WO2012014613A1 - Fiber substrate and fiber-reinforced composite material - Google Patents

Abstract

A fiber substrate (10) is constituted from multiple first fiber bundles (11) arranged in parallel rows relative to one another, multiple second fiber bundles (12) arranged in rows parallel to one another and intersecting the first fiber bundles (11), and multiple third fiber bundles (13) arranged in rows parallel to one another and such that the angles of intersection with the first fiber bundles (11) and with the second fiber bundles (12) are the same. The first fiber bundles (11) are constituted from fiber reinforcement bundles (15). The second fiber bundles (12) are constituted from auxiliary threads (16). The third fiber bundles (13) are constituted from fiber reinforcement bundles (15) and auxiliary threads (16) alternately arranged in rows. At the intersections (17b) where the fiber reinforcement bundles (13) intersect one another, the fiber reinforcement bundles (15) of the first fiber bundles (11) are arranged on the same side relative to the third fiber bundles (13) in the thickness direction of the fiber substrate (10).

Description

Fiber substrate and fiber reinforced composite material

The present invention relates to a fiber base material and a fiber reinforced composite material, and more particularly to a fiber base material suitable as a reinforcing material for the composite material and a fiber reinforced composite material including the fiber base material as a reinforcing material.

A fiber-reinforced composite material (hereinafter simply referred to as a composite material) is used as a lightweight, high-strength material. In a composite material, mechanical characteristics (mechanical characteristics) are enhanced by mixing reinforcing fibers in a matrix of resin, metal, or the like, as compared to the matrix itself. For this reason, a composite material is preferable as a structural component.

The following is known as a method for producing a composite material. First, a fabric composed of warps and wefts (for example, a plain fabric) or a sheet composed of fiber bundles arranged in one direction is prepared. Next, this sheet is impregnated with a resin to form a prepreg. Subsequently, a plurality of prepregs are formed and laminated to form a laminate. And a composite material is formed by heating and pressurizing a laminated body using a shaping | molding die. In addition to this, there may be mentioned a method of laminating a plurality of plain woven fabrics or the sheets in a mold, injecting a resin into the laminate in the mold, impregnating it, and then curing.

In order to give the composite material quasi-isotropic properties, it is preferable to set the arrangement direction of the fiber bundles constituting the laminate to 0 °, 90 °, + 45 °, and −45 °. As a method for obtaining such a laminate, a plurality of sheets made of fiber bundles arranged in one direction are prepared, and the arrangement direction of the fiber bundles is 0 °, 90 °, + 45 °, and −45 °. There is a method of laminating each sheet. Apart from this, there is a method in which a woven fabric is cut from a plain woven fabric in an oblique 45 ° direction with respect to warp and weft and the cut woven fabric is laminated on the plain woven fabric. However, in the former case, it takes time to form a prepreg in which fiber bundles are arranged in one direction (for example, 45 ° direction). In the latter case, there are many unusable parts in the method of cutting the fabric from the plain fabric in an oblique ± 45 ° direction. For this reason, the yield is poor, and the productivity is remarkably deteriorated particularly in the formation of long objects. In addition, it is difficult to maintain accuracy when the cut-out fabrics are joined together, and the strength of the seam portion is likely to decrease.

In order to solve these problems, Patent Document 1 discloses a method for producing a long axially threaded oblique fiber fabric with an axial yarn used for a very large FRP product (for example, a length of 6 m). . In the manufacturing method disclosed in this document, a braider (braiding machine) having an oblique yarn supply unit and an axial yarn supply unit is used. The oblique yarn supply unit supplies oblique yarn (braided yarn) at a predetermined angle ± θ with respect to the mandrel axis on the outer peripheral surface of the mandrel. The axial yarn supply unit supplies axial yarns arranged in the axial direction of the mandrel. The mandrel is inserted so as to be movable along the axial direction with respect to the braider. In this state, a plurality of axial yarns are supplied from the axial yarn supply unit and a plurality of oblique yarns are supplied from the oblique yarn supply unit to the outer peripheral surface of the mandrel. By forming the cylindrical fabric on the outer peripheral surface of the mandrel in this way, a polymerized cylindrical fabric formed by polymerizing the axial yarn and the cylindrical fabric is formed. Subsequently, the tubular fabric is cut open along the axial direction of the mandrel. As a result, a slanted yarn fiber fabric with a long axial direction yarn in which a plurality of slanting yarns are obliquely arranged and the axial direction yarns are arranged in the long direction is manufactured. As the brader, a known round hit braider is used.

Patent Document 2 discloses a unidirectional reinforcing fabric that exhibits excellent characteristics for composite materials. The unidirectional reinforcing fabric is a sheet composed of a group of flat reinforcing fiber multifilament yarns, a weft direction auxiliary yarn group which is provided on both upper and lower surfaces of the sheet and intersects with the reinforcing fiber multifilament yarn, and a weave structure together with the weft direction auxiliary yarn group And a warp direction auxiliary yarn group parallel to the reinforcing fiber multifilament yarn. The reinforcing fiber multifilament yarns are aligned in one direction and in parallel with each other so as not to bend the sheet.

However, in Patent Document 1, regarding the oblique yarn fiber woven fabric with the axial direction yarn, no consideration is given to a cross portion between the oblique yarns and a crimp generated at the intersection portion between the oblique yarn and the axial direction yarn. For this reason, when manufacturing a composite material including an axially threaded oblique yarn fiber woven fabric as a reinforcing material, one reinforcing fiber is arranged in a matrix while a crimp exists at each intersection with another reinforcing fiber. ing. For this reason, the characteristic which should originally express a reinforced fiber is not fully utilized. Patent Document 1 relates to the production of a long fiber fabric having fiber bundles (diagonal yarns) arranged obliquely with respect to the longitudinal direction (0 ° direction) of the fabric. However, Patent Document 2 does not mention anything about yield deterioration and productivity deterioration during manufacturing.

JP 2001-310393 A Japanese Patent No. 3279049

An object of the present invention is to provide a fiber base material having at least reinforcing fibers arranged so as to intersect with the longitudinal direction of the fiber base material, and suppressing crimping of the reinforcing fibers and having high productivity, and fiber It is providing the fiber reinforced composite material which contains a base material as a reinforcing material.

In order to solve the above problems, according to the first aspect of the present invention, a plurality of first fiber bundles arranged in parallel with each other and arranged so as to intersect with each other in parallel with each other. A fiber substrate composed of a plurality of second fiber bundles and a plurality of third fiber bundles that have the same angle intersecting the first fiber bundle and the second fiber bundle and are arranged in parallel to each other. Provided. The fiber base is a reinforcing fiber bundle composed of reinforcing fibers intersecting with the third fiber bundle, and an auxiliary yarn that is at least part of the first fiber bundle, the second fiber bundle, or the third fiber bundle. And an auxiliary yarn whose weight of auxiliary yarn is 20% or less of the weight of the reinforcing fiber. Moreover, in the fiber base material, when there is no crossing portion where the reinforcing fiber bundles cross each other, or when there is a crossing portion where the reinforcing fiber bundles cross each other, all of the crossing reinforcing fiber bundles are in the thickness direction of the fiber base material. Are arranged in the same order.

Here, “reinforcing fiber” means a fiber that plays a role of reinforcing the matrix of the composite material when the fiber base material is used as the reinforcing material of the composite material. “Auxiliary yarn” refers to a yarn that plays a role in preventing the fiber base material from being disturbed when the fiber base material is handled in the manufacturing process of the composite material. means. The auxiliary yarn itself need not contribute to the mechanical strength of the composite material. The auxiliary yarn also includes a single filament and is not necessarily a bundle of fibers. “Weight” means the weight of a predetermined length of yarn and is reflected in the thickness of the yarn.

According to this invention, the fiber base material is formed of a structure in which the first, second and third fiber bundles are arranged in three axial directions. The fiber base material has at least reinforcing fibers that intersect with the third fiber bundle. When the reinforcing fibers intersect with each other, all of the intersecting reinforcing fiber bundles are arranged in the same order in the thickness direction of the fiber base material. Thereby, the reinforcing fiber bundle which comprises a fiber base material can be arranged in the state which suppressed the crimp. Also, if the fiber base is formed from a cylindrical braid, the productivity is higher than when forming a fabric base (one-way reinforced fabric) in which fiber bundles are arranged in one direction (for example, the angle θ direction). Become. Therefore, it is possible to configure a fiber base material having at least reinforcing fibers arranged to intersect with the longitudinal direction of the fiber base material and suppressing crimping of the reinforcing fibers. In addition, the productivity of the fiber base material can be increased.

In the above fiber base material, it is preferable that either one of the first and second fiber bundles is constituted by a reinforcing fiber bundle and the other is constituted by an auxiliary yarn.

According to this invention, the reinforcing fibers do not intersect at the intersection of the first fiber bundle and the second fiber bundle. For this reason, compared with the case where the intersection part of reinforced fiber exists, the crimp of a reinforced fiber is easy to be suppressed.

In the above fiber base material, in the first fiber bundle and the second fiber bundle, it is preferable that reinforcing fiber bundles and auxiliary yarns constituted by reinforcing fibers are alternately arranged.

According to this invention, unlike the fiber base material in which either one of the first fiber bundle and the second fiber bundle is composed of reinforcing fibers, the reinforcing fibers intersecting with the third fiber bundle are biaxial. A fiber substrate arranged in the direction can be obtained. It is also possible to obtain a fiber base material in which reinforcing fibers and auxiliary yarns are evenly arranged.

In the above fiber base material, the third fiber bundle is a reinforcing fiber bundle that is arranged so as to correspond to all the intersections of the first fiber bundle and the second fiber bundle, and is configured by reinforcing fibers. It is preferable that the auxiliary yarns are alternately arranged.

According to the present invention, the number of fibers constituting the third fiber bundle can be maximized.

In the above fiber base material, it is preferable that all the third fiber bundles are made of auxiliary yarns.

According to this invention, the fiber base material has only reinforcing fibers arranged so as to intersect with the longitudinal direction (0 ° direction) of the composite material. For this reason, when laminating | stacking on the other fiber base material (woven fabric base material) which has the reinforced fiber arranged in the 0 degree direction of a composite material, and forming a composite material, strength calculation can be performed easily.

In the above fiber base material, the first fiber bundle and the second fiber bundle constitute a bundle of skewed yarns of the tubular braid, and the third fiber bundle comprises a bundle of axial yarns of the tubular braid. It is preferable to configure.

According to the present invention, it is possible to manufacture a composite material including a reinforcing fiber layer having reinforcing fibers that are arranged so as to intersect with the longitudinal direction (0 ° direction) of the composite material and in which crimping is suppressed. . Further, the productivity of the tubular braid is higher than that in the case of forming a fabric base material (unidirectional reinforcing fabric) in which fiber bundles are arranged in one direction (for example, the angle θ direction). For this reason, productivity of a fiber base material can also be improved.

In the above fiber base material, the fiber base material is preferably formed by flattening a tubular braid composed of the first fiber bundle, the second fiber bundle, and the third fiber bundle.

According to this invention, the fiber base material is obtained by flattening the tubular braid. For this reason, when a some reinforcing fiber layer is required as a reinforcement of a composite material, the effort which piles up a fiber base material decreases.

In the above fiber base material, the fiber base material is formed in a sheet shape by opening a tubular braid, and the first fiber bundle and the second fiber bundle constitute a bundle of skew yarns of the tubular braid, The third fiber bundle preferably constitutes a bundle of axial yarns of a tubular braid.

According to this invention, the reinforcing fiber layer constituting the fiber base is one layer. For this reason, when using as a reinforcing material of a composite material, it is possible to prevent the reinforcing fiber layers arranged in the 0 ° direction from overlapping. Therefore, the degree of freedom of the laminated configuration of the reinforcing fiber layer is increased.

In the above fiber base material, the fiber base material is formed into a sheet shape by cutting the cylindrical braid along the axial direction thereof, and the first fiber bundle and the second fiber bundle are the skewed yarns of the cylindrical braid. Preferably, the third fiber bundle constitutes a bundle of axial threads of a tubular braid.

根据 本 发明 ， 基本上 具有 与 权利 要求 6 的 发明 的 作用 效果。 According to the present invention, basically the same effect as the invention of claim 6. However, the reinforcing fiber layer constituting the fiber base is one layer. For this reason, unlike the invention described in claim 6, when used as a reinforcing material for a composite material, the reinforcing fiber layers arranged in the 0 ° direction can be prevented from overlapping. Therefore, the degree of freedom of the laminated configuration of the reinforcing fiber layer is increased.

In the above fiber base material, the angle is preferably 45 °.

According to this invention, a fiber base material in which fiber bundles are arranged at 45 ° or 45 ° can be obtained. Accordingly, the mechanical properties of the composite material can be made pseudo-isotropic.

In the above fiber base material, the auxiliary yarn is preferably composed of organic fibers.

According to this invention, the organic fiber is more flexible than the inorganic fiber. For this reason, compared with the case where inorganic fiber is used as an auxiliary yarn, the auxiliary yarn can be preferentially bent at the intersection of the auxiliary yarn and the reinforcing fiber. Thereby, the crimp which arises in a reinforced fiber can be suppressed.

In order to solve the above problems, according to a second aspect of the present invention, there is provided a fiber reinforced composite material including the above fiber base material as a reinforcing material.

The reinforcing material used in the fiber-reinforced composite material of the present invention has the effect of the fiber base according to any one of claims 1 to 11.

In order to solve the above problems, according to a third aspect of the present invention, there is provided a prepreg obtained by impregnating the above fiber base material with a resin.

(A) is a top view of the braid layer located on the upper side of the fiber base material of 1st Embodiment, (b) is a top view of the braid layer located on the lower side of the fiber base material, (c) is FIG. ) Is a cross-sectional view taken along line 1c-1c, (d) is a cross-sectional view taken along line 1d-1d in FIG. 1 (a), and (e) is a third fiber bundle without first and second fibers. Sectional drawing of the fiber base material whose fiber bundle is all reinforced fiber. The perspective view of a cylindrical braid. The partially broken perspective view of a composite material. (A) is a plan view of the braid layer positioned on the upper side of the fiber base material of the second embodiment, (b) is a sectional view taken along line 4b-4b of FIG. 4 (a), and (c) is FIG. Sectional drawing along the 4c-4c line of a). The top view of the fiber base material of 3rd Embodiment. The partially broken perspective view of a composite material. (A) is a top view of the braid layer located above the fiber base material of 4th Embodiment, (b) is a top view of the braid layer located below the fiber base material. The partially broken perspective view of a composite material. (A) is a top view of the fiber base material of 5th Embodiment, (b) is a partially broken perspective view of a composite material. The top view of the fiber base material of another embodiment. The top view of the fiber base material of another embodiment. The top view which shows the state which cuts out the fiber base material of another embodiment. (A), (b) is a top view which shows the state which cuts out the fiber base material of another embodiment, respectively.

(First embodiment)
Hereinafter, a first embodiment in which the fiber base material and fiber-reinforced composite material of the present invention are embodied will be described with reference to FIGS.

As shown in FIGS. 1A and 1B, the fiber base material 10 includes a plurality of first fiber bundles 11, a plurality of second fiber bundles 12, and a plurality of third fiber bundles 13. It is configured. The plurality of first fiber bundles 11 are arranged in parallel to each other. The plurality of second fiber bundles 12 are arranged in parallel to each other and cross the first fiber bundle 11. The plurality of third fiber bundles 13 intersect with each of the first and second fiber bundles 11 and 12 at the same angle and are arranged in parallel to each other.

As shown in FIG. 2, the fiber base material 10 is formed by flattening a tubular braid 14 formed in a tubular shape. Each of the first and second fiber bundles 11 and 12 constitutes a bundle of skew yarns of the tubular braid 14. The third fiber bundle 13 constitutes a bundle of axial threads of the tubular braid 14. The first fiber bundle 11 intersects with the axial direction of the tubular braid 14 (vertical direction in FIGS. 1A and 1B) at an angle θ. The second fiber bundle 12 intersects the axial direction of the tubular braid 14 at an angle −θ. That is, the angle that intersects the axial direction of the tubular braid 14 of the second fiber bundle 12 is opposite to the angle θ that intersects the axial direction of the tubular braid 14 of the first fiber bundle 11. . In the first embodiment, the angle θ is 45 °. The third fiber bundle 13 is arranged in parallel to the axial direction of the tubular braid 14.

One of the first and second fiber bundles 11 and 12 is constituted by a fiber reinforcing bundle 15 and the other is constituted by an auxiliary thread 16. In the first embodiment, the first fiber bundle 11 is constituted by the fiber reinforcing bundle 15, and the second fiber bundle 12 is constituted by the auxiliary yarn 16. The third fiber bundle 13 is arranged so as to correspond to all the intersecting portions of the first fiber bundle 11 and the second fiber bundle 12. In the third fiber bundle 13, fiber reinforcing bundles 15 and auxiliary yarns 16 are alternately arranged. The first fiber bundle 11 constituted by the fiber reinforced bundle 15 intersects the third fiber bundle 13 constituted by the reinforced fiber on the same side. Here, the 1st fiber bundle 11 cross | intersects the 3rd fiber bundle 13 comprised by the reinforced fiber in the state which passes the outer side of the cylindrical braid 14.

In the fiber base material 10, an intersecting portion 17 a where one fiber reinforced bundle 15 and two auxiliary yarns 16 intersect, and an intersecting portion where two fiber reinforced bundles 15 and one auxiliary yarn 16 intersect. 17b exists. At the intersection 17b, the fiber reinforced bundles 15 intersect. At the intersecting portion 17a, the second and third fiber bundles 12 and 13 constituted by the auxiliary yarn 16 and the first fiber bundle 11 constituted by the fiber reinforcing bundle 15 intersect. At the intersection 17b, the third fiber bundle 13 constituted by the fiber reinforced bundle 15, the first fiber bundle 11 constituted by the fiber reinforced bundle 15, and the second fiber bundle 12 constituted by the auxiliary yarn 16. And intersect.

“Reinforcing fiber” means a fiber that plays a role of reinforcing the matrix of the composite material when the fiber substrate 10 is used as a reinforcing material for the composite material. As the fiber reinforced bundle 15, a non-twisted fiber of light weight, high breaking strength, and high elastic modulus is used. Here, carbon fiber is used as the fiber reinforced bundle 15. The carbon fiber has, for example, about 10,000 to several tens of thousands of filaments depending on the required performance of the composite material, and has a number of filaments suitable for the required performance.

The auxiliary yarn 16 prevents the arrangement of the fiber reinforcing bundles 15 constituting the fiber base material 10 from being disturbed or the fiber base material 10 from being deformed when the composite material is manufactured. The auxiliary yarn 16 does not necessarily contribute to the mechanical strength of the composite material.

The auxiliary yarn 16 is composed of a yarn or a fiber bundle. The basis weight of the auxiliary yarn 16 is 20% or less of the basis weight of the fiber reinforced bundle 15, and preferably less than 10%. The auxiliary yarn 16 is set according to the strength required for the fiber base material 10 as a reinforcing material of the composite material and the material of the auxiliary yarn 16. “Weight” means the weight of a predetermined length of yarn and is reflected in the thickness. The auxiliary yarns 16 are preferably made of organic fibers that are lighter and more flexible than inorganic fibers, and here are made of polyester fibers.

The fiber base material 10 has a two-layer structure in which the tubular braid 14 is flattened. In any state of the tubular braid 14, the first fiber bundle 11 intersects the axis of the tubular braid 14 at an angle θ as shown in FIG. Intersects with the axial direction of the tubular braid 14 at an angle −θ. The third fiber bundle 13 is parallel to the axial direction of the tubular braid 14. Therefore, as shown in FIGS. 1 (a) and 1 (b), when the upper layer 10a and the lower layer 10b of the fiber base material 10 are viewed from above, the arrangement direction of the first fiber bundles 11 and the tubular braid The angle θ formed by the axial direction of 14 is 45 ° in the upper layer 10a and −45 ° in the lower layer 10b when the clockwise direction is + with respect to the axial direction. That is, the fiber base material 10 has a two-layer structure including an upper layer 10a and a lower layer 10b. The upper layer 10a has a fiber reinforced bundle 15 arranged at 0 ° with respect to the axial direction of the tubular braid 14 and a fiber reinforced bundle 15 arranged at 45 °. The lower layer 10b has a fiber reinforced bundle 15 arranged at 0 ° with respect to the axial direction of the tubular braid 14 and a fiber reinforced bundle 15 arranged at −45 °.

The cylindrical braid 14 constituting the fiber base material 10 is a three-dimensional braider (rotor carrier type three-dimensional weaving loom) disclosed in, for example, Japanese Patent Publication No. 3-64619 and Japanese Patent Publication No. 4-13463. Manufactured using. Here, a mandrel having an outer diameter equal to the inner diameter of the tubular braid 14 to be formed is used. The third fiber bundle 13 is wound around the outer peripheral surface of the mandrel so as to extend in the axial direction of the mandrel and to intersect the first and second fiber bundles 11 and 12 at a predetermined angle. Thus, the tubular braid 14 is formed by forming the braid structure. After the tubular braid 14 is cut to the length of the fiber base material 10, the tubular braid 14 is crushed and flattened. Thereby, the fiber base material 10 used as a reinforcement of a composite material is completed.

The fiber base material 10 is cut into a predetermined length. At the same time, the fiber base material 10 is laminated on another fiber base material to constitute a four-axis (0 °, 45 °, −45 °, 90 °) reinforcing material. The other fiber base material has a reinforcing fiber bundle 15 having an angle of 90 ° with the longitudinal direction of the composite material, that is, the arrangement direction of the third fiber bundles 13 of the fiber base material 10. As the other fiber base as described above, for example, a plain woven fabric using auxiliary yarns for warps and reinforcing fibers for wefts is used.

The composite material 18 shown in FIG. 3 is formed by laminating a plain fabric W1 on both sides of the fiber base material 10, and impregnating and hardening the resulting laminate with a matrix resin. An auxiliary yarn is used for the warp of the fiber substrate 10 and a reinforcing fiber is used for the weft. FIG. 3 shows the upper layer 10a and the lower layer 10b of the fiber base material 10, respectively. In order to give the mechanical properties of the composite material 18 quasi-isotropic properties, it is only necessary to have reinforcing fibers arranged at 0 °, 45 °, −45 ° and 90 ° with respect to the longitudinal direction of the composite material 18. . That is, when at least one plain fabric W1 and one fiber base material 10 are used, the composite material 18 having pseudo-isotropic mechanical characteristics can be obtained. Depending on the required performance of the composite material 18, the number of the fiber base material 10 and the plain fabric W1 to be laminated is set. In FIG. 3, the reinforcing fibers of the plain woven fabric W1 are indicated by thick lines, and the auxiliary yarns are indicated by thin lines.

The composite material 18 is manufactured by laminating the fiber base material 10 together with other fiber base materials in a mold, impregnating the laminate with a resin serving as a matrix, and curing the resin. As the matrix resin, for example, a thermosetting resin such as an epoxy resin, an unsaturated polyester resin, or a vinyl ester resin is used. For example, the resin is impregnated and cured by an RTM (resin transfer molding) method.

Next, the operation of the fiber substrate 10 will be described.

In the case where both the first and second fiber bundles 11 and 12 are constituted by the reinforcing fiber bundle 15, at the intersection where the first fiber bundle 11 and the second fiber bundle 12 constituting the fiber base material 10 intersect. The first and second fiber bundles 11 and 12 are both bent by receiving the same pressure. In addition, when one of the first and second fiber bundles 11 and 12 is constituted by the reinforcing fiber bundle 15 and the other is constituted by the auxiliary yarn 16, the fiber bundle constituted by the fiber reinforcing bundle 15 is almost bent. Instead, the fiber bundle constituted by the auxiliary yarns 16 is greatly bent. Therefore, when both the first and second fiber bundles 11 and 12 are constituted by the fiber reinforcing bundle 15, the cross section of the fiber base material 10 along the first fiber bundle 11 is shown in FIG. It becomes like this. In this case, the first fiber bundle 11 has a crimp that bends in the opposite direction to the second fiber bundle 12 at a location corresponding to the second fiber bundle 12. Moreover, in the cross section of the fiber base material 10 along the second fiber bundle 12, the second fiber bundle 12 is in the opposite direction to the first fiber bundle 11 for each portion corresponding to the first fiber bundle 11. There are bending crimps. Therefore, when the composite material 18 including the fiber base material 10 as a reinforcing material is manufactured, the high tensile strength of the reinforcing fiber bundle 15 is not sufficiently exhibited in the first and second fiber bundles 11 and 12.

In that respect, according to the first embodiment of the present invention, there is no intersection between the first fiber bundle 11 and the second fiber bundle 12 where the fiber reinforcing bundles 15 intersect each other. That is, the intersecting portion of the first fiber bundle 11 and the second fiber bundle 12 is limited to the intersecting portion 17 a between the fiber reinforcing bundle 15 and the auxiliary yarn 16. In addition, the first fiber bundle 11 constituted by the reinforcing fiber bundle 15 is on the same side (here, the outer side in the tubular braid 14) with respect to the third fiber bundle 13 constituted by the fiber reinforcing bundle 15. Crossed. That is, the first fiber bundle 11 constituted by the fiber reinforced bundle 15 and the third fiber bundle 13 constituted by the fiber reinforced bundle 15 are formed on the fiber base material 10 at the intersecting portion 17b where the fiber reinforced bundles 15 intersect each other. They are arranged in the same order in the thickness direction. Therefore, the third fiber bundle 13 constituted by the fiber reinforced bundle 15 is arranged in a state of extending straight in the axial direction of the tubular braid 14. FIG. 1C shows a cross section of the fiber base material 10 cut along the first fiber bundle 11. As shown in the figure, the first fiber bundle 11 constituted by the fiber reinforced bundle 15 is composed of the third fiber bundle 13 constituted by the fiber reinforced bundle 15 and the second fiber bundle constituted by the auxiliary yarn 16. 12 are arranged straight at a position corresponding to 12. On the other hand, as shown in FIG. 1 (d), the second fiber bundle 12 constituted by the auxiliary yarn 16 corresponds to the first fiber bundle 11 and the third fiber bundle 13 constituted by the fiber reinforced bundle 15. It is bent in the opposite direction to the fiber reinforced bundle 15 at the place where it does. Therefore, when the composite material 18 including the fiber base material 10 as a reinforcing material is manufactured, the first and third fiber bundles 11 and 13 configured by the fiber reinforced bundle 15 have sufficient high tensile strength of the fiber reinforced bundle 15. To be demonstrated. In FIGS. 1C and 1D, hatching representing a cross section of the fiber bundle along the cut surface is omitted. Further, the difference in the shape and size of the fiber bundle cross section due to the difference in angle intersecting the cut surface is ignored.

According to the first embodiment, the following effects can be obtained.

(1) The fiber substrate 10 includes a plurality of first fiber bundles 11 arranged in parallel to each other and a plurality of second fiber bundles arranged in parallel to each other so as to intersect the first fiber bundle 11. 12 and a plurality of third fiber bundles 13 having the same angle intersecting with the first and second fiber bundles 11 and 12 and arranged in parallel to each other. The fiber base 10 has at least a fiber reinforced bundle 15 that intersects with the third fiber bundle 13. Further, the fiber base 10 has an auxiliary yarn 16 that is at least a part of the first fiber bundle 11, the second fiber bundle 12, or the third fiber bundle 13. The basis weight of the auxiliary yarn 16 is 20% or less of the basis weight of the fiber reinforced bundle 15. Moreover, when the crossing part 17b where the fiber reinforced bundles 15 cross each other exists, all the fiber reinforced bundles 15 crossing at the crossing part 17b are arranged in the same order in the thickness direction of the fiber base 10. Therefore, the fiber reinforced bundle 15 (first fiber bundle 11) arranged so as to intersect with the third fiber bundle 13 is arranged in a state where the crimp is suppressed. Therefore, the fiber base material 10 in which at least the fiber reinforcing bundles 15 are arranged so as to intersect with the longitudinal direction of the fiber base material 10 and crimping of the fiber reinforcing bundles 15 is suppressed can be configured.

(2) Either one of the first and second fiber bundles 11, 12 (here, the first fiber bundle 11) is composed of the fiber reinforcing bundle 15, and the other is composed of the auxiliary yarn 16. . For this reason, there is no intersection between the fiber reinforced bundle 15 of the first fiber bundle 11 and the fiber reinforced bundle 15 of the second fiber bundle 12. Therefore, compared with the case where the intersection part of the fiber reinforcement bundle 15 of the 1st fiber bundle 11 and the fiber reinforcement bundle 15 of the 2nd fiber bundle 12 exists, the crimp of the fiber reinforcement bundle 15 is easy to be suppressed.

(3) The third fiber bundle 13 is arranged so as to correspond to all the intersections of the first fiber bundle 11 and the second fiber bundle 12. In the third fiber bundle 13, the fiber reinforcing bundles 15 and the auxiliary yarns 16 are alternately arranged. For this reason, the number of the 3rd fiber bundle 13 comprised by the fiber reinforcement bundle 15 can be made the most. Therefore, the composite material 18 can be manufactured without using another fabric base material including a reinforcing fiber layer extending in the longitudinal direction of the composite material 18.

(4) The fiber base material 10 is formed by flattening the tubular braid 14. The first and second fiber bundles 11 and 12 constitute a bundle of skewed yarns of the tubular braid 14, and the third fiber bundle 13 constitutes a bundle of axial yarns of the tubular braid 14. Therefore, the fiber base material 10 can be provided with a reinforced fiber layer having fiber reinforced bundles 15 that are arranged so as to intersect with the longitudinal direction (0 ° direction) of the composite material and in which crimping is suppressed. In addition, the productivity of the fiber base material 10 can be increased as compared with the conventional unidirectional reinforcing fabric. Moreover, since the fiber base material 10 is formed by flattening the tubular braid 14, it can have two reinforcing fiber layers. For this reason, when a some reinforcement fiber layer is required as a reinforcement of the composite material 18, the effort which overlaps the fiber base material 10 can be saved.

(5) The angle θ formed by the fiber reinforced bundle 15 constituting the first fiber bundle 11 and the third fiber bundle 13 is 45 °. For this reason, the fiber base material 10 in which the fiber bundles are arranged at 45 ° or −45 ° can be obtained, and the mechanical properties of the composite material 18 can be made pseudo-isotropic. Further, the arrangement direction of the first fiber bundles 11 constituted by the fiber reinforced bundles 15 is different between the upper layer 10 a and the lower layer 10 b of the fiber base material 10. For this reason, when used as a reinforcing material for the composite material 18, a single fiber base material 10 allows a reinforcing fiber layer in which the fiber reinforcing bundles 15 are arranged at 45 ° and a reinforcing fiber layer arranged at −45 °. Can be provided.

(6) The auxiliary thread 16 is made of organic fibers. For this reason, compared with the case where inorganic fiber is used as the auxiliary yarn 16, it is easy to suppress the crimping of the fiber reinforced bundle 15.

(Second Embodiment)
Next, a second embodiment will be described with reference to FIGS. The second embodiment differs from the first embodiment in the arrangement configuration of the first and second fiber bundles 11 and 12. The same parts as those of the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

As shown in FIG. 4A, in each of the first fiber bundle 11, the second and third fiber bundles 12, 13, the fiber reinforcing bundle 15 and the auxiliary yarn 16 are alternately arranged. In the fiber base material 10 of the first embodiment, two auxiliary yarns 16 (second and third fiber bundles 12 and 13) and one fiber reinforcing bundle 15 (first fiber bundle 11) intersect. There is an intersecting portion 17a and an intersecting portion 17b where two fiber reinforcing bundles 15 (first and third fiber bundles 11 and 13) and one auxiliary yarn 16 (second fiber bundle 12) intersect. It was.

In this embodiment, two auxiliary yarns 16 (one of the first and second fiber bundles 11 and 12 and the third fiber bundle 13) and one fiber reinforced bundle 15 (first and second fiber bundles). 11 and the other) and the three fiber reinforcing bundles 15 (the first fiber bundle 11, the second fiber bundle 12, and the third fiber bundle 13) intersect. And exist. In the intersecting portion 17 c, the three fiber reinforced bundles 15 are arranged in the same order at all locations in the thickness direction of the fiber base material 10. Here, the first fiber bundle 11, the third fiber bundle 13, and the second fiber bundle 12 are arranged in this order from the outside of the tubular braid 14.

The third fiber bundle 13 configured by the fiber reinforced bundle 15 includes a crossing portion of the first fiber bundle 11 and the second fiber bundle 12 configured by the fiber reinforced bundle 15 and the auxiliary yarn 16. The first fiber bundle 11 and the second fiber bundle 12 intersect each other at the intersection of one fiber bundle 11 and the second fiber bundle 12. The third fiber bundle 13 constituted by the auxiliary yarns 16 is the first fiber at the intersection of the first fiber bundle 11 and the second fiber bundle 12 which is the intersection of the fiber reinforcement bundle 15 and the auxiliary yarn 16. It intersects with the bundle 11 and the second fiber bundle 12, respectively.

The cross section of the fiber base material 10 along the first fiber bundle 11 constituted by the fiber reinforced bundle 15 is as shown in FIG. That is, on the inner side of the first fiber bundle 11 constituted by the fiber reinforced bundle 15 (lower side in FIG. 4B), the third fiber bundle 13 constituted by the fiber reinforced bundle 15 is the first fiber bundle. The second fiber bundle 12 formed by the fiber reinforced bundle 15 is orthogonal to the first fiber bundle 11 while intersecting 11 and 45 °. On the outside of the first fiber bundle 11 constituted by the fiber reinforced bundle 15 (the upper side in FIG. 4B), the third fiber bundle 13 constituted by the auxiliary yarn 16 is 45 ° with the first fiber bundle 11. And the second fiber bundle 12 constituted by the auxiliary yarns 16 is orthogonal to the first fiber bundle 11. The second and third fiber bundles 12 and 13 constituted by the second and third fiber bundles 12 and 13 constituted by the fiber reinforced bundle 15 and the auxiliary yarn 16 are both provided at a predetermined interval.

Moreover, the cross section of the fiber base material 10 along the 2nd fiber bundle 12 comprised by the auxiliary thread | yarn 16 becomes as shown in FIG.4 (c). That is, the second fiber bundle 12 constituted by the auxiliary yarn 16 is greatly bent. Thereby, the 1st and 3rd fiber bundles 11 and 13 comprised by the fiber reinforcement bundle 15 which cross | intersects the 2nd fiber bundle 12 comprised by the auxiliary yarn 16 are the same positions in the thickness direction of the fiber base material 10. Held in a relationship.

Therefore, even if there is an intersecting portion 17c where the three fiber reinforced bundles 15 intersect, the first fiber bundle 11, the second fiber bundle 12, and the third fiber bundle 13 configured by the fiber reinforced bundle 15 are The fiber substrate 10 is held in the same positional relationship in the thickness direction. For this reason, the crimp in the 1st fiber bundle 11, the 2nd fiber bundle 12, and the 3rd fiber bundle 13 is suppressed. Therefore, when the composite material 18 is manufactured using the fiber base material 10 as a reinforcing material, the first fiber bundle 11, the second fiber bundle 12, and the third fiber bundle 13 have high tensile strength that the fiber reinforcing bundle 15 has. It is fully demonstrated.

Therefore, according to the second embodiment, in addition to the same effects as (1), (3) to (6) of the first embodiment, the following effects can be obtained.

(7) In each of the first and second fiber bundles 11 and 12, the fiber reinforcing bundles 15 and the auxiliary yarns 16 are alternately arranged. For this reason, unlike the fiber base material 10 in which any one of the first and second fiber bundles 11 and 12 is constituted by the fiber reinforcement bundle 15, the fiber reinforcement bundle intersecting the third fiber bundle 13. The fiber base material 10 in which 15 is arranged in the biaxial direction can be obtained. Further, the fiber reinforced bundle 15 and the auxiliary yarns 16 can be evenly arranged.

(Third embodiment)
Next, a third embodiment will be described with reference to FIGS. The third embodiment is different from the first embodiment in that the fiber base material 20 is not one layer but one layer. The same parts as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

The fiber base material 20 is formed in a sheet shape by cutting the tubular braid 14 along its axial direction. Therefore, when the same cylindrical braid 14 is used, as shown in FIG. 5, the width of the fiber base 20 is twice the width of the fiber base 10 in which the cylindrical braid 14 is flattened. In the fiber base material 20, all the first fiber bundles 11 are constituted by the fiber reinforcing bundles 15, and all the second fiber bundles 12 are constituted by the auxiliary yarns 16. For this reason, in the fiber base material 20, the fiber reinforced bundle 15 intersects the axial direction of the tubular braid 14 at an angle θ (45 °).

The composite material 18 having pseudo-isotropic mechanical properties is manufactured using the fiber base material 20. In this case, the fiber base material 20 is laminated | stacked on another fiber base material, and comprises a 4-axis reinforcement. In addition, the other fiber base material has reinforcing fibers whose angle formed with the longitudinal direction of the composite material 18 is 90 °. As the other fiber base as described above, a plain woven fabric W1 using reinforcing fibers as wefts and auxiliary yarns as warps is used. At least two fiber base materials 20 are necessary. Both fiber base materials 20 are laminated with the front and back sides reversed. As shown in FIG. 6, both the fiber base materials 20 sandwich the plain woven fabric W <b> 1 and connect the first fiber bundle 11 of one fiber base material 20 and the first fiber bundle 11 of the other fiber base material 20. They are stacked in a symmetrical arrangement. Depending on the required performance of the composite material 18, the number of the fiber base material 20 and the plain fabric W1 to be laminated is set.

Therefore, according to the third embodiment, in addition to the same effects as (1) to (3) and (6) of the first embodiment, the following effects can be obtained.

(8) The fiber base material 20 is formed in a sheet shape by cutting the tubular braid 14 along its axial direction. In this case, the reinforcing fiber layer of the fiber base 20 is one layer. For this reason, when using the fiber base material 20 as a reinforcing material of the composite material 18, it is possible to prevent the two reinforcing fiber layers intersecting the fiber reinforcing bundle 15 arranged in the 0 ° direction from overlapping. Therefore, the degree of freedom of the laminated configuration of the reinforcing fiber layer is increased.

(Fourth embodiment)
Next, a fourth embodiment will be described with reference to FIGS. The fourth embodiment differs from the first embodiment in the configuration of the third fiber bundle 13. The same parts as those of the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

As shown in FIGS. 7A and 7B, in the fiber base material 10, all the first fiber bundles 11 are constituted by the fiber reinforcing bundles 15, and all the second fiber bundles 12 are formed by the auxiliary yarns 16. It is configured. All the third fiber bundles 13 are constituted by the auxiliary yarns 16. That is, there is no fiber reinforced bundle 15 arranged in the longitudinal direction (0 ° direction) of the composite material 18. Here, the fiber bundles constituted by the fiber reinforced bundles 15 are arranged in directions of 45 ° and −45 °, respectively.

The fiber base material 10 is laminated on another fiber base material to constitute a four-axis reinforcing material. The fiber base material has reinforcing fibers whose angles to the longitudinal direction of the composite material 18 are 0 ° and 90 °. As the other fiber base as described above, a plain fabric in which crimping of reinforcing fibers is suppressed by alternately arranging reinforcing fibers and auxiliary yarns on warps and wefts is used. In addition, a plain fabric using reinforcing fibers as warps and auxiliary yarns as wefts is used as a fiber base material in which reinforcing fibers are arranged only in the direction of 0 °. Further, as a fiber base material in which reinforcing fibers are arranged only in the direction of 90 °, a plain fabric W1 using reinforcing fibers as wefts and auxiliary yarns as warps is used.

As shown in FIG. 8, here, a plain woven fabric W2 in which reinforcing fibers and auxiliary yarns are alternately arranged on warps and wefts is used as another fiber base material. The composite material 18 is manufactured by impregnating a matrix resin into a laminate in which a plain woven fabric W2 is laminated on both sides of the fiber substrate 10 and curing the laminate.

Therefore, according to the fourth embodiment, the same effects as (1), (2), (4) to (6) of the first embodiment can be obtained.

(Fifth embodiment)
Next, a fifth embodiment will be described with reference to FIGS. 9 (a) and 9 (b). The fifth embodiment is greatly different from the above embodiments in that the angle θ formed by the first fiber bundle 11 and the second fiber bundle 12 and the axial direction of the tubular braid 14 is 30 ° instead of 45 °. Different. Other configurations are basically the same as those of the second embodiment, and the same parts as those of the second embodiment are denoted by the same reference numerals and detailed description thereof is omitted.

As shown in FIG. 9A, in the first and second fiber bundles 11 and 12, fiber reinforcing bundles 15 and auxiliary yarns 16 are alternately arranged. All of the third fiber bundles 13 are auxiliary yarns 16 and are arranged at positions corresponding to the intersecting portions 17b of the first fiber bundle 11 and the second fiber bundle 12 where the fiber reinforcing bundles 15 intersect each other. Yes.

In the fiber base material 10, the crossing part 17b of the fiber reinforcement bundles 15 exists. The intersecting portion 17b is constituted by fiber reinforcing bundles 15 constituting the first and second fiber bundles 11 and 12, respectively. The second fiber bundle 12 intersects the first fiber bundle 11 on the same side. For this reason, as in the second embodiment, although there is an intersecting portion 17b between the fiber reinforced bundles 15, crimping in the first fiber bundle 11 and the second fiber bundle 12 is suppressed.

The first fiber bundle 11 and the second fiber bundle 12 intersect so as to form an angle of 60 °. For this reason, as shown in FIG. 9B, when the fiber base material 10 is used as a reinforcing material for the composite material 18, it is laminated on another fiber base material to constitute a triaxial reinforcing material. . The other fiber base has reinforcing fibers having an angle of 90 ° with the longitudinal direction of the composite material 18. As the other fiber base as described above, a plain woven fabric W1 using reinforcing fibers as wefts and auxiliary yarns as warps is used.

Therefore, according to the fifth embodiment, in addition to the same effects as (1), (4), (6) of the first embodiment and (7) of the second embodiment, the following effects can be obtained. .

(9) The angle θ formed by the fiber reinforced bundle 15 and the axial direction of the tubular braid 14 is 30 °. The fiber base material 10 is formed by flattening the tubular braid 14. Therefore, the fiber base material 10 is suitable as a reinforcing material for the composite material 18 having pseudoisotropy in which triaxial reinforcing fibers are arranged so as to cross each other at 60 °.

In addition, you may change each said embodiment as follows.

In the first to third embodiments, the third fiber bundles 13 constituting the fiber base materials 10 and 20 are arranged corresponding to all the intersections of the first fiber bundle 11 and the second fiber bundle 12. There is no need to be done. For example, as shown in FIG. 10, you may remove all the 3rd fiber bundles 13 comprised with the auxiliary thread 16 from the fiber base material 10 of 1st Embodiment.

In the first to third embodiments, the third fiber bundle 13 is arranged corresponding to all the intersections of the first fiber bundle 11 and the second fiber bundle 12. In this configuration, in the third fiber bundle 13, the fiber bundles configured by the fiber reinforced bundle 15 do not have to be adjacent to each other. That is, in the third fiber bundle 13, a portion where a plurality of auxiliary yarns 16 are adjacent to each other and one fiber reinforced bundle 15 may be mixed. Moreover, you may remove a part or all of the 3rd fiber bundle 13 comprised by the auxiliary thread 16 from this structure.

In the first to third embodiments, in the tubular braid 14, all of the first fiber bundles 11 pass outside the specific third fiber bundle 13 (fiber bundle constituted by the fiber reinforced bundle 15), and It is not necessary for all the two fiber bundles 12 to pass inside the specific third fiber bundle 13. For example, as shown in FIG. 11, in the third fiber bundle 13, fiber reinforcing bundles 15 and auxiliary yarns 16 are alternately arranged. The first fiber bundle 11 includes a fiber bundle that passes through the inside of the specific third fiber bundle 13, and a fiber bundle that passes through the outside of the specific third fiber bundle 13 (fiber bundle formed by the auxiliary yarns 16). You may comprise by. Further, the second fiber bundle 12 may be constituted by the auxiliary yarn 16 and may be constituted by a fiber bundle passing through the inside of the specific third fiber bundle 13 (fiber bundle constituted by the fiber reinforcing bundle 15). . The inner side and the outer side of the fiber bundle correspond to the inner side and the outer side of the cylindrical braid 14 constituting the fiber base material 10.

In the fiber base material 10, one skewed yarn (for example, the first fiber bundle 11) is continuous on the upper side (or the lower side) with respect to the plurality of other skewed yarns (second fiber bundle 12). May be arranged.

The fiber base materials 10 and 20 have the same angle at which the first fiber bundle 11, the second fiber bundle 12 that intersects the first fiber bundle 11, and the first and second fiber bundles 11 and 12 intersect. The third fiber bundle 13 arranged in this manner and at least a part of the fiber bundle intersecting with the third fiber bundle 13 may be constituted by the reinforcing fibers. For example, the angle θ formed by the first fiber bundle 11 and the third fiber bundle 13 is not limited to 30 ° or 45 °, but 0 ° <θ <30 °, 30 ° <θ <45 °, or 45 °. It may be <θ <90 °. However, in order to reduce the number of laminated fiber base materials and obtain pseudoisotropy, the angle θ is preferably set to 30 ° or 45 °.

The fiber base materials 10 and 20 include at least a fiber reinforced bundle 15 that is a part of the first fiber bundle 11 or the second fiber bundle 12 that intersects the third fiber bundle, the first fiber bundle 11, and the second fiber bundle 12. And the auxiliary yarn 16 that is at least a part of the third fiber bundle 12 or the third fiber bundle 13 and satisfy the following conditions. The condition is that when the intersecting portions 17b and 17c where the fiber reinforcing bundles 15 intersect each other do not exist or when the intersecting portions 17b and 17c exist, all the intersecting fiber reinforcing bundles 15 are in the same order in the thickness direction of the fiber base material. It is arranged in. For example, one fiber bundle constituted by the fiber reinforced bundle 15 and a set of a plurality of auxiliary yarns 16 may be alternately arranged. However, in these cases, the fiber reinforced bundle 15 is reduced, and the strength of the fiber substrate 10 and the like is weakened.

The fiber base material 20 formed by cutting the tubular braid 14 along the axial direction into a sheet shape is not limited to the configuration of the third embodiment. For example, in each of the first fiber bundle 11, the second fiber bundle 12, and the third fiber bundle 13, the fiber reinforcing bundles 15 and the auxiliary yarns 16 are alternately arranged, or the third fiber bundle 13 assists. The thread 16 may be omitted. A part of the fiber reinforced bundle 15 may be used as the auxiliary yarn 16.

When the cylindrical braid 14 is cut open to form a sheet-like fiber base material, the direction in which the cylindrical braid 14 is cut open is not limited to the axial direction of the cylindrical braid 14. As shown in FIG. 12, all of the first fiber bundles 11 are composed of fiber reinforcing bundles 15, all of the second fiber bundles 12 and third fiber bundles 13 are composed of auxiliary yarns 16, and the first The fiber bundle 11 intersects with the axial direction of the tubular braid 14 at an angle of 45 °, and the second fiber bundle 12 intersects the axial direction of the tubular braid 14 with an angle of −45 °. You may cut along the fiber bundle 12. In this case, in the obtained sheet-like fiber base material, the fiber reinforced bundles 15 are arranged so as to form + 90 ° with respect to the two-dot chain line indicating the direction of opening the tubular braid 14. Further, as shown in FIG. 13A, all of the first fiber bundles 11 are constituted by the fiber reinforcing bundles 15, and all of the second fiber bundles 12 and the third fiber bundles 13 are constituted by the auxiliary yarns 16. The first fiber bundle 11 intersects with the axial direction of the tubular braid 14 at an angle of 60 °, and the second fiber bundle 12 intersects with the axial direction of the tubular braid 14 at an angle of −60 °. May be cut along the second fiber bundle 12. In this case, in the obtained sheet-like fiber base material, the fiber reinforced bundles 15 are arranged so as to form + 120 ° with respect to the two-dot chain line indicating the direction of opening the tubular braid 14.

The direction in which the tubular braid 14 is opened is not limited to the arrangement direction of the second fiber bundle 12 (auxiliary yarn 16). For example, as shown in FIG. 13B, all of the first fiber bundles 11 are constituted by the fiber reinforcing bundles 15, and all of the second fiber bundles 12 and the third fiber bundles 13 are constituted by the auxiliary yarns 16. The first fiber bundle 11 intersects with the axial direction of the tubular braid 14 at an angle of 60 °, and the second fiber bundle 12 intersects with the axial direction of the tubular braid 14 at an angle of −60 °. May be cut along a line that forms an angle of 15 ° with the axial direction. In this case, in the obtained sheet-like fiber base material, the fiber reinforced bundles 15 are arranged so as to form + 45 ° with respect to a two-dot chain line indicating a direction in which the tubular braid 14 is opened. When the tubular braid 14 is cut obliquely with respect to the axial direction, a longer unidirectional fiber base material can be obtained as compared with the case where the tubular braid 14 is cut along the axial direction. Moreover, since the fiber reinforced bundle 15 arranged in one direction is supported by the auxiliary yarns 16 arranged in two directions, the shape of the fiber reinforced bundle 15 is stabilized.

The fiber base material is not limited to the flat tubular braid 14 and may be bent in a cylindrical shape, a wave shape, or a zigzag shape, for example.

The fiber reinforced bundle 15 has high strength and high elastic modulus such as inorganic fibers such as glass fibers and ceramic fibers, or aramid fibers, poly-p-phenylenebenzobisoxazole fibers, and ultrahigh molecular weight polyethylene fibers in addition to carbon fibers. Organic fibers may be used. Carbon fiber is preferable when the required performance of rigidity and strength is high. Inexpensive glass fiber may be used for the reinforcing fiber because of low cost.

Different fiber reinforced bundles 15 may be used as the fiber reinforced bundles 15 constituting the first fiber bundle 11 and the second fiber bundle 12, respectively. For example, the first fiber bundle 11 may be a carbon fiber, and the second fiber bundle 12 may be a glass fiber. Alternatively, the first fiber bundle 11 may be an aramid fiber and the second fiber bundle 12 may be a carbon fiber.

The organic fiber constituting the auxiliary yarn 16 may be polyamide other than polyester. The organic fiber constituting the auxiliary yarn 16 is preferably one that does not melt due to the curing temperature of the thermosetting resin that is the matrix resin of the composite material 18. The auxiliary yarn 16 may be composed of reinforcing fibers. In that case, the basis weight of the auxiliary yarn 16 may be 20% or less of that of the fiber reinforced bundle 15.

In the composite material 18, it is not necessary to arrange the fiber reinforced bundles 15 so that the mechanical strength becomes pseudo-isotropic. The composite material 18 may be manufactured by laminating only the fiber base materials 10 and 20 in which the fiber reinforced bundles 15 are arranged in the biaxial direction or the triaxial direction.

The composite material 18 is manufactured by laminating the fiber substrate 10 together with other fiber substrates in a mold, and impregnating the matrix in the mold with a matrix resin and curing it. In this case, the fiber base material 10 and other fiber base materials are laminated in advance outside the mold, and a laminate such as the adjacent fiber base material 10 is bonded with a binder resin or binder fiber, and the resulting mold is used as a preform. You may make it accommodate in. In addition to the above method, for example, the composite material 18 may be manufactured by pressurizing and heating a prepreg in which the fiber base material 10 is previously impregnated with a resin with a molding die. The matrix is a metal other than the resin. May be. When the matrix is a metal, organic fibers cannot be used as the fiber reinforced bundle 15. Fibers that do not soften or melt at the melting point of the metal that forms the matrix, such as carbon fibers or ceramic fibers, are used.

The matrix resin constituting the fiber reinforced composite material may be a thermoplastic resin such as polyamide, polybutylene terephthalate, polycarbonate, polyoxymethylene, or polyphenylene ether, in addition to the thermosetting resin. For example, when the composite material 18 is used as an energy absorbing member, a thermosetting resin is more preferable than a thermoplastic resin in terms of strength. However, in terms of toughness, thermoplastic resins are superior to thermosetting resins. In this case, the entire cross section does not break at a stretch with respect to the collision load, and energy absorption is large and safety is improved. Among thermoplastic resins, polyamide is preferable in terms of moldability, mechanical properties, and cost.

Claims (13)

A plurality of first fiber bundles arranged parallel to each other; a plurality of second fiber bundles arranged parallel to each other and intersecting the first fiber bundle; the first fiber bundle and the A fiber substrate composed of a plurality of third fiber bundles having equal angles intersecting with the second fiber bundles and arranged in parallel to each other;
A reinforcing fiber bundle composed of reinforcing fibers intersecting with the third fiber bundle;
Auxiliary yarn that is at least part of the first fiber bundle, the second fiber bundle, or the third fiber bundle, wherein the weight of the auxiliary yarn is 20% or less of the weight of the reinforcing fiber Including thread,
When there is no intersection where the reinforcing fiber bundles intersect, or when there is an intersecting part where the reinforcing fiber bundles intersect, all the reinforcing fiber bundles intersecting in the thickness direction of the fiber base material in the same order. A fiber substrate characterized by being arranged. The fiber substrate according to claim 1, wherein
One of the first and second fiber bundles is constituted by the reinforcing fiber bundle, and the other is constituted by the auxiliary yarn. The fiber substrate according to claim 1, wherein
The fiber base material, wherein the first fiber bundle and the second fiber bundle each have the reinforcing fiber bundles and the auxiliary yarns formed by the reinforcing fibers alternately arranged. In the fiber base material according to any one of claims 1 to 3,
The third fiber bundle is arranged so as to correspond to all the intersections of the first fiber bundle and the second fiber bundle, and the reinforcing fiber bundle constituted by the reinforcing fibers and the auxiliary A fiber base material comprising yarns arranged alternately. In the fiber base material according to any one of claims 1 to 3,
All of the third fiber bundles are constituted by the auxiliary yarns. In the fiber base material according to any one of claims 1 to 5,
The first fiber bundle and the second fiber bundle constitute a skew yarn bundle of a cylindrical braid,
The fiber base material, wherein the third fiber bundle constitutes a bundle of axial threads of the tubular braid. The fiber substrate according to claim 6, wherein
The fiber base material is formed by flattening the tubular braid made of the first fiber bundle, the second fiber bundle, and the third fiber bundle. In the fiber substrate according to any one of claims 1 to 6,
The fiber base material is formed into a sheet by cutting a tubular braid,
The first fiber bundle and the second fiber bundle constitute a skew yarn bundle of the tubular braid,
The fiber base material, wherein the third fiber bundle constitutes a bundle of axial threads of the tubular braid. In the fiber base material according to any one of claims 1 to 5,
The fiber base material is formed into a sheet by cutting a tubular braid along its axial direction,
The first fiber bundle and the second fiber bundle constitute a skew yarn bundle of the tubular braid,
The fiber base material, wherein the third fiber bundle constitutes a bundle of axial threads of the tubular braid. In the fiber base material according to any one of claims 1 to 7 and 9,
The fiber base material, wherein the angle is 45 °. In the fiber substrate according to any one of claims 1 to 10,
The fiber base material, wherein the auxiliary yarn is composed of an organic fiber. A fiber-reinforced composite material comprising the fiber base material according to any one of claims 1 to 11 as a reinforcing material. A prepreg obtained by impregnating the fiber base material according to any one of claims 1 to 11 with a resin.

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