Stock material or miscellaneous articles – Structurally defined web or sheet – Including stitching and discrete fastener – coating or bond
Patent
1996-11-06
1998-07-21
Cannon, James C.
Stock material or miscellaneous articles
Structurally defined web or sheet
Including stitching and discrete fastener, coating or bond
139 11, 139457, 428337, 428340, 4285428, 428902, 442 60, 442108, 442179, 442186, B32B 502, B32B 506, B32B 528, D03D 1500
Patent
active
057832781
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a reinforcing woven fabric indicating excellent properties for fiber reinforced composite materials and method and apparatus for manufacturing the same, and specifically to a reinforcing woven fabric using flat reinforcing filamentary yarn.
BACKGROUND ART OF THE INVENTION
In fiber reinforced composite materials, particularly, fiber reinforced plastics (hereinafter, referred to as "FRP"), a reinforcing woven fabric formed as a woven fabric using carbon fiber yarn, glass fiber yarn, polyaramide fiber yarn, etc. is frequently used. Among these, a carbon fiber woven fabric formed from carbon fibers having a high specific elastic modulus and a high specific strength is usually woven by a common shuttle loom or rapier loom, and it is frequently used as a substrate for reinforcing a composite material such as a carbon fiber reinforced plastic (hereinafter, referred to as "CFRP") by forming it as a desired shape by combining with a synthetic resin.
Although a composite material using such a reinforcing substrate, for example, a CFRP, has been used for, for example, structural materials of aircrafts utilizing the excellent properties, in order to further enlarge the application of CFRP, not only molding therefor but also cost down of the reinforcing substrate of carbon fiber yarn or carbon fiber woven fabric are important subjects.
With carbon fiber yarn, usually, as the size (denier) becomes larger, the productivity of the precursor and in the oxidation process and the carbonization process increases and the yarn can be produced at a lower cost.
However, since a usual reinforcing woven fabric is formed using a reinforcing filamentary yarn prepared by binding reinforcing fibers in a form of a nearly circular cross section, in a formation of the woven fabric, the cross section of the reinforcing filamentary yarn indicates an oval shape at an intersection of warp and weft and a weaving thread is greatly crimped. In particular, in a case of a reinforcing woven fabric using a thick reinforcing filamentary yarn, this tendency becomes remarkable because a thick warp and a thick weft intersect with each other.
In such a reinforcing woven fabric wherein reinforcing filamentary yarns are greatly crimped, the fiber density is not uniform and the woven fabric cannot indicate a high strength sufficiently. Further, in a reinforcing-woven fabric using a thick reinforcing filamentary yarn, because usually the weight and the thickness of the woven fabric increase, resin impregnation property when a prepreg or an FRP is formed deteriorates.
Therefore, in an FRP or CFRP prepared using a reinforcing woven fabric woven with thick reinforcing filamentary yarns, there exist many voids in a resin, and a high strength cannot be expected.
On the other hand, if the weight of a woven fabric is reduced using thick reinforcing filamentary yarns, gaps formed between reinforcing filamentary yarns become great. When an FRP or CFRP is molded using such a reinforcing woven fabric having a small weight of woven fabric, the volume content of reinforcing fibers becomes low, voids of a resin are generated concentratively in gaps formed between reinforcing filamentary yarns, and a composite material having a high performance cannot be obtained.
For improving such a defect, JP-A-SHO 58-191244 discloses a thin woven fabric having a thickness of not more than 0.09 mm and a weight of not more than 85 g/m.sup.2 which is woven using a thin and flat carbon fiber filamentary yarn having a large width and a method for manufacturing it. This thin woven fabric has small crimp of weaving threads because of its very small thickness, it indicates a high effect for reinforcement, and it is an excellent substrate for molding a thin CFRP.
In a method for weaving such a reinforcing woven fabric using a flat carbon fiber filamentary yarn, warps are supplied from a yarn beam on which a required number of carbon fiber filamentary yarns are wound, or warps are supplied from bobbins of carbon fiber filament
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Homma Kiyoshi
Horibe Ikuo
Nishimura Akira
Cannon James C.
Copenheaver Blaine R.
Miller Austin R.
Toray Industries Inc.
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