Fiber structure and fiber reinforced composite material

Patent metadata

Field	Value
Publication number	US-10697094-B2
Application number	US-201615754898-A
Country	US
Kind code	B2
Filing date	Aug 16, 2016
Priority date	Aug 28, 2015
Publication date	Jun 30, 2020
Grant date	Jun 30, 2020

Abstract

A fiber structure includes a first fiber layer including first reinforcement fiber bundles extending in a first yarn main axis direction, a second fiber layer including second reinforcement fiber bundles extending in a second yarn main axis direction that is orthogonal to the first yarn main axis direction, and auxiliary yarns that join the first fiber layer with the second fiber layer in a stacking direction of the first fiber layer and the second fiber layer. At least either one of the first reinforcement fiber bundles and the second reinforcement fiber bundles each include a core yarn and a covering yarn spirally wound around the core yarn. A covering angle, which is an orientation angle of the covering yarn, corresponds to a direction that differs from the first yarn main axis direction and the second yarn main axis direction.

First claim

The invention claimed is:

1. A fiber structure comprising:
a first fiber layer including a plurality of first reinforcement fiber bundles arranged to extend in a first yarn main axis direction;
a second fiber layer including a plurality of second reinforcement fiber bundles arranged to extend in a second yarn main axis direction that is orthogonal to the first yarn main axis direction; and
auxiliary yarns that intersect the first reinforcement fiber bundles and the second reinforcement fiber bundles, wherein the auxiliary yarns join the first fiber layer with the second fiber layer in a stacking direction of the first fiber layer and the second fiber layer,
wherein each of the respective first and second reinforcement fiber bundles of at least either one of the respective first reinforcement fiber bundles and the second reinforcement fiber bundles include:
a core yarn formed by a first reinforcement fiber, and
a covering yarn formed by a second reinforcement fiber spirally wound around the core yarn, and
wherein a covering angle, which is an orientation angle of the covering yarn relative to the core yarn, corresponds to a direction that differs from the first yarn main axis direction and the second yarn main axis direction and exhibits dynamic properties in a fiber-reinforced composite that uses the fiber structure as a reinforcement base.

2. The fiber structure according to claim 1 , wherein
the core yarn has a flattened cross section, and
the core yarn includes two wide surfaces extending in a longitudinal direction of the core yarn, wherein portions of the covering yarn that are located on the two wide surfaces are oriented in the different direction.

3. The fiber structure according to claim 1 , wherein the first reinforcement fiber bundles and the second reinforcement fiber bundles each include the core yarn and the covering yarn.

4. The fiber structure according to claim 3 , wherein
in each of the first reinforcement fiber bundles and the second reinforcement fiber bundles,
the covering yarn forms a covering layer that covers the core yarn, wherein the covering layer includes a first cover that is formed by a portion of the covering yarn extending at a predetermined covering angle relative to a yarn main axis direction of the core yarn and a second cover that is formed by a portion of the covering yarn extending at an angle that is symmetrical to the predetermined covering angle of the first cover relative to the yarn main axis of the core yarn, and
a volume ratio of the core yarn, the first cover, and the second cover is 2:1:1.

5. The fiber structure according to claim 1 , wherein each of the plurality of first reinforcement fiber bundles includes the core yarn and the covering yarn.

6. The fiber structure according to claim 5 , wherein
the covering yarn forms a covering layer that covers the core yarn, wherein the covering layer includes a first cover that is formed by a portion of the covering yarn extending at a predetermined covering angle relative to a yarn main axis direction of the core yarn and a second cover that is formed by a portion of the covering yarn extending at an angle that is symmetrical to the predetermined covering angle of the first cover relative to the yarn main axis of the core yarn, and
a volume ratio of the core yarn and the second reinforcement fiber bundle is 1:1, and a volume ratio of the core yarn, the first cover, and the second cover is 1:1:1.

7. A fiber-reinforced composite obtained by impregnating a fiber structure with a matrix resin, wherein the fiber structure includes
a first fiber layer including a plurality of first reinforcement fiber bundles arranged to extend in a first yarn main axis direction,
a second fiber layer including a plurality of second reinforcement fiber bundles arranged to extend in a second yarn main axis direction that is orthogonal to the first yarn main axis direction, and
auxiliary yarns that intersect the first reinforcement fiber bundles and the second reinforcement fiber bundles, wherein the auxiliary yarns join the first fiber layer with the second fiber layer in a stacking direction of the first fiber layer and the second fiber layer,
wherein each of the respective first and second reinforcement fiber bundles of at least either one of the respective first reinforcement fiber bundles and the second reinforcement fiber bundles include
a core yarn formed by a first reinforcement fiber, and
a covering yarn formed by a second reinforcement fiber spirally wound around the core yarn, and
wherein a covering angle, which is an orientation angle of the covering yarn relative to the core yarn, corresponds to a direction that differs from the first yarn main axis direction and the second yarn main axis direction and exhibits dynamic properties in the fiber-reinforced composite.

Assignees

• Toyota Jidoshokki Kk

Inventors

• Kamiya Ryuta

Classifications

• D03D1/00 Primary

  Woven fabrics designed to make specified articles · CPC title

• D03D11/00

  Double or multi-ply fabrics not otherwise provided for · CPC title

• D10B2505/02

  Reinforcing materials; Prepregs · CPC title

• D03D15/267

  Glass · CPC title

• B29C70/24

  oriented in at least three directions forming a three-dimensional [3D] structure · CPC title