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US 2007/0232171 A1Published application
Three-dimensional fiber structure, composite, and method for manufacturing three-dimensional fiber structure
AssigneeKabushiki Kaisha Toyota Jidoshokki
InventorsAya Maki, Ryuta Kamiya
Life of this patent
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Abstract
A fiber lamination includes a plurality of fiber layers laminated on one another. The fiber layers are at least biaxially oriented. The fiber lamination is a three-dimensional plate. The fiber lamination includes a bent portion, a first flat portion, and a second flat portion. The angle at which a connection yarn crosses the fiber layers at the first flat portion differs from the angle at which the connection yarn crosses the fiber layers at the second flat portion. Therefore, a three-dimensional fiber structure is manufactured by bending a laminated body while suppressing generation of wrinkles and distortion at the bent portion.
Claims21
A three-dimensional fiber structure, comprising:
- a fiber lamination including a plurality of fiber layers laminated on one another, the fiber layers being at least biaxially oriented, each fiber layer being formed of a continuous fiber or a fabric texture, the fiber lamination being a three-dimensional plate, the fiber lamination including a bent portion, a first flat portion, and a second flat portion, the first flat portion and the second flat portion sandwiching the bent portion, and the first flat portion, the bent portion, and the second flat portion are continuous with one another;
- and
- a connection yarn arranged to cross the fiber layers,
- wherein the angle at which the connection yarn crosses the fiber layers at the first flat portion differs from the angle at which the connection yarn crosses the fiber layers at the second flat portion.
1 more element
A three-dimensional fiber structure, comprising:
- a fiber lamination including a plurality of fiber layers laminated on one another, the fiber layers being at least biaxially oriented, each fiber layer being formed of a continuous fiber or a fabric texture, the fiber lamination being a three-dimensional plate, the fiber lamination including a flat portion, two bent portions, which sandwich the flat portion, and the flat portion and the bent portions are continuous with one another;
- and
- a connection yarn arranged to cross the fiber layers,
- wherein the connection yarn is arranged to obliquely cross the fiber layers at the flat portion.
1 more element
A method for manufacturing a three-dimensional fiber structure, the method comprising:
- a continuous fiber arranging process for forming a plurality of fiber layers by arranging a continuous fiber on a jig, the jig including a plurality of restricting members arranged at a predetermined pitch, the continuous fiber being arranged between the restricting members, the continuous fiber engaging each restricting member so that the continuous fiber is folded back, and the fiber layers being laminated such that the fiber layers are at least biaxially oriented, and as a result, a fiber lamination is formed;
- a connection yarn inserting process for forming a flat primary structure by inserting the connection yarn into the fiber lamination, and the connection yarn crosses the fiber lamination;
- and
- a bending process for forming two bent portions, which are bent in different directions from each other, on the primary structure, as a result, the fiber lamination is formed into a three-dimensional plate, the three-dimensional plate including a flat portion located between the bent portions, the flat portion being adjacent to the bent portions, the bent portions being continuous with the flat portion, and the connection yarn crosses the fiber layers,
- wherein the primary structure includes a section that will be the flat portion at least after the bending process, and in the connection yarn inserting process, the connection yarn is inserted in the section such that the length of the connection yarn is longer than the thickness of the flat portion.
2 more elements
A method for manufacturing a three-dimensional fiber structure, the method comprising:
- a continuous fiber arranging process for forming a plurality of fiber layers by arranging a continuous fiber on a jig, the jig including a plurality of restricting members arranged at a predetermined pitch, the continuous fiber being arranged between the restricting members, the continuous fiber engaging each restricting member so that the continuous fiber is folded back, and the fiber layers being laminated such that the fiber layers are at least biaxially oriented, and as a result, a fiber lamination is formed,
- a connection yarn inserting process for forming a flat primary structure by inserting the connection yarn into the fiber lamination, and the connection yarn crosses the fiber lamination,
- a bending process for forming the fiber lamination into a three-dimensional plate by forming a bent portion on the primary structure, the three-dimensional plate including a pair of flat portions, which sandwich the bent portion, each flat portion being adjacent to the bent portion, each flat portion being continuous with the bent portion, and the connection yarn crossing the fiber layer,
- wherein the primary structure includes a section that will be one of the flat portions at least after the bending process, and in the connection yarn inserting process, the connection yarn being inserted in the section such that the length of the connection yarn is longer than the thickness of the flat portion.
1 more element
A method for manufacturing a three-dimensional fiber structure, the method comprising:
- a fabric laminating process for forming a fiber lamination by laminating a plurality of fiber layers such that the fiber layers are at least biaxially oriented, each fiber layer being formed of a fabric texture;
- a connection yarn inserting process for forming a flat primary structure by inserting the connection yarn into the fiber lamination, and the connection yarn crosses the fiber lamination;
- and
- a bending process for forming two bent portions, which are bent in different directions from each other, on the primary structure, as a result, the fiber lamination is formed into a three-dimensional plate, the three-dimensional plate including a flat portion located between the bent portions, the flat portion being adjacent to the bent portions, the bent portions being continuous with the flat portion, and the connection yarn crosses the fiber layers,
- wherein the primary structure includes a section that will be the flat portion at least after the bending process, and in the connection yarn inserting process, the connection yarn is inserted in the section such that the length of the connection yarn is longer than the thickness of the flat portion.
2 more elements
A method for manufacturing a three-dimensional fiber structure, the method comprising:
- a fabric laminating process for forming a fiber lamination by laminating a plurality of fiber layers such that the fiber layers are at least biaxially oriented, each fiber layer being formed of a fabric texture;
- a connection yarn inserting process for forming a flat primary structure by inserting the connection yarn into the fiber lamination, and the connection yarn crosses the fiber lamination;
- and
- a bending process for forming a bent portion in the primary structure, and as a result, forming the fiber lamination into a three-dimensional plate, the three-dimensional plate including a pair of flat portions, which sandwich the bent portion, each flat portion being adjacent to the bent portion, each flat portion being continuous with the bent portion, and the connection yarn crosses the fiber layers,
- wherein the primary structure includes a section that will be one of the pair of flat portions at least after the bending process, and in the connection yarn inserting process, the connection yarn is inserted in the section such that the length of the connection yarn is longer than the thickness of the flat portion.
2 more elements
Dependencies are inferred from the claim text.