JP5552655B2 - Preform of fiber reinforced composite material and method for producing the same - Google Patents
Preform of fiber reinforced composite material and method for producing the same Download PDFInfo
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- JP5552655B2 JP5552655B2 JP2009226832A JP2009226832A JP5552655B2 JP 5552655 B2 JP5552655 B2 JP 5552655B2 JP 2009226832 A JP2009226832 A JP 2009226832A JP 2009226832 A JP2009226832 A JP 2009226832A JP 5552655 B2 JP5552655 B2 JP 5552655B2
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- 239000003733 fiber-reinforced composite Substances 0.000 title claims description 21
- 238000004519 manufacturing process Methods 0.000 title claims description 12
- 239000000835 fiber Substances 0.000 claims description 314
- 239000011230 binding agent Substances 0.000 claims description 165
- 239000012783 reinforcing fiber Substances 0.000 claims description 61
- 238000007493 shaping process Methods 0.000 claims description 38
- 239000002759 woven fabric Substances 0.000 claims description 32
- 238000005452 bending Methods 0.000 claims description 18
- 238000009941 weaving Methods 0.000 claims description 13
- 238000010030 laminating Methods 0.000 claims description 10
- 238000003475 lamination Methods 0.000 claims description 5
- 229920005989 resin Polymers 0.000 description 32
- 239000011347 resin Substances 0.000 description 32
- 239000004744 fabric Substances 0.000 description 17
- 238000005470 impregnation Methods 0.000 description 16
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- 238000004804 winding Methods 0.000 description 7
- 238000010586 diagram Methods 0.000 description 6
- 229920000049 Carbon (fiber) Polymers 0.000 description 5
- 239000004917 carbon fiber Substances 0.000 description 5
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- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 5
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- 239000002131 composite material Substances 0.000 description 2
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- 239000003365 glass fiber Substances 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
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- 229920001169 thermoplastic Polymers 0.000 description 2
- ICXAPFWGVRTEKV-UHFFFAOYSA-N 2-[4-(1,3-benzoxazol-2-yl)phenyl]-1,3-benzoxazole Chemical compound C1=CC=C2OC(C3=CC=C(C=C3)C=3OC4=CC=CC=C4N=3)=NC2=C1 ICXAPFWGVRTEKV-UHFFFAOYSA-N 0.000 description 1
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- 239000002241 glass-ceramic Substances 0.000 description 1
- 239000012784 inorganic fiber Substances 0.000 description 1
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Description
本発明は、繊維強化複合材料のプリフォーム及びその製造方法に係り、詳しくは曲げ部を有するプリフォームを使用する繊維強化複合材料のプリフォーム及びその製造方法に関する。 The present invention relates to a preform of a fiber reinforced composite material and a manufacturing method thereof, and more particularly to a preform of a fiber reinforced composite material using a preform having a bent portion and a manufacturing method thereof.
繊維強化複合材料の製造方法として、例えば、ＲＴＭ（Resin Transfer Molding）法のように、予め所望の形状に賦形されたプリフォームを成形型内に配置した状態で、成形型内に注入孔から樹脂を注入してプリフォームに樹脂を含浸硬化させる方法がある。補強材（補強繊維）としてプリフォームを使用する場合は、プリフォームを取り扱う際や樹脂注入の際に形態が変形し易い。また、プリフォームをシート状の補強二次元繊維基材を積層して形成した場合には積層状態が変わってしまう問題もある。 As a method for producing a fiber-reinforced composite material, for example, a preform shaped into a desired shape in advance is placed in the mold as in the RTM (Resin Transfer Molding) method. There is a method in which a resin is injected and the preform is impregnated and cured. When a preform is used as a reinforcing material (reinforcing fiber), the shape is easily deformed when the preform is handled or when resin is injected. Further, when the preform is formed by laminating a sheet-like reinforcing two-dimensional fiber base material, there is a problem that the laminated state changes.
前記の問題を改善するため、実質的に編み構造からなる補強繊維三次元プリフォームを、バインダ用ポリマーからなるスプリットフィルム状、目の粗い布状又は繊維状のバインダ成分で接着・補強したプリフォームが提案されている（特許文献１参照）。特許文献１には、補強部位として、シート状形態のプリフォームの片面、両面あるいは注入口付近の特に変形し易いところなど、目的と成形条件特に注入速度により好適なところを選択できるとしている。 In order to improve the above-mentioned problem, a preform in which a reinforcing fiber three-dimensional preform substantially composed of a knitted structure is bonded and reinforced with a split film, coarse cloth or fibrous binder component made of a binder polymer. Has been proposed (see Patent Document 1). Patent Document 1 states that a reinforcing part can be selected in accordance with the purpose and molding conditions, particularly the injection speed, such as one side, both sides of the sheet-shaped preform, or a part that is particularly easily deformed near the injection port.
また、プリフォームを、経糸及び緯糸で構成された補強繊維織物基材が積層された構成として、経糸及び緯糸の少なくとも一方に、熱可塑性ポリマーを線状に、かつ連続又は不連続に付着させて、前記補強繊維織物基材同士を接合一体化することが提案されている（特許文献２参照）。特許文献２には、熱可塑性ポリマーが経糸に螺旋状に巻き付くように連続して付着された補強繊維織物基材も開示されている。 Further, the preform is formed by laminating a reinforcing fiber woven fabric base material composed of warp and weft, and a thermoplastic polymer is linearly and continuously or discontinuously attached to at least one of the warp and weft. It has been proposed that the reinforcing fiber fabric base materials are joined and integrated (see Patent Document 2). Patent Document 2 also discloses a reinforcing fiber woven fabric base material in which a thermoplastic polymer is continuously attached so as to be spirally wound around a warp.
ところが、特許文献１においては、シート状形態以外の、曲げ部を有するプリフォームについては何ら考慮がなされていない。曲げ部を有するプリフォームを形成するため、シート状（平板状）のプリフォームを賦形型で賦形した後にそのプリフォームを樹脂含浸用の成形型内に配置して樹脂含浸を行う際、曲げ部の外側部分（曲率半径の大きな部分）と成形型の面との間に隙間が生じる状態になる。その結果、繊維強化複合材料は曲げ部の外側部分におけるマトリックス樹脂量が多くなり、その部分の強度が低下するという問題がある。また、曲げ部を有するプリフォームは、プリフォームを取り扱う場合に、曲げ部やその近傍が変形し易いという問題もある。しかし、特許文献２においても、これらの問題に関しては配慮がなされていない。 However, in Patent Document 1, no consideration is given to a preform having a bent portion other than the sheet-like form. In order to form a preform having a bent portion, after forming a sheet-like (flat plate-like) preform with a shaping mold and placing the preform in a molding mold for resin impregnation , a state in which a gap is formed between the outer portion of the bent portion (large portion of the radius of curvature) and the surface of the formed shape type. As a result , the fiber reinforced composite material has a problem that the amount of the matrix resin in the outer portion of the bent portion increases, and the strength of the portion decreases. In addition, a preform having a bent portion has a problem that the bent portion and its vicinity are easily deformed when the preform is handled. However, in Patent Document 2, no consideration is given to these problems.
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、曲げ部を有するプリフォームを取り扱う場合に曲げ部やその近傍が変形し難く、そのプリフォームを使用した繊維強化複合材料の曲げ部における強度低下を抑制することができる繊維強化複合材料のプリフォーム及びその製造方法を提供することにある。 The present invention has been made in view of the above-mentioned conventional problems, and the object thereof is to reinforce the fiber reinforced using the preform, when the preform having the bent portion is handled, the bent portion and the vicinity thereof are not easily deformed. An object of the present invention is to provide a preform of a fiber reinforced composite material that can suppress a decrease in strength at a bending portion of the composite material, and a method for manufacturing the same.
前記の目的を達成するため、請求項１に記載の発明は、繊維強化複合材料のプリフォームであって、前記プリフォームは、連続繊維からなる繊維基材が、曲げ部と平面部とが連続する立体的な形状に形成されるとともに、前記繊維基材はバインダにより繊維が互いに接合されており、前記曲げ部のバインダ量が他の部分のバインダ量より多い。ここで、「繊維基材」とは、平織物、綾織物等の織物、組紐あるいは編み物のように複数の糸あるいは繊維束が交差する状態で平面状に結合された繊維基材や、複数の糸あるいは繊維束が一方向に配列されて平面状に結合された繊維基材、さらにはブレーディング等により製造される三次元繊維基材を意味する。 In order to achieve the above object, the invention according to claim 1 is a preform of a fiber reinforced composite material, wherein the preform has a fiber base made of continuous fibers, and a bent portion and a flat portion are continuous. The fiber base material is bonded to each other by a binder, and the amount of the binder in the bent portion is larger than the amount of the binder in other portions. Here, the “fiber base material” refers to a fiber base material in which a plurality of yarns or fiber bundles intersect in a plane state, such as a plain woven fabric, a twill woven fabric, a braided string, or a knitted fabric, It means a fiber base material in which yarns or fiber bundles are arranged in one direction and bonded in a plane, and further a three-dimensional fiber base material manufactured by braiding or the like.
この発明では、繊維基材を構成する繊維はバインダにより互いに接合されているため、曲げ部を有する立体的な形状に賦形されたプリフォームを搬送したり成形型内に配置したりするなどの取り扱いの際に、繊維基材を構成する繊維同士のずれが防止されるとともに曲げ部やその近傍がとくに変形し難い。また、繊維基材を賦形型で賦形して曲げ部を有するプリフォームを形成する際、繊維基材の曲げ部となる部分のバインダ量が他の部分のバインダ量より多いため、賦形後の曲げ部の形状安定性が増し、曲げ部の外側部分（曲率半径の大きな部分）と成形型の面との間に隙間が生じる状態にならない。そのため、プリフォームを樹脂含浸用の成形型内に配置して樹脂含浸を行った場合、繊維強化複合材料の曲げ部の外側部分におけるマトリックス樹脂量が多くなることに起因してその部分即ち曲げ部の強度が低下するということが抑制される。 In this invention, since the fibers constituting the fiber base material are bonded to each other by the binder, the preform shaped into a three-dimensional shape having a bent portion is transported or placed in the mold. During handling, the fibers constituting the fiber base material are prevented from shifting from each other, and the bent portion and its vicinity are particularly difficult to deform. In addition, when forming a preform having a bent part by shaping the fiber base with a shaping mold, the amount of binder in the part that becomes the bent part of the fiber base is larger than the amount of binder in the other part. The shape stability of the subsequent bent portion is increased, and a gap is not generated between the outer portion of the bent portion (the portion having a large radius of curvature) and the surface of the mold. Therefore, when a preform is placed in a mold for resin impregnation and resin impregnation is performed, the portion, that is, the bent portion, is caused by an increase in the amount of matrix resin in the outer portion of the bent portion of the fiber reinforced composite material. It is suppressed that the intensity | strength of this falls.
また、請求項１に記載の発明は、前記繊維基材は、連続繊維からなる繊維束の外側にバインダ繊維が螺旋状に巻き付けられた強化繊維で織られた織物を積層して構成され、前記曲げ部となる部分に使用される前記強化繊維のバインダ繊維の目付が他の部分に使用される前記強化繊維より大きい。 The invention of claim 1, prior Symbol fiber base material, binder fibers are constituted by laminating fabric woven with reinforcement fibers wound helically on the outside of the fiber bundle of continuous fibers, The basis weight of the binder fiber of the reinforcing fiber used in the portion to be the bent portion is larger than that of the reinforcing fiber used in the other portion.
この発明では、繊維基材が織物の積層体で構成され、曲げ部となる部分に配置される強化繊維と、他の部分に配置される強化繊維としてバインダ繊維の目付が目的の値に設定されたものを使用することで、曲げ部のバインダ量や他の部分のバインダ量を目的の値にすることができる。したがって、繊維基材を形成した後に、粉状、粒状あるいは繊維状のバインダを繊維基材の表面に結合させた構成に比較して、製造が簡単になる。 In this invention, the fiber base is composed of a laminate of woven fabric, and the basis weight of the binder fiber is set to a target value as the reinforcing fiber disposed in the portion that becomes the bending portion and the reinforcing fiber disposed in the other portion. By using a slab, the amount of the binder in the bent portion and the amount of the binder in other portions can be set to the target values. Therefore, after forming the fiber base material, the manufacturing is simplified as compared with a configuration in which a powdery, granular or fibrous binder is bonded to the surface of the fiber base material.
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、前記繊維基材は、前記プリフォームを構成する全層で同じ範囲に高バインダ付加部が形成されている。曲げ部の外側部分と成形型との隙間を生じさせないとの観点では、プリフォームは曲げ部のバインダ量が、少なくとも外側部分において他の部分のバインダ量より多く形成されていればよく、プリフォームを構成する全ての厚さで、曲げ部のバインダ量が他の部分のバインダ量より多く形成されている必要はない。しかし、バインダ量が異なる分布の複数種の織物（、具体的には、曲げ部と他の部分とでバインダ量の異なるものと、バインダ量が同じものの二種類の織物）を用いてプリフォームを形成する場合は、複数種の織物を形成するとともに適切な織物を選択して積層し、賦形する必要があり選択ミスが発生する虞がある。この発明では、繊維基材を構成する全ての織物が同じ範囲に高バインダ付加部が形成されているため、同じ構成の織物を所定枚数積層して賦形することで所望のプリフォームをミスなく形成することができる。 The invention according to claim 2 is the invention according to claim 1 , wherein the fiber base material has a high binder addition portion formed in the same range in all layers constituting the preform. From the standpoint that no gap is formed between the outer part of the bent part and the mold, the preform only needs to be formed so that the amount of binder in the bent part is larger than the amount of binder in other parts at least in the outer part. It is not necessary that the amount of the binder in the bent portion is larger than the amount of the binder in the other portions at all the thicknesses constituting the above. However, preforms using multiple types of fabrics with different distributions of binders (specifically, two types of fabrics with different binder amounts at the bent part and other parts and those with the same binder amount) are used. In the case of forming, it is necessary to form a plurality of types of woven fabrics, select appropriate woven fabrics, laminate them, and shape them, which may cause selection errors. In this invention, since all the woven fabrics constituting the fiber base are formed with the high binder addition portion in the same range, a desired preform can be formed without mistake by forming a predetermined number of woven fabrics having the same configuration. Can be formed.
請求項３に記載の発明は、連続繊維からなる繊維束の外側にバインダ繊維が螺旋状に巻き付けられた強化繊維を使用して、曲げ部となる部分のバインダ繊維量が他の部分のバインダ繊維量より多い繊維基材を形成する繊維基材形成工程と、前記繊維基材を賦形型により曲げ部と平面部とが連続する立体的な形状に賦形する積層・賦形工程とを備えている。 The invention according to claim 3 uses the reinforcing fiber in which the binder fiber is spirally wound around the outside of the fiber bundle made of continuous fibers, and the amount of the binder fiber in the bent portion is the binder fiber in the other portion. A fiber base material forming step for forming a fiber base material in excess of the amount, and a laminating / shaping step for shaping the fiber base material into a three-dimensional shape in which a bent portion and a flat surface portion are continuous by a shaping die. ing.
この発明では、繊維基材形成工程において、連続繊維からなる繊維束の外側にバインダ繊維が螺旋状に巻き付けられた強化繊維を使用して、曲げ部となる部分のバインダ繊維量が他の部分のバインダ繊維量より多い繊維基材が形成される。その後、積層・賦形工程において、繊維基材が賦形型により曲げ部と平面部とが連続する立体的な形状に賦形されてプリフォームが形成される。繊維基材は賦形型内で積層されても、賦形型の外で予め積層結合された後に賦形型内に配置されて、賦形型により賦形されても、ブレーディング等により三次元繊維基材として形成され、賦形型により賦形されてもよい。繊維基材は曲げ部となる部分のバインダ繊維量が他の部分のバインダ繊維量より多いため、賦形型で賦形されたプリフォームを樹脂含浸用の成形型内に配置して樹脂含浸を行う際、曲げ部の外側部分（曲率半径の大きな部分）と成形型の面との間に隙間が生じる状態になるのが防止される。そのため、プリフォームを樹脂含浸用の成形型内に配置して樹脂含浸を行った場合、繊維強化複合材料の曲げ部の外側部分におけるマトリックス樹脂量が多くなることに起因して、その部分即ち曲げ部の強度が低下するということが抑制される。 In this invention, in the fiber base material forming step, the reinforcing fiber in which the binder fiber is spirally wound around the outside of the fiber bundle made of continuous fibers is used, and the amount of the binder fiber in the bent portion is the other portion. A fiber substrate having a greater amount of binder fibers is formed. Thereafter, in the laminating and shaping step, the fiber base material is shaped into a three-dimensional shape in which the bent portion and the flat portion are continuous by the shaping die to form a preform. Even if the fiber base material is laminated in the shaping mold, or after being laminated and bonded in advance outside the shaping mold, it is placed in the shaping mold and shaped by the shaping mold, or tertiary by braiding, etc. It may be formed as a base fiber substrate and shaped by a shaping mold. Since the fiber substrate has a larger amount of binder fiber in the bent part than the amount of binder fiber in the other part, the preform formed by the shaping mold is placed in the mold for resin impregnation and resin impregnation is performed. It performed when, for a state of a gap between the outer portion (radius of curvature larger portion) and a form type surface bend is prevented. Therefore, when the preform is placed in a mold for resin impregnation and resin impregnation is performed, the amount of matrix resin in the outer portion of the bent portion of the fiber reinforced composite material is increased, so It is suppressed that the intensity | strength of a part falls.
請求項４に記載の発明は、請求項３に記載の発明において、前記繊維基材形成工程は、前記強化繊維を経糸及び緯糸として製織した織物を積層することにより前記繊維基材を形成し、バインダ繊維量を多くすべき部分の製織時には、緯糸を目付が大きなバインダ繊維が巻き付けられた強化繊維に代えて製織を行う。 The invention according to claim 4 is the invention according to claim 3 , wherein in the fiber base material forming step, the fiber base material is formed by laminating a woven fabric in which the reinforcing fibers are woven as warps and wefts, At the time of weaving the portion where the amount of the binder fiber should be increased, weaving is performed by replacing the weft with the reinforcing fiber wound with the binder fiber having a large basis weight.
強化繊維を経糸及び緯糸として製織した織物を積層することにより、特定の部分のバインダ繊維量が他の部分のバインダ繊維量より多くなる繊維基材を形成する場合、一部の経糸にバインダ繊維量の多い強化繊維を使用する方法と、特定の挿入部分において緯糸としてバインダ繊維量の多い強化繊維を使用する方法が考えられる。しかし、一部の経糸にバインダ繊維量の多い強化繊維を使用する方法では、異なるバインダ繊維量となる繊維基材を形成するたびに、経糸の交換を行う必要があり、準備に手間がかかる。この発明では、バインダ繊維量を多くすべき部分の製織時には、緯糸を目付が大きなバインダ繊維が巻き付けられた強化繊維に代えて製織を行うことにより、経糸の交換を行うことなしに、曲げ部になる部分のバインダ繊維量が所望の値になる繊維基材を形成することができる。したがって、異なるバインダ繊維量の繊維基材の形成を、経糸を変更する場合に比べて準備に手間がかからずに行うことができる。 When a woven fabric woven with reinforcing fibers as warps and wefts is laminated to form a fiber base in which the amount of binder fibers in a specific part is greater than the amount of binder fibers in other parts, the amount of binder fibers in some warps A method using a reinforcing fiber having a large amount of binder fiber and a method using a reinforcing fiber having a large amount of binder fiber as a weft in a specific insertion portion can be considered. However, in the method of using reinforcing fibers having a large amount of binder fibers for some warps, it is necessary to exchange the warps every time a fiber base material having a different amount of binder fibers is formed. In this invention, when weaving the portion where the amount of the binder fiber should be increased, weaving is performed by replacing the weft yarn with the reinforcing fiber wound with the binder fiber having a large basis weight, and without changing the warp, in the bending portion. It is possible to form a fiber base material in which the amount of the binder fiber in the part becomes a desired value. Therefore, the formation of the fiber base material having a different binder fiber amount can be performed without taking time and effort compared to the case of changing the warp.
本発明によれば、曲げ部を有するプリフォームを取り扱う場合に曲げ部やその近傍が変形し難く、そのプリフォームを使用した繊維強化複合材料の曲げ部における強度低下を抑制することができる繊維強化複合材料のプリフォームを提供することができる。 According to the present invention, when a preform having a bent portion is handled, the bent portion and the vicinity thereof are not easily deformed, and the fiber reinforcement capable of suppressing the strength reduction at the bent portion of the fiber-reinforced composite material using the preform. A composite preform can be provided.
以下、本発明を具体化した一実施形態を図１〜図３にしたがって説明する。
図１（ａ）に示すように、プリフォーム１１は、曲げ部１１ａと平面部１１ｂとが連続する立体的な形状、この実施形態では断面Ｌ字状に形成されている。プリフォーム１１は、連続繊維からなる繊維基材（この実施形態では二次元繊維基材が複数積層された少なくとも２軸配向となる積層繊維群）を賦形することにより形成されている。
Hereinafter, an embodiment embodying the present invention will be described with reference to FIGS.
As shown to Fig.1 (a), the preform 11 is formed in the three-dimensional shape with which the bending part 11a and the plane part 11b continue, and cross-sectional L-shape in this embodiment. The preform 11 is formed by shaping a fiber substrate made of continuous fibers (in this embodiment, a laminated fiber group having at least biaxial orientation in which a plurality of two-dimensional fiber substrates are laminated).
図２（ａ）に示すように、二次元繊維基材１２は、連続繊維からなる繊維束１４ａの外側にバインダとしてのバインダ繊維１４ｂが螺旋状に巻き付けられた強化繊維１４で織られた織物で構成されている。この実施形態では織物として平織物が採用されている。 As shown in FIG. 2A, the two-dimensional fiber base 12 is a woven fabric woven with reinforcing fibers 14 in which a binder fiber 14b as a binder is wound spirally around a fiber bundle 14a made of continuous fibers. It is configured. In this embodiment, a plain fabric is used as the fabric.
図２（ｂ）に示すように、積層繊維群１３は、二次元繊維基材１２がバインダ繊維１４ｂにより互いに接合されることで構成されており、曲げ部１１ａとなる部分のバインダ量が他の部分のバインダ量より多くなるように構成されている。曲げ部１１ａとなる部分とは、厳密に湾曲部（Ｒ部）のみに限らず、湾曲部の近傍の平面部１１ｂの部分も含む。そして、好ましくは曲げ部１１ａのみではなく、曲げ部１１ａの近傍の平面部１１ｂの部分のバインダ量も他の部分より多くなるように構成される。 As shown in FIG. 2 (b), the laminated fiber group 13 is configured by joining the two-dimensional fiber base material 12 to each other with the binder fiber 14b, and the amount of the binder in the portion that becomes the bent portion 11a is different from the other. It is comprised so that it may exceed the amount of binders of a part. The portion to be the bent portion 11a is not limited to the curved portion (R portion) strictly, but also includes a portion of the flat portion 11b in the vicinity of the curved portion. And it is comprised so that the amount of binders of not only the bending part 11a but the part of the plane part 11b of the vicinity of the bending part 11a may also be larger than another part.
曲げ部１１ａとなる部分に使用される強化繊維１４は、バインダ繊維１４ｂの目付が他の部分に使用される強化繊維１４より大きく形成されている。例えば、図１（ｂ）及び図１（ｃ）に示すように、同じバインダ繊維１４ｂを使用するとともに、繊維束１４ａに巻き付けられるバインダ繊維１４ｂのピッチを変更することで、強化繊維１４におけるバインダ繊維１４ｂの目付が所望の値に設定されている。 Reinforcing fibers 14 used in the portions that become the bent portions 11a are formed so that the basis weight of the binder fibers 14b is larger than the reinforcing fibers 14 used in other portions. For example, as shown in FIG. 1B and FIG. 1C, the binder fiber in the reinforcing fiber 14 is used by using the same binder fiber 14b and changing the pitch of the binder fiber 14b wound around the fiber bundle 14a. The basis weight of 14b is set to a desired value.
積層繊維群１３は、同じ部分を構成する強化繊維１４のバインダ繊維１４ｂの巻き付けピッチが同じになるように構成された二次元繊維基材１２が積層されて形成されている。即ち、二次元繊維基材１２は、プリフォーム１１を構成する全層で同じ範囲に高バインダ付加部が形成されている。 The laminated fiber group 13 is formed by laminating two-dimensional fiber base materials 12 configured to have the same winding pitch of the binder fibers 14b of the reinforcing fibers 14 constituting the same portion. That is, in the two-dimensional fiber base material 12, the high binder addition portion is formed in the same range in all layers constituting the preform 11.
強化繊維１４を構成する繊維束１４ａとしては軽量で破断強度が高く、弾性率の大きい例えば炭素繊維の無撚りの繊維束（ロービング）が使用される。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。 As the fiber bundle 14a constituting the reinforcing fiber 14, for example, a non-twisted fiber bundle (roving) of carbon fiber having a light weight, high breaking strength, and high elastic modulus 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.
強化繊維１４を構成するバインダ繊維１４ｂには、積層繊維群１３を賦形型で賦形する際の加熱温度で溶融可能な熱可塑性樹脂繊維（熱融着糸）が使用される。例えば、熱融着糸としてユニチカ製のエスポランが挙げられる。 For the binder fibers 14b constituting the reinforcing fibers 14, thermoplastic resin fibers (heat-bonded yarns) that can be melted at a heating temperature when the laminated fiber group 13 is shaped with a shaping mold are used. For example, Unitika esporan can be used as the heat fusing yarn.
繊維束１４ａにバインダ繊維１４ｂが螺旋状に巻き付けられた強化繊維１４は、例えば、ボビンに巻き付けられた状態の炭素繊維束を別のボビンに巻き付ける際に、熱融着糸をボビンから繰り出して螺旋状に巻き付けることにより形成される。バインダ繊維１４ｂの巻き付けピッチは、繊維束１４ａを構成する連続繊維の本数、熱融着糸の太さ、目的とするバインダ繊維１４ｂの必要量等に応じて適宜設定され、強化繊維１４のバインダ繊維の目付を大きくする場合はピッチを小さくする。なお、繊維束１４ａはボビンやガイド部材に押圧されることにより扁平になって幅が拡がるが、バインダ繊維１４ｂのピッチがあまり狭くなると繊維束１４ａが拡がり難くなる。そのため、バインダ繊維１４ｂの巻き付けピッチは繊維束１４ａが拡がるのを妨げない大きさに設定される。 For example, when the carbon fiber bundle wound around the bobbin is wound around another bobbin, the reinforcing fiber 14 in which the binder fiber 14b is spirally wound around the fiber bundle 14a is unwound from the bobbin. It is formed by winding in a shape. The winding pitch of the binder fiber 14b is appropriately set according to the number of continuous fibers constituting the fiber bundle 14a, the thickness of the heat-sealing yarn, the required amount of the target binder fiber 14b, and the like. To increase the basis weight, decrease the pitch. The fiber bundle 14a is flattened and expanded in width by being pressed by the bobbin or the guide member. However, if the pitch of the binder fibers 14b is too narrow, the fiber bundle 14a is difficult to expand. Therefore, the winding pitch of the binder fiber 14b is set to a size that does not prevent the fiber bundle 14a from spreading.
また、バインダ繊維１４ｂの繊維束１４ａに対する割合は、０．５〜５重量％の範囲が好ましい。バインダ繊維１４ｂの割合が０．５％より小さくなると、プリフォーム１１を取り扱う際に形態安定性が不十分になる。また、バインダ繊維１４ｂの割合が５％より大きくなると、そのプリフォーム１１を使用した繊維強化複合材の物性に悪影響を与え易くなる。本実施形態では、曲げ部１１ａのバインダ量は４〜５重量％程度、平面部１１ｂのバインダ量は０．５〜１重量％としている。 The ratio of the binder fiber 14b to the fiber bundle 14a is preferably in the range of 0.5 to 5% by weight. When the ratio of the binder fiber 14b is smaller than 0.5%, the form stability becomes insufficient when the preform 11 is handled. Moreover, when the ratio of binder fiber 14b becomes larger than 5%, it will become easy to have a bad influence on the physical property of the fiber reinforced composite material which uses the preform 11. FIG. In the present embodiment, the amount of binder in the bent portion 11a is about 4 to 5% by weight, and the amount of binder in the flat portion 11b is 0.5 to 1% by weight.
次に前記のように構成されたプリフォーム１１の製造方法を説明する。プリフォーム１１の製造方法は、二次元繊維基材形成工程と、積層・賦形工程とを備えている。二次元繊維基材形成工程では連続繊維からなる繊維束１４ａの外側にバインダ繊維１４ｂが螺旋状に巻き付けられた強化繊維１４を使用して、曲げ部１１ａとなる部分のバインダ繊維量が他の部分のバインダ繊維量より多い二次元繊維基材１２を形成する。この実施形態では、織機を用いて、強化繊維１４を経糸及び緯糸として織物を製織することにより二次元繊維基材１２を形成する。経糸にはバインダ繊維の目付が全て同じ強化繊維１４が使用される。また、バインダ繊維量を多くすべき部分の製織時には、緯糸をバインダ繊維１４ｂの目付が大きな強化繊維１４に代えて製織を行う。この実施形態では曲げ部１１ａとなる部分が織物の長手方向に所定間隔で存在する織物が製織される。そして、製織された織物をバインダ繊維量の大きな部分が所定の位置になるように切断することにより、二次元繊維基材１２が形成される。 Next, a method for manufacturing the preform 11 configured as described above will be described. The manufacturing method of the preform 11 includes a two-dimensional fiber substrate forming step and a lamination / shaping step. In the two-dimensional fiber base material forming step, the reinforcing fiber 14 in which the binder fiber 14b is spirally wound around the outer side of the fiber bundle 14a made of continuous fibers is used, and the amount of the binder fiber of the portion that becomes the bent portion 11a is the other portion. The two-dimensional fiber base 12 having a larger amount of the binder fiber is formed. In this embodiment, the two-dimensional fiber base material 12 is formed by weaving a woven fabric using the looms with the reinforcing fibers 14 as warps and wefts. The reinforcing fibers 14 having the same basis weight of the binder fibers are used for the warps. Further, when weaving a portion where the amount of the binder fiber should be increased, weaving is performed by replacing the weft with the reinforcing fiber 14 having a large basis weight of the binder fiber 14b. In this embodiment, a woven fabric in which portions that become the bent portions 11a exist at a predetermined interval in the longitudinal direction of the woven fabric is woven. And the two-dimensional fiber base material 12 is formed by cut | disconnecting the woven fabric so that a part with a large amount of binder fibers may become a predetermined position.
特定の部分のバインダ繊維量が他の部分のバインダ繊維量より多くなる二次元繊維基材１２を形成する場合、一部の経糸にバインダ繊維量の多い強化繊維１４を使用する方法も考えられる。しかし、一部の経糸にバインダ繊維量の多い強化繊維１４を使用する方法では、異なるバインダ繊維量となる二次元繊維基材１２を形成するたびに、経糸の交換を行う必要があり、準備に手間がかかる。しかし、この実施形態の方法では、経糸には全て同じ強化繊維１４が使用されるため、異なるバインダ繊維量となる二次元繊維基材１２を形成する場合でも経糸の交換を行う必要がない。 When forming the two-dimensional fiber base material 12 in which the amount of binder fibers in a specific portion is larger than the amount of binder fibers in other portions, a method of using reinforcing fibers 14 having a large amount of binder fibers for some warps is also conceivable. However, in the method of using the reinforcing fibers 14 having a large amount of binder fibers for some warps, it is necessary to replace the warps every time the two-dimensional fiber substrate 12 having a different amount of binder fibers is formed. It takes time and effort. However, in the method of this embodiment, since the same reinforcing fibers 14 are used for the warps, it is not necessary to replace the warps even when forming the two-dimensional fiber base 12 having different binder fiber amounts.
積層・賦形工程では二次元繊維基材１２を複数積層して積層繊維群１３を形成した後、積層繊維群１３を賦形型により曲げ部１１ａと平面部１１ｂとが連続する立体的な形状に賦形する。二次元繊維基材１２は賦形型内で積層されても、賦形型の外で予め積層された後、賦形型内に配置されてもよい。賦形型の外で予め積層する場合は、積層された積層繊維群１３を加圧加熱して、バインダ繊維１４ｂにより隣接する二次元繊維基材１２同士が結合された状態で賦形型内に配置するのが好ましい。そして、賦形型内に配置された積層繊維群１３は、賦形型により加熱加圧されて所定の立体形状に賦形される。 In the laminating / shaping step, a plurality of two-dimensional fiber base materials 12 are laminated to form a laminated fiber group 13, and then the laminated fiber group 13 is formed into a three-dimensional shape in which a bent portion 11a and a flat portion 11b are continuous by a shaping die. Shape it. The two-dimensional fiber substrate 12 may be laminated in the shaping mold, or may be placed in the shaping mold after being laminated in advance outside the shaping mold. When previously laminating outside the shaping mold, the laminated fiber group 13 is heated under pressure, and the adjacent two-dimensional fiber base materials 12 are bonded to each other by the binder fiber 14b in the shaping mold. It is preferable to arrange. And the laminated fiber group 13 arrange | positioned in a shaping type | mold is heat-pressed by a shaping type | mold, and is shaped by predetermined | prescribed solid shape.
積層された二次元繊維基材１２からなる積層繊維群１３が賦形型により加圧加熱されて賦形される際、バインダ繊維１４ｂは少なくとも一部が溶融状態となる。そして、曲げ部１１ａとなる部分のバインダ繊維量が他の部分のバインダ繊維量より多いため、賦形後の曲げ部１１ａの形状安定性が確保される。なお、曲げ部１１ａに加えて平面部１１ｂのバインダ量をも増やすことも考えられるが、その場合にはプリフォーム１１に使用する総バインダ量が増加してしまいコスト的に不利になるのに加え、バインダが繊維強化複合材の物性に悪影響を及ぼす可能性が高くなる。 When the laminated fiber group 13 composed of the laminated two-dimensional fiber base material 12 is pressurized and heated by a shaping mold, at least a part of the binder fiber 14b is in a molten state. And since the amount of the binder fiber of the part used as the bending part 11a is larger than the amount of the binder fiber of another part, the shape stability of the bending part 11a after shaping is ensured. Although it is conceivable to increase the amount of the binder in the plane portion 11b in addition to the bent portion 11a, in that case, the total amount of binder used for the preform 11 increases, which is disadvantageous in terms of cost. There is a high possibility that the binder will adversely affect the physical properties of the fiber-reinforced composite material.
プリフォーム１１は、樹脂含浸硬化工程において熱硬化性樹脂が含浸硬化されて繊維強化複合材料が形成される。樹脂の含浸硬化は、例えば、ＲＴＭ法で行われる。プリフォーム１１を樹脂含浸用の成形型内に配置した場合、曲げ部１１ａの形状安定性により、プリフォーム１１を成形型に配置する際にも曲げ部１１ａの外側部分の形状が崩れることがなく、プリフォーム１１は曲げ部の外側部分（曲率半径の大きな部分）と成形型の内面との間に隙間が生じない状態で配置され、樹脂含浸を行った場合、繊維強化複合材料の曲げ部の外側部分におけるマトリックス樹脂量が多くならず、曲げ部の強度が低下するということが抑制される。繊維強化複合材料のマトリックス樹脂としては、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等の熱硬化性樹脂が使用される。 The preform 11 is impregnated and cured with a thermosetting resin in a resin impregnation and curing step to form a fiber-reinforced composite material. For example, the resin is impregnated and cured by the RTM method. When the preform 11 is arranged in a resin-impregnated molding die, the shape stability of the bent portion 11a prevents the outer portion of the bent portion 11a from being deformed even when the preform 11 is arranged in the molding die. The preform 11 is arranged in a state where no gap is formed between the outer portion of the bent portion (the portion having a large radius of curvature) and the inner surface of the mold, and when resin impregnation is performed, It is suppressed that the amount of matrix resin in the outer portion does not increase and the strength of the bent portion decreases. As the matrix resin of the fiber reinforced composite material, a thermosetting resin such as an epoxy resin, an unsaturated polyester resin, or a vinyl ester resin is used.
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）プリフォーム１１は、連続繊維からなる二次元繊維基材１２が複数積層されて少なくとも２軸配向となる積層繊維群１３が、曲げ部１１ａと平面部１１ｂとが連続する立体的な形状に形成されるとともに、二次元繊維基材１２はバインダにより互いに接合されている。したがって、曲げ部１１ａを有する立体的な形状に賦形されたプリフォーム１１を搬送したり成形型内に配置したりするなどの取り扱いの際に、積層された二次元繊維基材１２同士のずれが防止される。
According to this embodiment, the following effects can be obtained.
(1) The preform 11 has a three-dimensional shape in which a laminated fiber group 13 in which a plurality of two-dimensional fiber bases 12 made of continuous fibers are laminated to be at least biaxially oriented includes a bent portion 11a and a flat portion 11b. The two-dimensional fiber base material 12 is joined to each other by a binder. Accordingly, the two-dimensional fiber bases 12 that are stacked are displaced when handling the preform 11 shaped into a three-dimensional shape having the bent portion 11a, such as transporting it or placing it in a mold. Is prevented.
（２）プリフォーム１１は、曲げ部１１ａのバインダ量が他の部分のバインダ量より多い。したがって、賦形後における積層された二次元繊維基材１２の曲げ部１１ａの形状安定性が確保される。そのため、プリフォーム１１を樹脂含浸用の成形型内に配置して樹脂含浸を行った場合、繊維強化複合材料の曲げ部の外側部分におけるマトリックス樹脂量が多くなることに起因して、その部分即ち曲げ部の強度が低下するということが抑制される。 (2) In the preform 11, the amount of binder in the bent portion 11 a is larger than the amount of binder in other portions. Therefore, the shape stability of the bending part 11a of the laminated two-dimensional fiber base material 12 after shaping is ensured. Therefore, when the preform 11 is placed in a mold for resin impregnation and resin impregnation is performed, the amount of matrix resin in the outer portion of the bent portion of the fiber reinforced composite material increases, It is suppressed that the intensity | strength of a bending part falls.
（３）二次元繊維基材１２は、連続繊維からなる繊維束１４ａの外側にバインダ繊維１４ｂが螺旋状に巻き付けられた強化繊維１４で織られた織物で構成され、曲げ部１１ａとなる部分に使用される強化繊維１４のバインダ繊維１４ｂの目付が他の部分に使用される強化繊維１４より大きい。したがって、二次元繊維基材１２を形成した後に、粉状、粒状あるいは繊維状のバインダを二次元繊維基材１２の表面に結合させた構成に比較して、製造が簡単になる。また、粉状、粒状あるいは繊維状のバインダを二次元繊維基材１２の表面に結合させた構成に比較して、プリフォーム１１を成形型内に配置して熱硬化性樹脂の含浸硬化を行う際に、繊維束１４ａを扁平な状態に保持しやすい。 (3) The two-dimensional fiber base material 12 is composed of a woven fabric woven with reinforcing fibers 14 in which binder fibers 14b are spirally wound around a fiber bundle 14a made of continuous fibers, and is a portion that becomes a bent portion 11a. The basis weight of the binder fiber 14b of the reinforcing fiber 14 used is larger than that of the reinforcing fiber 14 used for other portions. Therefore, after forming the two-dimensional fiber base material 12, the manufacturing is simplified as compared with a configuration in which a powdery, granular or fibrous binder is bonded to the surface of the two-dimensional fiber base material 12. Compared to a configuration in which a powdery, granular or fibrous binder is bonded to the surface of the two-dimensional fiber substrate 12, the preform 11 is placed in a mold and impregnated with a thermosetting resin. At this time, it is easy to hold the fiber bundle 14a in a flat state.
（４）強化繊維１４は連続繊維からなる繊維束１４ａの外側にバインダ繊維１４ｂが螺旋状に巻き付けられた構成であるため、バインダ繊維１４ｂの巻き付けピッチを変更することで、強化繊維１４におけるバインダ繊維１４ｂの目付を所望の値に設定することができる。したがって、プリフォーム１１を構成する二次元繊維基材１２間の接着力を所望の値に調整するのが容易になり、プリフォーム１１の賦形性及び形状保持性の制御が可能になる。 (4) Since the reinforcing fiber 14 has a configuration in which the binder fiber 14b is spirally wound around the outside of the fiber bundle 14a made of continuous fibers, the binder fiber in the reinforcing fiber 14 can be changed by changing the winding pitch of the binder fiber 14b. The basis weight of 14b can be set to a desired value. Therefore, it becomes easy to adjust the adhesive force between the two-dimensional fiber base materials 12 constituting the preform 11 to a desired value, and the shapeability and shape retention of the preform 11 can be controlled.
（５）バインダ繊維１４ｂは織物を構成する緯糸及び経糸の交差部において、緯糸及び経糸の接触面に位置する状態となる。そのため、製織された織物をバインダ繊維１４ｂが軟化して繊維束１４ａと接着する温度に加熱して、バインダ繊維１４ｂを繊維束１４ａに接着させることにより、強化繊維１４のほつれを防止することができる。 (5) The binder fiber 14b is in a state of being located on the contact surface of the weft and the warp at the intersection of the weft and the warp constituting the fabric. Therefore, fraying of the reinforcing fibers 14 can be prevented by heating the woven fabric to a temperature at which the binder fibers 14b are softened and bonded to the fiber bundles 14a to bond the binder fibers 14b to the fiber bundles 14a. .
（６）二次元繊維基材１２は、プリフォーム１１を構成する積層繊維群１３の全層で同じ範囲に高バインダ付加部が形成されている。したがって、バインダ量が異なる分布の複数の二次元繊維基材１２を用いてプリフォーム１１を形成する場合と比べて、所望のプリフォーム１１をミスなく容易に形成することができる。 (6) In the two-dimensional fiber base material 12, the high binder addition portion is formed in the same range in all layers of the laminated fiber group 13 constituting the preform 11. Therefore, compared with the case where the preform 11 is formed using a plurality of two-dimensional fiber base materials 12 having different distributions of the binder amount, the desired preform 11 can be easily formed without a mistake.
（７）プリフォーム１１の製造方法は、二次元繊維基材形成工程において連続繊維からなる繊維束１４ａの外側にバインダ繊維１４ｂが螺旋状に巻き付けられた強化繊維１４を使用して、曲げ部１１ａとなる部分のバインダ繊維量が他の部分のバインダ繊維量より多い二次元繊維基材１２を形成する。また、積層・賦形工程において二次元繊維基材１２を複数積層した積層繊維群１３を賦形型により曲げ部１１ａと平面部１１ｂとが連続する立体的な形状に賦形する。積層された二次元繊維基材１２は曲げ部１１ａとなる部分のバインダ繊維量が他の部分のバインダ繊維量より多いため、図３に示すように、賦形したプリフォーム１１を樹脂含浸用の成形型１５内に配置して樹脂含浸を行う際、曲げ部１１ａの外側部分（曲率半径の大きな部分）と成形型１５の面との間に隙間Δが生じる状態になるのが防止される。したがって、プリフォーム１１を樹脂含浸用の成形型１５内に配置して樹脂含浸を行った場合、繊維強化複合材料の曲げ部の外側部分におけるマトリックス樹脂量が多くなることに起因して、その部分即ち曲げ部の強度が低下するということが抑制される。 (7) The manufacturing method of the preform 11 uses the reinforcing fiber 14 in which the binder fiber 14b is spirally wound around the outer side of the fiber bundle 14a made of continuous fibers in the two-dimensional fiber base material forming step, and the bending portion 11a. The two-dimensional fiber base material 12 in which the amount of the binder fiber in the part becomes larger than the amount of the binder fiber in the other part is formed. Further, in the lamination / shaping step, the laminated fiber group 13 in which a plurality of two-dimensional fiber base materials 12 are laminated is shaped into a three-dimensional shape in which the bent portion 11a and the flat portion 11b are continuous by a shaping die. Since the laminated two-dimensional fiber base material 12 has a larger amount of binder fibers in the bent portion 11a than the amount of binder fibers in other portions, as shown in FIG. 3, the shaped preform 11 is used for resin impregnation. is prevented from becoming a state where a gap Δ is formed between the arranged in a mold 15 when performing resin impregnation, the outer portion (large portion of the radius of curvature) and forming the shape type 15 surface of the bending portion 11a . Therefore, when the preform 11 is placed in the mold 15 for resin impregnation and resin impregnation is performed, the amount of matrix resin in the outer portion of the bent portion of the fiber reinforced composite material increases, and the portion That is, a decrease in the strength of the bent portion is suppressed.
（８）二次元繊維基材形成工程は、強化繊維１４を経糸及び緯糸として織物を製織することにより二次元繊維基材１２を形成し、バインダ繊維量を多くすべき部分の製織時には、緯糸を目付が大きなバインダ繊維１４ｂが巻き付けられた強化繊維１４に代えて製織を行う。したがって、バインダ繊維量を多くすべき部分の製織時にも、経糸の交換を行うことなしに、所望の二次元繊維基材１２を形成することができる。その結果、異なるバインダ繊維量の二次元繊維基材１２の形成を、経糸を変更する場合に比べて準備に手間がかからずに行うことができる。 (8) The two-dimensional fiber base material forming step forms the two-dimensional fiber base material 12 by weaving a woven fabric using the reinforcing fibers 14 as warps and wefts, and when weaving a portion where the amount of binder fibers should be increased, Weaving is performed in place of the reinforcing fiber 14 around which the binder fiber 14b having a large basis weight is wound. Therefore, the desired two-dimensional fiber base material 12 can be formed without exchanging the warp yarns even when weaving the portion where the amount of the binder fiber should be increased. As a result, it is possible to form the two-dimensional fiber base material 12 having a different binder fiber amount without taking time and effort compared to the case of changing the warp.
実施形態は前記に限定されるものではなく、例えば次のように構成してもよい。
○ プリフォーム１１を形成する場合、１個のプリフォーム１１の大きさの二次元繊維基材１２を複数積層して形成するのではなく、複数個分の大きさの二次元繊維基材１２を複数積層して、複数個のプリフォーム１１が連続する状態で中間体を形成した後、その中間体を切断してプリフォーム１１を形成する場合が多い。その場合、プリフォーム１１の切断端部において強化繊維１４がほつれ易い。この不具合を防止するため、曲げ部１１ａのバインダ繊維量だけでなく、プリフォーム１１の切断端部となる部分のバインダ繊維量も他の部分のバインダ繊維量より多くしてもよい。例えば、図４に示すように、織物１６は、曲げ部対応部分１６ａの他、切断対応部分１６ｂのバインダ繊維量も他の部分のバインダ繊維量より多くする。また、織物の幅方向両端部も切断する場合は、織物の幅方向両側部分のバインダ繊維量も他の部分のバインダ繊維量より多くする。織物の幅方向両側部分のバインダ繊維量を多くするには、対応する部分の経糸となる強化繊維１４のバインダ繊維１４ｂの目付を大きくする。
The embodiment is not limited to the above, and may be configured as follows, for example.
○ When the preform 11 is formed, the two-dimensional fiber base material 12 having a size corresponding to a plurality of two-dimensional fiber base materials 12 having the size of one preform 11 is not formed. In many cases, a plurality of stacked layers are formed and an intermediate is formed in a state where the plurality of preforms 11 are continuous, and then the intermediate is cut to form the preform 11. In that case, the reinforcing fibers 14 are likely to fray at the cut end of the preform 11. In order to prevent this problem, not only the amount of binder fibers in the bent portion 11a but also the amount of binder fibers in the portion that becomes the cut end portion of the preform 11 may be larger than the amount of binder fibers in other portions. For example, as shown in FIG. 4, in the woven fabric 16, the amount of binder fibers in the cut-corresponding portion 16 b as well as the bent portion corresponding portion 16 a is larger than the amount of binder fibers in other portions. When cutting both ends in the width direction of the woven fabric, the amount of binder fibers in both sides in the width direction of the woven fabric is made larger than the amount of binder fibers in other portions. In order to increase the amount of binder fibers on both sides in the width direction of the woven fabric, the basis weight of the binder fibers 14b of the reinforcing fibers 14 serving as warps of the corresponding portions is increased.
○ 二次元繊維基材１２は連続繊維からなる繊維束１４ａの外側にバインダ繊維１４ｂが螺旋状に巻き付けられた強化繊維１４で織られた平織物で構成されるものに限らない。例えば、綾織物等の他の織物、組紐あるいは編み物のように複数の強化繊維１４が交差する状態で平面状に結合されたものや、図５に示すように複数の強化繊維１４が一方向に配列されるとともに、強化繊維１４と交差する結合繊維１７により平面状に結合された一方向繊維基材であってもよい。図６に示すように、一方向繊維基材は強化繊維１４の配列方向が直交する状態で複数積層される。また、一方向繊維基材を強化繊維１４の配列方向が直交する状態（配向角０°と９０°）に加えて、強化繊維１４の配向角が±４５°となるように二次元繊維基材１２を積層して４軸配向となるようにプリフォーム１１を構成してもよい。 The two-dimensional fiber substrate 12 is not limited to a plain fabric woven with reinforcing fibers 14 in which binder fibers 14b are spirally wound around a fiber bundle 14a made of continuous fibers. For example, other woven fabrics such as twill woven fabrics, braids or knitted fabrics in which a plurality of reinforcing fibers 14 are joined in a planar shape, or a plurality of reinforcing fibers 14 are unidirectional as shown in FIG. It may be a unidirectional fiber substrate that is arranged and bonded in a planar manner by a bonding fiber 17 that intersects the reinforcing fiber 14. As shown in FIG. 6, a plurality of unidirectional fiber base materials are laminated in a state where the arrangement directions of the reinforcing fibers 14 are orthogonal to each other. Further, in addition to the state in which the arrangement directions of the reinforcing fibers 14 are orthogonal to each other (orientation angles 0 ° and 90 °), the two-dimensional fiber substrate so that the orientation angles of the reinforcing fibers 14 are ± 45 °. The preform 11 may be configured such that the layers 12 are laminated to have a 4-axis orientation.
○ プリフォーム１１を構成する二次元繊維基材１２はバインダにより互いに接合されており、曲げ部１１ａのバインダ量が他の部分のバインダ量より多ければよく、バインダはバインダ繊維１４ｂに限らず、粉状や粒状の熱可塑性樹脂であってもよい。しかし、バインダとして粉状や粒状の熱可塑性樹脂を使用する場合、二次元繊維基材１２の適切な位置に適量の熱可塑性樹脂を接着させるのがバインダ繊維１４ｂを使用する場合に比べて手間がかかる。また、バインダを繊維束１４ａに巻き付けられたバインダ繊維１４ｂで構成する方が、バインダを二次元繊維基材１２全体に略均一に分布する状態で配置し易い。 ○ The two-dimensional fiber base material 12 constituting the preform 11 is bonded to each other by a binder, and the amount of the binder in the bent portion 11a may be larger than the amount of the binder in other portions. The binder is not limited to the binder fiber 14b, It may be a thermoplastic resin in the form or shape. However, when a powdery or granular thermoplastic resin is used as the binder, it is troublesome to attach an appropriate amount of the thermoplastic resin to an appropriate position of the two-dimensional fiber base 12 compared to the case where the binder fiber 14b is used. Take it. Moreover, it is easier to arrange the binder with the binder fibers 14b wound around the fiber bundle 14a in a state where the binder is distributed substantially uniformly over the entire two-dimensional fiber base 12.
○ プリフォーム１１の曲げ部１１ａのバインダ量を他の部分のバインダ量より多くする構成として、二次元繊維基材１２を連続繊維からなる繊維束１４ａの外側にバインダ繊維１４ｂが螺旋状に巻き付けられた強化繊維１４で織られた織物で構成し、プリフォーム１１の曲げ部１１ａとなる部分に粉状や粒状の熱可塑性樹脂を接合させてもよい。 ○ As a configuration in which the amount of binder in the bent portion 11a of the preform 11 is made larger than the amount of binder in other portions, the binder fiber 14b is spirally wound around the outside of the fiber bundle 14a made of continuous fibers. Alternatively, a woven fabric woven with the reinforcing fibers 14 may be used, and a powdery or granular thermoplastic resin may be bonded to the portion to be the bent portion 11 a of the preform 11.
○ 二次元繊維基材１２を平織物で構成する場合、図７（ａ）に示すように、経糸は繊維束１４ａの外側にバインダ繊維１４ｂ（図示せず）が螺旋状に巻き付けられた強化繊維１４で構成し、緯糸を熱可塑性樹脂繊維１８で構成する。そして、図７（ｂ）に示すように、複数の二次元繊維基材１２を隣り合う二次元繊維基材１２の強化繊維１４の配列方向が直交するように積層する。なお、曲げ部１１ａとなる部分に配列される熱可塑性樹脂繊維１８の太さを他の部分に配列される熱可塑性樹脂繊維１８より太くした平織物と、全て同じ太さの熱可塑性樹脂繊維１８を緯糸とした平織物とを交互に積層する。なお、バインダ量を緯糸としての熱可塑性樹脂繊維１８の密度で制御するようにしてもよい。 ○ When the two-dimensional fiber base 12 is composed of a plain woven fabric, as shown in FIG. 7A, the warp is a reinforcing fiber in which a binder fiber 14b (not shown) is spirally wound around the outside of the fiber bundle 14a. 14 and the weft is composed of thermoplastic resin fibers 18. And as shown in FIG.7 (b), the two-dimensional fiber base material 12 is laminated | stacked so that the sequence direction of the reinforcement fiber 14 of the adjacent two-dimensional fiber base material 12 may orthogonally cross. In addition, the flat woven fabric in which the thickness of the thermoplastic resin fiber 18 arranged in the portion to be the bent portion 11a is thicker than that of the thermoplastic resin fiber 18 arranged in the other portion, and the thermoplastic resin fiber 18 all having the same thickness. Are laminated alternately with plain weave fabrics. Note that the binder amount may be controlled by the density of the thermoplastic resin fibers 18 as wefts.
○ 曲げ部１１ａのバインダ繊維１４ｂの目付を調整する場合、繊維束１４ａに対して螺旋状に巻き付けられるバインダ繊維１４ｂの巻き付けピッチを変更する代わりに、巻き付けピッチを変更せずにバインダ繊維１４ｂの太さを変更してもよい。 ○ When adjusting the basis weight of the binder fiber 14b of the bent portion 11a, instead of changing the winding pitch of the binder fiber 14b wound spirally around the fiber bundle 14a, the thickness of the binder fiber 14b is changed without changing the winding pitch. You may change the size.
○ 二次元繊維基材１２は、プリフォーム１１を構成する積層繊維群１３の全層で同じ範囲に高バインダ付加部が形成されている構成に限らない。例えば、曲げ部１１ａの曲率半径が最も大きくなる部分、即ち積層繊維群１３の一方の最外層を構成する二次元繊維基材１２のみ、曲げ部１１ａのバインダ繊維１４ｂの目付を他の部分のバインダ繊維１４ｂの目付より大きくしてもよい。また、曲げ部１１ａの曲率半径が大きくなる二次元繊維基材１２ほど、曲げ部１１ａのバインダ繊維１４ｂの目付が大きくなるように、各層を構成する二次元繊維基材１２の曲げ部１１ａのバインダ繊維１４ｂの目付を調整してもよい。 The two-dimensional fiber base material 12 is not limited to the configuration in which the high binder addition portion is formed in the same range in all layers of the laminated fiber group 13 constituting the preform 11. For example, only the portion of the bent portion 11a where the radius of curvature is the largest, that is, the two-dimensional fiber base material 12 constituting one outermost layer of the laminated fiber group 13, the basis weight of the binder fiber 14b of the bent portion 11a is the binder of the other portion. You may make it larger than the fabric weight of the fiber 14b. Moreover, the binder of the bending part 11a of the two-dimensional fiber base material 12 which comprises each layer so that the fabric weight of the binder fiber 14b of the bending part 11a becomes so large that the two-dimensional fiber base material 12 in which the curvature radius of the bending part 11a becomes large. You may adjust the fabric weight of the fiber 14b.
○ 二次元繊維基材１２を織物で構成する場合、経糸及び緯糸とも連続繊維からなる繊維束１４ａの外側にバインダ繊維１４ｂが螺旋状に巻き付けられた強化繊維１４を使用するのではなく、経糸及び緯糸のいずれか一方のみ連続繊維からなる繊維束１４ａの外側にバインダ繊維１４ｂが螺旋状に巻き付けられた強化繊維１４を使用するようにしてもよい。 ○ When the two-dimensional fiber substrate 12 is formed of a woven fabric, the warp yarn and the weft yarn are not used as the reinforcing fiber 14 in which the binder fiber 14b is spirally wound around the outside of the fiber bundle 14a made of continuous fibers. You may make it use the reinforced fiber 14 by which the binder fiber 14b was wound around the outer side of the fiber bundle 14a which consists of continuous fibers only in any one of the weft.
○ バインダ繊維１４ｂは、積層繊維群１３を賦形型１５により加熱・加圧状態して賦形する際の加熱温度により繊維束１４ａと融着可能な軟化溶融可能であればよい。バインダ繊維をエンジニアリングプラスチック（エンプラ）製やスーパーエンプラ製とした場合はプリフォーム１１の靭性が向上するが、賦形温度を高くする必要があり、エネルギー消費量が多くなる。バインダ繊維１４ｂとして賦形温度が１００℃程度で繊維束１４ａと融着する融着繊維を使用すれば、エネルギー消費量を少なくできるとともに、プリフォーム１１の形態保持性を確保し易い。 The binder fiber 14b only needs to be softened and meltable so that it can be fused to the fiber bundle 14a at the heating temperature when the laminated fiber group 13 is heated and pressurized by the shaping mold 15 and shaped. When the binder fiber is made of engineering plastic (engineering plastic) or super engineering plastic, the toughness of the preform 11 is improved, but it is necessary to increase the forming temperature, and the energy consumption increases. If a fusion fiber that is fused with the fiber bundle 14a at a shaping temperature of about 100 ° C. is used as the binder fiber 14b, the energy consumption can be reduced and the form retainability of the preform 11 can be easily secured.
○ 強化繊維１４を構成する繊維束１４ａは炭素繊維製に限らない。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等を使用してもよく、要求性能に応じて適宜選択される。例えば、プリフォーム１１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１４ａに安価なガラス繊維を用いると低コストとなる。 (Circle) the fiber bundle 14a which comprises the reinforced fiber 14 is not restricted to carbon fiber. For example, inorganic fibers such as glass fibers and ceramic fibers, or high-strength organic fibers such as aramid fibers, poly-p-phenylenebenzobisoxazole fibers, and ultrahigh molecular weight polyethylene fibers may be used. It is selected as appropriate. For example, when the required performance of rigidity and strength for the preform 11 is high, carbon fiber is preferable. If an inexpensive glass fiber is used for the fiber bundle 14a, the cost is reduced.
○ プリフォーム１１は曲げ部と平面部とが連続する立体的な形状に形成されていればよく、断面略Ｌ字状に限らず、複数の曲げ部１１ａを有する断面コ字状やハット状、あるいは凹部と鍔部とが連続する形状であってもよい。 ○ The preform 11 only needs to be formed in a three-dimensional shape in which the bent portion and the flat portion are continuous, and is not limited to a substantially L-shaped cross section, but a cross-sectional U shape or a hat shape having a plurality of bent portions 11a, Or the shape where a recessed part and a collar part continue may be sufficient.
○ プリフォーム１１を構成する繊維基材は二次元のものに限られず、ブレーディング等により形成される三次元繊維基材であってもよい。 (Circle) the fiber base material which comprises the preform 11 is not restricted to a two-dimensional thing, The three-dimensional fiber base material formed by braiding etc. may be sufficient.
１１…プリフォーム、１１ａ…曲げ部、１１ｂ…平面部、１２…二次元繊維基材、１３…積層繊維群、１４…強化繊維、１４ａ…繊維束、１４ｂ…バインダとしてのバインダ繊維、１５…賦形型、１６…織物。 DESCRIPTION OF SYMBOLS 11 ... Preform, 11a ... Bending part, 11b ... Plane part, 12 ... Two-dimensional fiber base material, 13 ... Laminated fiber group, 14 ... Reinforcing fiber, 14a ... Fiber bundle, 14b ... Binder fiber as binder, 15 ... Addition Shape, 16 ... woven fabric.
Claims (4)
前記繊維基材を賦形型により曲げ部と平面部とが連続する立体的な形状に賦形する積層・賦形工程と
を備えている繊維強化複合材料のプリフォームの製造方法。 Using a reinforcing fiber in which a binder fiber is spirally wound around a fiber bundle made of continuous fibers, a fiber base material in which the amount of the binder fiber in the bent portion is larger than the amount of the binder fiber in other portions is formed. A fiber base material forming step;
A method for producing a preform of a fiber reinforced composite material, comprising: a lamination and shaping step of shaping the fiber base material into a three-dimensional shape in which a bent portion and a flat portion are continuous with a shaping die.
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