JP2002227066A - Reinforcing multiaxial stitched fabric and method for molding frp - Google Patents
Reinforcing multiaxial stitched fabric and method for molding frpInfo
- Publication number
- JP2002227066A JP2002227066A JP2001020030A JP2001020030A JP2002227066A JP 2002227066 A JP2002227066 A JP 2002227066A JP 2001020030 A JP2001020030 A JP 2001020030A JP 2001020030 A JP2001020030 A JP 2001020030A JP 2002227066 A JP2002227066 A JP 2002227066A
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- Japan
- Prior art keywords
- fabric
- multiaxial
- yarn
- frp
- stitch
- Prior art date
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Links
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明はＦＲＰの補強繊維基
材として使用する多軸ステッチ布帛およびその多軸ステ
ッチ布帛を用いてなるＦＲＰの成形方法ならびに自動車
外板に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a multiaxial stitch fabric used as a reinforcing fiber base material of an FRP, a method of forming an FRP using the multiaxial stitch fabric, and an automobile outer panel.
【０００２】[0002]
【従来の技術】連続補強繊維からなる繊維強化プラスチ
ックは、繊維軸方向の機械的特性には優れるが、繊維軸
から離れるに従い、その方向の機械的特性は急激に低下
する。この対策として、たとえば、機械的特性が疑似等
方性基材となるように繊維軸方向がＦＲＰ成形体の長さ
（０゜）方向、幅（９０゜）方向や斜め（±α゜）方向
となるよう積層され、成形されている。2. Description of the Related Art Fiber reinforced plastics made of continuous reinforcing fibers have excellent mechanical properties in the direction of the fiber axis, but the mechanical properties in that direction rapidly decrease as the distance from the fiber axis increases. As a countermeasure, for example, the fiber axis direction is the length (0 °) direction, the width (90 °) direction, or the oblique (± α °) direction of the FRP molded body so that the mechanical properties become a pseudo-isotropic base material. Laminated and molded.
【０００３】しかしながら、通常の織物を使用すると、
繊維の配列方向は織物の長さ（０゜）方向と幅（９０
゜）方向であるから、斜め（±α゜）方向の補強ができ
なくなる。この対策として、織物を斜め方向に裁断し、
裁断された織物の端部が０゜方向と９０゜方向に配列す
る織物と平行になるように積層し、斜め方向に裁断した
繊維の配列方向が±４５゜になるようにしている。しか
しながら、このような方法では織物の裁断や積層に手間
が掛かるし、また積層の際、（０゜／９０゜）配列織物
と（＋４５゜／−４５゜）配列織物がずれ、正確な繊維
配向が困難となる。[0003] However, when using ordinary fabrics,
The fiber arrangement direction is the length (0 °) direction and width (90 °) of the fabric.
゜) direction, the reinforcement in the oblique (± α 斜 め) direction cannot be performed. As a countermeasure, the fabric is cut diagonally,
The cut fabrics are laminated so that the end portions thereof are parallel to the fabrics arranged in the 0 ° direction and the 90 ° direction, and the arrangement direction of the diagonally cut fibers is ± 45 °. However, in such a method, it takes time and effort to cut and laminate the woven fabric, and at the time of lamination, the (0 ° / 90 °) aligned woven fabric and the (+ 45 ° / −45 °) aligned woven fabric are displaced from each other, resulting in accurate fiber orientation. Becomes difficult.
【０００４】一方、上記課題に対して、最近、よこ入れ
トリコット装置で、布帛の長さ方向に対して＋α゜、−
α゜やこれに０゜および／または９０゜方向に、すなわ
ち、２方向以上の多軸の各々の方向で層状に補強繊維が
並行に配列し、これらが積層した状態で、ポリエステル
繊維糸などのステッチで縫合一体化した、いわゆる多軸
ステッチ布帛が注目を浴びている。この布帛は＋α゜、
−α゜、０゜や９０゜配列繊維がステッチ糸で一体とな
っているから、わざわざ裁断によって、所定の方向に配
列するような準備作業が必要なくなり、１枚の布帛で疑
似等方性の特性が得られるので、積層作業が大幅に省力
化され、安価なＦＲＰ成形体が得られるという利点はあ
る。また、ステッチ糸のステッチ密度を最適化すること
によって、深絞り賦形が可能となり、成形のプリフォー
ムを容易に作製することもできる利点がある。On the other hand, in order to solve the above problem, recently, a weft insertion tricot device has been used to add + α ゜, −
The reinforcing fibers are arranged in parallel in α ゜ and 0 ° and / or 90 ° directions, that is, in layers in each of two or more multiaxial directions. A so-called multi-axis stitched fabric stitched and integrated with a stitch has attracted attention. This fabric is + α ゜,
-Α ゜, 0 ゜ and 90 ゜ arrangement fibers are united with stitch yarns, so cutting is not necessary, and preparation work for arranging in a predetermined direction is not required, so that a single piece of cloth can be made Since the characteristics can be obtained, there is an advantage that the laminating operation can be largely saved and an inexpensive FRP molded body can be obtained. Further, by optimizing the stitch density of the stitch yarn, deep drawing can be performed, and there is an advantage that a preform for molding can be easily manufactured.
【０００５】しかしながら、ステッチ布帛は、ステッチ
糸によって補強繊維を拘束する布帛構造となっているか
ら、各層内では補強繊維の拘束部分と補強繊維がまった
く存在しない部分が存在している。したがって、樹脂が
含浸され、樹脂が硬化すると樹脂が硬化収縮するので、
ＦＲＰの状態では補強繊維の拘束部部分の厚さ方向の収
縮量は補強繊維が存在するので小さく、補強繊維がまっ
たく存在しない部分の収縮量が大きくなって、ＦＲＰの
表面の凹凸が大きくなり、表面が平滑なＦＲＰが得られ
なかった。[0005] However, the stitched fabric has a fabric structure in which the reinforcing fibers are restrained by the stitch yarns. Therefore, in each layer, there are portions where the reinforcing fibers are restrained and portions where no reinforcing fibers are present. Therefore, when the resin is impregnated and cured, the resin cures and contracts,
In the state of FRP, the amount of shrinkage in the thickness direction of the constrained portion of the reinforcing fiber is small because the reinforcing fiber is present, the amount of shrinkage in the portion where no reinforcing fiber is present increases, and the unevenness of the surface of the FRP increases, FRP with a smooth surface could not be obtained.
【０００６】とくに、自動車の外板に要求される表面平
滑性はクラスＡの厳しいグレードが求められるので、Ｆ
ＲＰ表面をサンデングして塗装するか、ＦＲＰの表面に
よほど厚いゲルコート層を設けないと、クラスＡには到
達しなかった。In particular, since the surface smoothness required for the outer panel of an automobile is required to be a strict class A class,
Class A was not reached unless the RP surface was sanded and painted or the FRP surface was not provided with a thicker gel coat layer.
【０００７】[0007]
【発明が解決しようとする課題】本発明は、かかる従来
技術の背景に鑑み、表面平滑で、しかも安価なＦＲＰが
得られる多軸ステッチ布帛およびその成形方法、ならび
に自動車の外板を提供せんとするものである。SUMMARY OF THE INVENTION In view of the background of the prior art, an object of the present invention is to provide a multiaxial stitched fabric capable of obtaining an inexpensive FRP with a smooth surface, a method of forming the same, and an automobile outer panel. Is what you do.
【０００８】[0008]
【課題を解決するための手段】本発明は、かかる課題を
解決するために、次の手段を採用するものである。すな
わち、本発明の多軸ステッチ布帛は、 （１）多数本の強化繊維糸条が並行にシート状に配列し
て層構成をなし、前記層の少なくとも２層以上が交差積
層されて積層体をなし、該積層体が低融点ポリマー糸で
ステッチされて一体化されていることを特徴とする補強
用多軸ステッチ布帛。The present invention employs the following means in order to solve the above problems. That is, the multiaxial stitched fabric of the present invention comprises: (1) a multilayer structure in which a large number of reinforcing fiber yarns are arranged in parallel in a sheet form to form a layer structure, and at least two or more of the layers are cross-laminated to form a laminate. A multiaxial stitching fabric for reinforcement, wherein the laminate is stitched with a low-melting polymer yarn and integrated.
【０００９】（２）前記交差角度が布帛の長さ方向に対
して＋α゜、−α゜の２方向を少なくとも含むものであ
ることを特徴とする前記（１）に記載の補強用多軸ステ
ッチ布帛。(2) The reinforcing multiaxial stitched fabric according to (1), wherein the crossing angle includes at least two directions of + α ＋ and -α− with respect to the length direction of the fabric.
【００１０】（３）前記交差角度が布帛の長さ方向に対
して０゜、９０゜の２方向を少なくとも含むものである
ことを特徴とする前記（１）に記載の補強用多軸ステッ
チ布帛。(3) The multiaxial stitching fabric for reinforcement according to (1), wherein the crossing angle includes at least two directions of 0 ° and 90 ° with respect to the length direction of the fabric.
【００１１】（４）前記交差角度が布帛の長さ方向に対
して０゜、＋α゜、−α゜の３方向を少なくとも含むも
のであることを特徴とする前記（１）に記載の補強用多
軸ステッチ布帛。(4) The multiaxial reinforcing member according to (1), wherein the crossing angle includes at least three directions of 0 °, + α °, and −α ° with respect to the length direction of the fabric. Stitched fabric.
【００１２】（５）前記交差角度が布帛の長さ方向に対
して＋α゜、−α゜、９０゜の３方向を少なくとも含む
ものであることを特徴とする前記（１）に記載の補強用
多軸ステッチ布帛。(5) The multi-axis for reinforcement according to (1), wherein the crossing angle includes at least three directions of + α ＋, -α ゜, and 90 ° with respect to the length direction of the cloth. Stitched fabric.
【００１３】（６）前記交差角度が布帛の長さ方向に対
して０゜、＋α゜、−α゜、９０゜の４方向を少なくと
も含むものであることを特徴とする前記（１）に記載の
補強用多軸ステッチ布帛。(6) The reinforcement according to the above (1), wherein the intersection angle includes at least four directions of 0 °, + α °, −α °, and 90 ° with respect to the length direction of the cloth. For multi-axis stitch fabric.
【００１４】（７）前記角度α゜が４５゜であることを
特徴とする前記（２）、または前記（４）ないし（６）
のいずれかに記載の補強用多軸ステッチ布帛。(7) The above (2) or (4) to (6), wherein the angle α ゜ is 45 °.
A multiaxial stitch fabric for reinforcement according to any one of the above.
【００１５】（８）前記低融点ポリマー糸が共重合ナイ
ロン糸であることを特徴とする前記（１）ないし（７）
のいずれかに記載の補強用多軸ステッチ布帛。(8) The above (1) to (7), wherein the low-melting polymer yarn is a copolymerized nylon yarn.
A multiaxial stitch fabric for reinforcement according to any one of the above.
【００１６】（９）前記低融点ポリマー糸が変成ポリエ
ステル糸であることを特徴とする前記（１）ないし
（７）のいずれかに記載の補強用多軸ステッチ布帛。(9) The multiaxial stitching fabric for reinforcement according to any one of (1) to (7), wherein the low-melting polymer yarn is a modified polyester yarn.
【００１７】（１０）前記強化繊維が炭素繊維であるこ
とを特徴とする前記（１）ないし（９）のいずれかに記
載の補強用多軸ステッチ布帛。(10) The multiaxial stitching fabric for reinforcement according to any one of (1) to (9), wherein the reinforcing fibers are carbon fibers.
【００１８】（１１）前記（１）ないし（１０）のいず
れかに記載の補強用多軸ステッチ布帛に樹脂を含浸し、
低融点ポリマー糸の融点以上に加熱成形することを特徴
とするＦＲＰの成形方法。(11) Impregnating a resin into the reinforcing multiaxial stitched fabric according to any of (1) to (10),
A method for forming an FRP, comprising heating and forming the polymer at a temperature higher than the melting point of the low-melting polymer yarn.
【００１９】（１２）前記（１１）に記載の成形方法に
よって得られるＦＲＰを用いてなることを特徴とする自
動車外板。(12) An automobile outer panel using the FRP obtained by the molding method according to (11).
【００２０】[0020]
【発明の実施の形態】以下、図面に示す実施例に基づい
て本発明をさらに詳細に説明する。DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in more detail based on embodiments shown in the drawings.
【００２１】図１は、本発明に係る多軸ステッチ布帛の
一実施例を示す一部切り欠き概略斜視図である。図１に
示すように、布帛１の下面から、まず第一層が長さ方向
イに対して斜め方向に多数本の強化繊維糸条２が並行に
配列して＋α゜層６を構成し、次いで第二層が布帛の幅
方向に多数本の強化繊維糸条３が並行に配列して９０゜
層７を構成し、次いで第三層が斜め方向に多数本の強化
繊維糸条４が並行に配列して−α゜層８を構成し、次い
で第四層が布帛の長さ方向に多数本の強化繊維糸条５が
並行に配列して０゜層９を構成し、互いに配列方向が異
なる第一〜第４層が積層された状態で、ステッチ糸１０
でこれら４層が縫合一体化されている。縫合一体化にあ
たってのステッチ糸が形成する縫い組織としては、単環
縫い、１／１のトリコット編みなどが挙げられる。FIG. 1 is a partially cut-away schematic perspective view showing one embodiment of a multiaxial stitch fabric according to the present invention. As shown in FIG. 1, from the lower surface of the fabric 1, a first layer is composed of a number of reinforcing fiber yarns 2 arranged in parallel in a direction oblique to the length direction A to form a + α ゜ layer 6. Next, the second layer has a large number of reinforcing fiber yarns 3 arranged in parallel in the width direction of the fabric to form a 90 ° layer 7, and the third layer has a large number of reinforcing fiber yarns 4 arranged diagonally in parallel. To form the -α layer 8, and the fourth layer constitutes the 0 layer 9 by arranging a large number of reinforcing fiber yarns 5 in parallel in the length direction of the fabric. In a state where the different first to fourth layers are stacked, the stitch yarn 10
The four layers are stitched together. Examples of the sewing structure formed by the stitch thread for stitching integration include single-ring sewing and 1/1 tricot knitting.
【００２２】図２は、図１に示した多軸ステッチ布帛の
Ａ−Ａ´断面の拡大概略図である。図２に示すように、
−α゜層６、９０゜層７、＋α゜層８、０゜層９の４層
にステッチ糸１０が形成するトリコット編み組織で一体
化されている。なお、各層の糸条は層内において並行に
配列し、これら糸条に対してランダムにニードルが突き
刺さりステッチ糸が縫い組織を形成する。この時、ステ
ッチ糸の張力によりステッチ糸１０とステッチ糸１０の
間には、強化繊維１１が存在せず、大きな空隙部Ｂが形
成される。FIG. 2 is an enlarged schematic view of an AA 'cross section of the multiaxial stitched fabric shown in FIG. As shown in FIG.
The stitch yarn 10 is integrated with four layers of the -α layer 6, the 90 ° layer 7, the + α layer 8, and the 0 ° layer 9 by a tricot knitting structure. The yarns of each layer are arranged in parallel in the layer, and the needles pierce the yarns at random, and the stitch yarns form a sewing structure. At this time, the reinforcing fiber 11 does not exist between the stitch yarns 10 due to the tension of the stitch yarns, and a large gap B is formed.
【００２３】図３に従来の図２に示した多軸ステッチ布
帛を使用したＦＲＰ成形体の断面概略図を示したが、ス
テッチ糸１０とステッチ糸１０の間の空隙部Ｂには強化
繊維が存在しないので、多軸ステッチ布帛に含浸された
樹脂が硬化する際体積収縮し、その箇所の表面は凹む。
また、ステッチ糸１０は強化繊維層の外側に位置する部
分があるから、成形型に布帛が充填されて成形されて
も、ステッチ糸１０の部分はステッチ糸１０の存在しな
い箇所に比べて凸状態となり、ＦＲＰ表面が凸凹し、表
面平滑性はクラスＡにはとても到達しないのである。FIG. 3 is a schematic cross-sectional view of a conventional FRP molded article using the multiaxial stitched fabric shown in FIG. 2. In the void B between the stitch yarns 10, reinforcing fibers are provided. Since the resin does not exist, the volume of the resin impregnated in the multiaxial stitch fabric shrinks when the resin is cured, and the surface of the portion is dented.
Further, since the stitch yarn 10 has a portion located outside the reinforcing fiber layer, even if the forming die is filled with the fabric, the stitch yarn 10 is in a more protruding state than a portion where the stitch yarn 10 does not exist. Thus, the FRP surface is uneven, and the surface smoothness does not reach class A at all.
【００２４】本発明の多軸ステッチ布帛の布帛構造は、
従来の多軸ステッチ布帛となんら変わりはないが、本発
明ではステッチ糸として低融点ポリマー糸を使用するこ
とを特徴とする。The fabric structure of the multiaxial stitch fabric of the present invention is as follows:
Although not different from the conventional multiaxial stitch fabric, the present invention is characterized in that a low-melting polymer yarn is used as a stitch yarn.
【００２５】本発明に使用する低融点ポリマー糸は、融
点が８０〜２００℃のポリマーを溶融紡糸したもので、
成形時に溶融し、成形後ステッチ糸が形成しているステ
ッチ糸の組織が消滅してポリマーの状態となるものが好
ましい。融点が８０℃未満であると、繊維強化プラスチ
ック（以下ＦＲＰと呼称）に成形した時に、わずかな面
積、体積ではあるがＦＲＰ成形体が屋外暴露などによる
昇温により低融点ポリマーの存在箇所が溶融状態となる
ので好ましくない。また、融点が２００℃を越えると、
成形の際マトリックス樹脂の硬化のための成形型の昇温
および成形型の冷却に時間がかかり、成形サイクルが長
くなるので好ましくない。より好ましくは、低融点ポリ
マー糸の融点は１２０〜１６０℃である。The low-melting polymer yarn used in the present invention is obtained by melt-spinning a polymer having a melting point of 80 to 200 ° C.
It is preferable that the stitch yarn is melted at the time of molding and the structure of the stitch yarn formed by the stitch yarn disappears after the molding to be in a polymer state. If the melting point is less than 80 ° C., when molded into a fiber reinforced plastic (hereinafter referred to as FRP), the FRP molded body has a small area and volume, but the location of the low melting point polymer melts due to temperature rise due to outdoor exposure etc. It is not preferable because it becomes a state. When the melting point exceeds 200 ° C.,
In molding, it takes time to raise the temperature of the mold and to cool the mold for curing the matrix resin, which is not preferable because the molding cycle becomes longer. More preferably, the melting point of the low melting polymer yarn is from 120 to 160C.
【００２６】本発明に用いる低融点ポリマーは、通常、
ナイロン、共重合ナイロン、ポリエステル、変成ポリエ
ステル、塩化ビニリデン、塩化ビニル、ポリウレタン、
ポリプロピレン、ポリウレタンなどから選ばれたもので
ある。なかでも低温でポリマーを溶融でき、かつＦＲＰ
のマトリックス樹脂との接着性が良好な共重合ナイロン
が好ましい。The low melting point polymer used in the present invention is usually
Nylon, copolymerized nylon, polyester, denatured polyester, vinylidene chloride, vinyl chloride, polyurethane,
It is selected from polypropylene, polyurethane and the like. Above all, polymer can be melted at low temperature and FRP
Copolymer nylon having good adhesion to the matrix resin is preferred.
【００２７】また、低温でポリマーを溶融でき、マトリ
ックス樹脂との接着性が良好で、吸水率の小さな変成ポ
リエステルが好ましい。A modified polyester which can melt a polymer at a low temperature, has good adhesion to a matrix resin, and has a small water absorption is preferable.
【００２８】ステッチ糸の太さは、細いとステッチ操作
の際糸切れし、また太いとＦＲＰにした時ステッチ糸が
溶融して形成される低融点ポリマー部分が大きくなり、
塗装の際に色斑などになるので５０〜４００デシテック
スが好ましい。より好ましくは７０〜３００デシテック
スである。When the thickness of the stitch yarn is small, the thread breaks during the stitch operation, and when the thickness is large, the low melting point polymer portion formed by melting the stitch yarn when FRP is formed increases.
50 to 400 decitex is preferable because color unevenness or the like occurs at the time of coating. More preferably, it is 70 to 300 dtex.
【００２９】本発明に使用する強化繊維としては、ガラ
ス繊維、ポリアラミド繊維や炭素繊維が挙げられるが、
なかでも炭素繊維はマトリックス樹脂との接着性が良
く、引張強度や引張弾性率も高いのでＦＲＰ成形体の軽
量化が図られるので好ましく用いられる。The reinforcing fibers used in the present invention include glass fibers, polyaramid fibers and carbon fibers.
Among them, carbon fibers are preferably used because they have good adhesiveness to the matrix resin and high tensile strength and tensile modulus, so that the weight of the FRP molded article can be reduced.
【００３０】本発明に使用する強化繊維の太さは、３，
０００〜５０，０００デシテックス程度であることが好
ましい。とくに、太い強化繊維糸条を用いると、強化繊
維が安くなるので安価な布帛が得られ好ましい。しか
し、一層当たりの強化繊維の目付が小さいと、層内の糸
条と糸条の間に隙間ができ、ステッチ糸で一体化すると
繊維密度が部分的に不均一となり、成形すると繊維密度
が大きなところはＦＲＰが厚くなり、また繊維密度が小
さなところはＦＲＰが薄くなり、表面が凸凹したＦＲＰ
となる。さらに７，０００〜５０，０００デシテックス
の太い強化繊維糸条を用いる場合は、ステッチ糸による
一体化加工前に強化繊維糸条をローラの揺動操作やエア
ー・ジェット噴射で薄く拡げると、布帛の全面にわたり
強化繊維の密度が均一となり、表面が平滑なＦＲＰが得
られるので好ましい。The thickness of the reinforcing fiber used in the present invention is 3,
It is preferably about 000 to 50,000 decitex. In particular, it is preferable to use a thick reinforcing fiber yarn because the reinforcing fiber becomes cheaper and an inexpensive cloth can be obtained. However, if the basis weight of the reinforcing fiber per layer is small, there is a gap between the yarns in the layer, the fiber density becomes partially uneven when integrated with stitch yarn, and the fiber density becomes large when molded. Where the FRP is thicker, and where the fiber density is lower, the FRP is thinner and the surface is uneven.
Becomes Further, when a thick reinforcing fiber yarn of 7,000 to 50,000 decitex is used, if the reinforcing fiber yarn is spread thinly by a swinging operation of a roller or an air jet injection before the integration processing by the stitch yarn, the fabric is formed. This is preferable because the density of the reinforcing fibers becomes uniform over the entire surface and an FRP with a smooth surface can be obtained.
【００３１】もともとステッチ糸の役割は、布帛になっ
た状態で繊維配向が乱れないように、また並行に配列し
た多数本の強化繊維糸条がほつれないようにするもので
あり、布帛の層方向にステッチ糸が配列しているとはい
え、層方向に対する補強効果はさほど大きくはない。Originally, the role of the stitch yarn is to prevent the fiber orientation from being disturbed in the fabric state and to prevent a large number of reinforcing fiber yarns arranged in parallel from fraying. Although the stitch yarns are arranged in the same direction, the reinforcing effect in the layer direction is not so large.
【００３２】なお、図１に示した布帛の強化繊維の構成
は＋α゜層／９０゜層／−α゜層／０゜層の４層構成に
ついて説明したが、これに限定するものではなく、少な
くとも、布帛の長さ方向に対して−α゜層と＋α゜層の
バイアス（±α゜）の方向に層構成をなしておればよ
い。また、層構成の順番も−α゜／９０゜／＋α゜／０
゜の順番に限定するものではなく、０゜／−α゜／９０
゜／＋α゜や０゜／−α゜／＋α゜／９０゜など適宜設
計することができる。また、−α゜層と＋α゜層のバイ
アス方向のみに強化繊維が配列した布帛にすると、布帛
の長さ方向に引っ張ると簡単に強化繊維の方向がずれ、
布帛の幅方向が狭くなるなど、形態が不安定である。こ
のような時には、たとえば０゜方向やまたは９０゜方向
に細いガラス繊維、炭素繊維やポリアラミド繊維などの
補助糸を２０〜１００ｇ／ｍ2 程度配列し、−α゜層、
＋α゜層とステッチ糸で一体化すると形態を安定させる
ことができる。Although the structure of the reinforcing fibers of the fabric shown in FIG. 1 has been described as a four-layer structure of + α ゜ layer / 90 ゜ layer / −α ゜ layer / 0 ゜ layer, the present invention is not limited to this. At least the layer structure may be formed in the direction of the bias (± α ゜) between the −α ゜ layer and the + α ゜ layer with respect to the length direction of the fabric. Also, the order of the layer configuration is -α ゜ / 90 ° / + α ゜ / 0.
The order of ゜ is not limited, and 0 ゜ / −α ゜ / 90
゜ / + α ゜ or 0 ゜ / −α ゜ / + α ゜ / 90 ゜ can be appropriately designed. Further, when the fabric has reinforcing fibers arranged only in the bias direction of the -α ゜ layer and the + α ゜ layer, the direction of the reinforcing fibers easily shifts when the fabric is pulled in the length direction thereof,
The form is unstable, for example, the width direction of the fabric becomes narrow. In such a case, for example, auxiliary yarns such as glass fiber, carbon fiber, and polyaramid fiber which are thin in the 0 ° direction or the 90 ° direction are arranged in an amount of about 20 to 100 g / m 2 , and the -α ゜ layer,
When the + α ゜ layer and the stitch yarn are integrated, the form can be stabilized.
【００３３】なお、バイアス角α゜は、多軸ステッチ布
帛をＦＲＰ成形体の長さ方向に積層し、強化繊維による
剪断補強を効果的に行う観点から４５゜が好ましい。The bias angle α ゜ is preferably 45 ° from the viewpoint that the multiaxial stitch fabric is laminated in the longitudinal direction of the FRP molded body and the shear reinforcement by the reinforcing fibers is effectively performed.
【００３４】本発明の多軸ステッチ布帛を使用したＦＲ
Ｐは、たとえば次のように成形することができる。FR using the multiaxial stitch fabric of the present invention
P can be formed, for example, as follows.
【００３５】ＲＴＭ成形型の雌型に、本発明の多軸ステ
ッチ布帛を所定の方向に、所定の枚数積層し、この上に
雄型を乗せ、型の周囲をパテでシーリングする。つい
で、真空ポンプで型内を真空状態となるよう吸引し、そ
の後樹脂を注入する。次いで、成形型を低融点ポリマー
糸の融点以上になるよう十分に加熱して、注入した樹脂
を硬化させる。成形型を冷却し、脱型する。A predetermined number of the multiaxial stitch fabrics of the present invention are laminated in a predetermined direction on a female die of an RTM molding die, a male die is placed thereon, and the periphery of the die is sealed with a putty. Next, the inside of the mold is sucked by a vacuum pump so as to be in a vacuum state, and then the resin is injected. Next, the mold is sufficiently heated so as to have a temperature equal to or higher than the melting point of the low-melting polymer thread, and the injected resin is cured. Cool the mold and remove it.
【００３６】なお、本発明の成形方法は、上記のＲＴＭ
成形法に限定するものではなく、たとえば多軸ステッチ
布帛を、乾式法では低融点ポリマー糸の融点以下の温度
で加熱含浸、または、湿式法では融点以下の温度で加熱
乾燥することによってプリプレグ化し、これを成形型に
積層し、低融点ポリマー糸の融点以上の温度で加熱、加
圧して成形する方法でもよい。The molding method of the present invention is based on the above RTM.
The method is not limited to the molding method.For example, the multiaxial stitched fabric is prepreg by heating and impregnating at a temperature lower than the melting point of the low-melting polymer yarn in the dry method, or by heating and drying at a temperature lower than the melting point in the wet method, A method in which this is laminated on a mold and heated and pressed at a temperature equal to or higher than the melting point of the low-melting polymer yarn to form it may be used.
【００３７】本発明に用いる樹脂は、エポキシ樹脂、不
飽和ポリエステル樹脂、ビニルエステル樹脂やフェノー
ル樹脂などの熱硬化性樹脂やナイロン樹脂、ＰＢＴ樹
脂、ポリエチレン樹脂、ポリプロピレン樹脂などの熱可
塑性樹脂であってもよい。The resin used in the present invention is a thermosetting resin such as an epoxy resin, an unsaturated polyester resin, a vinyl ester resin or a phenol resin, or a thermoplastic resin such as a nylon resin, a PBT resin, a polyethylene resin or a polypropylene resin. Is also good.
【００３８】図４に、本発明の成形法によって得られる
ＦＲＰ成形体の断面概略図を示したが、型の加熱と同時
に多軸ステッチ布帛も低融点ポリマー糸の融点以上に加
熱されるから、低融点ポリマー糸が溶融し、ＦＲＰ中に
ポリマー糸が存在していた箇所に低融点ポリマー１２が
点在するようになる。また、低融点ポリマーからなるス
テッチ糸が形成していた縫い組織は、ステッチ糸の溶融
によって消滅するので、ステッチ糸による強化繊維の拘
束は解かれ、空隙部Ｂの箇所にも強化繊維が分散し、得
られるＦＲＰの表面は平滑となる。FIG. 4 shows a schematic cross-sectional view of the FRP molded product obtained by the molding method of the present invention. The multiaxial stitched fabric is heated to the melting point of the low-melting polymer yarn simultaneously with heating of the mold. The low-melting-point polymer yarn is melted, and the low-melting-point polymer 12 is scattered in the portion where the polymer yarn was present in the FRP. In addition, the stitched structure formed by the low-melting-point polymer stitch thread disappears due to the melting of the stitch thread, so that the binding of the reinforcing fiber by the stitch thread is released, and the reinforcing fiber is dispersed also in the space B. The surface of the obtained FRP becomes smooth.
【００３９】図５は自動車外板を説明する概略図で、フ
−ド１３、フェンダ−１４、ドア１５、ル−フ１６、ト
ランク・カバー１７などの外板に、本発明の補強用多軸
ステッチ布帛を使用し、樹脂を含浸し、低融点ポリマー
糸の融点以上に加熱成形することによって得られるＦＲ
Ｐ成形体を使用すると、表面が平滑で意匠性に優れ、安
価な自動車外板となる。FIG. 5 is a schematic diagram for explaining an automobile outer panel. The reinforcing multi-axle of the present invention is mounted on outer panels such as a hood 13, a fender 14, a door 15, a roof 16 and a trunk cover 17. FR obtained by using a stitch fabric, impregnating a resin, and heat-molding to a temperature equal to or higher than the melting point of the low-melting polymer yarn.
The use of the P molded body results in an inexpensive automobile outer panel having a smooth surface and excellent design.
【００４０】[0040]
【発明の効果】本発明の補強用多軸ステッチ布帛は低融
点ポリマー糸でステッチ一体化されているから、樹脂を
含浸し、低融点ポリマー糸の融点以上に加熱成形するこ
とによって表面が平滑なＦＲＰ成形体が得られる。As described above, the multiaxial stitching fabric for reinforcement of the present invention is stitch-integrated with a low-melting polymer yarn, so that it is impregnated with a resin and heat-molded to a temperature equal to or higher than the melting point of the low-melting polymer yarn. An FRP molded body is obtained.
【図１】本発明の多軸ステッチ布帛の一例を示す一部切
り欠き概略斜視図である。FIG. 1 is a partially cut-away schematic perspective view showing an example of a multiaxial stitched fabric of the present invention.
【図２】図１のＡ−Ａ´断面拡大概略図である。FIG. 2 is an enlarged schematic cross-sectional view taken along line AA ′ of FIG.
【図３】従来の多軸ステッチ布帛のＦＲＰ成形体の断面
概略図である。FIG. 3 is a schematic cross-sectional view of a conventional FRP molded product of a multiaxial stitch fabric.
【図４】本発明の多軸ステッチ布帛のＦＲＰ成形体の一
例を示す断面概略図である。FIG. 4 is a schematic cross-sectional view showing an example of an FRP molded product of the multiaxial stitched fabric of the present invention.
【図５】自動車外板を説明する概略図である。FIG. 5 is a schematic diagram illustrating an automobile outer panel.
【符号の説明】 １：多軸ステッチ布帛 ２：＋α゜層の強化繊維糸条 ３：９０゜層の強化繊維糸条 ４：−α゜層の強化繊維糸条 ５：０゜層の強化繊維糸条 ６：布帛を形成する＋α゜の強化繊維層 ７：布帛を形成する９０゜の強化繊維層 ８：布帛を形成する−α゜の強化繊維層 ９：布帛を形成する０゜の強化繊維層 １０：ステッチ糸 １１：強化繊維 １２：低融点ポリマー １３：自動車のフ−ド １４：自動車のフェンダ− １５：自動車のドア １６：自動車のル−フ １７：自動車のトランク・カバー イ：布帛の長手方向 Ａ−Ａ´：断面の基準線 Ｂ：空隙部[Description of Signs] 1: Multiaxial stitch fabric 2: Reinforcement fiber yarn of + α ゜ layer 3: Reinforcement fiber yarn of 90 ° layer 4: Reinforcement fiber yarn of -α ゜ layer 5: 0 Reinforcement fiber of 0 layer Thread 6: Reinforcing fiber layer of + α ： forming fabric 7: Reinforcing fiber layer of 90 ° forming fabric 8: Reinforcing fiber layer of -α ゜ forming fabric 9: Reinforcing fiber of 0 ° forming fabric Layer 10: Stitch yarn 11: Reinforcing fiber 12: Low melting point polymer 13: Car hood 14: Car fender 15: Car door 16: Car roof 17: Car trunk cover A: Fabric Longitudinal direction AA ': Reference line of cross section B: Void
───────────────────────────────────────────────────── フロントページの続き Ｆターム(参考） 4F204 AA39 AA41 AD16 AH18 FA01 FB01 FB12 FG02 FN12 FN15 4F205 AA04 AA11 AA25 AA29 AA36 AD16 AH18 HA06 HA08 HA14 HA25 HA33 HA34 HB01 HC05 HC07 HG02 HL16 4L002 AA05 AA06 AA07 AC00 CA01 DA00 EA05 FA06 4L047 AA03 AA21 AA23 AB10 BA24 BD02 CA03 CB09 CC13 ──────────────────────────────────────────────────続 き Continuing on the front page F term (reference) 4F204 AA39 AA41 AD16 AH18 FA01 FB01 FB12 FG02 FN12 FN15 4F205 AA04 AA11 AA25 AA29 AA36 AD16 AH18 HA06 HA08 HA14 HA25 HA33 HA34 HB01 HC05 HC07 HG02 HL16 A05A05 A05 A05 AC05 FA06 4L047 AA03 AA21 AA23 AB10 BA24 BD02 CA03 CB09 CC13
Claims (12)
配列して層構成をなし、前記層の少なくとも２層以上が
交差積層されて積層体をなし、該積層体が低融点ポリマ
ー糸でステッチされて一体化されていることを特徴とす
る補強用多軸ステッチ布帛。1. A layer structure in which a number of reinforcing fiber yarns are arranged in parallel in a sheet form to form a layer structure, and at least two or more of the layers are cross-laminated to form a laminate, wherein the laminate is a low-melting polymer. A multiaxial stitching fabric for reinforcement, which is stitched and integrated with a yarn.
α゜、−α゜の２方向を少なくとも含むものであること
を特徴とする請求項１に記載の補強用多軸ステッチ布
帛。2. The method according to claim 1, wherein the crossing angle is +
2. The multiaxial stitching fabric for reinforcement according to claim 1, including at least two directions of α ゜ and −α ゜. 3.
゜、９０゜の２方向を少なくとも含むものであることを
特徴とする請求項１に記載の補強用多軸ステッチ布帛。3. The crossing angle is 0 with respect to the length direction of the cloth.
The multiaxial stitching fabric for reinforcement according to claim 1, wherein the fabric includes at least two directions of {, 90}.
゜、＋α゜、−α゜の３方向を少なくとも含むものであ
ることを特徴とする請求項１に記載の補強用多軸ステッ
チ布帛。4. The method according to claim 1, wherein the intersection angle is 0 with respect to the length direction of the cloth.
2. The multiaxial stitching fabric for reinforcement according to claim 1, which includes at least three directions of ゜, + α ゜, and −α ゜. 3.
α゜、−α゜、９０゜の３方向を少なくとも含むもので
あることを特徴とする請求項１に記載の補強用多軸ステ
ッチ布帛。5. The method according to claim 1, wherein said crossing angle is +
The multiaxial stitching fabric for reinforcement according to claim 1, wherein the fabric includes at least three directions of α ゜, -α ゜, and 90 °.
゜、＋α゜、−α゜、９０゜の４方向を少なくとも含む
ものであることを特徴とする請求項１に記載の補強用多
軸ステッチ布帛。6. The crossing angle is 0 with respect to the length direction of the cloth.
2. The multiaxial stitching fabric for reinforcement according to claim 1, comprising at least four directions of ゜, + α ゜, −α ゜, and 90 °. 3.
する請求項２、または請求項４ないし６のいずれかに記
載の補強用多軸ステッチ布帛。7. The multiaxial stitching fabric for reinforcement according to claim 2, wherein said angle α ゜ is 45 °.
であることを特徴とする請求項１ないし７のいずれかに
記載の補強用多軸ステッチ布帛。8. The multiaxial stitching fabric for reinforcement according to claim 1, wherein said low melting point polymer yarn is a copolymerized nylon yarn.
糸であることを特徴とする請求項１ないし７のいずれか
に記載の補強用多軸ステッチ布帛。9. The reinforcing multiaxial stitched fabric according to claim 1, wherein said low-melting polymer yarn is a modified polyester yarn.
徴とする請求項１ないし９のいずれかに記載の補強用多
軸ステッチ布帛。10. The multiaxial stitching fabric for reinforcement according to claim 1, wherein said reinforcing fibers are carbon fibers.
補強用多軸ステッチ布帛に樹脂を含浸し、低融点ポリマ
ー糸の融点以上に加熱成形することを特徴とするＦＲＰ
の成形方法。11. An FRP comprising impregnating a resin into the multiaxial stitching fabric for reinforcement according to any one of claims 1 to 10, and heat-molding the cloth to a temperature equal to or higher than the melting point of the low-melting polymer yarn.
Molding method.
られるＦＲＰを用いてなることを特徴とする自動車外
板。12. An automobile outer panel using the FRP obtained by the molding method according to claim 11.
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| JP2001020030A JP4599718B2 (en) | 2001-01-29 | 2001-01-29 | Multiaxial stitch fabric for reinforcement and method for forming FRP |
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| JP2007092232A (en) * | 2005-09-29 | 2007-04-12 | Toray Ind Inc | Preform and method for producing preform |
| WO2008062818A1 (en) | 2006-11-22 | 2008-05-29 | Fukui Prefectural Government | Reinforced thermoplastic-resin multilayer sheet material, process for producing the same, and method of forming molded thermoplastic-resin composite material |
| JP2008265108A (en) * | 2007-04-18 | 2008-11-06 | Toyota Motor Corp | Fiber-reinforced plastic |
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| JP2007504029A (en) * | 2003-05-26 | 2007-03-01 | ユーロコプター・ドイッチェランド・ゲゼルシャフト・ミット・ベシュレンクテル・ハフツング | Manufacturing method for fiber composite parts and intermediate product for the manufacturing method |
| JP2006052633A (en) * | 2004-07-15 | 2006-02-23 | Mitsubishi Kagaku Sanshi Corp | Structure and its reinforcing member and method |
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