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JPH02134233A - 成形可能な複合材料の製造方法 - Google Patents

成形可能な複合材料の製造方法

Info

Publication number
JPH02134233A
JPH02134233A JP1248248A JP24824889A JPH02134233A JP H02134233 A JPH02134233 A JP H02134233A JP 1248248 A JP1248248 A JP 1248248A JP 24824889 A JP24824889 A JP 24824889A JP H02134233 A JPH02134233 A JP H02134233A
Authority
JP
Japan
Prior art keywords
fibers
layers
composite material
moldable composite
layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
JP1248248A
Other languages
English (en)
Inventor
Jeffrey A Vane
ジェフリー　アルバート　ベイン
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tech Textiles Ltd
Original Assignee
Tech Textiles Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=10644219&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=JPH02134233(A) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Tech Textiles Ltd filed Critical Tech Textiles Ltd
Publication of JPH02134233A publication Critical patent/JPH02134233A/ja
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/12—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B29C70/202—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/543—Fixing the position or configuration of fibrous reinforcements before or during moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/28—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
    • D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
    • D04B21/165—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads with yarns stitched through one or more layers or tows, e.g. stitch-bonded fabrics
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
    • D04H3/115—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by applying or inserting filamentary binding elements
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    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
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    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
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    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
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    • D10B2505/00—Industrial
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    • Y10T428/24091—Strand or strand-portions with additional layer[s]
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    • Y10T428/24124—Fibers
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    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2929—Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Inorganic Chemistry (AREA)
  • Reinforced Plastic Materials (AREA)
  • Laminated Bodies (AREA)
  • Macromolecular Compounds Obtained By Forming Nitrogen-Containing Linkages In General (AREA)
  • Woven Fabrics (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Abstract

(57)【要約】本公報は電子出願前の出願データであるた
め要約のデータは記録されません。

Description

【発明の詳細な説明】 （産業上の利用分野） 本発明は補強されたプラスチック等の製品を作るための
成形可能な複合材料の製造方法に関するものである。
（従来の技術） 合成樹脂マトリックス材料を包含せしめた織られた又は
織られないガラス繊維又は他の補強材料のマントより成
る、１プレープレゲス”（ｐｒｅ−ｐｒｅｇｓ）と呼ば
れる形の成形可能な複合材料を作ることは既知である。
（発明が解決しようとする課題） 然しなからこのような既知の成形可能な複合材料は不織
マット内の繊維の配列が不揃いで制御不能でありこの材
料から作られた製品の強度特性は予知することが出来な
い欠点がある。又織られたマント内では横糸と縦糸が互
いに交叉して縮れ、この結果強度が低下し棚寿命（ｓｈ
ｅｌｆ　１ｉｆｅ）に制限がある。
本発明の目的は補強材料が多軸構造であり、特別な用途
に適する′°エンジニアド”（ｅｎｇｉｎｅｅｒｅｄ）
となし得る成形可能な複合材料の製造方法を得るにある
。
（課題を解決するための手段） 本発明の成形可能な複合材料の製造方法は側方に並んで
単一方向に延びる複数の不織繊維より成る層の複数を積
重して補強材料を形成する工程を有し、上記層のうち少
なくとも幾つかの異なる層内の繊維が異なる方向に延び
ており、これらの層が一体に縫われており、この縫い工
程の前に前記補強材料とマトリックス材料が結合される
ことを特徴とする。
上記複数の層はニッテングによって一体に縫われ、上記
各層を互いに固定するように縫うことによって各層内の
繊維が保持されるのが好ましい。
上記マトリックス材料は熱可塑性又は熱硬化性樹脂材料
又は金属又はセラミック材料であり、加熱、加圧によっ
て上記複合材料が成形される間に固められ補強材料の周
りにマトリックスを形成する。
織布又は不織布、例えば発泡材料又はポリエステル又は
他の熱硬化性プラスチック材料のシート。
フィルム、ナイス（ｔｉｓｓｕｅ）　、　　リボン又は
テープは上記２つの層間に挿入されており、及び又は補
強材料の少なくとも外面に設けられており、上記層に縫
われて複合材料に所望の特性を付与している。
本発明の好ましい実施例においては前記マトリックス材
料は熱可塑性材＄４の少なくとも１枚のフィルム、シー
ト、リボン、テープ又はナイスであり、上記層なくとも
２つの層間に挿入されており、及び又は積層された層の
一面又は両面に設けられており、上記層と共に縫われて
いる。上記熱可塑性材料のフィルム、シート、リボン、
テープ又はナイスは上記補強材料の隣接する層の夫々の
間に挿入されるのが好ましい。このような複合材料は永
い棚寿命を有し、貯蔵、取り扱いに便利である。
又この複合材料は成形前に加熱すれば熱可塑性材料が軟
化し複合材料が成形する前又は間にこれに補強材料を包
含せしめることが出来、使用に便利である。更に本発明
による複合材料では熱可塑性マトリックス材料が補強材
料内に均一に配分されたものとなる。
本発明の他の実施例においては補強材料にはその縫い工
程の前に合成樹脂マトリックス材料、例えば熱可塑性又
は熱硬化性樹脂材料がスプレー等によって含浸される。
この方法によって従来のプレープレゲス型が形成され、
補強材料内の繊維の配向が知られるようになり、この繊
維は縮れることなく直線状に延び、従ってこの複合材料
によって形成された製品の強度特性を最良ならしめ、且
つ予知することが出来るようになる。
本発明の他の実施例においては熱硬化性樹脂材料等の合
成樹脂マトリックス材料の被覆を、縫い工程の前に上記
補強材料の一面又は両外面に設ける。上記被覆は粘着性
とし、この上に上記縫い工程の前後において引き剥がし
紙を設け、複合材料が使用されるようになったときこれ
を剥がすようにすることが出来る。
本発明の更に他の実施例においては上記層の幾つかにお
ける補強材料の繊維を上記マトリックス材料と共に用い
、又はこれらを挿入せしめる。補強材料の繊維を熱可塑
性樹脂材料の繊維内に挿入せしめても良い、又補強材料
の少なくとも幾つかの繊維をマトリックス材料によって
被覆せしめるか又はマトリックス材料を含浸せしめても
良い。
又補強材料の少なくとも幾つかの繊維を、熱可塑性材料
の外面被覆又は外層の代わりに粉体状のマトリックス材
料によって被覆するか又は上記繊維内に粉体状のマトリ
ックス材料を包含せしめても良い、粉体状マトリックス
材料は熱可塑性又は熱硬化性樹脂材料か、又はセラミッ
ク又は金属材料である０例えば補強材料はカーボン繊維
とカーボンの粉末状マトリックス材料であり、カーボン
とカーボンの複合材料が形成される。本発明の複合材料
は取り扱いが便利であり、棚寿命が長く、使用に便利で
ある。以上述べた繊維なる用語は従来既知の連続した又
は非連続の糸、華−繊維、粗糸、粗麻等を意味する。
上記補強材料の繊維は例えばガラス繊維、カーボン繊維
、アラミド繊維、セラミック繊維、ポリエチレン繊維、
ポリエステルファイバー、金属又はこれらの混合物であ
る。上記少なくとも２つの層内の繊維は互いに９０″異
なる方向に延びているのが好ましい、少なくとも更に他
の１つの層内の繊維は上記少なくとも２つの層の少なく
とも１つの層内の繊維に対して４５°〜９０°の角度で
延びているのが好ましい。上記層は第１方向に延びてい
る繊維を有する層と、上記第１方向に対して９０″の第
２方向に延びている繊維を有する層と、上記第１方向に
対して４５°の第３方向に延びている繊維を有する層と
、第１方向に対して４５′であり第３方向に対して９０
°である第４方向に延びる繊維を有する層とより成るこ
とが好ましい、上記補強材料は例えば等方性である。
上記層の少なくとも１つの層内で繊維は層の異なる部分
内で異なる密度で配置されており、補強材料の異なる部
分が異なる強度特性を有するようになる。この結果複合
材料は“エンジニアド″となり特殊な用途に用い得る。
上記縫い工程において用いる糸は、複合材料に望まれる
特性、例えば所望の機械的、電気的特性を与えるため選
択される。例えば繊維は、加熱、加圧下で複合材料を成
形するときマトリックスの一部となる熱可塑性材料とす
る。
上記補強材料の異なる層及び又は上記補強材料の異なる
層内又は間のマトリックス材料は、所望の特性を有する
“ハイブリッド°複合材料を作るため異なる特性、例え
ば異なる機械的、物理的又は電気的特性、例えば異なる
機械的強度又は異なる電気伝導度、及び又は電気抵抗、
及び又は誘電体特性を有する。
補強材料の付加的小片を縫い工程の前に上記２以上の層
間に設けて、付加的に補強するか又は複合材料の選択さ
れた部分の厚さを変え、複合材料を最終用途に適するよ
う゛エンジニアビならしめる。
（実　施　例） 以下図面によって本発明の詳細な説明する。
第１図は積重された複数の層１〜６を有する補強材料９
を示す。Ｊ１１〜６の夫々は単一方向に延びる複数の不
織糸又は繊維ｌＯと、異なる方向に異なる層内で延びる
糸又は繊１ｆｔＩＯより成る。即ちＮｌ内の繊維１０は
補強材料９に対し縦方向に延び、層２内の繊維１０は層
１内の繊維１０に対し直角方向に延び、層３内の繊維１
０は層１及び２内の繊維１０に対し４５″傾斜して延び
ている。
上記補強材料９は所望の数の層によって形成することが
出来、各層内の繊維の延びる方向は任意に定めることが
出来る１層１〜６のうちの少なくとも２つの層、好まし
くは互いに隣接する層間に熱可塑性材料のフィルム又は
シート８が介挿されている。更に補強材料９の片面又は
両面には熱可塑性材料のフィルム又はシート７が設けら
れている。
補強材料９の層１〜６及びフィルム又はシート７８は編
機１１によって一体に縫われ縫い部１２を形成している
。この縫い部１２においては各層１〜６内の繊維が所定
位置で互いに固定されている。
熱可塑性材料の糸又は繊維１３を層１〜６の１つ又はそ
れ以上の層内の繊維１０間に１４で示すように挿入又は
混入して複合材料内に付加的な熱可塑性材料のシートを
作るか、又はこのシートをシート７及び又は８の代わり
に作ることが出来る。
必要に応じて補強材料の小片１５を上記縫い作業の前に
層１〜６の隣接するものへ間に挿入して複合材料の最終
製品に所望の位置に所望のサイズ及び形の他の補強を形
成せしめることが出来る。
異なる層１〜６内の繊維１０は複数の方向に延びており
、異なる層内の繊維１０は縫い部１２によって強固に保
持されているため本発明方法によって作られた複合材料
はしわになること無しに複雑な形となし得る。
第２図に示す例においては繊維１０及び又は１３の少な
くとも幾つかを補強繊維の芯工６と、この芯１６の周り
のマトリックス材料の層１７と、この層１７の周りの被
覆１８とにより形成する。
上記芯１６はガラス繊維、アラミド繊維、カーボン繊維
、セラミック繊維、金属、ポリエステル繊維、ポリエチ
レン繊維又は他の補強材料、又はこれらの混合物より成
る繊維より成る。マトリックス材料１７は例えば粉末で
あり、熱可塑性又は熱硬化性樹脂材料、セラミック、カ
ーボン、金属又は他の好適なマトリックス形成材料より
成る。上記被覆１８は例えば熱可塑性材料である０本発
明においては補強及びマトリックス材料の種々の異なる
組み合わせ、例えばガラス繊維と熱硬化性樹脂又はカー
ボンとカーボンの組み合わせで複合材料を作ることが出
来る０本発明における繊維ｌＯはシート７及び又は８及
び又は繊維１３の代わりに、又はこれと共に使用するこ
とが出来る。
用いる繊維の拡大断面図を示す。
１〜６・・・層、７．８・・・フ ート、９・・・補強材料、１Ｏ１１ は繊維、１１・・・編機、１２・・ ４・・・シート、１５・・・小片、 １７・・・マトリックス材料の層、 覆。
ィルム又はシ ３・・・糸又 ・縫い部、１ １６・・・芯、 １８・・・被
【図面の簡単な説明】

Claims (1)

  1. 【特許請求の範囲】 （１）側方に並んで単一方向に延びる複数の不織繊維よ
    り成る層の複数を積重して補強材料を形成する工程を有
    し、上記層のうち少なくとも幾つかの異なる層内の繊維
    が異なる方向に延びており、これらの層が一体に縫われ
    ており、この縫い工程の前に前記補強材料とマトリック
    ス材料が結合されることを特徴とする成形可能な複合材
    料の製造方法。 （２）上記複数の層がエッチングによって一体に縫われ
    る請求項１記載の成形可能な複合材料の製造方法。 （３）上記各層を互いに固定するように縫うことによっ
    て各層内の繊維が保持される請求項１又は２記載の成形
    可能な複合材料の製造方法。 （４）上記マトリックス材料が熱可塑性又は熱硬化性樹
    脂材料又は金属又はセラミック材料である請求項１、２
    又は３記載の成形可能な複合材料の製造方法。 （５）織布又は不織布のシート、フィルム、ティス、リ
    ボン又はテープが少なくとも上記２つの層間に挿入され
    ており、及び又は補強材料の少なくとも外面に設けられ
    ており、上記層に縫われている請求項１、２、３又は４
    記載の成形可能な複合材料の製造方法。 （６）上記シート、フィルム、ティス、リボン又はテー
    プが発泡材料又はポリエステル又は他の熱硬化性プラス
    チック材料である請求項５記載の成形可能な複合材料の
    製造方法。（７）前記マトリックス材料が熱可塑性材料
    のフィルム、シート、リボン又はテープであり、上記少
    なくとも２つの層間に挿入されており、及び又は積層さ
    れた層の一面又は両面に設けられており、上記層と共に
    縫われている請求項１、２、３、４、５又は６記載の成
    形可能な複合材料の製造方法。 （８）上記熱可塑性材料のフィルム、シート、リボン又
    はテープが上記補強材料の隣接する層の夫々の間に挿入
    されている請求項７記載の成形可能な複合材料の製造方
    法。 （９）上記補強材料に合成樹脂マトリックス材料が包含
    されている請求項１、２、３、４、５又は６記載の成形
    可能な複合材料の製造方法。 （１０）上記補強材料の少なくとも外面に合成樹脂マト
    リックス材料の被覆が設けられている請求項１、２、３
    、４、５又は６記載の成形可能な複合材料の製造方法。 （１１）上記被覆が粘着性であり、この上に引き剥がし
    紙が設けられている請求項１０記載の成形可能な複合材
    料の製造方法。 （１２）上記合成樹脂が熱硬化性樹脂材料である請求項
    ９、１０又は１１記載の成形可能な複合材料の製造方法
    。 （１３）上記繊維がガラスより成る請求項１、２、３、
    ４、５、６、７、８、９、１０、１１、又は１２記載の
    成形可能な複合材料の製造方法。 （１４）上記繊維がガラス繊維、カーボン繊維、アラミ
    ド繊維、セラミック繊維、金属、ポリエチレン又はこれ
    らの混合物である請求項１、２、３、４、５、６、７、
    ８、９、１０、１１、又は１２記載の成形可能な複合材
    料の製造方法。 （１５）上記繊維が熱可塑性樹脂材料の繊維と共に用い
    られ、又はこれらの間に挿入されている請求項１、２、
    ３、４、５、６、７、８、９、１０、１１、１２、１３
    又は１４記載の成形可能な複合材料の製造方法。 （１６）上記繊維の少なくとも幾つかが補強繊維の芯と
    、この芯の周りのマトリックス材料の層と、及びこのマ
    トリックス材料の層の周りの外層とより成る請求項１、
    ２、３、４、５、６、７、８、９、１０、１１、１２、
    １３、１４又は１５記載の成形可能な複合材料の製造方
    法。 （１７）上記少なくとも２つの層内の繊維が互いに９０
    °異なる方向に延びている請求項１、２、３、４、５、
    ６、７、８、９、１０、１１、１２、１３、１４、１５
    又は１６記載の成形可能な複合材料の製造方法。 （１８）少なくとも更に他の１つの層内の繊維が上記少
    なくとも２つの層の少なくとも１つの層内の繊維に対し
    て４５°〜９０°の角度で延びている請求項１７記載の
    成形可能な複合材料の製造方法。 （１９）上記層が第１方向に延びている繊維を有する層
    と、上記第１方向に対して９０°の第２方向に延びてい
    る繊維を有する層と、上記第１方向に対して４５°の第
    ３方向に延びている繊維を有する層と、第１方向に対し
    て４５°であり第３方向に対して９０°である第４方向
    に延びる繊維を有する層とより成る請求項１８記載の成
    形可能な複合材料の製造方法。 （２０）上記補強材料が等方性である請求項１９記載の
    成形可能な複合材料の製造方法。（２１）上記層の少な
    くとも１つの層内で繊維が層の異なる部分内で異なる密
    度で配置されており、補強材料の異なる部分が異なる強
    度特性を有するようになる請求項１、２、３、４、５、
    ６、７、８、９、１０、１１、１２、１３、１４、１５
    、１６、１７、１８又は１９記載の成形可能な複合材料
    の製造方法。 （２２）上記縫い工程の前に上記層間の選択された位置
    で補強材料の小片が挿入されている請求項１、２、３、
    ４、５、６、７、８、９、１０、１１、１２、１３、１
    ４、１５、１６、１７、１８、１９、２０又は２１記載
    の成形可能な複合材料の製造方法。
JP1248248A 1988-09-26 1989-09-26 成形可能な複合材料の製造方法 Pending JPH02134233A (ja)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB8822521.4 1988-09-26
GB888822521A GB8822521D0 (en) 1988-09-26 1988-09-26 Method of producing formable composite material

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JPH02134233A true JPH02134233A (ja) 1990-05-23

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US (1) US5445693A (ja)
EP (1) EP0361796B1 (ja)
JP (1) JPH02134233A (ja)
KR (1) KR900004485A (ja)
AT (1) ATE155071T1 (ja)
DE (1) DE68928158T2 (ja)
ES (1) ES2108000T3 (ja)
GB (1) GB8822521D0 (ja)
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GB8822521D0 (en) 1988-11-02
ATE155071T1 (de) 1997-07-15
DE68928158D1 (de) 1997-08-14
EP0361796B1 (en) 1997-07-09
ZA897316B (en) 1991-01-30
EP0361796A3 (en) 1991-12-18
ES2108000T3 (es) 1997-12-16
US5445693A (en) 1995-08-29
EP0361796A2 (en) 1990-04-04
DE68928158T2 (de) 1998-01-08
KR900004485A (ko) 1990-04-12

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