の長さの強化繊維束を複数配設して得られる、N層(Nは3以上の整数)の積層構造を有する、シート状強化繊維基材であって、以下の(1)~(5)の各条件を満たす、シート状強化繊維基材。
(1)各層の層内において、隣接する前記強化繊維束同士が平行に配列されるとともに、隣接する前記強化繊維束間のクリアランスが前記強化繊維束の幅以上である
(2)上下に接する層を構成する強化繊維束はそれぞれ異なる方向に配列される
(3)任意の第no層目(noは3以上N以下の奇数)である奇数層を構成する強化繊維束の長手方向と、第(no-2)層目の層を構成する強化繊維束の長手方向とが平行であり、かつ、それぞれの層を構成する強化繊維束は相互に重ならない
(4)前記Nが4以上の場合、任意の第ne層目(neは4以上N以下の偶数)である偶数層を構成する強化繊維束の長手方向と、第(ne-2)層目の層を構成する強化繊維束の長手方向とが平行であり、かつ、それぞれの層を構成する強化繊維束は相互に重ならない
(5)前記奇数層を構成する強化繊維束と前記偶数層を構成する強化繊維束が直接重なる部分である交差領域の少なくとも一部において、交差する強化繊維束同士が互いに接合されている - 任意の長さの強化繊維束を複数配設して得られる、N層(Nは4以上の偶数)の積層構造を有する、シート状強化繊維基材であって、
隣接する前記強化繊維束同士が平行に配列されるとともに、隣接する前記強化繊維束間のクリアランスが前記強化繊維束の幅以上である第1層目の層と、
前記第1層目の層の上部に、前記第1層目の層を構成する強化繊維束の長手方向とは異なる方向に、隣接する前記強化繊維束同士が平行に配列されるとともに、隣接する前記強化繊維束間のクリアランスが前記強化繊維束の幅以上である第2層目の層と、
第(n-2)層目の層(nは4以上N以下の偶数)の上部に、第(n-3)層目の層を構成する強化繊維束の長手方向と平行に、前記第1層目の層ないし第(n-3)層目の層までの奇数層を構成する強化繊維束のいずれとも重ならず、隣接する前記強化繊維束同士が平行に配列されるとともに、隣接する前記強化繊維束間のクリアランスが前記強化繊維束の幅以上である第(n-1)層目の層と、
前記第(n-1)層目の層の上部に、第(n-2)層目の層を構成する強化繊維束の長手方向と平行に、前記第2層目の層ないし第(n-2)層目の層までの偶数層を構成する強化繊維束のいずれとも重ならず、隣接する前記強化繊維束同士が平行に配列されるとともに、隣接する前記強化繊維束間のクリアランスが前記強化繊維束の幅以上である第n層目の層が、
第N層目まで繰り返し載置され、前記第1層目の層を構成する強化繊維束と前記第N層目の層を構成する強化繊維束が直接重なる部分である交差領域の少なくとも一部において、交差する強化繊維束同士が互いに接合されている、請求項1に記載のシート状強化繊維基材。 - 前記Nは3以上の奇数であって、第1層目の層を構成する強化繊維束と第2層目から第N-1層目までのいずれかの偶数層目の層(第Ne1層)を構成する強化繊維束の交差領域の少なくとも一部において、交差する強化繊維束同士が互いに接合され、第N層目の層を構成する強化繊維束と第2層目から第N-1層目までのいずれかの偶数層目の層(第NeN層)を構成する強化繊維束の交差領域の少なくとも一部において、交差する強化繊維束同士が互いに接合されている、請求項1に記載のシート状強化繊維基材。
- 前記の強化繊維束の交差領域のすべての箇所において、交差する強化繊維束同士が互いに接合されている、請求項2または3に記載のシート状強化繊維基材。
- すべての偶数層の層を構成する複数の強化繊維束のうち、偶数層を構成するいずれの強化繊維束に対しても片側のみ隣接して存在する強化繊維束、および、すべての奇数層の層を構成する複数の強化繊維束のうち、奇数層を構成するいずれの強化繊維束に対しても片側のみ隣接して存在する強化繊維束が、それぞれ、交差するいずれかの強化繊維束との交差領域の少なくとも一部において、強化繊維束同士が互いに接合されている、請求項1~4のいずれかに記載のシート状強化繊維基材。
- 外周形状が、繊維強化樹脂成形品の形状と同一となるように、各強化繊維束の長手方向の長さが決定された、請求項1~5のいずれかに記載のシート状強化繊維基材。
- 前記奇数層を構成する強化繊維束の長手方向と前記偶数層を構成する強化繊維束の長手方向の間の角度が45°~90°のいずれかである、請求項1~6のいずれかに記載のシート状強化繊維基材。
- 前記Nの値が4である、請求項1~7のいずれかに記載のシート状強化繊維基材。
- 前記強化繊維束同士が、樹脂バインダによって互いに接合されている、請求項1~8のいずれかに記載のシート状強化繊維基材。
- 前記強化繊維束同士が、補助糸での縫合によって互いに接合されている、請求項1~8のいずれかに記載のシート状強化繊維基材。
- 前記強化繊維束が炭素繊維である、請求項1~10のいずれかに記載のシート状強化繊維基材。
- 任意の長さの強化繊維束を複数配設して得られる、N層(Nは3以上の整数)の積層構造を有する、シート状強化繊維基材の製造方法であって、次の(a)~(f)の工程を含むことを特徴とする、シート状強化繊維基材の製造方法。
(a)強化繊維束間のクリアランスが前記強化繊維束の幅以上で、複数の強化繊維束を平行に配列し、第1層目の奇数層を形成する工程
(b)前記第1層目の奇数層の上部に、前記第1層目の奇数層を構成する強化繊維束の長手方向とは異なる方向に、強化繊維束間のクリアランスが前記強化繊維束の幅以上で、複数の強化繊維束を平行に配列した、第1層目の偶数層である第2層目の層を形成する工程
(c)1層前の偶数層の上部に、2層前の奇数層を構成する強化繊維束の長手方向と平行に、それまでに積層したすべての奇数層を構成する強化繊維束のいずれとも重ならないよう、強化繊維束間のクリアランスが前記強化繊維束の幅以上で、複数の強化繊維束を平行に配列し、第no層目(noは3以上N以下の奇数)の奇数層を形成する工程
(d)前記Nが4以上の場合、1層前の奇数層の上部に、2層前の偶数層を構成する強化繊維束の長手方向と平行に、それまでに積層したすべての偶数層を構成する強化繊維束のいずれとも重ならないよう、強化繊維束間のクリアランスが前記強化繊維束の幅以上で、複数の強化繊維束を平行に配列し、第ne層目(neは4以上N以下の偶数)の偶数層を形成する工程
(e)前記Nが5以上の場合、noまたはneが所定のNの値に達するまで、(c)工程および(d)工程を交互に繰り返し行う工程
(f)前記奇数層を構成する強化繊維束と前記偶数層を構成する強化繊維束の交差領域の少なくとも一部において、交差する強化繊維束同士を互いに接合する工程 - 上記(a)~(e)の工程において、強化繊維束の配列を、ファイバープレイスメント法により行うことを特徴とする、請求項12に記載のシート状強化繊維基材の製造方法。
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EP3888905A4 (en) | 2022-08-03 |
CN113165314A (zh) | 2021-07-23 |
JP7528443B2 (ja) | 2024-08-06 |
KR20210098999A (ko) | 2021-08-11 |
US20220009197A1 (en) | 2022-01-13 |
ES2980681T3 (es) | 2024-10-02 |
AU2019390895A1 (en) | 2021-06-17 |
EP3888905A1 (en) | 2021-10-06 |
EP3888905B1 (en) | 2024-05-01 |
JPWO2020111215A1 (ja) | 2021-10-14 |
US12090743B2 (en) | 2024-09-17 |
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