Fiber laminate, method for manufacturing fiber laminate, and fiber reinforced composite

Patent metadata

Field	Value
Publication number	US-10357937-B2
Application number	US-201615741302-A
Country	US
Kind code	B2
Filing date	Jun 20, 2016
Priority date	Jul 7, 2015
Publication date	Jul 23, 2019
Grant date	Jul 23, 2019

Abstract

A fiber laminate W is configured by laminating first to fourth fiber layers. The fiber laminate is provided with a taper section, in which the thickness changes depending on the position in the longitudinal direction. The first to fourth fiber layers are formed by discontinuous fibers and are configured with the orientation angles of the discontinuous fibers aligned in one direction. The orientation angles of the discontinuous fibers in the first to fourth fiber layers are different. In addition, the first to fourth fiber layers are provided with thickness changing sections, in which the thickness changes continuously while the density of fibers is kept constant irrespective of the position in the longitudinal direction. The taper section is configured by stacking the thickness changing sections. The change amount of the thickness of each thickness changing section is the same irrespective of the position in the longitudinal direction.

First claim

The invention claimed is:

1. A fiber laminate comprising, at least in a part, a taper section, a thickness of which continuously changes depending on a position in a predetermined direction, the fiber laminate being configured by stacking a plurality of fiber layers, wherein
each fiber layer is formed by discontinuous fibers and configured with orientation angles of the discontinuous fibers aligned in one direction,
the orientation angles of the discontinuous fibers of at least two fiber layers among the fiber layers are different,
each of the fiber layers includes a thickness changing section, a thickness of which continuously changes while a density of fibers is kept constant irrespective of a position in the predetermined direction, and
the taper section is configured by stacking a plurality of the thickness changing sections, and a change amount of the thicknesses of each thickness changing section is the same irrespective of a position in the predetermined direction.

2. The fiber laminate according to claim 1 , further comprising a constant thickness section where the thickness of the fiber layer does not change irrespective of a position in the predetermined direction.

3. A fiber reinforced composite formed by impregnating a matrix resin into a reinforced base material made of fiber, wherein the reinforced base material is the fiber laminate according to claim 1 .

4. A method for manufacturing a fiber laminate including, at least in a part, a taper section, a thickness of which continuously changes depending on a position in a predetermined direction, the fiber laminate being configured by stacking a plurality of fiber layers, wherein
each fiber layer is formed by discontinuous fibers and configured with orientation angles of the discontinuous fibers aligned in one direction,
the orientation angles of the discontinuous fibers of at least two fiber layers among the fiber layers are different,
each fiber layer is manufactured by stretching a web formed by the discontinuous fibers with a web drafter including a roller section formed by a plurality of roller groups, and
circumferential velocities of the roller groups are relatively differentiated such that a thickness continuously changes while a density is kept constant irrespective of a position in the predetermined direction, thereby differentiating a draft rate of the roller section.

5. The method for manufacturing a fiber laminate according to claim 4 , wherein a width of the web is restricted by a restricting member on a downstream side of the roller section.

Assignees

• Toyota Jidoshokki Kk

Inventors

• Yoshikawa Genki
• Kamiya Ryuta

Classifications

• Y10T428/24612

  Composite web or sheet · CPC title

• Y10T428/24124

  Fibers · CPC title

• D04H1/74

  the fibres being orientated, e.g. in parallel {(anisotropic fleeces)} · CPC title

• C08J5/04

  Reinforcing macromolecular compounds with loose or coherent fibrous material · CPC title

• B32B2605/18

  Aircraft · CPC title