Three-dimensional fiber-reinforced composite material

Patent metadata

Field	Value
Publication number	US-9415566-B2
Application number	US-201314422220-A
Country	US
Kind code	B2
Filing date	Aug 20, 2013
Priority date	Aug 21, 2012
Publication date	Aug 16, 2016
Grant date	Aug 16, 2016

Abstract

A three-dimensional fiber-reinforced composite includes a laminate having fiber bundle layers that are laminated in the laminating direction and include first and second outermost layers, primary and secondary retention yarns, and a binding yarn. The binding yarn includes a fold-back section, primary and secondary traverse yarn sections, a surface yarn section that extends along the surface of the second outermost layer in the direction substantially perpendicular to the secondary retention yarn, and a bifurcated section that is formed on the surface of the second outermost layer and connected to the primary and secondary traverse yarn sections. The bifurcated section is formed by crossing the surface yarn section that extends in opposite directions in the outside in the laminating direction of the secondary retention yarn.

First claim

The invention claimed is:

1. A three-dimensional fiber-reinforced composite comprising:
a laminate including fiber bundle layers that are layered in a lamination direction, wherein the fiber bundle layers include a first outermost layer and a second outermost layer;
a matrix resin with which the laminate is impregnated;
a primary retention yarn located along a surface of the first outermost layer;
a secondary retention yarn located along a surface of the second outermost layer; and
a binding yarn that binds the fiber bundle layers in the lamination direction, wherein the binding yarn includes:
a fold-back section that is folded back such that the fold-back section runs on an outer side of the primary retention yarn in the lamination direction;
a primary traverse yarn section and a secondary traverse yarn section that are continuous with the fold-back section and extended in the lamination direction between the primary retention yarn and the secondary retention yarn in the laminate;
surface yarn sections extending in directions that are substantially perpendicular to the secondary retention yarn and along the surface of the second outermost layer; and
a bifurcated section that is formed on the surface of the second outermost layer and continuous with the primary traverse yarn section and the secondary traverse yarn section, and

the bifurcated section is formed by the surface yarn sections that extend in opposite directions from the secondary retention yarn on the outer side of the secondary retention yarn in the lamination direction and cross each other.

2. The three-dimensional fiber-reinforced composite according to claim 1 , wherein the primary traverse yarn section and the secondary traverse yarn section cross each other between the primary retention yarn and the secondary retention yarn.

3. The three-dimensional fiber-reinforced composite according to claim 1 , wherein the laminate includes a holding layer located in the vicinity of the bifurcated section in the lamination direction.

4. The three-dimensional fiber-reinforced composite according to claim 3 , wherein the holding layer is the second outermost layer.

5. The three-dimensional fiber-reinforced composite according to claim 3 , wherein
the holding layer is a woven fabric including primary yarns that are arranged in parallel to one another and secondary yarns that are arranged parallel to one another and extended in a direction that intersects the primary yarns, and
each of the primary and secondary yarns is a fiber bundle.

6. The three-dimensional fiber-reinforced composite according to claim 3 , wherein the fiber bundle layers, the primary retention yarn, the secondary retention yarn, the binding yarn, and the holding layer are made of carbon fibers.

Assignees

• Toyota Jidoshokki Kk

Inventors

• Kamiya Ryuta

Classifications

• B32B5/024

  Woven fabric · CPC title

• D10B2505/02

  Reinforcing materials; Prepregs · CPC title

• C08J5/04

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

• B29C70/24

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

• D04H3/04 Primary

  in rectilinear paths, e.g. crossing at right angles · CPC title