U.S. patent application number 16/484230 was filed with the patent office on 2020-01-30 for fiber structure and fiber reinforced composite material.
This patent application is currently assigned to KABUSHIKI KAISHA TOYOTA JIDOSHOKKI. The applicant listed for this patent is KABUSHIKI KAISHA TOYOTA JIDOSHOKKI. Invention is credited to Mari KAWAHARA.
Application Number | 20200032433 16/484230 |
Document ID | / |
Family ID | 63107370 |
Filed Date | 2020-01-30 |
![](/patent/app/20200032433/US20200032433A1-20200130-D00000.png)
![](/patent/app/20200032433/US20200032433A1-20200130-D00001.png)
![](/patent/app/20200032433/US20200032433A1-20200130-D00002.png)
![](/patent/app/20200032433/US20200032433A1-20200130-D00003.png)
![](/patent/app/20200032433/US20200032433A1-20200130-D00004.png)
United States Patent
Application |
20200032433 |
Kind Code |
A1 |
KAWAHARA; Mari |
January 30, 2020 |
FIBER STRUCTURE AND FIBER REINFORCED COMPOSITE MATERIAL
Abstract
A fiber structure includes a multilayer fabric including first
yarns and second yarns. The fiber structure includes a first fabric
edge, a second fabric edge, and fabric-style fixing portions. The
fabric-style fixing portions are formed at least one of an
outermost yarn and ends of one of the two types of yarns. Of the
one of the two types of yarns, the outermost yarn is located
closest to the ends of the other of the two types of yarns. The
ends of the one of the two types of yarns are located closer to the
ends than the outermost yarn.
Inventors: |
KAWAHARA; Mari; (Kariya-shi,
Aichi-ken, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KABUSHIKI KAISHA TOYOTA JIDOSHOKKI |
Kariya-shi, Aichi-ken |
|
JP |
|
|
Assignee: |
KABUSHIKI KAISHA TOYOTA
JIDOSHOKKI
Kariya-shi, Aichi-ken
JP
|
Family ID: |
63107370 |
Appl. No.: |
16/484230 |
Filed: |
January 23, 2018 |
PCT Filed: |
January 23, 2018 |
PCT NO: |
PCT/JP2018/001963 |
371 Date: |
August 7, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D03D 11/00 20130101;
D04H 1/46 20130101; D03D 5/00 20130101; D03D 1/00 20130101; D06M
17/04 20130101 |
International
Class: |
D03D 5/00 20060101
D03D005/00; D03D 1/00 20060101 D03D001/00; D06M 17/04 20060101
D06M017/04; D03D 11/00 20060101 D03D011/00; D04H 1/46 20060101
D04H001/46 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 8, 2017 |
JP |
2017-021130 |
Claims
1. A fiber structure comprising: a multilayer fabric including:
first yarns; and second yarns arranged orthogonally to the first
yarns, the first yarns and the second yarns being bundles of
reinforcing fibers, wherein, the fiber structure includes: a first
fabric edge of the multilayer fabric where ends of the first yarns
are located in a yarn main axis direction of the first yarns; a
second fabric edge of the multilayer fabric where ends of the
second yarns are located in a yarn main axis direction of the
second yarns; and fabric-style fixing portions disposed in only
either the first fabric edge or the second fabric edge, or only
both the first fabric edge and the second fabric edge, the
fabric-style fixing portions are formed by entangling the
reinforcing fibers of yarns of the first yarns and the second yarns
overlapped in a lamination direction of the multilayer fabric, the
fabric-style fixing portions are formed in at least one of an
outermost yarn and ends of one of the two types of yarns, wherein
of the one of the two types of yarns arranged side by side in a
yarn main axis direction of the other of the two types of yarns
forming the fabric edges, the outermost yarn is located closest to
the ends of the other of the two types of yarns, the ends of the
one of the two types of yarns are located closer to the ends than
the outermost yarn in the yarn main axis direction of the one of
the two types of yarns.
2. The fiber structure according to claim 1, wherein the
fabric-style fixing portions are disposed only in the outermost
yarn.
3. The fiber structure according to claim 1, wherein the first
yarns and the second yarns are made of discontinuous fibers.
4. The fiber structure according to claim 1, wherein the
fabric-style fixing portions are formed by needle punching.
5. A fiber-reinforced composite material formed by impregnating a
reinforcing base material being the fiber structure with matrix
resin, wherein the fiber structure is a fiber structure according
to claim 1.
Description
TECHNICAL FIELD
[0001] The present invention relates to a fiber structure made of a
multilayer fabric having first yarns and second yarns and a
fiber-reinforced composite material using the fiber structure. The
first yarns and the second yarns are 11) bundles of reinforcing
fibers.
BACKGROUND ART
[0002] Fiber-reinforced composite materials are widely used as
lightweight structural materials. A fiber structure is a
reinforcing base material for a fiber-reinforced composite
material, and the fiber-reinforced composite material formed by
combining the fiber structure with resin as a matrix is used as
structural materials for airplanes, vehicles, buildings, and the
like. The fiber structure is made of a multilayer fabric.
[0003] A laminated fabric as a multilayer fabric is formed by, for
example, laminating several single-layer fabrics formed by plain
weave. In some cases, such laminated several single-layer fabrics
are joined with each other in the lamination direction to form the
laminated fabrics. By the way, when the fiber structure is carried
or shaped, of fabric edges of the fiber structure, for example, one
fabric edge in which each ends of warps extending in a yarn main
axis direction of the warps are located has a possibility of
fraying. Then, wefts extending orthogonally to the warps may be
pulled out from the frayed fabric edge. To prevent such fraying at
the fabric edge of the fiber structure, for example, tapes are
attached to fabric edges of a fiber structure in Patent Document
1.
CITATION LIST
Patent Document
[0004] Patent Document 1: Japanese Patent Application Publication
No. 2002-249957
SUMMARY OF INVENTION
Technical Problem
[0005] However, in Patent Document 1, to prevent the fraying of the
fabric edge of the fiber structure, the tapes which are separate
members from the fiber structure are needed, increasing costs for
manufacturing the fiber structure. Furthermore, the tapes used to
prevent the fraying may adversely affect the combining of the fiber
structure with a matrix.
[0006] It is an objective of the present invention to provide a
fiber structure and a fiber-reinforced composite material that
prevent fraying of fabric edges without adding any separate
members.
Solution to Problem
[0007] To achieve the foregoing objective and in accordance with
one aspect of the present invention, a fiber structure includes a
multilayer fabric including first yarns and second yarns arranged
orthogonally to the first yarns, the first yarns and the second
yarns being bundles of reinforcing fibers. The fiber structure
includes a first fabric edge of the multilayer fabric wherein ends
of the first yarns are located in a yarn main axis direction of the
first yarns, a second fabric edge of the multilayer fabric wherein
ends of the second yarns are located in a yarn main axis direction
of the second yarns, and fabric-style fixing portions disposed in
at least one of the first fabric edge and the second fabric edge.
The fabric-style fixing portions are formed by entangling the
reinforcing fibers of yarns of the first yarns and the second yarns
overlapped in a lamination direction of the multilayer fabric. The
fabric-style fixing portions are formed in at least one of an
outermost yarn and ends of one of the two types of yarns, Of the
one of the two types of yarns arranged side by side in a yarn main
axis direction of the other of the two types of yarns forming the
fabric edges, the outermost yarn is located closest to the ends of
the other of the two types of yarns. The ends of the one of the two
types of yarns are located closer to the ends than the outermost
yarn in the yarn main axis direction of the one of the two types of
yarns.
[0008] With this configuration, if the fabric-style fixing portions
are formed in the 11) outermost yarn, the reinforcing fibers of
each yarn overlapped with the outermost yarn in the lamination
direction are entangled with each other, thereby preventing pulling
out of the outermost yarn from the fabric edge. In addition, if the
fabric-style fixing portions are formed in the ends of the one of
the two types of yarns, the reinforcing fibers are entangled at a
position closer to the ends of the one of the two types of yarns
than the outermost yarn in the yarn main axis direction of the one
of the two types of yarns, thereby preventing pulling out of the
outermost yarn over the ends of the one of the two types of yarns.
This means that forming the fabric-style fixing portions prevent
the fraying in the fabric edge. The fabric-style fixing portions
are formed by entangling the reinforcing fibers of yarns overlapped
in the lamination direction. Therefore, no separate members are
needed to prevent the fraying in the fabric edge.
[0009] The fabric-style fixing portions may be disposed only in the
outermost yarn in the fiber structure.
[0010] This means that the fiber structure does not have the
fabric-style fixing portions more inside than the outermost yarn
extending in a yarn main axis direction of the one of the two types
of yarns. This configuration minimizes twisting of the reinforcing
fibers caused by forming the fabric-style fixing portions.
[0011] The first yarns and the second yarns of the fiber structure
may be made of discontinuous fibers.
[0012] With this configuration, in the fabric-style fixing
portions, the discontinuous fibers are entangled in many portions
between the yarns overlapped in the lamination direction, thereby
effectively preventing the fraying.
[0013] The fiber-reinforced composite material to solve the above
issues is formed by impregnating a reinforcing base material made
of a fiber structure with matrix resin. The aforesaid fiber
structure corresponds to the fiber structure according to any one
of claims 1 to 3.
[0014] This means that the fabric-style fixing portions prevents
the fraying of the fabric edges of the fiber structure. The
fabric-style fixing portions are formed by entangling the
reinforcing fibers of yarns overlapped in the lamination direction.
Therefore, no separate members are needed to prevent the fraying in
the fabric edges Therefore, in the fiber-reinforced composite
material formed by impregnating the fiber structure with matrix
resin, no separating members will adversely affect the combining of
the matrix resin.
Advantageous Effects of Invention
[0015] According to the present invention, it is possible to
prevent fraying in fabric edges without adding separate
members.
BRIEF DESCRIPTION OF DRAWINGS
[0016] FIG. 1 is a view schematically showing a fiber-reinforced
composite material of a present embodiment.
[0017] FIG. 2 is a partial plan view showing a fiber structure of
the present embodiment.
[0018] FIG. 3 is a view of the fiber structure of the present
embodiment as viewed in the direction indicated by arrow A of FIG.
2.
[0019] FIG. 4 is a view of the fiber structure of the present
embodiment as viewed in the direction indicated by arrow B of FIG.
2.
[0020] FIG. 5 is an enlarged view showing a fabric-style fixing
portion.
[0021] FIG. 6 is a schematic view showing a fiber structure formed
by 3D-weave.
[0022] FIG. 7 is a view showing another embodiment of fabric-style
fixing portions.
[0023] FIG. 8 is a view showing still another embodiment of
fabric-style fixing portions.
DESCRIPTION OF EMBODIMENTS
[0024] A fiber structure and a fiber-reinforced composite material
according to an embodiment of the present invention will now be
described with reference to FIG. 1 to FIG. 5.
[0025] Referring to FIG. 1, a fiber-reinforced composite material
10 is formed by impregnating a reinforcing base material being a
fiber structure 11 made of a multilayer fabric with matrix resin
Ma. As the matrix resin Ma, for example, thermosetting epoxy resin
is used. The fiber structure 11 is formed by laminating a plurality
of fabrics 20.
[0026] Referring to FIG. 2, each fabric 20 is formed by interlacing
a plurality of warps 21 with a plurality of wefts 31, and has a
rectangular shape in a plan view. The warps 21 and the wefts 31
correspond to first yarns and second yarns, respectively. Each
fabric 20 is formed by plain weave to interlace the warps 21 and
the wefts 31. The wefts 31 are arranged orthogonally to the warps
21. The warps 21 and the wefts 31 are made of discontinuous fibers
11a. Organic fibers and inorganic fibers that are the reinforcing
fibers may be used as the discontinuous fibers 11a. The organic
fibers include aramid fibers, poly(p-phenylenebenzobisoxazole)
fibers, ultra-high molecular weight polyethylene fibers, and the
like. The inorganic fibers include carbon fibers, glass fibers,
ceramic fibers, and the like. The form of yarn bundles made of the
discontinuous fibers 11a includes a spun yarn, a stretch-broken
yarn, and the like.
[0027] The direction in which a yarn main axis L1 of the warps 21
extends is defined as the first direction X of the fiber structure
11. The direction in which a yarn main axis L2 of the wefts 31
extends, and orthogonal to the first direction X is defined as the
second direction Y of the fiber structure 11. The plurality of the
warps 21 are arranged side by side in the second direction Y of the
fiber structure 11 and parallel to each other in the fiber
structure 11. Furthermore, the plurality of the wefts 31 are
arranged side by side in the first direction X of the fiber
structure 11 and parallel to each other in the fiber structure 11.
Referring to FIG. 3, the fabrics 20 overlapped in the lamination
direction are configured such that the warps 21 of one fabric 20
overlap with the wefts 31 of the other fabric 20 in the fiber
structure 11. The one fabric 20 is laminated on the other fabric
20. The fabrics 20 overlapped in the lamination direction are bound
in the lamination direction by binder yarns (not shown).
[0028] Referring to FIG. 2, the fiber structure 11 includes
opposite first fabric edges 12 of the multilayer fabric where the
ends 21a of the warps 21 are located in a yarn main axis direction
of the warps 21 (the first direction X). In each of the first
fabric edges 12, the wefts 31 are located more inside than the end
21a of the warps 21 in the first direction X (closer to the center
of the fiber structure 11). Of the plurality of the wefts 31
arranged side by side in the first direction X forming the second
fabric edge 13, the outermost weft 31 located closest to the ends
21a of the warps 21 and at the outermost side is an outermost weft
32 as the outermost yarn. In this case, the warps 21 correspond to
one of the two types of yarns, and the wefts 31 correspond to the
other of the two types of yarns. The outermost weft 32 is arranged
beside the ends 21a of the warps 21. Therefore, in the first fabric
edge 12, the outermost weft 32 is located at a position closer to
the center of the fiber structure 11 than the end 21a of the warps
21.
[0029] The fiber structure 11 includes opposite second fabric edges
13 of the multilayer fabric where the ends 31a of the wefts 31 are
located in the yarn main axis direction of the wefts 31 (the second
direction Y). In each of the second fabric edges 13, the warps 21
are located more inside than the end 31a of the wefts 31 in the
second direction Y (closer to the center of the fiber structure
11). Of the plurality of the warps 21 arranged side by side in the
second direction Y forming the first fabric edge 12, the outermost
warp 21 located closest to the ends 31a of the wefts 31 and at the
outermost side is an outermost warp 22 as the outermost yarn. In
the second fabric edge 13, the outermost warp 22 is located at a
position closer to the center of the fiber structure 11 than the
end 31a of the wefts 31. In this case, the wefts 31 correspond to
the one of the two types of yarns, and the warps 21 correspond to
the other of the two types of yarns. The outermost warp 22 is
arranged beside the ends 31a of the wefts 31.
[0030] The fiber structure 11 includes fabric-style fixing portions
14 in each of the first fabric edges 12 and each of the second
fabric edges 13. The fabric-style fixing portions 14 disposed in
the first fabric edge 12 are formed by needle punching on the
outermost weft 32.
[0031] Referring to FIG. 3 or FIG. 4, the fabric-style fixing
portions 14 disposed in the first fabric edge 12 are formed to
entangle the discontinuous fibers 11a of the outermost weft 32 and
the warps 21 overlapping the outermost weft 32 in the lamination
direction with each other in each fabric 20. In other words, the
fabric-style fixing portions 14 disposed in the first fabric edge
12 are formed to entangle the discontinuous fibers 11a of the
outermost weft 32 of the one fabric 20 and the warps 21 of the
other fabric 20 with each other between the fabrics 20 overlapped
in the lamination direction. When the fabrics 20 are punched
through with a needle N at the opposite sides of each warp 21 in
the width direction, the fabric-style fixing portions 14 are formed
to entangle the discontinuous fibers 11a of the wefts 31 overlapped
in the lamination direction with each other, which is not
illustrated.
[0032] Referring to FIG. 2, the fabric-style fixing portions 14
disposed in the second fabric edge 13 are formed by needle punching
on the outermost warp 22. The fabric-style fixing portions 14
disposed in the second fabric edge 13 are formed to entangle the
discontinuous fibers 11a of the outermost warp 22 and the wefts 31
overlapping the outermost warp 22 in the lamination direction with
each other in each fabric 20. The fabric-style fixing portions 14
disposed in the second fabric edge 13 are formed to entangle the
discontinuous fibers 11a of the outermost warp 22 of the one fabric
20 and the wefts 31 of the other fabric 20 with each other between
the fabrics 20 overlapped in the lamination direction. When the
fabrics 20 are punched through with a needle N at the opposite
sides of each weft 31 in the width direction, the fabric-style
fixing portions 14 are formed to entangle the discontinuous fibers
11a of the wefts 31 overlapped in the lamination direction with
each other, which is not illustrated.
[0033] Referring to FIG. 5, in the fabric-style fixing portions 14
of the configuration described above, the discontinuous fibers 11a
are twisted and entangled in a complicated manner between the warps
21 and the wefts 31, between the warps 21, and between the wefts
31, overlapped in the lamination direction. The warps 21 and the
wefts 31 are made of the discontinuous fibers 11a, so that the
discontinuous fibers 11a are entangled in many portions at the
fabric-style fixing portions 14.
[0034] The fiber structure 11 made of a multilayer fabric
configured as described above is impregnated with matrix resin Ma,
and then the matrix resin Ma is cured, thereby producing the
fiber-reinforced composite material 10. The impregnation and the
cure of the matrix resin Ma is performed by, for example, RTM
(resin transfer molding) method. When the fiber structure 11 is
impregnated with the matrix resin Ma and the matrix resin Ma is
cured, the warps 21 and the wefts 31 of the fiber structure 11 are
combined with the matrix resin Ma to produce the fiber-reinforced
composite material 10.
[0035] The following will describe an operation of the fiber
structure 11 and the fiber-reinforced composite material 10. The
fabric-style fixing portions 14 disposed in the fiber structure 11
prevent the fraying in the first fabric edge 12 and the second
fabric edge 13.
[0036] The above-described embodiment has the following
advantages.
[0037] (1) The fabric-style fixing portions 14 are formed by
entangling the reinforcing fibers of yarns of the warps 21 and the
wefts 31 overlapped in the lamination direction of the multilayer
fabric. Therefore, the fraying of the first fabric edge 12 and the
second fabric edge 13 is prevented without using a separate member,
resulting in saving of a manufacturing cost.
[0038] Furthermore, in the fiber-reinforced composite material 10
formed by the fiber structure 11, the fraying is prevented without
using a separating member. This means that, unlike the case in
which separating members are added to prevent the fraying, a
failure in impregnation of the matrix resin Ma (an adverse effect
on the combining of the matrix resin Ma) does not occur, and the
fiber-reinforced composite material 10 does not lower a strength on
account of separate members.
[0039] (2) The fabric-style fixing portions 14 disposed in the
first fabric edge 12 are formed by needle punching on the outermost
weft 32. This needle punching entangles the discontinuous fibers
11a of the outermost weft 32 having a possibility of being pulled
out from the first fabric edge 12 and the warps 21 with each other,
thereby preventing the outermost weft 32 from being pulled out.
Furthermore, the fabric-style fixing portions 14 disposed in the
second fabric edge 13 are formed by needle punching on the
outermost warp 22. This needle punching entangles the discontinuous
fibers 11a of the outermost warp 22 having a possibility of being
pulled out from the second fabric edge 13 and the wefts 31, thereby
preventing the outermost warp 22 from being pulled out.
[0040] (3) The fabric-style fixing portions 14 disposed in each of
the first fabric edges 12 and in each of the second fabric edges 13
are formed by needle punching on the outermost weft 32 and on the
outermost warp 22, respectively. Therefore, the fiber structure 11
does not have the fabric-style fixing portions 14 more inside than
the outermost weft 32 in the first direction X (closer to the
center of the fiber structure 11), and more inside than the
outermost warp 22 in the second direction Y (closer to the center
of the fiber structure 11). As a result, in the produced
fiber-reinforced composite material 10, the twisting of the
discontinuous fibers 11a caused by forming the fabric-style fixing
portions 14 is minimized, resulting in minimizing of the reduction
in the strength of the fiber-reinforced composite material 10.
[0041] (4) The warps 21 and the wefts 31 are made of the
discontinuous fibers 11a. Thus, in the fabric-style fixing portions
14, the discontinuous fibers 11a are entangled in many portions
between the warps 21 and the wefts 31, between the warps 21, and
between the wefts 31, overlapped in the lamination direction.
Therefore, the fraying in the fabric-style fixing portions 14 is
prevented, that is, the fraying in the first fabric edge 12 and the
second fabric edge 13 is also prevented effectively.
[0042] The above embodiment may be modified as follows.
[0043] The warps 21 and the wefts 31 need not necessarily be made
of the discontinuous fibers 11a, and may be continuous yarns which
are formed by bundling several hundreds to several tens of
thousands of continuous fibers.
[0044] As shown in FIG. 6, a fiber structure 40 may be a multilayer
fabric formed by 3D-weave. The fiber structure 40 includes warp
layers 41, 43, 45 in each of which the warps 21 corresponding to
the first yarns are arranged parallel to each other, and weft
layers 42, 44, 46 in each of which the wefts 31 corresponding to
the second yarns are arranged to each other. Specifically, the
fiber structure 40 includes the first warp layer 41, the first weft
layer 42, the second warp layer 43, the second weft layer 44, the
third warp layer 45, and the third weft layer 46 in this order from
top to bottom.
[0045] In the fiber structure 40, the first warp layer 41, the
first weft layer 42, the second warp layer 43, the second weft
layer 44, the third warp layer 45, and the third weft layer 46 are
bound by binder yarns 48 in the lamination direction. The binder
yarns 48 are warps used for holding the shape of the fiber
structure 40.
[0046] The fiber structure 40 includes the fabric-style fixing
portions 14 in opposite first fabric edges 51 in which the ends 21a
of the warps 21 are located in the yarn main axis direction of the
warps 21. Furthermore, the fiber structure 40 includes the
fabric-style fixing portions 14 in opposite second fabric edges in
which the ends 31a of the wefts 31 are located in the yarn main
axis direction of the wefts 31, which is not illustrated.
[0047] As shown in FIG. 7, in each first fabric edge 12, a
plurality of the fabric-style fixing portions 14 may be disposed
along the first direction X by needle punching on the wefts 31
which are located more inside than the outermost weft 32 in the
first direction X. Similar to the first fabric edge 12, in each
second fabric edge 13, a plurality of the fabric-style fixing
portions 14 may be disposed along the second direction Y by needle
punching on the warps 21 which are located more inside than the
outermost warp 22 in the second direction Y.
[0048] As shown in FIG. 8, in each first fabric edge 12, the
fabric-style fixing portions 14 may be disposed only in the ends
21a of the warps 21 which are located more outside than the
outermost weft 32 in the first direction X. In other words, the
fabric-style fixing portions 14 may be disposed in the ends 21a of
the warps 21 that are located closer to the ends than the outermost
weft 32 in the yarn main axis direction of the warps 21
corresponding to the one of the two types of yarns (in the first
direction X). Similar to the first fabric edge 12, in each second
fabric edge 13, the fabric-style fixing portions 14 may be disposed
only in the ends 31a of the wefts 31 which are located more outside
than the outermost warp 22 in the second direction Y. In other
words, the fabric-style fixing portions 14 may be disposed in the
ends 31a of the wefts 31 that are located closer to the ends than
the outermost warp 22 in the yarn main axis direction of the wefts
31 corresponding to the one of the two types of yarns (in the
second direction Y).
[0049] With this configuration, in the first fabric edge 12, the
discontinuous fibers 11a are entangled between the warps 21
overlapped in the lamination direction in the ends 21a closer to
the ends in the yarn main axis direction of the warps 21 than the
outermost weft 32, so that the outermost weft 32 is prevented from
being pulling out over the ends 21a of the warps 21. Similar to the
first fabric edge 12, in the second fabric edge 13, the
discontinuous fibers 11a are entangled between the wefts 31
overlapped in the lamination direction in the ends 31a closer to
the ends in the yarn main axis direction of the wefts 31 than the
outermost warp 22, so that the outermost warp 22 is prevented from
being pulling out over the end 31a of the wefts 31. Thus, forming
the fabric-style fixing portions 14 prevent the fraying in the
fabric edge 12, 13. The fabric-style fixing portions 14 are formed
such that the discontinuous fibers 11a are entangled between the
warps 21 overlapped in the lamination direction, and between the
wefts 31 overlapped in the lamination direction. Therefore, no
separate members are needed to prevent the fraying in the fabric
edge 12, 13.
[0050] The fabric-style fixing portions 14 may be added by needle
punching on the outermost weft 32 in each first fabric edge 12 and
on the outermost warp 22 in each second fabric edge 13. Owing to
this addition, both the fabric-style fixing portions 14 which are
located on the outermost weft 32 and the fabric-style fixing
portions 14 which are located on the ends 21a of the warps 21
cooperate to effectively prevent the fraying in the first fabric
edge 12. Similar to the first fabric edge 12, both the fabric-style
fixing portions 14 which are located on the outermost warp 22 and
the fabric-style fixing portions 14 which are located on each end
31a of the wefts 31 cooperate to effectively prevent the fraying in
the second fabric edge 13.
[0051] The fabric-style fixing portions 14 may be disposed in only
either the first fabric edges 12 and the second fabric edges 13 in
the fiber structure 11, and in only either the first fabric edges
51 and the second fabric edges in the fiber structure 40. In this
case, the opposite edges on the upstream and downstream sides in
the weaving direction of the fiber structures 11, 40 are cut after
the fiber structures 11, 40 are completed. Therefore, the
fabric-style fixing portions 14 may be disposed only in the cut
edges and may not be disposed in the opposite sides in the weaving
width direction.
[0052] Although needle punching is applied as a method to form the
fabric-style fixing portions 14, tufting may be applied. Besides
needle punching and tufting, any method may be applied if the
reinforcing fibers (the discontinuous fibers 11a) are entangled
with each other between adjacent layers.
[0053] Although the fabrics 20 are formed by plain weave in the
above embodiment, the fabrics 20 may be formed by satin weave or
twill weave.
[0054] The number of laminated weft layers and warp layers may be
changed as required in the fiber structure 40.
[0055] When the fiber structures 11, 40 are used as a reinforcing
base material of the fiber-reinforced composite material 10, the
type of matrix resin and the method for manufacturing the
fiber-reinforced composite material 10 are not limited to any
particular resin or method.
[0056] Next, the following will describe a technical idea
comprehended from the above embodiment and the modifications.
[0057] (1) In the fiber structure, the fabric-style fixing portions
are formed by needle punching.
REFERENCE SIGNS LIST
[0058] Ma matrix resin [0059] 10 fiber-reinforced composite
material [0060] 11, 40 fiber structure [0061] 11a discontinuous
fiber [0062] 12, 51 first fabric edge [0063] 13 second fabric edge
[0064] 14 fabric-style fixing portion [0065] 20 fabric [0066] 21
warp corresponding to the first yarn [0067] 21a, 31a end [0068] 22
outermost warp corresponding to the outermost yarn [0069] 31 weft
corresponding to the second yarn [0070] 32 outermost weft
corresponding to the outermost yarn
* * * * *