JP2012255222A - Fiber bundle sheet comprising reinforcing fibers - Google Patents

Fiber bundle sheet comprising reinforcing fibers Download PDF

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JP2012255222A
JP2012255222A JP2011127615A JP2011127615A JP2012255222A JP 2012255222 A JP2012255222 A JP 2012255222A JP 2011127615 A JP2011127615 A JP 2011127615A JP 2011127615 A JP2011127615 A JP 2011127615A JP 2012255222 A JP2012255222 A JP 2012255222A
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fiber bundle
fiber
support frame
main
sheet
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Mari Kawahara
真梨 河原
Fujio Hori
藤夫 堀
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Toyota Industries Corp
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Toyota Industries Corp
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Priority to JP2011127615A priority Critical patent/JP2012255222A/en
Priority to PCT/JP2012/061895 priority patent/WO2012169308A1/en
Priority to TW101119935A priority patent/TW201303099A/en
Publication of JP2012255222A publication Critical patent/JP2012255222A/en
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    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D25/00—Woven fabrics not otherwise provided for
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/587—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads adhesive; fusible
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/283—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
    • D03D15/44—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads with specific cross-section or surface shape
    • D03D15/46—Flat yarns, e.g. tapes or films
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/02—Reinforcing materials; Prepregs

Abstract

PROBLEM TO BE SOLVED: To provide a fiber bundle sheet comprising reinforcing fibers, which is excellent in shape formability as compared to a unidirectional woven fabric using fusible yarns, so that it is unnecessary to use expensive fusible yarns.SOLUTION: A fiber bundle sheet 11 comprises a fiber bundle layer 13 formed by aligning fiber bundles 12, each comprising a plurality of reinforcing fibers, in one direction. The fiber bundles 12 are joined to each other by lock stitches with a needle thread 14 and a bobbin thread 15 in the direction crossing the alignment direction of the fiber bundles 12, thereby forming the fiber bundle layer 13 into a sheet-like form. The lock stitches are so formed that the bobbin thread 15 extends linearly. The fiber bundle layer 13 has a basis weight of 0.1 kg/mto 2 kg/m. The pitch P of the lock stitches is set to be constant.

Description

本発明は、強化繊維からなる繊維束シートに係り、詳しくは繊維強化複合材料の強化繊維基材として好適に使用され、一方向に配列された繊維束がシート状態で取り扱えるように補助糸により結合された繊維束シートに関する。   The present invention relates to a fiber bundle sheet composed of reinforcing fibers, and more specifically, is suitably used as a reinforcing fiber base material of a fiber reinforced composite material, and is bound by auxiliary yarn so that fiber bundles arranged in one direction can be handled in a sheet state. It is related with the made fiber bundle sheet.

繊維強化複合材料の製造方法として、型内に配置した強化繊維基材に液状の熱硬化性樹脂を注入し、加熱硬化して繊維強化複合材料を得るレジン・トランスファー・モールディング法（ＲＴＭ法）がある。ＲＴＭ法で繊維強化複合材料を製造する場合、強化繊維基材として繊維配列方向が一方向の繊維束層を複数積層するとともに目的とする繊維強化複合材料の形状に賦形した状態で液状の熱硬化性樹脂が注入される。   As a method for producing a fiber reinforced composite material, there is a resin transfer molding method (RTM method) in which a liquid thermosetting resin is injected into a reinforced fiber base disposed in a mold and heat cured to obtain a fiber reinforced composite material. is there. When a fiber reinforced composite material is manufactured by the RTM method, a plurality of fiber bundle layers having a fiber arrangement direction in one direction are laminated as a reinforcing fiber base material, and liquid heat is formed in a state of being formed into the shape of the target fiber reinforced composite material. A curable resin is injected.

繊維配列方向が一方向の繊維束層として、一方向織物（一方向性織物）と呼ばれる織物がある。一方向織物は、経糸に強化繊維として機能する繊維束を使用し、緯糸に強化繊維として機能しないほど細い糸を使用して平織物と同様に織製された織物であり、緯糸は経糸を結合して織物として取り扱える役割を果たす補助糸として機能する。緯糸を細くして経糸のうねりをできるだけ小さくすると、織物としての拘束力がなくなり、結果として織物として成立しなくなる。そのため、緯糸に融着糸を使用し、一方向織物の緯糸を加熱して緯糸と経糸との交差部で緯糸を経糸に融着させて織物としての拘束力を持たせたものがある（例えば、特許文献１参照）。   As a fiber bundle layer in which the fiber arrangement direction is unidirectional, there is a woven fabric called a unidirectional woven fabric (unidirectional woven fabric). A unidirectional fabric is a fabric woven using a fiber bundle that functions as a reinforcing fiber for the warp and a thin thread that does not function as a reinforcing fiber for the weft. And functions as an auxiliary thread that can be handled as a fabric. If the weft is thinned to reduce the warp undulation as much as possible, the binding force as a woven fabric is lost, and as a result, the woven fabric cannot be established. For this reason, a fusion yarn is used as the weft, the weft of the unidirectional fabric is heated, and the weft is fused to the warp at the intersection of the weft and the warp to give the fabric a binding force (for example, , See Patent Document 1).

実開平３−１８１８９号公報Japanese Utility Model Publication No. 3-18189

ところが、特許文献１に開示されたような一方向織物では、経糸と緯糸の交差部が緯糸の融着部で結合されているため賦形性に劣る。また、融着糸は高価なため製造コストが上昇するという問題もある。   However, in the unidirectional woven fabric as disclosed in Patent Document 1, the intersecting portion of the warp and the weft is joined by the fused portion of the weft, so that the formability is inferior. Moreover, since the fused yarn is expensive, there is a problem that the manufacturing cost increases.

本発明は、前記従来の問題に鑑みてなされたものであって、その目的は、融着糸を使用した一方向織物に比べて賦形性に優れ、高価な融着糸を使用する必要がない繊維束シートを提供することにある。   The present invention has been made in view of the above-described conventional problems, and its purpose is to have an excellent formability as compared with a unidirectional fabric using a fused yarn and to use an expensive fused yarn. There is no fiber bundle sheet to provide.

前記の目的を達成するため、請求項１に記載の発明は、複数本の強化繊維である繊維束が一方向に配列された少なくとも１層の繊維束層が、第１糸及び第２糸による前記繊維束の配列方向と交差する方向への本縫いで互いに結合されてシート状に形成されている。   In order to achieve the above-mentioned object, the invention according to claim 1 is characterized in that at least one fiber bundle layer in which fiber bundles that are a plurality of reinforcing fibers are arranged in one direction is composed of a first yarn and a second yarn. They are joined together by a main stitch in a direction crossing the arrangement direction of the fiber bundles to form a sheet.

ここで強化繊維とは、炭素繊維、ガラス繊維、セラミック繊維等の無機繊維またはアラミド繊維、ポリ−ｐ−フェニレンベンゾビスオキサゾール繊維、超高分子量ポリエチレン繊維等の高強度の有機繊維を指す。   Here, the reinforcing fiber refers to an inorganic fiber such as carbon fiber, glass fiber, or ceramic fiber, or high-strength organic fiber such as aramid fiber, poly-p-phenylenebenzobisoxazole fiber, or ultrahigh molecular weight polyethylene fiber.

ここで一方向とは、複数本の繊維束が略並行に揃った方向に配列している場合を指し、繊維束が右側から左側に配向される場合と左側から右側に配向されている場合とを区別しない、例えば、繊維束が折り返し状に配列されている場合を含む。   Here, the one direction refers to a case where a plurality of fiber bundles are arranged in a substantially parallel direction, and the fiber bundle is oriented from the right side to the left side and the case where the fiber bundle is oriented from the left side to the right side. For example, the case where the fiber bundles are arranged in a folded shape is included.

ここで本縫いとは、第１糸及び第２糸の２本の糸を用い、第１糸のループに第２糸が交差する状態となる縫い方を意味し、一般の本縫いでは家庭用ミシンの縫い目のように、縫い目の表裏が同じかつ縫い目構成が１縫い目ごとに独立した縫い方となるが、第１糸がループを形成して折り返し、第２糸が直線状に延びる状態となる縫い方も含む。   Here, the term “sewing” means a sewing method in which two threads of the first thread and the second thread are used, and the second thread intersects the loop of the first thread. Like the seam of the sewing machine, the front and back of the seam are the same and the seam configuration is an independent stitching method for each stitch. However, the first thread forms a loop and turns, and the second thread extends in a straight line. Includes how to sew.

この発明の繊維束シートは、繊維束層を構成する一方向に配列された繊維束が第１糸及び第２糸による本縫いで互いに結合されているため、第１糸及び第２糸で囲まれた部分の繊維束が、融着糸の融着により結合された一方向織物に比べて動き易いため、賦形性に優れる。また、隣り合う本縫い列の間隔を所望の間隔にして本縫いを行うことが容易なため、隣り合う本縫い列の間隔を変更することにより、繊維束層の厚さに対応して適切な賦形性を有する繊維束シートを製造することが、一方向織物に比べて容易になる。また、高価な融着糸を使用する必要がない。   The fiber bundle sheet of this invention is surrounded by the first and second yarns because the fiber bundles arranged in one direction constituting the fiber bundle layer are joined together by the main sewing with the first yarn and the second yarn. Since the fiber bundle in the part is easy to move as compared with the unidirectional fabric bonded by fusing of the fusing yarn, it is excellent in formability. Further, since it is easy to perform the main sewing by setting the interval between the adjacent main sewing rows to a desired interval, it is possible to change the interval between the adjacent main sewing rows to an appropriate value corresponding to the thickness of the fiber bundle layer. It is easier to manufacture a fiber bundle sheet having formability compared to a unidirectional fabric. Moreover, it is not necessary to use an expensive fused yarn.

請求項２に記載の発明は、請求項１に記載の発明において、前記第２糸が直線状に延びる。本発明では、一般の本縫いと異なり、第２糸が直線状に延びる本縫いによって繊維束が結合されているため、この繊維束シートを積層した積層繊維束層を強化繊維基材とした繊維強化複合材料の物性は、第２糸が第１糸と同様に屈曲して互いに交差する本縫いによって繊維束が結合されている場合に比べて良くなる。   The invention according to claim 2 is the invention according to claim 1, wherein the second yarn extends linearly. In the present invention, unlike a general lock stitch, the fiber bundles are joined by lock stitches in which the second thread extends in a straight line. Therefore, a fiber using a laminated fiber bundle layer in which the fiber bundle sheets are laminated as a reinforcing fiber base The physical properties of the reinforced composite material are improved as compared with the case where the fiber bundles are joined by the main stitches where the second yarn is bent in the same manner as the first yarn and intersects each other.

請求項３に記載の発明は、請求項１又は請求項２に記載の発明において、前記繊維束層は目付けが０．１ｋｇ／ｍ２〜２ｋｇ／ｍ２である。繊維束層の目付けは、繊維束の太さが反映され、繊維束の太さがあまり細いと繊維強化複合材料の強化繊維基材として好ましい繊維束シートが得難くなり、繊維束の太さがあまり太くても、繊維強化複合材料の強化繊維基材として好ましい繊維束シートが得難くなる。そのため、繊維束層として目付けを０．１ｋｇ／ｍ２〜２ｋｇ／ｍ２の範囲の中で要求性能に合わせて設定することにより、適切な繊維束シートを得ることができる。 The invention of claim 3 is the invention according to claim 1 or claim 2, wherein the fiber bundle layer basis weight is 0.1kg / m 2 ~2kg / m 2 . The basis weight of the fiber bundle layer reflects the thickness of the fiber bundle, and if the thickness of the fiber bundle is too thin, it becomes difficult to obtain a fiber bundle sheet that is preferable as a reinforcing fiber base material for the fiber-reinforced composite material. Even if it is too thick, it is difficult to obtain a fiber bundle sheet that is preferable as a reinforcing fiber substrate of a fiber-reinforced composite material. Therefore, by setting to suit the required performance of the basis weight as the fiber bundle layer within the range of 0.1kg / m 2 ~2kg / m 2 , it is possible to obtain an appropriate fiber bundle sheet.

請求項４に記載の発明は、請求項１〜請求項３のいずれか一項に記載の発明において、前記本縫いはピッチが一定である。ここで、「本縫いのピッチ」とは、本縫いを構成する上糸の隣り合う折り返し部（屈曲部）の間隔を意味する。この発明では、繊維束シートを製造する際に、本縫いを一定条件で行うことができ、本縫いのピッチを変更する場合に比べて製造が容易になる。   According to a fourth aspect of the present invention, in the invention according to any one of the first to third aspects, the pitch of the main sewing is constant. Here, “the pitch of the main sewing” means an interval between adjacent folded portions (bending portions) of the upper thread constituting the main sewing. In the present invention, when the fiber bundle sheet is manufactured, the main sewing can be performed under a certain condition, and the manufacturing becomes easier as compared with the case where the pitch of the main sewing is changed.

請求項５に記載の発明は、請求項１〜請求項３のいずれか一項に記載の発明において、前記本縫いは、前記繊維束層の幅方向の一端から他端までピッチが一定であるものと、前記繊維束層の幅方向の一端から他端まで小さなピッチの範囲及び大きなピッチの範囲が繰り返されるものとが、前記繊維束層の幅方向と直交する方向に予め設定された間隔で存在する。この発明の繊維束シートでは、繊維束シートを強化繊維基材として使用する場合、繊維強化複合材料の形状にあわせて賦形するのがより容易になる。   The invention according to claim 5 is the invention according to any one of claims 1 to 3, wherein the main stitch has a constant pitch from one end to the other end in the width direction of the fiber bundle layer. And the one in which the range of the small pitch and the range of the large pitch are repeated from one end to the other end in the width direction of the fiber bundle layer at predetermined intervals in a direction orthogonal to the width direction of the fiber bundle layer. Exists. In the fiber bundle sheet of the present invention, when the fiber bundle sheet is used as a reinforcing fiber base, it becomes easier to shape according to the shape of the fiber reinforced composite material.

請求項６に記載の発明は、請求項１〜請求項５のいずれか一項に記載の発明において、前記本縫いはピッチが１．５ｍｍ〜６ｍｍである。本縫いのピッチがあまり小さいと繊維強化複合材料の強化繊維基材として好ましい繊維束シートが得難くなる。また、本縫いのピッチがあまり大きくても、繊維強化複合材料の強化繊維基材として好ましい繊維束シートが得難くなる。そのため、本縫いのピッチを１．５ｍｍ〜６ｍｍの範囲の中で要求性能に合わせて設定することにより、適切な繊維束シートを得ることができる。   The invention according to claim 6 is the invention according to any one of claims 1 to 5, wherein the pitch of the main stitch is 1.5 mm to 6 mm. If the pitch of the main stitch is too small, it is difficult to obtain a fiber bundle sheet that is preferable as a reinforcing fiber base material for the fiber-reinforced composite material. Moreover, even if the pitch of the main stitch is too large, it is difficult to obtain a fiber bundle sheet that is preferable as a reinforcing fiber base material for the fiber-reinforced composite material. Therefore, an appropriate fiber bundle sheet can be obtained by setting the pitch of the main stitch in accordance with the required performance within the range of 1.5 mm to 6 mm.

請求項７に記載の発明は、請求項１〜請求項６のいずれか一項に記載の発明において、繊維束の配列方向が異なる複数層の前記繊維束層が前記本縫いで互いに結合されてシート状に形成されている。繊維強化複合材料として高性能が要求される用途では、強化繊維基材として繊維配列方向が一方向の繊維束層を、その配列方向が異なるように複数積層して擬似等方性の積層繊維束層を構成したもの（積層強化材）が使用される。この発明では、繊維束の配列方向が異なる複数層の前記繊維束層が前記本縫いで互いに結合されてシート状に形成されているため、各繊維束層に対応する１層の繊維束シートをそれぞれ製造した後、積層する場合に比べて工数を低減することができる。   The invention according to claim 7 is the invention according to any one of claims 1 to 6, wherein the plurality of fiber bundle layers having different fiber bundle arrangement directions are joined to each other by the main stitching. It is formed in a sheet shape. In applications where high performance is required as a fiber reinforced composite material, a quasi-isotropic laminated fiber bundle is obtained by laminating a plurality of fiber bundle layers having a single fiber arrangement direction as the reinforcing fiber base material so that the arrangement directions are different. What constitutes the layer (laminate reinforcement) is used. In this invention, since the plurality of fiber bundle layers having different fiber bundle arrangement directions are joined to each other by the main stitch and formed into a sheet shape, one fiber bundle sheet corresponding to each fiber bundle layer is formed. Manufacture can be reduced after each manufacture compared with the case of laminating.

本発明によれば、融着糸を使用した一方向織物に比べて賦形性に優れ、高価な融着糸を使用する必要がない強化繊維からなる繊維束シートを提供することができる。   ADVANTAGE OF THE INVENTION According to this invention, the fiber bundle sheet | seat which consists of a reinforced fiber which is excellent in the shapeability compared with the unidirectional fabric using a fused yarn, and does not need to use an expensive fused yarn can be provided.

第１の実施形態を示し、（ａ）は繊維束シートの模式斜視図、（ｂ）は（ａ）のＡ−Ａ線における模式断面図。The 1st Embodiment is shown, (a) is a schematic perspective view of a fiber bundle sheet | seat, (b) is a schematic cross section in the AA of (a). 支持枠、繊維束層、押さえ部材、針等の位置関係を示す模式平面図。The schematic plan view which shows positional relationships, such as a support frame, a fiber bundle layer, a pressing member, and a needle | hook. 繊維束層を支持する構成と針等との位置関係を示す模式斜視図。The model perspective view which shows the positional relationship with the structure, needle | hook, etc. which support a fiber bundle layer. 本縫いの状態を示す模式斜視図。The model perspective view which shows the state of the main sewing. （ａ）は第２の実施形態の支持枠、繊維束層、押さえ部材、針等の位置関係を示す模式平面図、（ｂ）は本縫い時の針の移動方向を示す模式図。(A) is a schematic top view which shows the positional relationship of the support frame of the 2nd Embodiment, a fiber bundle layer, a pressing member, a needle | hook, etc., (b) is a schematic diagram which shows the movement direction of the needle | hook at the time of main sewing. （ａ）は別の実施形態における本縫い時の針の移動方向を示す模式図、（ｂ）は押さえ部材及び針の関係を示す概略斜視図。(A) is a schematic diagram which shows the movement direction of the needle | hook at the time of the main sewing in another embodiment, (b) is a schematic perspective view which shows the relationship between a pressing member and a needle | hook. （ａ）は別の実施形態における繊維束シートの模式斜視図、（ｂ）は（ａ）のＢ−Ｂ線における模式断面図。(A) is a schematic perspective view of the fiber bundle sheet | seat in another embodiment, (b) is a schematic cross section in the BB line of (a). （ａ）は別の実施形態における繊維束シートの模式斜視図、（ｂ）は（ａ）のＣ−Ｃ線における模式断面図。(A) is a schematic perspective view of the fiber bundle sheet | seat in another embodiment, (b) is a schematic cross section in CC line of (a). 別の実施形態の繊維束シートの模式断面図。The schematic cross section of the fiber bundle sheet | seat of another embodiment.

（第１の実施形態）
以下、本発明を具体化した第１の実施形態を図１〜図４にしたがって説明する。
図１（ａ），（ｂ）に示すように、繊維束シート１１は、複数本の強化繊維である繊維束１２が一方向に配列された１層の繊維束層１３が、第１糸としての上糸１４及び第２糸としての下糸１５による本縫いで互いに結合されてシート状に形成されている。図１（ｂ）に示すように、本縫いは下糸１５が直線状に延びるように行われている。下糸１５の張力を上糸１４の張力より大きくすることにより、下糸１５が直線状に延びる状態の本縫い構造が形成される。下糸１５が直線状に延びるとは、下糸１５が真っ直ぐ延びる状態に限らず、下糸１５が多少湾曲する状態で延びる場合も含む。本縫いはピッチＰが一定で、ピッチＰは繊維束１２の幅と略同じに設定されている。また、本縫いは上糸１４が繊維束１２の幅方向のほぼ両端部で折り返すようにピッチＰが設定されている。なお、図では繊維束１２と上糸１４との位置関係を分かり易くするため、隣り合う繊維束１２同士が離れた状態に図示しているが、実際は隣り合う繊維束１２の幅方向の端部同士が重なった状態に配列されている。 (First embodiment)
Hereinafter, a first embodiment of the present invention will be described with reference to FIGS.
As shown in FIGS. 1A and 1B, the fiber bundle sheet 11 includes a single fiber bundle layer 13 in which fiber bundles 12 that are a plurality of reinforcing fibers are arranged in one direction. The upper thread 14 and the lower thread 15 as the second thread are joined together by a main sewing to form a sheet. As shown in FIG. 1B, the main sewing is performed such that the lower thread 15 extends linearly. By making the tension of the lower thread 15 greater than the tension of the upper thread 14, a lock stitch structure in which the lower thread 15 extends linearly is formed. That the lower thread 15 extends linearly includes not only the state where the lower thread 15 extends straight, but also includes the case where the lower thread 15 extends in a slightly curved state. In the main sewing, the pitch P is constant, and the pitch P is set to be substantially the same as the width of the fiber bundle 12. Further, the pitch P is set so that the upper thread 14 is folded back at substantially both ends in the width direction of the fiber bundle 12 in the main sewing. In the figure, in order to make the positional relationship between the fiber bundle 12 and the upper thread 14 easier to understand, the adjacent fiber bundles 12 are illustrated as being separated from each other. They are arranged in a state where they overlap each other.

繊維束１２としては軽量で破断強度が高く、弾性率の大きい繊維、例えば炭素繊維の無撚りの繊維束（トウ）が使用されている。炭素繊維束は細い繊維が数百〜数万本束ねられて１本の繊維束が構成されており、要求性能に適した繊維の本数の繊維束が選択される。繊維束１２は開繊された状態で一方向に配列されて繊維束層１３を構成している。「開繊される」とは、繊維束１２を構成する繊維間隔が拡げられて繊維束１２が扁平な状態になることを意味する。なお、繊維束１２をなす強化繊維としては、炭素繊維に限らず、例えば、ガラス繊維やセラミック繊維等の無機繊維、あるいは、アラミド繊維、ポリ−ｐ−フェニレンベンゾビスオキサゾール繊維、超高分子量ポリエチレン繊維等の高強度の有機繊維であってもよく、要求性能に応じて適宜選択される。例えば、繊維強化複合材料に対する剛性・強度の要求性能が高い場合は、炭素繊維が好ましい。繊維束１２に安価なガラス繊維を用いると低コストとなる。繊維束層１３は目付けが０．１ｋｇ／ｍ２〜２ｋｇ／ｍ２の範囲の中で要求性能に合わせて適宜設定され、繊維束１２としては設定された目付の繊維束層１３を得るのに適した太さのものが使用される。本縫いはピッチが１．５ｍｍ〜６ｍｍである。 As the fiber bundle 12, a fiber that is lightweight, has high breaking strength, and has a large elastic modulus, for example, a carbon fiber non-twisted fiber bundle (tow) is used. In the carbon fiber bundle, hundreds to tens of thousands of thin fibers are bundled to form one fiber bundle, and the fiber bundle having the number of fibers suitable for the required performance is selected. The fiber bundles 12 are arranged in one direction in the opened state to constitute a fiber bundle layer 13. “Opened” means that the fiber bundle 12 is flattened by expanding the interval between the fibers constituting the fiber bundle 12. The reinforcing fiber forming the fiber bundle 12 is not limited to carbon fiber, but, for example, inorganic fiber such as glass fiber or ceramic fiber, aramid fiber, poly-p-phenylenebenzobisoxazole fiber, ultrahigh molecular weight polyethylene fiber Such high-strength organic fibers may be selected as appropriate according to the required performance. For example, when the required performance of rigidity and strength for the fiber reinforced composite material is high, carbon fiber is preferable. If an inexpensive glass fiber is used for the fiber bundle 12, the cost is reduced. The fiber bundle layer 13 having a basis weight is set as appropriate in accordance with required performance within the range of 0.1kg / m 2 ~2kg / m 2 , to obtain a fiber bundle layer 13 having a basis weight which is set in the fiber bundle 12 A suitable thickness is used. The main stitch has a pitch of 1.5 mm to 6 mm.

上糸１４及び下糸１５としてはナイロン、ポリエステル等の有機繊維製の糸が使用されている。上糸１４及び下糸１５は、繊維束シート１１を繊維強化複合材料の強化繊維基材として使用する状態において強化繊維基材として機能する必要はないため、細い方が良い。   As the upper thread 14 and the lower thread 15, threads made of organic fibers such as nylon and polyester are used. The upper thread 14 and the lower thread 15 do not need to function as a reinforcing fiber base in a state where the fiber bundle sheet 11 is used as a reinforcing fiber base of the fiber reinforced composite material, and therefore the thinner one is preferable.

前記のように構成された繊維束シート１１は、繊維束層１３を構成する一方向に配列された繊維束１２が上糸１４及び下糸１５による本縫いで互いに結合されているため、上糸１４及び下糸１５で囲まれた部分の繊維束１２が、融着糸の融着により結合された一方向織物に比べて動き易いため、賦形性に優れる。また、隣り合う本縫い列の間隔を所望の間隔にして本縫いを行うことが容易なため、隣り合う本縫い列の間隔を変更することにより、繊維束層１３の厚さに対応して適切な賦形性を有する繊維束シート１１を製造することが、一方向織物に比べて容易になる。   In the fiber bundle sheet 11 configured as described above, since the fiber bundles 12 arranged in one direction constituting the fiber bundle layer 13 are joined to each other by the main sewing with the upper thread 14 and the lower thread 15, the upper thread Since the fiber bundle 12 of the part surrounded by 14 and the lower thread | yarn 15 is easy to move compared with the one-way textile fabric couple | bonded by melt | fusion of the fused thread, it is excellent in shaping property. In addition, since it is easy to perform the main sewing by setting the interval between the adjacent main sewing rows to a desired interval, the interval between the adjacent main sewing rows can be changed appropriately according to the thickness of the fiber bundle layer 13. It is easier to manufacture the fiber bundle sheet 11 having a good shapeability as compared with a unidirectional fabric.

次に前記のように構成された繊維束シート１１の製造方法を説明する。
製造装置は一般的な本縫いミシンと同様な方式で本縫いを行う。しかし、本縫いミシンと異なり、図２に示すように、繊維束層１３全体を支持する支持枠２１と、支持枠２１を支持枠２１に支持された繊維束層１３と共に繊維束１２の延びる方向及び幅方向へ移動させる図示しない支持枠駆動機構と、支持枠２１に支持された繊維束層１３を所定の位置で保持する一対の繊維束押さえ部２２，２３とを備えている。支持枠２１にはその長手方向両側に、ピン２４が一定間隔で取り外し可能に固定されている。また、支持枠２１は、支持枠駆動機構に対して取り外し可能に構成されており、支持枠２１に対して繊維束層１３を支持する作業は、支持枠２１を支持枠駆動機構から取り外した状態で行われる。 Next, the manufacturing method of the fiber bundle sheet 11 comprised as mentioned above is demonstrated.
The manufacturing apparatus performs the main sewing in the same manner as a general main sewing machine. However, unlike a lockstitch sewing machine, as shown in FIG. 2, the support frame 21 that supports the entire fiber bundle layer 13 and the direction in which the fiber bundle 12 extends together with the fiber bundle layer 13 that supports the support frame 21 on the support frame 21. And a support frame driving mechanism (not shown) that moves in the width direction, and a pair of fiber bundle pressing portions 22 and 23 that hold the fiber bundle layer 13 supported by the support frame 21 at a predetermined position. Pins 24 are detachably fixed to the support frame 21 at regular intervals on both sides in the longitudinal direction. Further, the support frame 21 is configured to be removable from the support frame drive mechanism, and the operation of supporting the fiber bundle layer 13 with respect to the support frame 21 is a state in which the support frame 21 is removed from the support frame drive mechanism. Done in

図２及び図３に示すように、繊維束押さえ部２２，２３は、本縫い針２５及び本縫いミシンの布押さえに相当する押さえ部材２６を挟んで左右両側に配置可能に設けられている。図３に示すように、繊維束押さえ部２２，２３は、それぞれ繊維束１２を同時に上下方向から挟持可能に、上側押さえ部２２ａ，２３ａ及び下側押さえ部２２ｂ，２３ｂを備えている。繊維束押さえ部２２，２３は、上側押さえ部２２ａ，２３ａが繊維束１２の上面を押圧し、下側押さえ部２２ｂ，２３ｂが繊維束１２の下面を押圧した状態で繊維束１２を挟持する。また、本縫い針２５の下方には釜２７が設けられている。なお、図示の都合上、上側押さえ部２２ａ，２３ａの形状は図２及び図３で一致していない。   As shown in FIGS. 2 and 3, the fiber bundle pressers 22 and 23 are provided so as to be arranged on both the left and right sides with a presser member 26 corresponding to a cloth presser of the main sewing needle 25 and the main sewing machine interposed therebetween. As shown in FIG. 3, the fiber bundle pressers 22 and 23 include upper pressers 22 a and 23 a and lower pressers 22 b and 23 b so that the fiber bundle 12 can be sandwiched from above and below at the same time. The fiber bundle pressing portions 22 and 23 hold the fiber bundle 12 with the upper pressing portions 22 a and 23 a pressing the upper surface of the fiber bundle 12 and the lower pressing portions 22 b and 23 b pressing the lower surface of the fiber bundle 12. A hook 27 is provided below the main sewing needle 25. For convenience of illustration, the shapes of the upper pressing portions 22a and 23a do not match in FIGS.

上側押さえ部２２ａ，２３ａは、その下面が支持枠２１に支持された全ての繊維束１２に同時に弱く接した状態で、支持枠２１の所定位置にボルト２８により固定可能に構成されている。図２において左側に配置される上側押さえ部２２ａには、一列の本縫いが完了した状態で本縫い針２５及び押さえ部材２６と対応する部分が、支持枠２１と共に上側押さえ部２２ａ，２３ａが図３の右側へ移動する際に本縫い針２５及び押さえ部材２６と干渉しないように上側が切り欠かれて切り欠き部２２ｃが形成されている。図２において右側に配置される上側押さえ部２３ａには、一列の本縫いが完了した状態で本縫い針２５及び押さえ部材２６と対応する部分が、支持枠２１と共に上側押さえ部２２ａ，２３ａが図３の左側へ移動する際に本縫い針２５及び押さえ部材２６と干渉しないように上側が切り欠かれて切り欠き部２３ｃが形成されている。   The upper pressing portions 22a and 23a are configured to be fixable to predetermined positions of the support frame 21 by bolts 28 in a state where the lower surfaces thereof are in weak contact with all the fiber bundles 12 supported by the support frame 21 simultaneously. In the upper pressing portion 22a arranged on the left side in FIG. 2, the portions corresponding to the main sewing needle 25 and the pressing member 26 in a state where one row of main sewing has been completed are illustrated with the upper pressing portions 22a and 23a together with the support frame 21. The upper side is notched so as not to interfere with the main sewing needle 25 and the pressing member 26 when moving to the right side of FIG. In the upper pressing portion 23 a arranged on the right side in FIG. 2, the portions corresponding to the main sewing needle 25 and the pressing member 26 in a state where one row of main sewing has been completed are illustrated with the upper pressing portions 22 a and 23 a together with the support frame 21. The upper side is notched so as not to interfere with the main sewing needle 25 and the pressing member 26 when moving to the left side of FIG.

下側押さえ部２２ｂ，２３ｂは、その上面が上側押さえ部２２ａ，２３ａの下面と協働して繊維束１２を押圧する挟持位置と、挟持位置の下方の待機位置とに図示しない駆動機構により移動可能に構成されている。また、下側押さえ部２２ｂ，２３ｂは、その駆動機構と共に、支持枠駆動機構により支持枠２１と一体的に移動可能に構成されている。また、下側押さえ部２２ｂ，２３ｂは、支持枠２１と一体的に支持枠２１の長手方向に移動される際に釜２７と干渉しないように、上側押さえ部２２ａ，２３ａより短く形成されている。下側押さえ部２２ｂ，２３ｂの駆動機構は、支持枠２１がその長手方向に移動されるときには下側押さえ部２２ｂ，２３ｂを待機位置に配置し、本縫い時には下側押さえ部２２ｂ，２３ｂを挟持位置に配置した状態で保持する。   The lower pressing portions 22b and 23b are moved by a driving mechanism (not shown) between a holding position where the upper surface of the lower pressing portions 22b and 23b presses the fiber bundle 12 in cooperation with the lower surface of the upper pressing portions 22a and 23a, and a standby position below the holding position. It is configured to be possible. The lower pressing portions 22b and 23b are configured to be movable together with the support frame 21 by the support frame drive mechanism together with the drive mechanism. The lower pressing portions 22b and 23b are formed shorter than the upper pressing portions 22a and 23a so as not to interfere with the shuttle 27 when moved in the longitudinal direction of the support frame 21 integrally with the support frame 21. . The driving mechanism of the lower pressing portions 22b and 23b is arranged such that the lower pressing portions 22b and 23b are arranged at the standby position when the support frame 21 is moved in the longitudinal direction, and the lower pressing portions 22b and 23b are clamped at the time of sewing. Hold in place.

支持枠駆動機構は本縫いが行われる際、支持枠２１及び繊維束押さえ部２２，２３を本縫い針２５の上下動に同期して支持枠２１の幅方向に本縫いのピッチＰで間欠的に移動させる。支持枠駆動機構は、１列の本縫いが完了すると、支持枠２１及び繊維束押さえ部２２，２３を設定された本縫い列の間隔分、長手方向に移動させる。その後、支持枠２１及び繊維束押さえ部２２，２３をその列の本縫い開始位置が本縫い針２５と対向する位置まで幅方向に移動させる。   When the main frame is sewn, the support frame driving mechanism intermittently moves the support frame 21 and the fiber bundle pressing portions 22 and 23 in the width direction of the support frame 21 at the pitch P of the main sewing in synchronization with the vertical movement of the main sewing needle 25. Move to. The support frame driving mechanism moves the support frame 21 and the fiber bundle presser portions 22 and 23 in the longitudinal direction by the set interval between the main sewing rows when one row of the main sewing is completed. Thereafter, the support frame 21 and the fiber bundle pressing portions 22 and 23 are moved in the width direction to a position where the main sewing start position of the row faces the main sewing needle 25.

次に前記のように構成された製造装置による繊維束シート１１の製造手順を説明する。先ず、支持枠２１を支持枠駆動機構から取り外し、かつ支持枠２１から上側押さえ部２２ａ，２３ａを取り外した状態で、支持枠２１に対して、繊維束１２を複数本の繊維束が一方向に配列された状態で１層の繊維束層１３を構成するように固定する。具体的には、繊維束１２の一端を支持枠２１のピン２４が固定された近くに接着剤で固着し、繊維束１２を開繊しつつ支持枠２１の長手方向に移動させ、ピン２４の部分でピン２４を巻くように折り返して反対側に移動させるとともに、再び次のピン２４の部分でピン２４を巻くように折り返す操作を繰り返して所定の幅の繊維束層１３を構成する。そして、繊維束１２の他端を支持枠２１に接着剤で固定した後、上側押さえ部２２ａ，２３ａを支持枠２１に取り付ける。   Next, the manufacturing procedure of the fiber bundle sheet 11 by the manufacturing apparatus configured as described above will be described. First, in a state where the support frame 21 is removed from the support frame drive mechanism and the upper pressing portions 22a and 23a are removed from the support frame 21, a plurality of fiber bundles are arranged in one direction with respect to the support frame 21. It fixes so that the one fiber bundle layer 13 may be comprised in the arranged state. Specifically, one end of the fiber bundle 12 is fixed with an adhesive near the pin 24 of the support frame 21 fixed, and the fiber bundle 12 is moved in the longitudinal direction of the support frame 21 while opening the fiber bundle 12. The fiber bundle layer 13 having a predetermined width is formed by repeating the operation of folding back the pin 24 so that the pin 24 is wound around the portion and moving it to the opposite side and then folding back the pin 24 around the next pin 24 again. Then, after fixing the other end of the fiber bundle 12 to the support frame 21 with an adhesive, the upper pressing portions 22 a and 23 a are attached to the support frame 21.

次に支持枠２１を支持枠駆動機構に取り付ける。そして、図２に実線で示すように、繊維束押さえ部２２，２３、本縫い針２５及び押さえ部材２６が繊維束層１３の本縫い開始位置に位置する状態に支持枠２１を配置した状態から本縫いを開始する。図４に示すように、本縫いは、一般の本縫いミシンと同様に、上糸１４が針孔に挿通された状態で本縫い針２５が上下動するとともに、釜２７内に保持されたボビン２９に巻かれた下糸１５が釜２７の作用により上糸１４のループに通されることにより形成される。なお、図４では釜２７の図示を省略している。そして、この実施形態では下糸１５が真っ直ぐに延びる状態で本縫いが形成されるように、即ち下糸の張力が上糸１４の張力より大きな状態になるように上糸１４の張力と、下糸１５の張力とが調整された状態で本縫いが行われる。上糸１４及び下糸１５の張力調整は公知の構成で行われる。   Next, the support frame 21 is attached to the support frame drive mechanism. Then, as shown by a solid line in FIG. 2, from the state in which the support frame 21 is arranged in a state where the fiber bundle pressing portions 22 and 23, the main sewing needle 25 and the pressing member 26 are located at the main sewing start position of the fiber bundle layer 13. Start lockstitching. As shown in FIG. 4, the main sewing is performed in the same manner as a general main sewing machine. The main sewing needle 25 moves up and down while the upper thread 14 is inserted into the needle hole, and the bobbin held in the hook 27 is shown in FIG. The lower thread 15 wound around the thread 29 is passed through the loop of the upper thread 14 by the action of the hook 27. In FIG. 4, the hook 27 is not shown. In this embodiment, the tension of the upper thread 14 is adjusted so that the main stitch is formed with the lower thread 15 extending straight, that is, the tension of the lower thread is larger than the tension of the upper thread 14. The main sewing is performed in a state where the tension of the thread 15 is adjusted. The tension adjustment of the upper thread 14 and the lower thread 15 is performed with a known configuration.

支持枠２１は、本縫いが１列分完了するまで、本縫い針２５の上下動に同期して幅方向に１ピッチずつ間欠的に移動される。上側押さえ部２２ａ，２３ａ及び下側押さえ部２２ｂ，２３ｂは挟持位置に保持された状態で支持枠２１と一体に移動される。繊維束層１３は、押さえ部材２６に接触した状態で支持枠２１の移動に伴って押さえ部材２６に対して相対移動するが、繊維束１２が上側押さえ部２２ａ，２３ａ及び下側押さえ部２２ｂ，２３ｂにより挟持された状態に保持されるため、繊維束１２が弛んだりせずに、本縫いが連続して円滑に行われる。   The support frame 21 is intermittently moved by one pitch in the width direction in synchronization with the vertical movement of the main sewing needle 25 until the main sewing is completed for one row. The upper pressing portions 22a and 23a and the lower pressing portions 22b and 23b are moved integrally with the support frame 21 while being held at the holding positions. The fiber bundle layer 13 moves relative to the pressing member 26 in accordance with the movement of the support frame 21 while being in contact with the pressing member 26. However, the fiber bundle 12 has the upper pressing portions 22a and 23a and the lower pressing portion 22b, Since the fiber bundle 12 is not slackened, the main stitching is continuously and smoothly performed because the fiber bundle 12 is held in a state of being sandwiched by 23b.

１列分の本縫いが完了すると、本縫い針２５及び押さえ部材２６が繊維束層１３と係合しない待機位置に配置され、かつ下側押さえ部２２ｂ，２３ｂが待機位置に配置されて繊維束層１３の挟持が解除される。その状態で、支持枠２１がその長手方向に本縫い列の間隔分だけ移動される際に、上側押さえ部２２ａが本縫い針２５及び押さえ部材２６と干渉しないように、図２に鎖線で示すように、支持枠２１は上側押さえ部２２ａ，２３ａの切り欠き部２２ｃ，２３ｃが本縫い針２５及び押さえ部材２６と干渉しない位置まで支持枠２１の幅方向へ移動される。そして、支持枠２１がその長手方向に本縫い列の間隔分だけ移動される。このとき、下側押さえ部２２ｂ，２３ｂは釜２７と干渉しない位置に配置されているため、支持枠２１は支障なく移動することができる。   When the main sewing for one row is completed, the main sewing needle 25 and the presser member 26 are arranged at a standby position where they are not engaged with the fiber bundle layer 13, and the lower pressers 22b and 23b are arranged at the standby position so that the fiber bundle The sandwiching of the layer 13 is released. In this state, when the support frame 21 is moved in the longitudinal direction by the interval of the main sewing row, the upper pressing portion 22a is shown by a chain line in FIG. 2 so as not to interfere with the main sewing needle 25 and the pressing member 26. As described above, the support frame 21 is moved in the width direction of the support frame 21 until the notches 22c and 23c of the upper pressing portions 22a and 23a do not interfere with the main sewing needle 25 and the pressing member 26. Then, the support frame 21 is moved in the longitudinal direction by the interval of the main sewing row. At this time, since the lower pressing portions 22b and 23b are arranged at positions that do not interfere with the shuttle 27, the support frame 21 can move without any trouble.

次に、支持枠２１は、新たに本縫いを行う箇所（列）の本縫い開始位置が本縫い針２５と対向する位置まで、繊維束押さえ部２２，２３と共に支持枠２１の幅方向に移動される。そして、その位置で下側押さえ部２２ｂ，２３ｂが挟持位置に移動され、押さえ部材２６が繊維束層１３を押圧する位置に配置された状態で、本縫いが開始される。以下、同様の手順が繰り返されて繊維束層１３全体に本縫いが形成される。繊維束層１３全体に本縫いが形成された後、繊維束層１３を支持枠２１から取り外し、不要部分を除去して繊維束シート１１が完成する。   Next, the support frame 21 moves in the width direction of the support frame 21 together with the fiber bundle pressing portions 22 and 23 until the position at which the main sewing start of the place (row) where new main sewing is performed is opposed to the main sewing needle 25. Is done. Then, at the position, the lower pressing portions 22b and 23b are moved to the clamping position, and the main sewing is started in a state where the pressing member 26 is disposed at a position where the fiber bundle layer 13 is pressed. Thereafter, the same procedure is repeated to form the main stitch on the entire fiber bundle layer 13. After the main stitch is formed on the entire fiber bundle layer 13, the fiber bundle layer 13 is removed from the support frame 21, and unnecessary portions are removed to complete the fiber bundle sheet 11.

前記のように構成された繊維束シート１１は、製造すべき繊維強化複合材料の厚さに対応する枚数積層された積層繊維束層の状態で樹脂の含浸、硬化を行って繊維強化複合材料が製造される。樹脂の含浸、硬化には、例えば、ＲＴＭ法が採用される。ＲＴＭ法では、樹脂含浸用型内に積層繊維束層を配置した状態で、型内に液状の熱硬化性樹脂を注入し、加熱硬化して繊維強化複合材料を得る。熱硬化性樹脂として、例えばエポキシ樹脂が使用される。積層繊維束層を擬似等方性に構成する場合は、複数の繊維束シート１１をその配列方向が異なるように積層して積層繊維束層構成する。   The fiber bundle sheet 11 configured as described above is impregnated and cured with a resin in the state of a laminated fiber bundle layer corresponding to the thickness of the fiber reinforced composite material to be manufactured. Manufactured. For the impregnation and curing of the resin, for example, the RTM method is employed. In the RTM method, a liquid thermosetting resin is injected into a mold and the fiber reinforced composite material is obtained by injecting the liquid thermosetting resin into the mold in a state where the laminated fiber bundle layer is disposed in the resin impregnation mold. For example, an epoxy resin is used as the thermosetting resin. When the laminated fiber bundle layer is configured to be pseudo-isotropic, a plurality of fiber bundle sheets 11 are laminated so that their arrangement directions are different to form a laminated fiber bundle layer.

この実施形態によれば、以下に示す効果を得ることができる。
（１）繊維束シート１１は、複数本の強化繊維である繊維束１２が一方向に配列された１層の繊維束層１３が、上糸１４（第１糸）及び下糸１５（第２糸）による繊維束１２の配列方向と交差する方向への本縫いで互いに結合されてシート状に形成されている。したがって、融着糸を使用した一方向織物に比べて賦形性に優れ、高価な融着糸を使用する必要がない。このため、製造コストをその分、安くすることができる。 According to this embodiment, the following effects can be obtained.
(1) The fiber bundle sheet 11 includes a single fiber bundle layer 13 in which fiber bundles 12 that are a plurality of reinforcing fibers are arranged in one direction, an upper yarn 14 (first yarn) and a lower yarn 15 (second yarn). Are formed into a sheet by being joined to each other by main sewing in a direction intersecting with the arrangement direction of the fiber bundles 12 by the thread). Therefore, it is excellent in formability compared with the unidirectional fabric using the fused yarn, and it is not necessary to use an expensive fused yarn. For this reason, the manufacturing cost can be reduced accordingly.

（２）本縫いは下糸１５が直線状に延びる。したがって、この繊維束シート１１を積層した積層繊維束層を強化繊維基材とした繊維強化複合材料の物性は、下糸１５が上糸１４と同様に屈曲して互いに交差する本縫いによって繊維束１２が結合されている場合に比べて良くなる。   (2) In the main sewing, the lower thread 15 extends linearly. Therefore, the physical properties of the fiber reinforced composite material using the laminated fiber bundle layer in which the fiber bundle sheets 11 are laminated as the reinforcing fiber base material are as follows. Compared to the case where 12 are combined.

（３）繊維束層１３は目付けが０．１ｋｇ／ｍ２〜２ｋｇ／ｍ２である。目付けは、繊維束１２の太さが反映され、繊維束１２の太さがあまり細いと繊維強化複合材料の強化繊維基材として好ましい繊維束シート１１が得難くなり、繊維束１２の太さがあまり太くても、繊維強化複合材料の強化繊維基材として好ましい繊維束シート１１が得難くなる。そのため、繊維束層として目付けを０．１ｋｇ／ｍ２〜２ｋｇ／ｍ２の範囲の中で要求性能に合わせて設定することにより、適切な繊維束シート１１を得ることができる。 (3) the fiber bundle layer 13 having a basis weight is 0.1kg / m 2 ~2kg / m 2 . The basis weight reflects the thickness of the fiber bundle 12, and if the thickness of the fiber bundle 12 is too thin, it becomes difficult to obtain a fiber bundle sheet 11 that is preferable as a reinforcing fiber base of the fiber-reinforced composite material. Even if it is too thick, it becomes difficult to obtain a fiber bundle sheet 11 that is preferable as a reinforcing fiber base material for a fiber-reinforced composite material. Therefore, by setting to suit the required performance of the basis weight as the fiber bundle layer within the range of 0.1kg / m 2 ~2kg / m 2 , it is possible to obtain an appropriate fiber bundle sheet 11.

（４）本縫いはピッチＰが一定である。したがって、繊維束シート１１を製造する際に、本縫いを一定条件で行うことができ、本縫いのピッチＰを変更する場合に比べて製造が容易になる。   (4) The pitch P is constant in the main sewing. Therefore, when the fiber bundle sheet 11 is manufactured, the main sewing can be performed under a certain condition, and the manufacturing becomes easier as compared with the case where the pitch P of the main sewing is changed.

（５）本縫いはピッチが１．５ｍｍ〜６ｍｍである。本縫いのピッチがあまり小さいと繊維強化複合材料の強化繊維基材として好ましい繊維束シート１１が得難くなる。また、本縫いのピッチがあまり大きくても、繊維強化複合材料の強化繊維基材として好ましい繊維束シート１１が得難くなる。そのため、本縫いのピッチを１．５ｍｍ〜６ｍｍの範囲の中で要求性能に合わせて設定することにより、適切な繊維束シート１１を得ることができる。   (5) The pitch of the main stitch is 1.5 mm to 6 mm. If the pitch of the main stitch is too small, it is difficult to obtain a fiber bundle sheet 11 that is preferable as a reinforcing fiber base material for the fiber-reinforced composite material. Moreover, even if the pitch of the main stitch is too large, it is difficult to obtain the fiber bundle sheet 11 that is preferable as the reinforcing fiber base material of the fiber-reinforced composite material. Therefore, the appropriate fiber bundle sheet | seat 11 can be obtained by setting the pitch of this stitching according to a required performance in the range of 1.5 mm-6 mm.

（６）本縫いは上糸１４が繊維束１２の幅方向の両端部で折り返すようにピッチＰが設定されている。したがって、上糸１４が繊維束１２の幅方向の中間部で折り返す場合に比べて繊維束１２が動き易いため、賦形性に優れる。   (6) The pitch P is set so that the upper thread 14 is folded back at both ends in the width direction of the fiber bundle 12 in the main sewing. Therefore, since the fiber bundle 12 is easy to move as compared with the case where the upper thread 14 is folded back at the intermediate portion in the width direction of the fiber bundle 12, the shapeability is excellent.

（第２の実施形態）
次に第２の実施形態を図５にしたがって説明する。この実施形態では、繊維束シートの製造装置の構成が第１の実施形態と異なっている。第１の実施形態と同一部分は同一符号を付して詳しい説明を省略する。 (Second Embodiment)
Next, a second embodiment will be described with reference to FIG. In this embodiment, the configuration of the fiber bundle sheet manufacturing apparatus is different from that of the first embodiment. The same parts as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

支持枠２１はその長手方向にのみ支持枠駆動機構により移動可能に構成されている。一方、本縫い針２５、押さえ部材２６及び釜２７は、本縫いが行われる際、本縫い針２５が繊維束層１３と係合しない状態、即ち上昇位置に配置された状態において、図示しない移動装置により、同時に支持枠２１の幅方向に本縫いのピッチＰで間欠的に移動されるようになっている。また、本縫い針２５、押さえ部材２６及び釜２７は、１列の本縫いが完了すると、本縫い針２５、押さえ部材２６及び釜２７が繊維束層１３と係合しない状態において、移動装置により、同時に次の列の本縫い開始位置まで移動されるようになっている。   The support frame 21 is configured to be movable only in the longitudinal direction by the support frame drive mechanism. On the other hand, the main sewing needle 25, the pressing member 26, and the shuttle 27 are moved in a state where the main sewing needle 25 is not engaged with the fiber bundle layer 13 when the main sewing is performed, that is, in a state where the main sewing needle 25 is disposed at the raised position. At the same time, the apparatus is intermittently moved in the width direction of the support frame 21 at the pitch P of the main sewing. Further, the main sewing needle 25, the pressing member 26, and the hook 27 are moved by the moving device when the main sewing needle 25, the pressing member 26, and the hook 27 are not engaged with the fiber bundle layer 13 when one row of the main sewing is completed. At the same time, the sewing machine is moved to the main sewing start position of the next row.

上側押さえ部２２ａ，２３ａは、下側押さえ部２２ｂ，２３ｂと同じ長さに、即ち図５（ａ）に示すように、支持枠２１の枠内において繊維束層１３と係合可能な長さに形成されている。そして、上側押さえ部２２ａ，２３ａは、その下面が下側押さえ部２２ｂ，２３ｂの上面と協働して繊維束１２を押圧する挟持位置と、挟持位置の上方の待機位置とに図示しない駆動機構により移動可能に構成されている。また、前記実施形態と異なり、上側押さえ部２２ａ，２３ａ及び下側押さえ部２２ｂ，２３ｂは、支持枠２１と一体的に移動せず、所定の位置において挟持位置と待機位置とに移動配置され、支持枠２１が長手方向に移動される際は待機位置に配置されるようになっている。   The upper pressing portions 22a and 23a have the same length as the lower pressing portions 22b and 23b, that is, a length that can be engaged with the fiber bundle layer 13 within the frame of the support frame 21, as shown in FIG. Is formed. The upper pressing portions 22a and 23a are driven at a clamping position where the lower surface cooperates with the upper surfaces of the lower pressing portions 22b and 23b to press the fiber bundle 12, and a standby mechanism (not shown) above the clamping position. Is configured to be movable. Further, unlike the above-described embodiment, the upper pressing portions 22a and 23a and the lower pressing portions 22b and 23b do not move integrally with the support frame 21, but are moved and arranged between the holding position and the standby position at a predetermined position. When the support frame 21 is moved in the longitudinal direction, the support frame 21 is arranged at the standby position.

この実施形態では、図５（ａ）に実線で示すように、本縫い針２５及び押さえ部材２６が繊維束層１３の幅方向の一端側に配置され、上側押さえ部２２ａ，２３ａ及び下側押さえ部２２ｂ，２３ｂが挟持位置に配置された状態から本縫いが開始される。そして、本縫い針２５、押さえ部材２６及び釜２７が、本縫いのピッチＰで間欠的に繊維束層１３の幅方向の他端側に向かって移動される。そして、本縫い針２５及び押さえ部材２６が図５（ａ）に二点鎖線で示す位置まで移動すると、１列分の本縫いが完了する。   In this embodiment, as shown by a solid line in FIG. 5A, the main sewing needle 25 and the pressing member 26 are arranged on one end side in the width direction of the fiber bundle layer 13, and the upper pressing portions 22a and 23a and the lower pressing portion are arranged. The main sewing is started from the state where the portions 22b and 23b are arranged at the clamping positions. Then, the main sewing needle 25, the pressing member 26, and the shuttle 27 are intermittently moved toward the other end side in the width direction of the fiber bundle layer 13 at the pitch P of the main sewing. When the main sewing needle 25 and the pressing member 26 move to the position indicated by the two-dot chain line in FIG. 5A, the main sewing for one row is completed.

次に本縫い針２５及び押さえ部材２６が繊維束１２と係合しない上昇位置に配置され、上側押さえ部２２ａ，２３ａ及び下側押さえ部２２ｂ，２３ｂが待機位置に配置された状態で、支持枠２１がその長手方向、図５（ａ）の左方へ本縫い列の間隔分だけ移動される。次に上側押さえ部２２ａ，２３ａ及び下側押さえ部２２ｂ，２３ｂが挟持位置に配置された後、本縫い針２５、押さえ部材２６及び釜２７は、次の列の本縫い開始位置まで移動される。そして、その位置で押さえ部材２６が繊維束層１３と警固する押さえ位置に配置された状態で、本縫いが開始される。以下、同様の手順が繰り返されて、図５（ｂ）に矢印で示すように、繊維束層１３の長手方向の一端側（図では左端側）で、かつ幅方向の一端側（図では上端側）から開始された本縫いが、１列ずつ順に繊維束層１３に形成されて繊維束層１３全体に本縫いが形成される。   Next, the main sewing needle 25 and the pressing member 26 are arranged at the raised position where they do not engage with the fiber bundle 12, and the upper holding parts 22a, 23a and the lower holding parts 22b, 23b are arranged at the standby position. 21 is moved in the longitudinal direction, to the left in FIG. Next, after the upper presser portions 22a and 23a and the lower presser portions 22b and 23b are arranged in the clamping position, the main sewing needle 25, the presser member 26, and the shuttle 27 are moved to the main sewing start position of the next row. . Then, the main sewing is started in a state in which the pressing member 26 is disposed at the pressing position where the pressing member 26 and the fiber bundle layer 13 are secured. Thereafter, the same procedure is repeated, and as indicated by an arrow in FIG. 5B, one end side in the longitudinal direction of the fiber bundle layer 13 (left end side in the figure) and one end side in the width direction (upper end in the figure). The main stitches started from the side) are formed in the fiber bundle layer 13 one by one in order, and the main stitches are formed on the entire fiber bundle layer 13.

この第２の実施形態によれば、第１の実施形態の（１）〜（６）と同じ効果に加えて以下の効果を得ることができる。
（７）上側押さえ部２２ａ，２３ａ及び下側押さえ部２２ｂ，２３ｂは、所定の位置において挟持位置と待機位置とに移動配置される構成のため、上側押さえ部２２ａ，２３ａ及び下側押さえ部２２ｂ，２３ｂを支持枠２１と一体に移動させる構成が不要になる。また、支持枠２１に上側押さえ部２２ａ，２３ａを固定する作業や、固定用のボルト２８が不要になるとともに、切り欠き部２２ｃ，２３ｃが不要になる。 According to this 2nd Embodiment, in addition to the same effect as (1)-(6) of 1st Embodiment, the following effects can be acquired.
(7) Since the upper pressing portions 22a and 23a and the lower pressing portions 22b and 23b are arranged to be moved between the holding position and the standby position at predetermined positions, the upper pressing portions 22a and 23a and the lower pressing portion 22b are arranged. , 23b can be moved integrally with the support frame 21. Further, the work of fixing the upper pressing portions 22a and 23a to the support frame 21 and the fixing bolts 28 are unnecessary, and the notches 22c and 23c are unnecessary.

実施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。
○ 繊維束シート１１の製造装置は、本縫い針２５、押さえ部材２６及び釜２７が支持枠２１の幅方向の一端側の本縫い開始位置に配置された状態から本縫いを開始して、支持枠２１の幅方向の他端側へ向かって本縫い針２５、押さえ部材２６及び釜２７が移動して１列の本縫いを行う構成に限らない。例えば、図６（ａ）に示すように、本縫い針２５、押さえ部材２６及び釜２７が支持枠２１の幅方向の一端側から他端側へ向かって移動して１列の本縫いが完了すると、次の列の本縫いは、本縫い針２５、押さえ部材２６及び釜２７が支持枠２１の幅方向の他端側から一端側へ向かって移動して本縫いを行う構成にしてもよい。この場合、押さえ部材２６は、繊維束層１３に係合した状態で一方向に円滑に移動可能な形状ではなく、反対方向へも繊維束層１３に係合した状態で円滑に移動可能な形状に形成される。例えば、図６（ｂ）に示すように、押さえ部材２６は円筒状に形成されるとともに、本縫い針２５が円筒状の押さえ部材２６の内部で移動する構成にする。押さえ部材２６の下端は、繊維束層１３と係合した状態で繊維束層１３に対して相対移動する際の摩擦抵抗が小さくなるように面取りがされている。この構成は、第１の実施形態のように支持枠２１が幅方向に移動する構成の場合に対しても、第２の実施形態のように本縫い針２５、押さえ部材２６及び釜２７が支持枠２１の幅方向に移動する構成に対しても適用することができる。 The embodiment is not limited to the above, and may be embodied as follows, for example.
○ The fiber bundle sheet 11 manufacturing apparatus starts the main sewing from the state in which the main sewing needle 25, the pressing member 26, and the shuttle 27 are arranged at the main sewing start position on one end side in the width direction of the support frame 21, and supports The present invention is not limited to the configuration in which the main sewing needle 25, the pressing member 26, and the shuttle 27 move toward the other end side in the width direction of the frame 21 to perform one row of main sewing. For example, as shown in FIG. 6A, the main sewing needle 25, the pressing member 26, and the shuttle 27 move from one end side in the width direction of the support frame 21 toward the other end side to complete one row of main sewing. Then, the main sewing of the next row may be configured such that the main sewing needle 25, the pressing member 26, and the shuttle 27 move from the other end side in the width direction of the support frame 21 toward one end side to perform the main sewing. . In this case, the pressing member 26 does not have a shape that can be smoothly moved in one direction while being engaged with the fiber bundle layer 13, but can be smoothly moved while being engaged with the fiber bundle layer 13 in the opposite direction. Formed. For example, as shown in FIG. 6B, the pressing member 26 is formed in a cylindrical shape, and the main sewing needle 25 is configured to move inside the cylindrical pressing member 26. The lower end of the pressing member 26 is chamfered so as to reduce the frictional resistance when moving relative to the fiber bundle layer 13 while being engaged with the fiber bundle layer 13. In this configuration, even when the support frame 21 moves in the width direction as in the first embodiment, the main sewing needle 25, the pressing member 26, and the shuttle 27 are supported as in the second embodiment. The present invention can also be applied to a configuration that moves in the width direction of the frame 21.

○ 繊維束シート１１は、図７（ａ），（ｂ）に示すように、本縫いのピッチＰは一定で、隣り合う本縫いのライン同士で上糸１４の折り返し位置が半ピッチずれている構成としてもよい。   ○ In the fiber bundle sheet 11, as shown in FIGS. 7A and 7B, the pitch P of the main sewing is constant, and the return position of the upper thread 14 is shifted by a half pitch between the adjacent main sewing lines. It is good also as a structure.

○ 繊維束シート１１は、図８（ａ），（ｂ）に示すように、本縫いとして、繊維束層１３の幅方向の一端から他端までピッチＰが一定であるものと、繊維束層１３の幅方向の一端から他端まで小さなピッチの範囲及び大きなピッチの範囲が繰り返されるものとが、繊維束層１３の幅方向と直交する方向に予め設定された間隔で存在する構成としてもよい。即ち、賦形しやすいように、部分的にスティッチ（縫合部）をなくすようにしてもよい。この場合、大きなピッチの範囲が小さなピッチの範囲に比べて、繊維束シート１１の賦形性が高くなり、繊維強化複合材料の形状に合わせて大きなピッチの範囲と小さなピッチの範囲とを設定することにより、繊維束シート１１がより適正な賦形性を備えたものとなる。従来技術の融着糸を用いた一方向織物ではこのように部分的に繊維束１２の結合を無くすことはできない。   As shown in FIGS. 8 (a) and 8 (b), the fiber bundle sheet 11 has a constant pitch P from one end to the other end in the width direction of the fiber bundle layer 13, as shown in FIGS. A structure in which a small pitch range and a large pitch range are repeated from one end to the other end in the width direction of 13 may exist at a predetermined interval in a direction orthogonal to the width direction of the fiber bundle layer 13. . That is, the stitches (stitched portions) may be partially eliminated so that shaping is easy. In this case, the formability of the fiber bundle sheet 11 is higher in the large pitch range than in the small pitch range, and the large pitch range and the small pitch range are set according to the shape of the fiber reinforced composite material. As a result, the fiber bundle sheet 11 has a more appropriate shapeability. In the unidirectional woven fabric using the fusion yarn of the prior art, the binding of the fiber bundles 12 cannot be partially eliminated.

○ 融着糸を用いた一方向織物として、全ての緯糸に融着糸を使用する代わりに、一部の緯糸に融着糸を使用するとともに、残りの緯糸に融着糸ではない糸を使用して一方向織物を織製することも考えられる。この場合、全ての緯糸に融着糸を使用した場合に比べて賦形性は向上する。   ○ As a unidirectional fabric using fused yarns, instead of using fused yarns for all wefts, use fused yarns for some wefts and non-fused yarns for the remaining wefts. It is also possible to weave a unidirectional fabric. In this case, the formability is improved as compared with the case where fused yarns are used for all the wefts.

○ 本縫いは、下糸１５が真っ直ぐに延びる構成に限らず、図９に示すように、一般的な本縫いのように上糸１４及び下糸１５が繊維束１２の厚さ方向の略中央で折り返す構成、即ち縫い目の表裏が同じかつ縫い目構成が１縫い目ごとに独立した縫い方としてもよい。   ○ The main stitching is not limited to the configuration in which the lower thread 15 extends straight, but the upper thread 14 and the lower thread 15 are substantially in the center in the thickness direction of the fiber bundle 12 as shown in FIG. In other words, the stitches may be folded back, i.e., the front and back of the seam may be the same and the stitch structure may be an independent stitch for each stitch.

○ 繊維束層１３を支持する構成は、繊維束１２を支持枠２１に固定されたピン２４で折り返すように配列した状態で支持する構成に限らない。例えば、支持枠２１の長手方向両側の枠部に開繊された繊維束１２の各端部を接着で固定して、支持枠２１に繊維束層１３を支持してもよい。   The configuration for supporting the fiber bundle layer 13 is not limited to the configuration for supporting the fiber bundle 12 in a state of being arranged so as to be folded back by the pins 24 fixed to the support frame 21. For example, the fiber bundle layer 13 may be supported on the support frame 21 by fixing each end of the fiber bundle 12 opened to the frame portions on both sides in the longitudinal direction of the support frame 21 by adhesion.

○ 繊維束層１３を支持する構成は、繊維束１２の両端を支持枠２１で支持する構成に限らない。例えば、本縫いで結合すべき繊維束層１３が長いと支持枠２１が大きくなって装置全体が大型化する。本縫いで結合すべき繊維束層１３が長い場合でも装置全体の大型化を抑制する構成として、開繊された繊維束１２を回転駆動可能な一対のロール間に支持する構成がある。開繊された繊維束１２を回転駆動可能な一対のロール間に支持する構成とした場合は、１列の本縫いが完了したときに、支持枠２１を長手方向に移動させて繊維束層１３の次の本縫いを行う位置を本縫い針２５等と対応させる代わりに、ロールを回転させて対応することができる。そのため、支持枠２１を長手方向に移動させる構成が不要になり、繊維束層１３が長い場合でも装置全体の大型化を抑制することができ、装置の設置スペースを小さくすることができる。   The configuration for supporting the fiber bundle layer 13 is not limited to the configuration in which both ends of the fiber bundle 12 are supported by the support frame 21. For example, if the fiber bundle layer 13 to be joined by the main sewing is long, the support frame 21 becomes large and the entire apparatus becomes large. As a configuration for suppressing the enlargement of the entire apparatus even when the fiber bundle layer 13 to be joined by the main sewing is long, there is a configuration in which the opened fiber bundle 12 is supported between a pair of rolls that can be rotationally driven. In the case where the opened fiber bundle 12 is supported between a pair of rolls that can be rotationally driven, the support frame 21 is moved in the longitudinal direction when one row of main stitches is completed, and the fiber bundle layer 13 is moved. Instead of making the next main sewing position corresponding to the main sewing needle 25 and the like, the roll can be rotated to correspond. Therefore, the structure which moves the support frame 21 to a longitudinal direction becomes unnecessary, and when the fiber bundle layer 13 is long, the enlargement of the whole apparatus can be suppressed and the installation space of an apparatus can be made small.

○ 繊維束シート１１は、複数本の繊維束１２が一方向に配列された少なくとも１層の繊維束層１３が上糸１４及び下糸１５による本縫いで互いに結合されてシート状に形成されていればよく、繊維束層１３は１層に限らない。例えば、各繊維束層１３の繊維束１２の配列方向が異なるように積層された積層繊維束層を上糸１４及び下糸１５による本縫いで結合した構成としてもよい。また、複数の繊維束層１３を各繊維束層１３の繊維束１２の配列方向が同じになるように積層した状態で、上糸１４及び下糸１５による本縫いにより結合してもよい。   The fiber bundle sheet 11 is formed into a sheet shape in which at least one fiber bundle layer 13 in which a plurality of fiber bundles 12 are arranged in one direction is joined to each other by main sewing with an upper thread 14 and a lower thread 15. The fiber bundle layer 13 is not limited to one layer. For example, a configuration may be adopted in which laminated fiber bundle layers that are laminated so that the arrangement direction of the fiber bundles 12 of each fiber bundle layer 13 are different are joined by main stitching with the upper thread 14 and the lower thread 15. In addition, a plurality of fiber bundle layers 13 may be joined by main stitching with the upper thread 14 and the lower thread 15 in a state where the fiber bundle layers 13 are stacked so that the arrangement directions of the fiber bundles 12 are the same.

○ 上糸１４及び下糸１５として有機繊維製の糸に限らず、ガラス繊維や炭素繊維あるいはセラミック繊維等の無機繊維を使用してもよい。しかし、無機繊維は有機繊維に比べて曲率の大きな曲げに弱いため、有機繊維の方が好ましい。   The upper yarn 14 and the lower yarn 15 are not limited to organic fiber yarns, and inorganic fibers such as glass fibers, carbon fibers, or ceramic fibers may be used. However, since inorganic fibers are weaker to bending with a large curvature than organic fibers, organic fibers are preferred.

○ 繊維束シート１１を製造する際、本縫い開始位置を繊維束層１３の長手方向の左端側ではなく、右端側にしてもよい。   When the fiber bundle sheet 11 is manufactured, the main sewing start position may be the right end side instead of the left end side in the longitudinal direction of the fiber bundle layer 13.

Ｐ…ピッチ、１１…繊維束シート、１２…繊維束、１３…繊維束層、１４…第１糸としての上糸、１５…第２糸としての下糸。   P ... pitch, 11 ... fiber bundle sheet, 12 ... fiber bundle, 13 ... fiber bundle layer, 14 ... upper thread as the first thread, 15 ... lower thread as the second thread.

Claims (7)

複数本の強化繊維である繊維束が一方向に配列された少なくとも１層の繊維束層が、第１糸及び第２糸による前記繊維束の配列方向と交差する方向への本縫いで互いに結合されてシート状に形成されていることを特徴とする繊維束シート。   At least one fiber bundle layer in which fiber bundles that are a plurality of reinforcing fibers are arranged in one direction is bonded to each other by main stitching in a direction intersecting the arrangement direction of the fiber bundle by the first yarn and the second yarn. The fiber bundle sheet is formed into a sheet shape. 前記第２糸が直線状に延びることを特徴とする請求項１に記載の繊維束シート。   The fiber bundle sheet according to claim 1, wherein the second yarn extends linearly. 前記繊維束層は目付けが０．１ｋｇ／ｍ２〜２ｋｇ／ｍ２である請求項１又は請求項２に記載の繊維束シート。 The fiber bundle sheet according to claim 1 or 2 , wherein the fiber bundle layer has a basis weight of 0.1 kg / m 2 to 2 kg / m 2 . 前記本縫いはピッチが一定である請求項１〜請求項３のいずれか一項に記載の繊維束シート。   The fiber bundle sheet according to any one of claims 1 to 3, wherein the pitch of the main stitch is constant. 前記本縫いは、前記繊維束層の幅方向の一端から他端までピッチが一定であるものと、前記繊維束層の幅方向の一端から他端まで小さなピッチの範囲及び大きなピッチの範囲が繰り返されるものとが、前記繊維束層の幅方向と直交する方向に予め設定された間隔で存在する請求項１〜請求項３のいずれか一項に記載の繊維束シート。   The main stitch has a constant pitch from one end to the other end in the width direction of the fiber bundle layer, and a small pitch range and a large pitch range from one end to the other end in the width direction of the fiber bundle layer. The fiber bundle sheet as described in any one of Claims 1-3 which exists in the space | interval preset in the direction orthogonal to the width direction of the said fiber bundle layer. 前記本縫いはピッチが１．５ｍｍ〜６ｍｍである請求項１〜請求項５のいずれか一項に記載の繊維束シート。   The fiber bundle sheet according to any one of claims 1 to 5, wherein the main stitch has a pitch of 1.5 mm to 6 mm. 繊維束の配列方向が異なる複数層の前記繊維束層が前記本縫いで互いに結合されてシート状に形成されている請求項１〜請求項６のいずれか一項に記載の繊維束シート。   The fiber bundle sheet according to any one of claims 1 to 6, wherein a plurality of the fiber bundle layers having different fiber bundle arrangement directions are joined to each other by the main sewing and formed into a sheet shape.
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