JP2002180356A - Three-dimensional fiber structure - Google Patents
Three-dimensional fiber structureInfo
- Publication number
- JP2002180356A JP2002180356A JP2000375732A JP2000375732A JP2002180356A JP 2002180356 A JP2002180356 A JP 2002180356A JP 2000375732 A JP2000375732 A JP 2000375732A JP 2000375732 A JP2000375732 A JP 2000375732A JP 2002180356 A JP2002180356 A JP 2002180356A
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- Japan
- Prior art keywords
- yarn
- dimensional
- thickness direction
- yarns
- composite material
- Prior art date
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Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は三次元繊維構造体に
関するものである。TECHNICAL FIELD The present invention relates to a three-dimensional fiber structure.
【０００２】[0002]
【従来の技術】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。複合材用補強基材として三次元織
物（三次元繊維構造体）がある。この三次元織物を骨格
材として、樹脂あるいは無機物をマトリックスとした複
合材はロケット、航空機、自動車、船舶及び建築物の構
造材として幅広い用途が期待されている。BACKGROUND OF THE INVENTION Fiber reinforced composites are widely used as lightweight structural materials. There is a three-dimensional woven fabric (three-dimensional fiber structure) as a reinforcing base material for a composite material. A composite material using this three-dimensional fabric as a skeleton material and a resin or an inorganic material as a matrix is expected to be widely used as a structural material for rockets, aircraft, automobiles, ships, and buildings.
【０００３】実公平３−２４３５６号公報には、補強繊
維からなる複数枚の織物が、それら各織物の織目が互い
に一致するように積層され、かつその積層体には、繊維
強化樹脂又は繊維強化金属からなる棒体が前記織目に挿
通された複合材料用三次元繊維組織体が開示されてい
る。[0003] Japanese Utility Model Publication No. 3-24356 discloses that a plurality of woven fabrics composed of reinforcing fibers are laminated so that the textures of the respective woven fabrics coincide with each other, and the laminated body includes a fiber-reinforced resin or fiber. A three-dimensional fibrous structure for a composite material in which a rod made of reinforced metal is inserted into the weave is disclosed.
【０００４】また、特開平１１−４９５７８号公報に
は、半導体装置用放熱部材として、黒鉛化カーボンのマ
トリックスに、黒鉛化カーボン長繊維を電子部品搭載面
と平行に２次元面内で直交又は所定の角度に疑似等方で
配列し、さらに電子部品搭載面に垂直な方向に配向した
繊維群を有する黒鉛化カーボン繊維／黒鉛化カーボンの
複合体が提案されている。Japanese Patent Application Laid-Open No. H11-49578 discloses that as a heat dissipation member for a semiconductor device, a graphitized carbon long fiber is interspersed with a matrix of graphitized carbon in a two-dimensional plane in parallel with a mounting surface of an electronic component. A graphitized carbon fiber / graphitized carbon composite having fibers arranged in a pseudo-isotropic manner at an angle and oriented in a direction perpendicular to the electronic component mounting surface has been proposed.
【０００５】[0005]
【発明が解決しようとする課題】複合材は一般にマトリ
ックスの量が少ない方が強度は強くなる。従って、三次
元繊維構造体を使用して複合材を構成する場合、三次元
繊維構造体の密度が高い方が複合材の強度が強くなる。
ところが、実公平３−２４３５６号公報に開示された三
次元繊維組織体のように、二次元の織物を積層した状態
で棒体を織目に挿通して三次元化したものでは、層間を
締め付ける力が弱く、形態保持が難しく、取り扱いが難
しい。特に熱伝導率を高める目的で高温焼成処理してグ
ラファイト化を進行させた場合、繊維構造体としての一
体性が損なわれ易い。The strength of a composite material generally increases as the amount of matrix decreases. Therefore, when a composite material is formed using a three-dimensional fiber structure, the strength of the composite material increases as the density of the three-dimensional fiber structure increases.
However, in a three-dimensional fiber structure body disclosed in Japanese Utility Model Publication No. 3-24356, a rod body is inserted into a weave in a state where two-dimensional woven fabrics are laminated to form a three-dimensional structure, and the layers are tightened. Poor power, difficult to maintain shape, and difficult to handle. In particular, when the graphite is formed by high-temperature baking for the purpose of increasing the thermal conductivity, the integrity of the fibrous structure is easily lost.
【０００６】また、三次元繊維組織体の厚さのコントロ
ールが難しい。なぜならば、棒体挿通後に織物層を圧縮
する場合、棒体の長さを圧縮後の織物層の厚さにする
と、圧縮時に棒体が曲がる虞がある。また、棒体の長さ
を圧縮後の織物層の厚さより長くすると、プレス型とし
て棒体の侵入を許容する孔を有する特殊な型が必要とな
るとともに、圧縮後に棒体を切断する必要がある。Further, it is difficult to control the thickness of the three-dimensional fiber tissue. This is because when the woven fabric layer is compressed after the insertion of the rod, if the length of the rod is set to the thickness of the woven fabric layer after compression, the rod may be bent at the time of compression. Further, if the length of the rod is longer than the thickness of the woven fabric layer after compression, a special mold having a hole that allows the penetration of the rod is required as a press die, and it is necessary to cut the rod after compression. is there.
【０００７】また、熱伝導率が高くて強度が優れた複合
材の強化材として、炭素繊維のみで三次元繊維構造体を
構成する場合、炭素繊維は比較的曲げに弱く、三次元織
物を製造する場合に糸（繊維）同士の擦れにより切断し
易く、特に繊維層を結合するための糸が切断し易い。挿
入密度を高くするとこの現象が発生し易い。Further, when a three-dimensional fiber structure is composed of only carbon fibers as a reinforcing material for a composite material having high thermal conductivity and excellent strength, carbon fibers are relatively weak in bending, and a three-dimensional fabric is manufactured. In this case, the yarns (fibers) are liable to be cut due to rubbing, and particularly the yarns for bonding the fiber layers are easily cut. This phenomenon is likely to occur when the insertion density is increased.
【０００８】本発明は前記の従来の問題点に鑑みてなさ
れたものであって、その第１の目的は、製造が比較的簡
単で密度の高い三次元繊維構造体を提供することにあ
る。また、第２の目的は例えば半導体装置の放熱部材や
電子部品搭載基材として使用する複合材を製造する際の
強化材とした場合に必要な熱伝導率を有する三次元繊維
構造体を提供することにある。The present invention has been made in view of the above-mentioned conventional problems, and a first object of the present invention is to provide a high-density three-dimensional fiber structure which is relatively easy to manufacture. A second object of the present invention is to provide a three-dimensional fiber structure having a necessary thermal conductivity when used as a reinforcing material when manufacturing a composite material used as a heat dissipation member of a semiconductor device or an electronic component mounting base material. It is in.
【０００９】[0009]
【課題を解決するための手段】前記第１の目的を達成す
るため請求項１に記載の発明では、少なくとも面内２軸
配向となる糸層を複数積層して形成された積層糸群と、
前記積層糸群の各糸層と直交する方向に配列された厚さ
方向糸とを含む少なくとも３軸で構成された三次元織物
に、繊維強化複合材製または金属製のロッドを挿入し
た。According to the first aspect of the present invention, there is provided a laminated yarn group formed by laminating a plurality of yarn layers having at least in-plane biaxial orientation.
A rod made of a fiber-reinforced composite material or a metal was inserted into a three-dimensional fabric composed of at least three axes including a thickness direction yarn arranged in a direction orthogonal to each yarn layer of the laminated yarn group.
【００１０】従って、この発明では、三次元織物に、繊
維強化複合材製または金属製のロッドが挿入されている
ため、ロッドの挿入本数を増やすことで、密度の高い三
次元繊維構造体を比較的簡単に製造できる。また、繊維
強化複合材製のロッドを使用した場合は、三次元織物Ｆ
の繊維体積含有率（Ｖｆ）を高くできる。Therefore, according to the present invention, since a rod made of a fiber-reinforced composite material or a metal is inserted into the three-dimensional woven fabric, the number of inserted rods is increased to compare a three-dimensional fiber structure with a high density. Can be easily manufactured. When a rod made of a fiber-reinforced composite material is used, the three-dimensional fabric F
Can increase the fiber volume content (Vf).
【００１１】請求項２に記載の発明では、請求項１に記
載の発明において、前記ロッドは前記厚さ方向糸と平行
に挿入されている。厚さ方向糸の密度を高めようとする
と、積層糸群の密度が高い所に挿入する必要があり、挿
入時の抵抗が大きくなる。その結果、厚さ方向糸として
炭素繊維等の脆い糸を使用した場合、挿入の際に糸（繊
維）同士の擦れによって糸が切断し易くなる。しかし、
ロッド挿入時の抵抗は厚さ方向糸の挿入時の抵抗に比較
して大幅に低下するため、厚さ方向糸に代えてロッドを
使用して厚さ方向の配向成分を増加させるのが簡単にな
る。According to a second aspect of the present invention, in the first aspect, the rod is inserted in parallel with the thickness direction thread. In order to increase the density of the thickness direction yarn, it is necessary to insert the yarn at a place where the density of the laminated yarn group is high, and the resistance at the time of insertion increases. As a result, when a brittle yarn such as carbon fiber is used as the thickness direction yarn, the yarn (fiber) is liable to be cut by the rubbing between the yarns at the time of insertion. But,
Since the resistance at the time of rod insertion is significantly lower than the resistance at the time of insertion of the thickness direction yarn, it is easy to increase the orientation component in the thickness direction by using a rod instead of the thickness direction yarn. Become.
【００１２】前記第２の目的を達成するため請求項３に
記載の発明では、請求項１又は請求項２に記載の発明に
おいて、前記積層糸群及び前記厚さ方向糸には炭素繊維
が使用されている。ロッドを挿入するための三次元織物
を炭素繊維で構成した場合、炭素繊維は合成樹脂繊維や
他の無機繊維に比較して熱伝導率が高いため、マトリッ
クスとともに複合材を構成した際に複合材の熱伝導率が
高くなる。その結果、半導体装置の放熱部材や電子部品
搭載基材として使用する複合材を製造する際の強化材と
して必要な熱伝導率を確保できる。According to a third aspect of the present invention, in order to achieve the second object, in the first or second aspect of the present invention, carbon fibers are used for the laminated yarn group and the thickness direction yarn. ing. When the three-dimensional woven fabric for inserting the rod is made of carbon fiber, the carbon fiber has a higher thermal conductivity than synthetic resin fiber and other inorganic fibers. Has a high thermal conductivity. As a result, the thermal conductivity required as a reinforcing material when manufacturing a composite material used as a heat dissipation member of a semiconductor device or an electronic component mounting base material can be secured.
【００１３】請求項４に記載の発明では、請求項３に記
載の発明において、前記厚さ方向糸は太さが前記積層糸
群を構成する糸の１／２以下である。炭素繊維は曲げに
弱く、糸（繊維）同士の擦れにより切断し易いため、厚
さ方向糸に太い糸を使用すると、積層糸群に挿入される
際や積層糸群を締め付ける際に、糸が切断し易くなる。
また、厚さ方向糸は針を使用して積層糸群に挿入される
ため、糸が太いと針も太くなり、積層糸群が毛羽立ち易
くなる。しかし、この発明では厚さ方向糸に細い糸を使
用することで、生産性が向上する。According to a fourth aspect of the present invention, in the third aspect of the invention, the thickness direction yarn has a thickness equal to or less than の of the thickness of the yarn constituting the laminated yarn group. Since carbon fibers are weak to bending and easy to cut due to rubbing between yarns (fibers), if a thick yarn is used for the thickness direction yarn, the yarn will break when inserted into the laminated yarn group or when tightening the laminated yarn group. It will be easier.
Further, since the thickness direction yarn is inserted into the laminated yarn group using a needle, the thicker the yarn, the thicker the needle, and the more easily the laminated yarn group becomes fluffy. However, in the present invention, productivity is improved by using a thin yarn for the thickness direction yarn.
【００１４】請求項５に記載の発明では、請求項３又は
請求項４に記載の発明において、前記ロッドはアルミニ
ウムと同等以上の熱伝導率を有する金属製のロッドであ
る。この場合、半導体装置の放熱部材や電子部品搭載基
材として使用する複合材を製造する際の強化材として使
用した場合、炭素繊維として黒鉛化の進行した特殊な炭
素繊維を使用しなくても、複合材の熱伝導率を高くでき
る。According to a fifth aspect of the present invention, in the third or fourth aspect, the rod is a metal rod having a thermal conductivity equal to or higher than that of aluminum. In this case, when used as a reinforcing material when manufacturing a composite material used as a heat dissipating member of a semiconductor device or a base material for mounting electronic components, even if a graphitized special carbon fiber is not used as a carbon fiber, The thermal conductivity of the composite material can be increased.
【００１５】[0015]
【発明の実施の形態】以下、本発明を具体化した一実施
の形態を図１〜図３に従って説明する。図１は三次元繊
維構造体１の一部破断模式斜視図である。三次元繊維構
造体１は、三次元織物Ｆにロッド２が挿入されて構成さ
れている。三次元織物Ｆは、繊維が相互に平行に配列さ
れた糸層としてのｘ糸層３及びｙ糸層４を複数積層して
面内２軸配向となるように形成された積層糸群５と、積
層糸群５の各ｘ糸層３及びｙ糸層４と直交する方向に配
列された厚さ方向糸ｚとを含み、３軸方向に糸が配列さ
れた構成となっている。DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to FIGS. FIG. 1 is a partially cutaway perspective view of a three-dimensional fiber structure 1. The three-dimensional fiber structure 1 is configured by inserting a rod 2 into a three-dimensional fabric F. The three-dimensional woven fabric F has a laminated yarn group 5 formed by laminating a plurality of x yarn layers 3 and y yarn layers 4 as yarn layers in which fibers are arranged in parallel with each other so as to have an in-plane biaxial orientation, It has a thickness direction yarn z arranged in a direction orthogonal to each of the x yarn layer 3 and the y yarn layer 4 of the laminated yarn group 5, and the yarns are arranged in three axial directions.
【００１６】ｘ糸層３は三次元繊維構造体１の厚さ方向
（図１の上下方向）と直交する面内において、Ｘ方向
（この実施の形態では長さ方向）に沿って配列された第
１の面内配列糸ｘからなり、１本の糸が折り返し状に配
列されて形成されている。ｙ糸層４はｘ糸層３と平行な
面内で第１の面内配列糸ｘと直交する方向（Ｙ方向）に
配列され、１本の糸が折り返し状に配列された第２の面
内配列糸ｙからなっている。各面内配列糸ｘ，ｙは所定
のピッチ（例えば３ｍｍのピッチ）で配列されている。The x yarn layers 3 are arranged along the X direction (the length direction in this embodiment) in a plane orthogonal to the thickness direction (the vertical direction in FIG. 1) of the three-dimensional fiber structure 1. It is composed of a first in-plane arrangement thread x, and one thread is arranged in a folded manner. The y yarn layer 4 is arranged in a direction (Y direction) orthogonal to the first in-plane arrangement yarn x in a plane parallel to the x yarn layer 3, and the second surface on which one yarn is arranged in a folded shape. It is composed of an inner array yarn y. The in-plane arrangement yarns x and y are arranged at a predetermined pitch (for example, a pitch of 3 mm).
【００１７】厚さ方向糸ｚは積層糸群５の一方の面（図
１の下面側）で折り返すように上面側から挿入されると
ともに、図２に示すように、下面側において幅方向、即
ち第２の面内配列糸ｙと平行に配列された抜け止め糸６
により抜け止めされている。厚さ方向糸ｚが抜け止め糸
６と共同でｘ糸層３及びｙ糸層４を締め付けることによ
り、各糸層が結合されている。厚さ方向糸ｚも所定のピ
ッチで配列されている。この実施の形態では、厚さ方向
糸ｚは第１の面内配列糸ｘの延びる方向には、各面内配
列糸ｘ，ｙの配列ピッチの２倍のピッチで配列され、第
２の面内配列糸ｙの延びる方向には、各面内配列糸ｘ，
ｙの配列ピッチと同じピッチで配列されている。厚さ方
向糸ｚには太さが各面内配列糸ｘ，ｙの１／２以下、こ
の実施の形態では１／１０程度のものが使用されてい
る。The thickness direction yarn z is inserted from the upper surface side so as to be folded on one surface (the lower surface side in FIG. 1) of the laminated yarn group 5, and as shown in FIG. Retaining yarns 6 arranged in parallel with the in-plane arrangement yarns y
Has been prevented by. When the thickness direction yarn z tightens the x yarn layer 3 and the y yarn layer 4 in cooperation with the retaining yarn 6, the respective yarn layers are joined. The thickness direction yarns z are also arranged at a predetermined pitch. In this embodiment, the thickness direction yarns z are arranged in the direction in which the first in-plane arrangement yarn x extends at a pitch twice as large as the arrangement pitch of the in-plane arrangement yarns x and y. The in-plane arrangement yarns x, x,
They are arranged at the same pitch as the arrangement pitch of y. The thickness direction yarn z has a thickness of 1/2 or less of the in-plane arrangement yarns x and y, and about 1/10 in this embodiment.
【００１８】ロッド２は厚さ方向糸ｚと平行に挿入され
ている。ロッド２は厚さ方向糸ｚが挿入されていない位
置に所定ピッチ、この実施の形態では各面内配列糸ｘ，
ｙの配列ピッチの２倍のピッチで配列されている。ロッ
ド２は炭素繊維を強化繊維として使用した繊維強化複合
材で、三次元織物Ｆの厚さとほぼ同じ長さに形成されて
いる。繊維強化複合材のマトリックス樹脂にはフェノー
ル樹脂又はエポキシ樹脂が使用されている。The rod 2 is inserted in parallel with the thickness direction thread z. The rod 2 has a predetermined pitch at a position where the thickness direction thread z is not inserted, and in this embodiment, each in-plane arrangement thread x,
They are arranged at a pitch that is twice the arrangement pitch of y. The rod 2 is a fiber-reinforced composite material using carbon fibers as reinforcing fibers, and is formed to have a length substantially equal to the thickness of the three-dimensional fabric F. A phenol resin or an epoxy resin is used as a matrix resin of the fiber-reinforced composite material.
【００１９】第１の面内配列糸ｘにはピッチ系炭素繊維
が使用されている。ピッチ系炭素繊維の中でもメソフェ
ーズピッチ系炭素繊維が熱伝導率の点で好ましい。第２
の面内配列糸ｙ及び厚さ方向糸ｚにはＰＡＮ系炭素繊維
が使用されている。各炭素繊維はロービング（トウ）の
状態で使用されている。ロービング（トウ）とは細い単
繊維のフィラメントを多数本束ねた実質無撚りの繊維束
を意味する。Pitch-based carbon fibers are used for the first in-plane arrangement yarn x. Among pitch-based carbon fibers, mesophase pitch-based carbon fibers are preferred in terms of thermal conductivity. Second
PAN-based carbon fiber is used for the in-plane arrangement yarn y and the thickness direction yarn z. Each carbon fiber is used in a roving (tow) state. Roving (tow) means a substantially non-twisted fiber bundle obtained by bundling a number of thin filaments of a single fiber.
【００２０】次に前記のように構成された三次元繊維構
造体１の製造方法を説明する。三次元繊維構造体１は、
２段階に分けて製造される。第１段階では、三次元織物
Ｆが、例えば、特開平５−１０６１３９号公報や特開平
８−２１８２４９号公報に開示された方法のように、四
角形状の基板又は枠体に多数のピンが装着されたものを
使用する方法で製造される。即ち、基板又は枠体上にｘ
糸層３及びｙ糸層４を所定数積層して形成した積層糸群
５を、厚さ方向糸ｚと抜け止め糸６とで結合することに
よって形成される。Next, a method of manufacturing the three-dimensional fiber structure 1 configured as described above will be described. The three-dimensional fiber structure 1
It is manufactured in two stages. In the first stage, the three-dimensional fabric F is mounted with a large number of pins on a square substrate or frame, for example, as disclosed in JP-A-5-106139 and JP-A-8-218249. Manufactured by the method of using what has been done. That is, x on the substrate or frame
A layered yarn group 5 formed by laminating a predetermined number of yarn layers 3 and y yarn layers 4 is formed by joining a thickness direction yarn z and a retaining yarn 6.
【００２１】次に第２段階として、前記三次元織物Ｆに
対してロッド２が挿入される。図３（ａ），（ｂ）に示
すように、ロッド２は三次元織物Ｆの一端から、複数本
ずつ第１の面内配列糸ｘの配列方向に沿って１列に並ん
だ状態で順に挿入される。Next, as a second step, the rod 2 is inserted into the three-dimensional fabric F. As shown in FIGS. 3A and 3B, the rods 2 are sequentially arranged in a row from one end of the three-dimensional fabric F in a line along the arrangement direction of the first in-plane arrangement yarns x. Inserted.
【００２２】前記のように構成された三次元繊維構造体
１は、マトリックスとしてアルミニウムと同等以上の熱
伝導率の大きな金属を含浸することにより、複合材を製
造し、例えば半導体装置用放熱部材として使用される。
金属としてはＣｕやアルミニウムが使用される。複合材
は所望の大きさ及び厚さの板状に加工され、一方の面に
おいて銀ペーストを介して半導体チップに接合され、半
導体チップとの接合面と反対側にサーマルシートを介し
てヒートシンクが接合された状態で使用される。The three-dimensional fiber structure 1 constructed as described above is impregnated with a metal having high thermal conductivity equal to or higher than aluminum as a matrix to produce a composite material, for example, as a heat dissipation member for a semiconductor device. used.
Cu or aluminum is used as the metal. The composite material is processed into a plate having a desired size and thickness, and is bonded to a semiconductor chip via a silver paste on one surface, and a heat sink is bonded via a thermal sheet to a side opposite to a bonding surface with the semiconductor chip. Used in the state that was done.
【００２３】三次元繊維構造体１にマトリックスとして
金属を含浸させて複合材を製造すると、金属は三次元繊
維構造体１を構成している、各糸ｘ，ｙ，ｚ及びロッド
２の隙間を埋めるように充填される。複合材を放熱材用
に使用する場合、三次元織物Ｆを構成する繊維の熱伝導
率は、一般にマトリックス金属として使用されるＣｕや
アルミニウムより低い。従って、単純に考えると、三次
元繊維構造体１の密度を高めると、即ち各糸ｘ，ｙ，ｚ
及びロッド２の占める体積を高めると、その分金属の割
合が減り、複合材の熱伝導率が低下するように思える。
しかし、ロッド２を挿入した場合、ロッド２に沿って真
っ直ぐに延びる含浸金属の経路ができるため、厚さ方向
の熱伝導率が高くなる。When a composite material is manufactured by impregnating the three-dimensional fiber structure 1 with a metal as a matrix, the metal forms gaps between the yarns x, y, z and the rods 2 that constitute the three-dimensional fiber structure 1. Filled to fill. When the composite material is used for a heat radiating material, the thermal conductivity of the fibers constituting the three-dimensional fabric F is lower than that of Cu or aluminum generally used as a matrix metal. Therefore, when simply considered, if the density of the three-dimensional fiber structure 1 is increased, that is, each yarn x, y, z
When the volume occupied by the rod 2 is increased, the ratio of the metal is reduced by that amount, and the thermal conductivity of the composite material seems to be reduced.
However, when the rod 2 is inserted, a path of the impregnated metal extending straight along the rod 2 is formed, so that the thermal conductivity in the thickness direction increases.
【００２４】この実施の形態では以下の効果を有する。 （１） 面内２軸配向となる糸層３，４を複数積層して
形成された積層糸群５と、積層糸群５の各糸層３，４と
直交する方向に配列された厚さ方向糸ｚとを含む三次元
織物Ｆに、繊維強化複合材製のロッド２を挿入して三次
元繊維構造体１を構成した。従って、三次元織物Ｆを製
造する段階では厚さ方向糸ｚの挿入密度を高める必要が
なく、ロッド２の挿入本数を増やすことで、密度の高い
三次元繊維構造体１を比較的簡単に製造でき、複合材を
形成した際に強度が高くなる。また、繊維強化複合材製
のロッド２を使用しているため、三次元織物Ｆの繊維体
積含有率（Ｖｆ）を高くできる。This embodiment has the following effects. (1) A laminated yarn group 5 formed by laminating a plurality of yarn layers 3 and 4 having in-plane biaxial orientation, and a thickness direction yarn arranged in a direction orthogonal to each of the yarn layers 3 and 4 of the laminated yarn group 5. The rod 2 made of the fiber-reinforced composite material was inserted into the three-dimensional fabric F containing z and the three-dimensional fiber structure 1. Therefore, at the stage of manufacturing the three-dimensional fabric F, it is not necessary to increase the insertion density of the thickness direction thread z, and by increasing the number of rods 2 to be inserted, it is possible to relatively easily manufacture the high-density three-dimensional fiber structure 1. The strength can be increased when the composite material is formed. Further, since the rod 2 made of the fiber-reinforced composite material is used, the fiber volume content (Vf) of the three-dimensional fabric F can be increased.
【００２５】（２） 各糸層３，４を構成する面内配列
糸ｘ，ｙがそれぞれ、互いに平行な平面上に配列されて
積層糸群５が構成されているため、積層糸群５を二次元
織物で構成する場合に比較して各面内配列糸ｘ，ｙが真
っ直ぐに延び、補強効果が高くなる。(2) Since the in-plane arranged yarns x and y constituting each of the yarn layers 3 and 4 are arranged on planes parallel to each other to form the laminated yarn group 5, the laminated yarn group 5 is two-dimensionally arranged. The in-plane arrangement yarns x and y extend straight as compared with the case where they are made of woven fabric, and the reinforcing effect is enhanced.
【００２６】（３） 三次元織物Ｆにロッド２が挿入さ
れているため、二次元織物を単に積層したものにロッド
を挿入した三次元繊維構造体に比較して、複合材を製造
した際に、複合材の剛性が高くなるとともに、厚さ方向
への膨張抑制効果が向上する。その結果、複合材を半導
体装置の放熱部材として使用した場合に半導体装置に過
大な応力が作用するのが防止される。また、金属との複
合材を製造する際、マトリックス金属を含浸させる工程
で繊維組織が乱れ難く、形状安定性が良くなる。(3) Since the rods 2 are inserted into the three-dimensional woven fabric F, compared to a three-dimensional fiber structure in which the rods are inserted into a two-dimensional woven fabric simply laminated, a composite material is produced. In addition, the rigidity of the composite material is increased, and the effect of suppressing expansion in the thickness direction is improved. As a result, when the composite material is used as a heat dissipating member of the semiconductor device, an excessive stress is prevented from acting on the semiconductor device. Further, when producing a composite material with a metal, the fiber structure is not easily disturbed in the step of impregnating the matrix metal, and the shape stability is improved.
【００２７】（４） ロッド２が厚さ方向糸ｚと平行に
挿入されているため、厚さ方向の配向成分を増加させる
のが簡単になり、マトリックスを含浸させて複合材を製
造した場合、板厚方向に高強度、高弾性率及び低熱膨張
率の材料が得られる。(4) Since the rod 2 is inserted in parallel with the thickness direction thread z, it is easy to increase the orientation component in the thickness direction, and when a matrix is impregnated to produce a composite material, A material having high strength, high elastic modulus and low thermal expansion coefficient in the thickness direction can be obtained.
【００２８】（５） ロッド２の挿入本数を変えること
で、厚さ方向の配向成分の割合を調整できるため、三次
元織物Ｆの製造条件を変えること無く、種々の特性の三
次元繊維構造体１を得ることができ、三次元繊維構造体
１の製造コストを低減できる。(5) The ratio of the orientation component in the thickness direction can be adjusted by changing the number of inserted rods 2, so that the three-dimensional fiber structure having various characteristics can be obtained without changing the manufacturing conditions of the three-dimensional fabric F. 1 can be obtained, and the manufacturing cost of the three-dimensional fiber structure 1 can be reduced.
【００２９】（６） 積層糸群５及び厚さ方向糸ｚに炭
素繊維が使用されているため、合成樹脂繊維や他の無機
繊維を使用して三次元織物Ｆを形成した場合に比較し
て、マトリックスとともに複合材を製造した際に複合材
の熱伝導率が高くなる。また、合成樹脂繊維に比較して
板厚方向の力学的特性（強度、弾性率）が向上する。(6) Since carbon fibers are used for the laminated yarn group 5 and the thickness direction yarn z, compared with the case where the three-dimensional fabric F is formed using synthetic resin fibers or other inorganic fibers, When the composite is manufactured together with the matrix, the thermal conductivity of the composite increases. Further, the mechanical properties (strength and elastic modulus) in the thickness direction are improved as compared with synthetic resin fibers.
【００３０】（７） 厚さ方向糸ｚは太さが積層糸群５
を構成する糸（両面内配列糸ｘ，ｙ）の１／２以下で、
この実施の形態ではほぼ１／１０程度である。従って、
曲げに弱く、糸（繊維）同士の擦れにより切断し易い炭
素繊維を厚さ方向糸ｚに使用しても、積層糸群５を締め
付ける際等に、厚さ方向糸ｚが切断し難くなるととも
に、毛羽立ち難くなる。また、厚さ方向糸挿入針の太さ
を細くできるため、挿入抵抗が小さくなり、挿入速度を
高めることにより生産性が向上する。また、図２に示す
厚さ方向糸ｚの折り返しループ７が三次元織物Ｆから飛
び出す量を少なくできる。(7) The thickness direction yarn z has a thickness of the laminated yarn group 5
Less than の of the yarn (the yarns x and y arranged in both sides)
In this embodiment, it is about 1/10. Therefore,
Even if a carbon fiber which is weak to bending and is easily cut by rubbing between yarns (fibers) is used for the thickness direction yarn z, the thickness direction yarn z becomes difficult to cut when the laminated yarn group 5 is tightened, and the like. It becomes less fuzzy. Further, since the thickness of the thickness direction thread insertion needle can be reduced, the insertion resistance is reduced, and the productivity is improved by increasing the insertion speed. Further, the amount of the return loop 7 of the thickness direction thread z shown in FIG.
【００３１】（８） マトリックスとしてアルミニウム
を使用して複合材を製造した場合、アルミニウムは熱伝
導率がＣｕの６割程度であるが、密度がほぼ１／３のた
め、軽量化に寄与する。また、アルミニウムの融点は６
６０℃とＣｕの融点より４００℃以上低いため、含浸時
の温度を低くでき、溶融に必要なエネルギーが少なくな
る。従って、熱伝導率がさほど要求されない放熱部材と
して使用する複合材では、マトリックスとしてアルミニ
ウムを使用するのが好ましい。(8) When a composite material is manufactured using aluminum as a matrix, aluminum has a thermal conductivity of about 60% of Cu, but has a density of approximately 1/3, which contributes to weight reduction. The melting point of aluminum is 6
Since the temperature is 60 ° C., which is lower than the melting point of Cu by 400 ° C. or more, the temperature at the time of impregnation can be lowered, and the energy required for melting is reduced. Therefore, in a composite material used as a heat dissipating member that does not require much thermal conductivity, it is preferable to use aluminum as the matrix.
【００３２】実施の形態は前記に限定されるものではな
く、例えば、次のように具体化してもよい。 ○ 三次元繊維構造体１を焼成して、炭素繊維の黒鉛化
を進行させるとともに、ロッド２を炭化させてもよい。
この場合、マトリックス金属を含浸させて複合材を製造
した際に、熱伝導率のより高い複合材が得られる。The embodiment is not limited to the above, and may be embodied as follows, for example. The three-dimensional fiber structure 1 may be fired to progress the graphitization of the carbon fiber and the rod 2 may be carbonized.
In this case, when a composite material is manufactured by impregnation with a matrix metal, a composite material having higher thermal conductivity can be obtained.
【００３３】○ ロッド２に使用する炭素繊維として石
炭ピッチ系炭素繊維を使用すると、複合材を製造した際
に、板厚方向の熱伝導率がより高められた複合材が得ら
れる。When a coal pitch-based carbon fiber is used as the carbon fiber used for the rod 2, a composite material having a higher thermal conductivity in the thickness direction can be obtained when the composite material is manufactured.
【００３４】○ 三次元織物Ｆを製造可能な柔軟性を有
するピッチ系の炭素繊維を使用して炭素繊維織物を製造
し、ロッド２を挿入後、３０００℃程度の焼成温度で焼
成して炭素繊維の黒鉛化を進行させる。この場合、炭素
繊維の熱伝導率がより向上する。この三次元繊維構造体
焼成物を使用した場合、マトリックスとして金属に代え
て樹脂を使用しても、熱伝導率がさほど要求されない放
熱部材として使用する複合材に使用可能となる。A carbon fiber fabric is manufactured using a pitch-based carbon fiber having flexibility capable of manufacturing a three-dimensional fabric F, and after inserting the rod 2, firing at a firing temperature of about 3000 ° C. The graphitization of the material proceeds. In this case, the thermal conductivity of the carbon fiber is further improved. When this three-dimensional fibrous structure fired product is used, even if a resin is used instead of metal as the matrix, it can be used for a composite material used as a heat dissipating member that does not require much thermal conductivity.
【００３５】○ 三次元繊維構造体１を熱伝導率の高い
複合材を製造するために使用する場合、ロッド２をアル
ミニウムと同等以上の熱伝導率を有する金属製のロッド
（例えば、Ｃｕやアルミニウム）としてもよい。この場
合、炭素繊維として黒鉛化の進行した特殊な炭素繊維を
使用しなくても、複合材の熱伝導率を高くできる。When the three-dimensional fiber structure 1 is used for manufacturing a composite material having a high thermal conductivity, the rod 2 is made of a metal rod having a thermal conductivity equal to or higher than that of aluminum (for example, Cu or aluminum). ). In this case, the thermal conductivity of the composite material can be increased without using a special carbon fiber having advanced graphitization as the carbon fiber.
【００３６】○ 三次元繊維構造体１を熱伝導率の高い
複合材を製造するために使用するのではなく、複合材の
強度の向上を目的とする場合は、三次元織物の構成繊維
として炭素繊維に代えて、ガラス繊維、アラミド繊維、
セラミック繊維（例えば、炭化ケイ素繊維、アルミナ繊
維）等の高強度、高弾性繊維を使用してもよい。In the case where the three-dimensional fiber structure 1 is not used for producing a composite material having a high thermal conductivity, but is intended to improve the strength of the composite material, carbon fibers may be used as constituent fibers of the three-dimensional fabric. Instead of fiber, glass fiber, aramid fiber,
High-strength, high-elastic fibers such as ceramic fibers (for example, silicon carbide fibers and alumina fibers) may be used.
【００３７】○ 三次元繊維構造体１を強度及び耐熱性
に優れた複合材を製造するために使用する場合は、三次
元織物Ｆを炭素繊維やセラミック繊維で製造するのが好
ましい。そして、マトリックスをカーボンやセラミック
スとすると、より耐熱性に優れた複合材を製造できる。When the three-dimensional fiber structure 1 is used for producing a composite material having excellent strength and heat resistance, it is preferable that the three-dimensional fabric F is produced from carbon fibers or ceramic fibers. When the matrix is made of carbon or ceramics, a composite material having more excellent heat resistance can be manufactured.
【００３８】○ 三次元織物Ｆを構成する積層糸群５
は、少なくとも面内２軸配向となる糸層を複数積層して
形成されていればよい。例えば、第１の面内配列糸ｘに
対して所定の角度（例えば±４５°）で傾斜するように
配列された２層一組のバイアス糸からなるバイアス糸層
を有する面内４軸、合計５軸の三次元織物としてもよ
い。この場合、三次元織物Ｆの形状安定性がより向上す
る。また、積層糸群５を、互いに６０°の角度で交差す
るように延びる３種類の糸で面内３軸に構成してもよ
い。The laminated yarn group 5 constituting the three-dimensional woven fabric F
May be formed by laminating a plurality of yarn layers having at least in-plane biaxial orientation. For example, four in-plane axes having a bias yarn layer including a pair of bias yarns arranged so as to be inclined at a predetermined angle (for example, ± 45 °) with respect to the first in-plane arrangement yarn x, total It may be a five-axis three-dimensional fabric. In this case, the shape stability of the three-dimensional fabric F is further improved. Further, the laminated yarn group 5 may be constituted by three types of yarns extending so as to intersect with each other at an angle of 60 ° so as to have three in-plane axes.
【００３９】○ 二次元織物を積層することにより積層
糸群５を構成し、二次元織物をステッチ糸で縫い合わせ
て三次元織物Ｆを形成してもよい。二次元織物は平織物
に限らず任意の織物を使用できる。The laminated yarn group 5 may be formed by laminating two-dimensional fabrics, and the two-dimensional fabrics may be sewn with stitch threads to form the three-dimensional fabric F. The two-dimensional fabric is not limited to a plain fabric, and any fabric can be used.
【００４０】○ ロッド２の断面形状は円形に限らず、
四角形、楕円形等の他の形状としてもよい。積層糸群５
がＸ，Ｙ２軸配向の場合、ロッド２の断面形状を四角形
にすると円形断面のロッド２を使用した場合に比較して
三次元繊維構造体１の密度を高くすることができる。The sectional shape of the rod 2 is not limited to a circle,
Other shapes such as a quadrangle and an ellipse may be used. Laminated yarn group 5
When the rods 2 are oriented in the X- and Y-axes, the cross-sectional shape of the rod 2 can be made quadrangular, so that the density of the three-dimensional fiber structure 1 can be increased as compared with the case where the rod 2 having a circular cross-section is used.
【００４１】○ 抜け止め糸６を使用せずに、厚さ方向
糸ｚが積層糸群５を一方の側から貫通した後、貫通位置
を所定ピッチずらして他方の側から積層糸群５を貫通す
るように配列してもよい。この場合、抜け止め糸６を使
用する構成に比較して厚さ方向糸ｚを太くでき、三次元
織物Ｆの繊維体積含有率（Ｖｆ）を大きくするために厚
さ方向糸ｚの締め付け力を強くできる。After the thickness direction yarn z penetrates the laminated yarn group 5 from one side without using the retaining yarn 6, the penetration position is shifted by a predetermined pitch to penetrate the laminated yarn group 5 from the other side. May be arranged. In this case, the thickness direction yarn z can be made thicker than the configuration using the retaining yarn 6, and the tightening force of the thickness direction yarn z is increased in order to increase the fiber volume content (Vf) of the three-dimensional fabric F. Can be strong.
【００４２】○ ロッド２を厚さ方向ではなくＸ軸方向
あるいはＹ軸方向に挿入してもよい。 ○ 三次元織物Ｆを炭素繊維で形成し、ロッド２を炭素
繊維強化複合材製とした三次元繊維構造体１の使用方法
としては、放熱部材用の複合材に限らず、ブレーキディ
スク用のカーボン・カーボン複合材としてもよい。The rod 2 may be inserted not in the thickness direction but in the X-axis direction or the Y-axis direction. The method of using the three-dimensional fiber structure 1 in which the three-dimensional fabric F is formed of carbon fiber and the rod 2 is made of carbon fiber reinforced composite material is not limited to the composite material for the heat radiation member, but may be the carbon material for the brake disk. -It may be a carbon composite material.
【００４３】前記実施の形態から把握できる発明（技術
的思想）について、以下に記載する。 （１） 請求項１〜請求項５のいずれかに記載の発明に
おいて、前記三次元織物は５軸の三次元織物である。The invention (technical idea) that can be grasped from the above embodiment will be described below. (1) In the invention according to any one of claims 1 to 5, the three-dimensional fabric is a five-axis three-dimensional fabric.
【００４４】（２） 請求項３又は請求項４に記載の発
明の三次元繊維構造体を焼成して炭素繊維を黒鉛化した
三次元繊維構造体。 （３） 請求項３〜請求項５及び（２）のいずれかに記
載の発明の三次元繊維構造体を強化材に使用して、マト
リックスをアルミニウムと同等以上の金属とした複合
材。(2) A three-dimensional fiber structure obtained by firing the three-dimensional fiber structure according to claim 3 or 4 to graphitize carbon fibers. (3) A composite material in which the three-dimensional fiber structure according to any one of claims 3 to 5 and (2) is used as a reinforcing material, and a matrix is made of a metal equivalent to or more than aluminum.
【００４５】[0045]
【発明の効果】以上詳述したように、請求項１〜請求項
５に記載の発明によれば、製造が比較的簡単で密度の高
い三次元繊維構造体を得ることができる。また、請求項
３〜請求項５に記載の発明によれば、例えば半導体装置
の放熱部材や電子部品搭載基材として使用する複合材を
製造する際の強化材とした場合に必要な熱伝導率を有す
る三次元繊維構造体を得ることができる。As described in detail above, according to the first to fifth aspects of the present invention, it is possible to obtain a three-dimensional fiber structure having a relatively simple production and a high density. According to the third to fifth aspects of the present invention, for example, the thermal conductivity required when a reinforcing material is used when manufacturing a composite material used as a heat dissipation member of a semiconductor device or a base material for mounting electronic components. Can be obtained.
【図１】 一実施の形態の三次元繊維構造体の一部破断
模式斜視図。FIG. 1 is a partially broken schematic perspective view of a three-dimensional fiber structure according to an embodiment.
【図２】 厚さ方向糸の配列状態を示す模式断面図。FIG. 2 is a schematic cross-sectional view showing an arrangement state of thickness direction yarns.
【図３】 ロッドの挿入状態を示す一部破断模式斜視図FIG. 3 is a partially cutaway perspective view showing an inserted state of a rod.
１…三次元繊維構造体、２…ロッド、３…ｘ糸層、４…
ｙ糸層、５…積層糸群、ｚ…厚さ方向糸、Ｆ…三次元織
物。DESCRIPTION OF SYMBOLS 1 ... Three-dimensional fiber structure, 2 ... Rod, 3 ... x thread layer, 4 ...
Y yarn layer, 5: laminated yarn group, z: thickness direction yarn, F: three-dimensional fabric.
───────────────────────────────────────────────────── フロントページの続き (72)発明者 神谷 隆太 愛知県刈谷市豊田町２丁目１番地 株式会 社豊田自動織機製作所内 Ｆターム(参考） 4L048 AA05 AA48 AA52 AC09 AC13 BA22 CA01 CA05 DA41 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Ryuta Kamiya 2-1-1 Toyota-cho, Kariya-shi, Aichi F-term in Toyota Industries Corporation (reference) 4L048 AA05 AA48 AA52 AC09 AC13 BA22 CA01 CA05 DA41
Claims (5)
数積層して形成された積層糸群と、前記積層糸群の各糸
層と直交する方向に配列された厚さ方向糸とを含む少な
くとも３軸で構成された三次元織物に、繊維強化複合材
製または金属製のロッドを挿入した三次元繊維構造体。1. A laminated yarn group formed by laminating a plurality of yarn layers having at least in-plane biaxial orientation, and a thickness direction yarn arranged in a direction orthogonal to each yarn layer of the laminated yarn group. A three-dimensional fiber structure in which a rod made of a fiber-reinforced composite material or a metal is inserted into a three-dimensional fabric composed of three axes.
入されている請求項１に記載の三次元繊維構造体。2. The three-dimensional fiber structure according to claim 1, wherein the rod is inserted in parallel with the thickness direction yarn.
素繊維が使用されている請求項請求項１又は請求項２に
記載の三次元繊維構造体。3. The three-dimensional fiber structure according to claim 1, wherein carbon fibers are used for the laminated yarn group and the thickness direction yarn.
構成する糸の１／２以下である請求項３に記載の三次元
繊維構造体。4. The three-dimensional fiber structure according to claim 3, wherein the thickness direction yarn has a thickness equal to or less than の of a yarn constituting the laminated yarn group.
熱伝導率を有する金属製のロッドである請求項３又は請
求項４に記載の三次元繊維構造体。5. The three-dimensional fiber structure according to claim 3, wherein the rod is a metal rod having a thermal conductivity equal to or higher than that of aluminum.
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| JP4062879B2 JP4062879B2 (en) | 2008-03-19 |
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| US7504153B2 (en) | 2003-05-13 | 2009-03-17 | Showa Denko K.K. | Porous body, production method thereof and composite material using the porous body |
| EP2264088A2 (en) | 2003-05-13 | 2010-12-22 | Showa Denko K.K. | Porous body, production method thereof and composite material using the porous body |
| JP2007301838A (en) * | 2006-05-11 | 2007-11-22 | Fuji Heavy Ind Ltd | Three-dimensional fiber-reinforced resin composite |
| JP2011000921A (en) * | 2009-06-17 | 2011-01-06 | Ihi Aerospace Co Ltd | Entry capsule and method of manufacturing head top part thereof |
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| CN105835258A (en) * | 2016-05-24 | 2016-08-10 | 颜本善 | Carbon fiber bar framework of seven-dimensional carbon fiber bar structure composite material |
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