JP2012255222A - Fiber bundle sheet comprising reinforcing fibers - Google Patents

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

  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.

  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.

  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).

Japanese Utility Model Publication No. 3-18189

  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.

  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.

  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.

  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.

  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.

  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.

  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.

  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.

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.

  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.

  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.

  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.

  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.

  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.

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). The schematic plan view which shows positional relationships, such as a support frame, a fiber bundle layer, a pressing member, and a needle | hook. The model perspective view which shows the positional relationship with the structure, needle | hook, etc. which support a fiber bundle layer. The model perspective view which shows the state of the main sewing. (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) 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) 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) 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). The schematic cross section of the fiber bundle sheet | seat of another embodiment.

(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.

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.

  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.

  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.

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

  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.

  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.

  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.

  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.

  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.

  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.

  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.

  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.

  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.

  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.

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) 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) 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) 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) 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) 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.

(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.

  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.

  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.

  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.

  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.

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.

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.

  ○ 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.

  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.

  ○ 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.

  ○ 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.

  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.

  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.

  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.

  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.

  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 ... 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)

  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.   The fiber bundle sheet according to claim 1, wherein the second yarn extends linearly. 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 .   The fiber bundle sheet according to any one of claims 1 to 3, wherein the pitch of the main stitch is constant.   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.   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.   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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