CONSTRUCTION MATERIAL REINFORCING FIBER STRUCTURE

Abstract: A construction material reinforcing fiber structure con­ sisting of a first cord (1) extending in a zigzag fashion, con­ tinuously, in layers without forming cut ends at the folded portions thereof, a second cord (2) extending zigzag con­ tinuously without forming cut ends at the folded portions (T) thereof, in such a manner that the second cord (2) passes through the planes in which the layers of the first cord (1) are arranged, and a third cord (3) constituting a member for pre­ venting the separation of the cords (1), (2) and extending zig­ zag through the loop portions of the first cord (1).

Description: ¯. Textile Structure¯Textile'S'tructbre ¯. Textile Structure¯Textile'S'tructbre for Reinfoliced for.Reinforced for Reinfoliced for.Reinforced Composite Material TECHNICAL FIELD The present invention relates to a textile structure for a reinforced composite material and more particularly it relates to a textile structure wherein there are no cut ends of filaments on the end surfaces of tne textile structure. BACKGROUND ART Composite materials reinforced such by textile structures, as woven glass fiber fabrics and woven carbon fiber fabrics, have been used as materials for machine parts requiring strength, such as aircraft, automobiles, railroad vehicles and ships, and as building members. Further, composite materials, such as carbon fiber/carbon llj#trices, graphite fiber/carbon matrices and graphite fiber/graphite matrices, have been used for .machine parts requiring heat resistance above lO00 C, Such composite nlaterials,n[NR]aterials, nlaterials,n[NR]aterials, which areate areate reinforced by textile structures, are li#ht in weight weight and physically and cile:llically cli[NR]:i[NR][NR] c[NR] [NR] ly cile:llically cli[NR]:i[NR][NR] c[NR] [NR] ly strong and they #are valued for their usefulness not only in the aforesaid field of application but also in various fields of industries. Thus, the strength characteristics of such composite materials (for example, carbon-carbon composite) depend largely on the construction of a textile structure incorporated in a matrix as a reinforcing base material, for example, a woven fabric. For this reason , reason , these textile structures have their consLruction so selected as to maxielizemaxin,ize maxielizemaxin,ize the disposition density of filancctsfi1a,.ents filancctsfi1a,.ents constituting the textile structures, as disclosed, for example, in Japanese Patent Application Laid-Open No 57-176232 and United States Patent No. . . 3,904,464, in order to increase the strength of finally cjtainedcbtai-ned cjtainedcbtai-ned composite materials. These known textile structures, however, each have numerous filament ends exposed in their cut state on the end surfaces, with the result that when the textile structure is impregnated with thermosetting resin, filaments come off, leading to the textile structure losing shape, or it becomes necessary to apply mechanical cutting operation to tize shape#lost portion after the setting of the resin to remove that portion, a fact which imposes heavy restrictions on saving resources and on increasing productivity. Further, the production of a composite material which is complicated in shape encounters another problem ol strength being decreased owing to alacEIiningm3Chini'!1[NR] alacEIiningm3Chini'!1[NR] involved. DISCLOSURE OF THE INVENTION An important object or the invention is to provide a textile structure for a reinforced composite material which is free of the aforesaid problems inherent in the conventional three dimensional fibrous materials and particularly in the textile structure used as a base material therefor. Another important object of the invention is to provide a textile structure having peculiar structural features wherein no ends of filaments constituting the base material are exposed on the surface of a composite material. The essence of the invention is a textile structure comprising a first filament which is disposed on the same plane without forming a cut end at each turn and then disposed in the next filament-disposition plane where it extends in a direction different from the direction of filament disposition in the first plane, whereafter it repeats the laminating motion, a second filament which is zigzag disposed piercing through the planes of disposition of the first filament without forming a cut end at each turn, and a third filament which is disposed on the uppermost surface of the lamination of the fiz'Jt filament to serve as a preventive membe#melllLel membe#melllLel for prevelltil.g prevent n[NR] prevelltil.g prevent n[NR] the second fi#ament from coming off. In the textile structure according to the invention, although the filament ends appear at the start and end points of filament disposition, there is no cut filament end at each turn. Therefore, there is no need to apply a special filament end treatment n4¯nd n4¯nd yet there is no ranger of filaments coming off during fl#atrix fl#atrix itaprernatin itaprernatin process, this making i possible to secure a satisfactor,°.atisSactor) satisfactor,°.atisSactor) yield. Further, since I.e filawents constituting the textile structure mair#tars mair#tars a lamination density, the reinforcing effect can thcthri thcthri final product can be maintained at an extret'..elyextre7ely extret'..elyextre7ely high level as compared with a known three-di#ensional three-di#ensional .koran .koran fabric. As for the secondary effect of the invention, thanks to the control of coming-off of filaments, little tT#achining tT#achining allowance is needed, which means that the amount of filaments and synthetic resin material to be used can be greatly reduced. BRIEF DESCRIPTION OF TTIJ TTIJ .sINGSJrRA.[NR]It:Gs .sINGSJrRA.[NR]It:Gs Fig. 1 is an enlarged perspective viet. for explaining an example of a textile structure ror a reinforced composite material accordillr,accordint5. accordillr,accordint5. to the invetition;inwel1tion; invetition;inwel1tion; Fig. 2 is a perspective view of composite material using the textile structure of Fig. 1 as a reinforcing material; Figs. 3 to 5 are explanatory views showing how filaments are disposed in a textile structure when the composite material is an apertured cylindrical body; ; Fig. 6 is an explanatory view showing how filaments are disposed { whe the composite material is an octagonal prism body; Fig. 7 shows by way of3f of3f example the respective shapes of colfiposltecomp[NR]s2 te colfiposltecomp[NR]s2 te r-.ateriaAs¯T[NR].-.atcria r-.ateriaAs¯T[NR].-.atcria #5using textile structures according to the ivetlsinvent 3 'on ivetlsinvent 3 'on as re enforcing members; Fig. 8 is a plan view of a textile structure showing another ernbodir:ent ernbodir: :ent of the invention employing a different method of filament d.ssosition[NR][NR]sposition d.ssosition[NR][NR]sposition frown that used in the embodiment shown in Fig. 1; Fig. 9 is a perspective view showing a structure in the form of an apertured plate. BEST 'lODE FOR CARRYING OUT THE INVENTION In Fig. 1, a textile structure having three filament array axes X, Y and Z crossing each other at predetermined crossing angles 01, 02 and 03 is formed of three filaments different in tnet1[NR]e tnet1[NR]e way they are disposed. That is, the textile :,structure :,structure shown in this einbodiment[NR]mbodiment einbodiment[NR]mbodiment comprises a first filâlilentfilar;ieiit filâlilentfilar;ieiit 1 extending flO;:ìfi¯i[NR];:i flO;:ìfi¯i[NR];: :i a first end surface S1Si S1Si in the direction of a first filament-dis-filament-dis[NR] filament-dis-filament-dis[NR] position axis (X-axis) to a second end surface S2 opposite to the first end surface S1, to form a first turn T7 on the second end surface, turning around one or two or more courses of a second filament 2 and extending back to the first end surface S1 to form a second turn T2 on the first end surface, turning around one or two or .TOre:nore .TOre:nore courses Df[NR]f Df[NR]f the second filanent 2 and #xteflJ': :0g again to the second end surface, thereafter repeating the turn-back motion until it reaches the terminal end 4 of a first filament-disposition plane1 at which terminal end it curves in a direction Y-axis direction different from the preceding direction of filament Jisposition tc move to a second filament-disposition plane forming a crossing angle of 900 with the direction of filament disposition which is prior to arrival at the terminal end 4 of the first filament-disposition plane, thereafter repeating the turn-back motion while forming third and fourth turns T3 and T4 on third and fourth end surfaces 53 and S4, respectively, until it forts a second filament-disposition plane in which it turns around one or two or more courses of the second filament at tile third and fourth turns T3 and T4, whereafter it repeats the turn-back motion in the first and second filament-disposition planes, the second filament 2 t#stelldint##exte[NR][NR]d[NR]'ng in t#stelldint##exte[NR][NR]d[NR]'ng in oce direction (Z-axis direction) so as to be orthogonal to the first and second filament-disposition planes, to form a third filament-disposition plane in which it spans the first filament 1 at its turns T5 and T6, whereafter it repeatedly forms the third filament-disposition plane, and a third filament 3 which extends t t 1; 1; through loops 5 formed of the second filament 2 at the turns T5 and T6 for the second filament 2, to forxn 3 fourth fila:ncrt-disposition plane in such a manner as to tighten the lanination of the first filament 1. In the present invention, the filaments 1, 2 and 3 forming the textile structure may be suitably selected in accordance with t t the characteristics of the final product from the class consisting of such inorganic fibers as glass fiber, carbon or graphite fiber, silicon carbide fiber and alumina fiber, and such synthetic fibers as polyester fiber, apliphatic or aromatic fiber (for example, the heat resistant fiber, KEVLOR or NOt4EX, by Du Pont). For example, if the finally obtained composite material is a rocket nose corn, a part for brake devices subjected to a high instantaneous load such as vehicle brake devices for aircraft and ShinkansenS h i 17 k a n s c n ShinkansenS h i 17 k a n s c n Line, or a mechanical part requiring heat resistance and wear resistance, such as a current collector for electric cars, ttien it is desirable to use carbon fiber or gl'3phi te fiber for tile lilalTlentsfilamer[NR]ts lilalTlentsfilamer[NR]ts 1, 2 and 3. These filaments are formed into a textile structure having a high filament lamination density in accordance with the procedure described above, the textile structure being then impregnated with a thermosetting resin, such as epoxy resin or phenol resin, to be molded into a desired shape, and through curing and n.#chining n.#chining it is finished Into a final product .4ofie:ery;r[NR][NR]IL[NR][NR]er, .4ofie:ery;r[NR][NR]IL[NR][NR]er, ir.ir: ir.ir: a field requirir. h bh-r heat resistance, it is possible to use carton as t.%'e matrix. Further, it is possible to incorporate carbon powder or the like in the thermosetting resin as a second reinforcing con.ponent.conponent. con.ponent.conponent. Further, the textile structure according to the invention may be used as it is, or without being impregnated with thermosettinb resin, for a packing material of complicated shape, a shock absorbing material or a filler. In the embodiment shown in Fig. 1, the first through third filaments with the directions of filament axes crossing each other at right angles are each formed of carbon fiber but are differently colored to facilitate the understanding thereof; the first filament 71 71 is shown as a white continuous filament, the second filament 2 as a black continuous filament and the third filament 3 as a shaded continuous filament. The first and second filaments 1 1 and 2 form the textile structure in accordance with tulle aforesaid pllcedure, wllilewlii l(' wllilewlii l(' the third filament 3 functions as a locking member, or a latch, for preventing filaments from coWingco[NR]ing coWingco[NR]ing off from the end surface of the laminate of the filaments 1 and 2. As for the arrangement of these filaments 1, 2 and 3, it is preferable to minimize the spacing of the filaments 1 and 2 so that the textile structure may have a high filament lanination jest. The te > :t I t t le structure thus construcbedconst ructe[NR] construcbedconst ructe[NR] is e e d d iS its iS its lrnpre- nated with epoxy rein, phenol resin or the like and then, in the usual mariner such as curing etc ., it is finished into a composite molded article as the final product. In the above embodiment, tne crossing angles 01, 02 and 03 are each set at 900 50 that the axial directions of the first through third filaments 1, 2 and 3 cross each other at right angles, but the essence of the invention is not limited to such example; any desired filament crossing angle, such as 750 or 600, may be selected in accordance with the characteristics of the load acting on the composite material or in accordance with the shape of the textile structure. Further, there is no special restriction on the shape and size of the final product so long as the aforesaid arrangement is adopted; the reinforcing performance can be exerted in connectionc o n n e c t i o n connectionc o n n e c t i o n with all composite material hav it#g, hav it#g, for aUxamp'e, aUxamp'e, a cyl , , a a indrica i C zylinJrical c indrica i C zylinJrical c SllDe¯e v[NR][NR]'-5eCt SllDe¯e v[NR][NR]'-5eCt lona # ha pe ot'Ol¯ ot'Ol¯ prof 1 lepl'Orile prof 1 lepl'Orile cross-sections including H-shape, U-shape and so on shown in Fig. 7. In producing a reinforced L-shaped textile structure shown in Fig. 2, it is possible to employ a method of filament disposition shown in Fig. 8 as an alternative method in order to increase the strength of the inside corner portion of the structure. That is, in this s ecnb s ecnb e#nbod'ment,efllbodiment } e#nbod'ment,efllbodiment } the first filamenr î 1 1 lies in a single in ent [NR]e'it ent [NR]e'it In L-shape nd repeats a zigzag travel along tne bent shape to form first filament-disposition planes rlrl rlrl nereupon it repeats a zigzag travel in a direction ap#roxitrately <RTI ID=10.12> ap#roxitrately orthogonal to the direction of travel in .r.er*e .r.er*e first filament-disposition planes so as to form second filament-disposition planes P2 above the first f#l#ment-dispositionfllanent-disposition f#l#ment-dispositionfllanent-disposition planes P1. Thereafter, the formation of filament-disposition planes P3 through Pn by the 'first filament in accordance with the same procedure is repeated a predetermined number of times. On the other hand, the second filament 2 repeats a zigzag travel in a direction orthgunalortllgonal orthgunalortllgonal to tri." tri." filament-dispositionfilament-dispositiotj filament-dispositionfilament-dispositiotj planes P1 through Pn of the first filament 1 in accordance with the same procedure as SI0CWtl ill the embodiment in Fig. 1. I I In this manner, a tt¯stilebexti'e tt¯stilebexti'e structure having the stlengthstl¯cllgth stlengthstl¯cllgth of the inside cortercortex cortercortex portion tEIereofttt[NR]reof tEIereofttt[NR]reof increased, is formed of LheLliC LheLliC first 1 #lr-::.et#t1, the se.v-ndsL'C[NR]w[NR]0d se.v-ndsL'C[NR]w[NR]0d filament 2 snd[NR]:id snd[NR]:id tulle tllirdthird tllirdthird f,1all.e:.tfl -amC[NR]i[NR]t f,1all.e: :.tfl -amC[NR]i[NR]t (not shown) In addition, in the above embodiments, the first filament 1 has been shown as a single continuous filament. However, in the case of a textile structure complicated in shape, two or more filaments having no cut end at each turn may be used as the first filaments. Further, it is not necessary for the first and second filaments 1 and 2 to be free of a knot t'1roul > !DuL thr0'jL[NR].iD'Jt t'1roul > !DuL thr0'jL[NR].iD'Jt the len#th; a plurality of filaments may be joined together by known methods, such as bonding, fusion and knotting, so long as the cut ends are not positioned at the turns, in forming a textile structure. Figs. 3 through 5 are explanatory views showing how the filaments 1 and 2 are disposed in the case where the composite material is an apertured cylindrical body, and Fig. 6 is an explanatory view showing how the filaments are disposed in the case where the composite material is an octagonal prism body. Fig. 9 shows a structure in the form of an apertured plate. In forming such apertured plate by the conventional method, an unapertured block is iiolded, is impregnated with resin and is subjected to a desired aperturing or or¯ our¯ or¯ our¯ punching operation using 3 cutting tool such as a drill, with which method, however, tl0C component filaments of the reinforcing textile structure ire liabl¯li3bl[NR] liabl¯li3bl[NR] to be cut or frayed. Furt!i#i', the tool life is shortened. In the present invention, since the aperture can be formed simultaneously with the formation of the textile structure, the decrease in the strength of the structural material due to the cuttirig of filaments, which has been a problem in the conventional method, can be effectively avoided. IN-LTh'sf":# AL IN-LTh'sf":# AL Af#F'LiCA±1LITY The textile structure according to the present invention can be used as a composite zatenl--l!t[NR]t[NR]rI & i zatenl--l!t[NR]t[NR]rI & i for machines and equipment requiring strength, such as space projectiles, aircraft, automobiles, railroad *,ehi.les':hi[NR]les *,ehi.les':hi[NR]les and ships, or as a building member. Further, excellent strength characteristics can also be available when it is used for the face insert of a golf club.

Claims: WHAT IS CLAIMED IS: 1. A textile structure for a reinforced composite material comprising a first filament which is disposed on the same plane without formin a cut end at each turn and then disposed in the next filament-disposition plane where it extends in a directIondil-ecticrl directIondil-ecticrl dilf¯erentdii'ferent dilf¯erentdii'ferent from the direction of flianentfiianzent flianentfiianzent i#sp0'it:#n i#sp0'it:#n an t t :in:in :in: :inin it in it said first plane, wher-afterrJ h [NR] [NR][NR][NR]a f' t- e r wher-afterrJ h [NR] [NR][NR][NR]a f' t- e r it repeats said i d la rti IZa} naL i d la rti IZa} naL gna gna iT)Ctljfl, iT)Ctljfl, a , , c c second filament which is zIg#agzigza,T zIg#agzigza,T d d disposed piercing through the planes of disposition of t t ##I ##I the first filament without forming a cut end at each turn, and a third filament which is disposed on the uppermostup,,er.TJost uppermostup,,er.TJost surface of the lamination of said first filament to serve s3. s3. a preventive member for prevent nag said second filament from coming off.

Inventors: HIROKAWA, TETSURO
Applicants: SHIKISHIMA CANVAS KABUSHIKI KAISHA
Application year: 1985
Main classification: D03D25
IPC codes: B29C70, D04H3, D03D25