JP2012224964A - Carbon fiber reinforced fabric - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a carbon fiber reinforced fabric which can prevent a fabric easily causing yarn slippage such as a twill woven structure from causing the yarn slippage at the step of weaving the fabric and does not cause the yarn slippage at the respective steps of the weaving to a CFRP production, without using a weaving machine interlocked with special additional equipment.SOLUTION: There is provided a carbon fiber reinforced fabric in which a warp and a weft comprising a carbon fiber multifilament are woven in a twill woven structure and the like, and another weft comprising a monofilament is woven between the wefts. Another weft comprising the monofilament is not arranged with the adjacent wefts comprising the carbon fiber multifilament on both sides thereof, and intersects the warp comprising the carbon fiber multifilament in a rise and a fall independent of the wefts.

Description

  The present invention relates to a carbon fiber reinforced fabric having excellent characteristics as a reinforcing material for fiber reinforced composite materials.

  Among fiber reinforced composite materials, carbon fiber reinforced plastics (hereinafter referred to as “CFRP”) using carbon fiber as a reinforcing material are excellent in specific strength and specific elastic modulus, and are used as various structural materials. Widely used as exterior materials and interior materials for transportation equipment such as automobiles, ships and aircraft. This CFRP is constituted by impregnating and molding an epoxy resin or the like around a reinforcing material made of carbon fiber woven fabric or carbon fiber nonwoven fabric. Hereinafter, a carbon fiber woven fabric used as a CFRP reinforcing material is referred to as a carbon fiber reinforced fabric.

  As the carbon fiber reinforced fabric, carbon fiber yarn, for example, carbon fiber multifilament is woven as warp and weft. Since these carbon fiber multifilaments are woven mainly in an untwisted state, since the binding at the intersection of the warp and the weft is weak, the arrangement of the warp and the weft is disturbed, and the fabric is likely to be misaligned. Such misalignment occurs in each process from weaving to CFRP production, such as a scraping process or a shaking process in a loom of a carbon fiber reinforced fabric, or a resin impregnation process as CFRP. Thus, when misalignment occurs in the carbon fiber reinforced fabric, there is a problem that the strength as a reinforcing material is lowered and the original performance of CFRP cannot be exhibited.

  As a method for preventing misalignment of such a carbon fiber reinforced fabric, a method of impregnating a woven carbon fiber reinforced fabric with a heat-melting low melting point resin in advance after weaving has been taken.

  On the other hand, carbon fiber reinforced fabrics have so far mainly consisted of plain weave textures, but instead of these, it is possible to use oblique fabric textures, satin weave textures, or change weave textures (hereinafter referred to as “oblique texture structures”). The use of a carbon fiber reinforced fabric having a change in appearance on the surface of the fabric is attracting attention. In this case, by using a transparent resin as the resin to be impregnated, the texture of the reinforcing material is expressed as a pattern on the surface of the CFRP, and the CFRP is used as a surface material while being a CFRP. For example, CFRP has been proposed that emphasizes a pattern of carbon fiber reinforced fabric as an interior material for automobiles.

  In such a weave weave structure, a warp or the like is formed by jumping a plurality of warps or wefts over the intersecting yarns. In such a wrinkle portion, since a plurality of yarns are jumped, there are few entangled portions of warps and wefts, and there is a problem that misalignment is easier than in a conventional plain weave structure. Such a carbon fiber reinforced fabric such as an obliquely woven structure that is easily misaligned is easily misaligned even in the step of weaving after weaving on a loom, and the step of rolling out the weaveed fabric and impregnating with the above resin However, there was a further problem of misalignment.

  Therefore, Patent Document 1 below proposes a sealing method for preventing misalignment in a state in which the fabric woven by the loom is set on the loom before being scraped off.

JP-A-8-158207

  By the way, in the method for producing a seam woven fabric disclosed in Patent Document 1, hot melt resin is applied to the woven fabric by roll coating or the like. This is insufficient for a fabric that easily shifts, and there is a problem that a wrinkle pattern or the like is distorted when the fabric comes into contact with the coater and the folded wrinkle pattern is distorted. In addition, it is not realistic to link ancillary equipment such as a roll coater to the loom, and there is a problem that operational troubles are likely to occur.

  Accordingly, the present invention addresses the above-described problems, and weaves the woven fabric without using a loom interlocking with a special incidental facility for a fabric that is easily misaligned, such as an oblique weave structure. An object of the present invention is to provide a carbon fiber reinforced fabric that can prevent misalignment at each stage and does not cause misalignment in each process from weaving to CFRP production.

  In solving the above-mentioned problems, the present inventor, as a result of earnest research, weaved a monofilament weft yarn in addition to the carbon fiber multifilament as the weft yarn when weaving an oblique weave structure or the like using the carbon fiber multifilament as the warp and weft yarn. The present inventors have found that carbon fiber reinforced fabrics can be woven without misalignment between warps and wefts made of carbon fiber multifilaments, and the present invention has been completed.

That is, according to the first aspect of the carbon fiber reinforced fabric according to the present invention, the warp yarn (1) and the weft yarn (2) made of carbon fiber multifilaments are an oblique weave texture, a satin weave texture, or a changed weave texture. A carbon fiber reinforced fabric (10) woven into
The other wefts (3) made of monofilaments are interwoven between the wefts made of carbon fiber multifilaments,
Other wefts made of the above monofilaments intersect with the warps made of the carbon fiber multifilaments by ups and downs independent of these wefts without being aligned with the wefts made of the carbon fiber multifilaments adjacent to both sides. It is characterized by.

  According to the above configuration, in addition to the carbon fiber multifilament, a monofilament is woven into the carbon fiber multifilament warp. The monofilament wefts are woven by ups and downs independent of these wefts without being aligned with the wefts of adjacent carbon fiber multifilaments. If the monofilament wefts are woven together with the adjacent carbon fiber multifilament wefts, these monofilaments and carbon fiber multifilament wefts are warp together like a single weft. It becomes easy to miss the top.

  On the other hand, in the above configuration, the monofilament weft is entangled with the warp yarn independently of the adjacent carbon fiber multifilament weft. As a result, even if the carbon fiber multifilament weft attempts to move on the warp, it is suppressed from being misaligned on the warp by being pressed by the adjacent monofilament weft.

  Therefore, in the invention described in claim 1, the misalignment at the stage of weaving the fabric without using a loom interlocking with a special incidental equipment for a fabric easily misaligned, such as an oblique weave structure. It is possible to provide a carbon fiber reinforced fabric that can be prevented and does not cause misalignment in each process from weaving to CFRP production.

According to a second aspect of the present invention, there is provided the carbon fiber reinforced fabric according to the first aspect, wherein the warp made of the carbon fiber multifilament is at least two adjacent ones made of the carbon fiber multifilament. Floating on the weft to form a wrinkle on the fabric surface,
The other wefts made of the monofilament between the adjacent wefts intersect with the warp so that they float on the fabric surface side of the heel, and the two warps adjacent to both sides of the warp are It is characterized by crossing each other on the back side.

  In the above configuration, the portion where the warp of the carbon fiber multifilament floats on at least two adjacent wefts made of the carbon fiber multifilament indicates a portion forming a wrinkle such as an oblique weave structure. In this portion, the floated warp has few entangled portions with the weft and is more likely to be misaligned than the other portions. Therefore, the monofilament weft between two adjacent wefts sinking into this heel part is entangled with this part from the top of the heel formed by the warp, and the floating warp causes misalignment. Is preventing.

  In addition, the monofilament weft crosses the two warps adjacent on both sides of the warp on the back side of the fabric, making it difficult for the monofilament weft to be misaligned. Becomes difficult to miss. Therefore, in the invention described in claim 2, the same effect as that of the invention described in claim 1 can be achieved more specifically.

According to a third aspect of the present invention, there is provided the carbon fiber reinforced fabric according to the first or second aspect, wherein the warp and the weft made of the carbon fiber multifilament have an independent fineness of 100 tex. In the range of ~ 1000 tex,
Another weft made of the monofilament has a wire diameter in the range of 0.2 mm to 1.0 mm.

  According to the above configuration, the fineness of the carbon fiber multifilament warp and weft is in the above range, and the monofilament weft wire diameter is in the above range, so that the aesthetic appearance of the woven structure of the carbon fiber reinforced fabric is good. The monofilament is not easily noticeable and the prevention of misalignment is good. Therefore, in the invention described in claim 3, the same effect as that of the invention described in claim 1 or 2 can be achieved more specifically.

  Moreover, according to the description of claim 4, the present invention is the carbon fiber reinforced fabric according to any one of claims 1 to 3, wherein the warp density of the warp composed of the carbon fiber multifilament is 10 to 10. The weft density of the weft yarn made of the carbon fiber multifilament and the other weft yarn made of the monofilament is in the range of 7 to 16 yarns / inch, respectively.

  According to the above configuration, the weaving densities of the carbon fiber multifilament warp and weft and the monofilament weft are in the above ranges, respectively, so that the fabric has less mesh opening and further prevents misalignment. Therefore, in the invention described in claim 4, it is possible to achieve the same effect as the invention described in any one of claims 1 to 3 more specifically.

  According to a fifth aspect of the present invention, there is provided the carbon fiber reinforced fabric according to any one of the first to fourth aspects, wherein the monofilament is a metal monofilament.

  According to the above configuration, the monofilament constituting the weft may be a metal monofilament. Thus, in the invention described in claim 5, it is possible to achieve the same effect as the invention described in any one of claims 1 to 4 more specifically.

  According to a sixth aspect of the present invention, there is provided the carbon fiber reinforced fabric according to the fifth aspect, wherein the metal monofilament is made of aluminum having a wire diameter in the range of 0.2 mm to 0.5 mm. It is a metal wire.

  According to the above configuration, the metal monofilament constituting the weft may be an aluminum metal wire having a wire diameter in the above range. Thus, in the invention described in claim 6, the same effect as that of the invention described in claim 5 can be achieved more specifically.

  In addition, the code | symbol in the bracket | parenthesis of each said means shows a corresponding relationship with the specific means as described in embodiment mentioned later.

1 is a front view showing an embodiment of a carbon fiber reinforced fabric according to the present invention. FIG. 2 is a front view showing a basic woven structure in a state where a monofilament weft is pulled out from the carbon fiber reinforced fabric of FIG. 1.

  The present invention will be described below with reference to the drawings. Here, the carbon fibers constituting the warp and weft of the carbon fiber reinforced fabric include PAN-based carbon fibers and PITCH-based carbon fibers. In the present invention, the use as a reinforcing material for CFRP and the gloss of the yarn surface are used. It is preferable to use a PAN-based carbon fiber because of its beautiful appearance. Moreover, in this invention, it is preferable to use the untwisted carbon fiber multifilament which bundled the single fiber of the PAN system carbon fiber.

  In the carbon fiber reinforced fabric according to the present invention, the basic woven structure is not a conventional plain weave structure, but an oblique weave structure, a satin weave structure, or a changed weave structure. The oblique weave is also called a twill weave, and a plurality of wefts or warps where warp yarns and / or weft yarns are crossed to form cocoons, and the arrangement of the cocoons appears on the surface of the fabric as diagonal lines to express aesthetics. The yarn that floats at the wrinkle portion does not constitute a texture point (portion where warp and weft yarns are entangled), and therefore contributes little to the strength of the structure and easily causes misalignment.

  Also, satin weaving is also called satin, and it has as few warp and weft texture points as possible and is dispersed so that the texture points are not continuous and only warp or only wefts are floated on the surface of the fabric. It is. This floating yarn expresses aesthetics with luster, but this structure is also prone to misalignment.

  In addition, the change weave is a change in the conventional plain weave structure and the above-mentioned oblique weave structure and satin weave structure, or a combination of these to create a complex weave structure, and there are many floating yarns that are misaligned. Prone to occur.

  In this embodiment, a carbon fiber reinforced fabric will be described using an oblique weave structure. First, the carbon fiber woven fabric which consists only of the carbon fiber multifilament used as the foundation of the carbon fiber reinforced fabric concerning this embodiment is demonstrated. In FIG. 2, a carbon fiber fabric 11 is an oblique weaving made of carbon fiber multifilament warp 1 (hereinafter also referred to as “warp 1”) and carbon fiber multifilament weft 2 (hereinafter also referred to as “weft 2”). Tissue fabric.

  The woven structure of the carbon fiber woven fabric 11 is “2, 2 italic”, which goes up to the left, and the warp 1 (explained with the reference numerals in FIG. 2) is the top of the two wefts 2 from the top of the figure. A floating warp is formed on (the front side of the woven fabric) and sinks under the two subsequent wefts 2 (the back side of the woven fabric), and this operation is repeated. The warp 1 adjacent to the warp 1 repeats the same ups and downs as the warp 1 only by sequentially shifting the position intersecting the weft 2 one by one. As a result, the warp formed by the warp 1 appears on the surface of the fabric as a diagonal line that rises to the left (from the lower right to the upper left in the drawing).

  On the other hand, the weft thread 2 (described with reference numerals in FIG. 2) forms a floating weft on the two warp threads 1 (on the surface side of the woven fabric) from the right side of the figure, followed by two warp threads Sink under 1 (the back side of the fabric) and repeat this action. The weft 2 following the weft 2 repeats the same ups and downs as the weft 2 only by sequentially shifting the position intersecting the warp 1 one by one. As a result, the wefts formed by the wefts 2 appear on the surface of the fabric as diagonal lines that rise to the left (from the lower right to the upper left in the figure).

  As described above, in a woven fabric with an oblique weave structure having many warps and wefts, diagonal lines formed on the surface of the woven fabric by these wrinkles represent the beauty of the carbon fiber multifilament. However, there is little entanglement between the carbon fiber multifilaments including the wrinkles, and the warp and weft yarns easily slip on the intersecting yarns, and misalignment of the woven structure tends to occur.

  Here, it is preferable that the carbon fiber multifilament used for the warp 1 and the weft 2 of the present invention is independently in the range of fineness of 100 tex to 1000 tex. When the fineness is in the range of 100 tex to 1000 tex, the surface shape such as the wrinkles of the weave texture can be expressed beautifully. Further, in the case of a yarn having a fineness of less than 100 tex, the weaving density is increased and a large number of crrills are required to warp the warp 1, and the number of driven wefts 2 is increased, both of which are not economical. On the other hand, when the yarn is thicker than the fineness of 1000 tex, it is difficult to express the aesthetic appearance of the woven structure.

  Moreover, the carbon fiber multifilament used for the warp 1 and the weft 2 may be woven with the same fineness, or may be woven with different finenesses. When weaving the warp 1 and the weft 2 with different fineness, the warp 1 is preferably in the range of fineness 100 tex to 400 tex, and more preferably in the range of fineness 150 tex to 300 tex. On the other hand, the weft 2 is preferably in the range of 200 tex to 800 tex, and more preferably in the range of fineness of 300 tex to 600 tex. Thus, by weaving the warp 1 and the weft 2 with different finenesses, for example, in the oblique weave structure of the present embodiment, the aesthetic appearance of the wrinkles on the fabric surface is more emphasized.

  On the other hand, the weave density of the warp yarn 1 is in the range of 10 to 20 yarns / inch (3.9 to 7.9 yarns / cm), and the weave density of the weft yarn 2 is 7 to 16 yarns / inch (2.7 to 2.7). 6.3 / cm) is preferable. When the weaving density of the warp 1 and the weft 2 is within this range, the distance between the stitches becomes close, the misalignment between the warp 1 and the weft 2 hardly occurs, and the aesthetic appearance of the fabric surface is further emphasized.

  Next, the carbon fiber reinforced fabric shown in FIG. 1 according to the present embodiment will be described using the carbon fiber fabric 11 of “2, 2 oblique” ascending to the left shown in FIG. In FIG. 1, a carbon fiber reinforced fabric 10 is a fabric with an oblique weave structure (see FIG. 2) woven from a warp 1 and a weft 2, and a monofilament weft 3 (hereinafter referred to as a “weave”) between each weft 2. (Also referred to as “monofilament 3”).

  Here, as the monofilament 3 woven between the wefts 2, a monofilament made of organic fiber or inorganic fiber is used. As the monofilament made of organic fiber, any material such as heat-meltable fiber such as nylon or polyester, or thermoplastic fiber such as aramid or epoxy may be used. On the other hand, as a monofilament made of inorganic fibers, for example, glass fibers or metal fibers may be used. Examples of the metal fiber include an aluminum single wire, a stainless steel single wire, a nichrome single wire, and a copper single wire.

  Further, the wire diameter of the monofilament 3 may be appropriately selected according to the fineness and weave density of the warp and weft constituting the carbon fiber reinforced fabric, but generally it is preferably in the range of 0.2 mm to 1.0 mm. More preferably, it is in the range of 0.2 mm to 0.5 mm. When the wire diameter of the monofilament 3 is in the range of 0.2 mm to 1.0 mm, the aesthetic appearance of the woven structure of the carbon fiber reinforced fabric is good, the monofilament 3 is hardly noticeable, and misalignment prevention is good.

  In particular, when the monofilament 3 is a metal fiber, the effect of preventing misalignment is greater than that of an organic fiber or the like, and a narrower range of 0.2 mm to 0.5 mm is sufficient. Further, the metal fiber is less noticeable on the surface of the fabric and can be easily cut during the transverse insertion process.

  The weaving density of the monofilament 3 is preferably in the range of 7 to 16 yarns / inch (2.7 to 6.3 yarns / cm), which is the same as the weft yarn 2.

  In FIG. 1, a monofilament 3 (explained by a yarn with a reference numeral in FIG. 1) sinks from the right side of the figure under three warp yarns 1 (the back side of the fabric), and continues with one warp yarn 1 (this The yarn floats above (forms the warp described above) (the surface side of the fabric) and repeats this action.

  Thus, the monofilament 3 is woven by ups and downs independent of the wefts 2 without being aligned with the wefts 2 adjacent to both sides thereof. Accordingly, even if the weft 2 adjacent to the monofilament 3 tries to move on the warp 1, it cannot be misaligned on the warp 1 by being pressed by the monofilament 3.

  Here, the monofilament 3 may be woven into all the portions between the weft yarns 2, or may be woven every few. In the present embodiment, the monofilament 3 is woven into all the portions between the wefts 2, and this can further suppress misalignment of the wefts 2.

  On the other hand, as described above, the monofilament 3 intertwines with the warp 1 forming the warp from the surface side of the fabric and presses the warp 1 that is easily misaligned. Further, the monofilament 3 crosses the two warps 1 adjacent to both sides of the warp 1 forming the warp on the back side of the woven fabric, and the monofilament 3 itself is not easily misaligned. Furthermore, the warp yarns 1 forming the wrinkles are not easily misaligned.

  As described above, in this embodiment, by weaving the monofilament 3 only on the weft side, misalignment of both the warp 1 and the weft 2 made of carbon fiber multifilament that is slippery can be sufficiently prevented.

  Hereinafter, in this embodiment, the carbon fiber reinforced fabric 10 of the following examples was created. Any weaving machine may be used for weaving the carbon fiber reinforced fabric 10, but a rapier loom is used in this embodiment. In addition, the warp 1 was knitted using krill for tension control. On the other hand, for horizontal insertion, two types of wefts were used to alternately drive, so that two systems were used. Opening was carried out by a dobby device, and hammering was performed with different strengths according to two types of wefts.

  In this example, as the warp 1, a PAN-based carbon fiber yarn having a fineness of 200 tex made of single filament 3000 filament (3K) having a fiber diameter of 7.0 μm was used. On the other hand, as the weft 2, a PAN-based carbon fiber yarn having a fineness of 400 tex made of a single yarn 6000 filament (6K) having a fiber diameter of 7.0 μm was used. As the monofilament 3, an aluminum single wire having a wire diameter of 0.3 mm was used.

  The weaving structure is “2, 2 diagonal” as shown in FIG. 1, and the weaving density is 15 yarns / inch (5.9 yarns / cm) for warp 1 and 11 yarns / inch (4. 3 / cm), and the monofilament 3 was 11 / inch (4.3 / cm), which is the same as the weft 2.

  The woven carbon fiber reinforced fabric 10 was a fabric in which a beautifully shaded wrinkle of oblique weaving appeared on the surface, while warps and wefts were not easily misaligned. In addition, CFRP was prototyped by impregnating the carbon fiber reinforced fabric 10 with a transparent epoxy resin as a reinforcing material, but there was no misalignment during the production. The diagonal line was expressed.

  From the above, in this embodiment, it is possible to prevent misalignment at the stage of weaving the fabric without using a loom linked to a special accessory facility for easily misaligned fabric such as an oblique weave structure. Therefore, it is possible to provide a carbon fiber reinforced fabric that does not cause misalignment in each process from weaving to CFRP production.

In implementing the present invention, not only the above-described embodiment but also the following various modifications can be mentioned.
(1) In the above-described embodiment, “2, 2 italic” that is left-upward is adopted as the basic weaving structure of the carbon fiber reinforced fabric, but the present invention is not limited to this. It may be a weave or a change weave. The weave density of the warp and weft may be any.
(2) In the above embodiment, wefts made of a single aluminum wire are woven between wefts made of carbon fiber multifilaments of carbon fiber reinforced fabric, but this is not restrictive, and other metal wires, glass fibers or organic fibers are used. A monofilament may be woven.
(3) In the above embodiment, wefts made of a single aluminum wire are woven into all parts between the wefts made of carbon fiber multifilaments of the carbon fiber reinforced fabric, but this is not restrictive, and wefts made of carbon fiber multifilaments Alternatively, wefts made of monofilaments may be woven in a ratio of one to several.

  The carbon fiber reinforced fabric according to the present invention is characterized in that it can be used as a surface material that utilizes the aesthetics of the surface shape of the woven structure, in addition to its use as a reinforcing material for CFRP, which is the original application. As a result, it can be used in a wide range of fields as surface materials such as interior materials for automobiles, ships, aircraft, and the like.

1. Warp made of carbon fiber multifilament,
2 ... Weft made of carbon fiber multifilament,
3 ... Weft made of single aluminum wire,
10 ... carbon fiber reinforced fabric, 11 ... carbon fiber woven fabric which is a basic woven structure of carbon fiber reinforced fabric.

Claims (6)

A carbon fiber reinforced fabric formed by weaving warps and wefts made of carbon fiber multifilament into an oblique weave structure, satin weave structure, or a change weave structure,
Weaving other wefts made of monofilaments between the wefts made of carbon fiber multifilaments,
The other wefts made of the monofilaments cross the warp made of the carbon fiber multifilaments by ups and downs independent from the wefts made of the carbon fiber multifilaments adjacent to both sides, without being aligned with the wefts made of the carbon fiber multifilaments. Carbon fiber reinforced fabric characterized by The warp made of the carbon fiber multifilament floats on at least two adjacent wefts made of the carbon fiber multifilament to form a fold on the surface of the fabric.
The other wefts made of the monofilament between the adjacent wefts intersect with the warp so that they float on the fabric surface side of the heel, and the two warps adjacent to both sides of the warp are The carbon fiber reinforced fabric according to claim 1, wherein the fabrics cross each other on the back side. The warps and wefts composed of the carbon fiber multifilaments each independently have a fineness in the range of 100 tex to 1000 tex,
The carbon fiber reinforced fabric according to claim 1 or 2, wherein the other weft made of monofilament has a wire diameter in a range of 0.2 mm to 1.0 mm.   The weave density of the warp made of the carbon fiber multifilament is in the range of 10 to 20 yarns / inch, and the weave density of the weft made of the carbon fiber multifilament and the other weft made of the monofilament is 7 to 16, respectively. The carbon fiber reinforced fabric according to any one of claims 1 to 3, wherein the woven fabric is in a range of / inch.   The carbon fiber reinforced fabric according to any one of claims 1 to 4, wherein the monofilament is a metal monofilament.   The carbon fiber reinforced fabric according to claim 5, wherein the metal monofilament is a metal wire made of aluminum having a wire diameter in a range of 0.2 mm to 0.5 mm.