Knitting method of a knitted substrate and knitted substrate

Abstract

The present invention provides a weaving method of a woven fabric base material, in which a pattern is expressed by a fixing yarn in a woven fabric base material having a pattern, and thus the orientation of warp yarns and weft yarns is not affected, and strength unevenness can be prevented. A weaving method of a woven fabric base material (1) having a base material (2) and a weaving yarn (3), the base material being provided in a plurality of layers in a manner in which warp yarns (first base yarns (10)) composed of reinforcing fiber yarns and weft yarns (second base yarns (20)) cross each other, the weaving yarn fixing the base material (2) of the plurality of layers by a woven fabric, and a pattern is expressed on the surface of the woven fabric base material (1) using the weaving yarn (3) when the woven fabric is formed.

Description

TECHNICAL FIELD

[0001] The present application relates to a weaving method of a woven fabric base material and a woven fabric base material. BACKGROUND

[0002] Conventionally, a weaving method of a woven fabric base material and a woven fabric base material are known. For example, as described in Patent Literature 1.

[0003] In Patent Literature 1, a woven fabric base material that can be used for a fiber reinforced plastic is disclosed. Specifically, in Patent Literature 1, a woven fabric base material that has a base material and a fixing yarn is disclosed, the base material is provided with a plurality of layers of warp yarns and weft yarns that are arranged side by side in a prescribed direction, and the fixing yarn fixes the plurality of layers of the base material by a woven fabric.

[0004] PRIOR ART DOCUMENTS

[0005] PATENT LITERATURE

[0006] Patent Literature 1: Japanese Patent Application Laid-Open No. 2000-501792 SUMMARY

[0007] PROBLEMS TO BE SOLVED BY THE INVENTION

[0008] In the woven fabric base material as described in Patent Literature 1, a pattern can be implemented by locally changing the weaving method of the warp yarns and the weft yarns. However, in the case where the weaving method of the warp yarns and the weft yarns is locally changed, in the fiber reinforced plastic formed using the woven fabric base material, it is possible that strength unevenness caused by the local change of the weaving method is generated.

[0009] The present application has been achieved in view of the above-described circumstances. The problem to be solved by the present application is to provide a weaving method of a woven fabric base material and a woven fabric base material in which strength unevenness can be prevented in a woven fabric base material having a pattern.

[0010] MEANS FOR SOLVING THE PROBLEM

[0011] The problem to be solved by the present application is as described above, and the means for solving the problem will be described next.

[0012] That is, the weaving method of a woven fabric base material of the present application is a weaving method of a woven fabric base material that has a base material and a fixing yarn, the base material is provided with a plurality of layers in which warp yarns and weft yarns composed of reinforcing fiber yarns are interlaced with each other, the fixing yarn fixes the plurality of layers of the base material by a woven fabric, and a pattern is expressed on the surface of the woven fabric base material using the fixing yarn when the woven fabric is formed.

[0013] By being configured in this way, in the woven fabric base material having a pattern, a pattern is expressed using the fixing yarn, and therefore the orientation of the warp yarns and the weft yarns is not affected, and it is possible to prevent strength unevenness from being generated.

[0014] In addition, the pattern expression can use at least one of tuck stitches, intarsia, and jacquard.

[0015] With this configuration, the pattern expression can be performed using tuck stitches, intarsia, or jacquard.

[0016] In addition, the fixed yarn can use at least two kinds of knitting yarn, and at least one of the knitting yarns can function to make the other knitting yarn conspicuous.

[0017] With this configuration, the other knitting yarn can be emphasized, and various pattern expressions can be performed.

[0018] In addition, at least one of the knitting yarns can be transparent or translucent, or can have a property of being transparentized or translucentized when resin is impregnated in the knitting fabric base material.

[0019] With this configuration, by making at least one of the fixed yarns inconspicuous with respect to the other knitting yarn, the other knitting yarn can be emphasized, and various pattern expressions can be performed.

[0020] In addition, at least one of the knitting yarns can use a wire having a smaller diameter than the other knitting yarn.

[0021] With this configuration, by making at least one of the fixed yarns inconspicuous with respect to the other knitting yarn, the other knitting yarn can be emphasized, and various pattern expressions can be performed.

[0022] At least one of the knitting yarns can be the same color as the reinforcing fiber yarn.

[0023] With this configuration, by making at least one of the fixed yarns inconspicuous with respect to the other knitting yarn, the other knitting yarn can be emphasized, and various pattern expressions can be performed.

[0024] In addition, the fixed yarn can use at least two kinds of knitting yarn, and at least one of the knitting yarns can use a colored knitting yarn that transfers a coloring material to resin when the resin is impregnated in the knitting fabric base material.

[0025] With this configuration, when resin is impregnated in the knitting fabric base material, the coloring material is transferred to the surrounding portion of the knitting yarn, and in addition to the pattern expression using the fixed yarn, the coloring material can be used for the pattern expression. Thus, various pattern expressions can be performed.

[0026] In addition, in the weaving method of the woven fabric base material, a colored yarn that causes a colorant to transfer to a resin when the resin is impregnated in the woven fabric base material can be provided between the plurality of reinforcing fiber yarns in parallel or in alignment with the reinforcing fiber yarns.

[0027] By so configuring, when the resin is impregnated in the woven fabric base material, the colorant can be transferred to the resin regardless of the pattern expression (shape) and arrangement of the fixed yarn, and the pattern expression can be performed using the colorant in addition to the pattern expression using the fixed yarn. Thus, various pattern expressions can be performed.

[0028] In addition, the woven fabric base material of the present application is formed by the weaving method of the woven fabric base material.

[0029] By so configuring, without locally changing the weaving method of the reinforcing fiber yarn, the pattern expression using the fixed yarn can be performed, and the pattern can be provided and the strength unevenness can be prevented.

[0030] Effects of the Invention

[0031] As an effect of the present application, the following effect is provided: in the woven fabric base material having the pattern, the pattern expression is performed using the fixed yarn, and thus the orientation of the warp yarn and the weft yarn is not affected, and the strength unevenness can be prevented. BRIEF DESCRIPTION OF DRAWINGS

[0032] Figure 1 is a front view showing an example of the woven fabric base material of the first embodiment.

[0033] Figure 2 is an enlarged view of the P1 portion of Figure 1

[0034] Figure 3 is a front view schematically showing the first region of the woven fabric base material.

[0035] Figure 4 is a front view schematically showing the second region of the woven fabric base material.

[0036] Figure 5 is a plan view schematically showing the woven fabric base material.

[0037] Figure 6 is an enlarged view of the P2 portion of Figure 4

[0038] Figure 7 is a front view schematically showing the woven fabric base material of the second embodiment, the third embodiment, and the fourth embodiment.

[0039] Figure 8 ​​is a front view schematically showing a woven fabric base material (and an FRP using the woven fabric base material) of a fifth embodiment.

[0040] Figure 9 is a front view schematically showing a woven fabric base material (and an FRP using the woven fabric base material) of a sixth embodiment.

[0041] Figure 10 is a front view schematically showing a woven fabric base material (and an FRP using the woven fabric base material) of a seventh embodiment.

[0042] Figure 11 (a) of is a front view schematically showing an example of a pattern expression using inlay. (b) of is a front view schematically showing another example of a pattern expression using inlay. DETAILED DESCRIPTION

[0043] Hereinafter, directions indicated by an arrow U, an arrow D, an arrow L, an arrow R, an arrow F, and an arrow B shown in the drawings are defined as an upward direction, a downward direction, a leftward direction, a rightward direction, a frontward direction, and a rearward direction, respectively, to be described.

[0044] First, a structure of a woven fabric base material 1 of a first embodiment of the present application is described.

[0045] Figures 1 to 6 The woven fabric base material 1 shown in is a base material formed by weaving fibers (woven yarns 3 described later). It is assumed that the woven fabric base material 1 of the present embodiment is used as a base material of a fiber reinforced plastic (FRP: Fiber Reinforced Plastic).

[0046] In addition, Figure 1 and Figure 2 a photograph showing an example of the woven fabric base material 1, Figure 2 is a view enlarging a P1 portion of Figure 1 In addition, other views schematically show the woven fabric base material 1. Specifically, Figure 3 and Figure 4 schematically show Figure 1 and Figure 2 the first region R1 and the second region R2 shown in Figure 5 is a plan view schematically showing the woven fabric base material 1. Figure 6 is a view enlarging a P2 portion of Figure 4

[0047] The woven fabric base material 1 mainly includes a base material 2 and woven yarns 3.

[0048] Figures 1 to 5 The base material 2 shown in is formed by appropriately arranging a reinforcing fiber yarn. The base material 2 mainly includes a first base yarn 10 and a second base yarn 20.​

[0049] Reinforcing fibers (e.g., carbon fibers) are used as the first matrix yarn 10 and the second matrix yarn 20. Specifically, the first matrix yarn 10 and the second matrix yarn 20 are formed by twisting bundled carbon fibers together using an appropriate twisting method. It should be noted that the first matrix yarn 10 and the second matrix yarn 20 do not necessarily have to be formed by twisting fibers together; for example, bundled reinforcing fibers can also be used directly as the first matrix yarn 10 and the second matrix yarn 20.

[0050] The first base yarn 10 is a warp yarn arranged in a vertical direction. Multiple first base yarns 10 are arranged side-by-side in a horizontal arrangement. The first base yarns 10 are arranged at predetermined intervals.

[0051] The second base yarn 20 is a weft yarn arranged in a left-right direction. Specifically, the second base yarn 20 is arranged as a single yarn extending in the left-right direction, and is arranged in a meandering manner by folding back to the opposite left and right sides at appropriate positions to extend to the next loop row. Thus, multiple second base yarns 20 are arranged side by side with their left-right extending straight portions arranged vertically. The second base yarns 20 are arranged so that their left-right extending straight portions intersect the first base yarn 10 at approximately right angles.

[0052] like Figure 5 As shown, multiple layers of the first base yarn 10 and the second base yarn 20 are arranged along the front-to-back direction. Specifically, a layer composed of multiple first base yarns 10 arranged in a left-to-right manner and a layer composed of a single second base yarn 20 arranged in a meandering manner are arranged in an alternating front-to-back layering manner. In this case, the first base yarns 10 and the second base yarns 20 are arranged in a manner where their front-to-back positions are not interchanged (they do not form a fabric). Figure 5 As an example, a case is shown where the first substrate yarn 10 and the second substrate yarn 20 are overlapped in six layers in the front-to-back direction. It should be noted that the multilayer substrate 2 can be formed by overlapping the first substrate yarn 10 and the second substrate yarn 20 by at least one layer each (a total of two layers), and the number of such layers is not limited.

[0053] The braided yarn 3 is a braided yarn (fixing yarn) that fixes the substrate 2, which is formed by multiple layers, through a braided fabric. Furthermore, the braided yarn 3 uses various weaving structures to create patterns on the surface of the substrate 1. As the material for the braided yarn 3, any material such as polyester, nylon, or polypropylene can be selected. Figures 3 to 5As shown, the knitting yarn 3 is knitted in such a manner that the crossing portions 3a extending across between the adjacent loops in the loop row direction (left-right direction) are disposed on the rear side of the first base yarn 10 disposed at the rearmost position. Further, the loop portions 3b between the loops in the loop column direction (up-down direction) are knitted in such a manner that they are disposed on the front side of the second base yarn 20 disposed at the foremost position. In this way, the knitting yarn 3 is held in such a manner that the crossing portions 3a and the loop portions 3b sandwich the base material 2 formed of a plurality of layers from the front and the rear, and thus the first base yarn 10 and the second base yarn 20 can be fixed.

[0054] Further, the knitting yarn 3 of the present embodiment forms the knitted fabric by using a plurality of knitting stitches, and expresses a prescribed pattern on the surface of the knitted fabric base material 1. Figure 1 In the present embodiment, a knitted fabric base material 1 in which a pattern of a character "G" is expressed based on a difference in appearance of the knitting stitch of the knitting yarn 3 is exemplified. Note that, in the present embodiment, the outline of the character "G" is drawn in white lines so as to make the pattern conspicuous for easy observation of the pattern. Hereinafter, a region of the knitted fabric base material 1 other than the pattern (outside of the character "G") is referred to as a first region Rl, and a region of the pattern is referred to as a second region R2. Figure 1 In the present embodiment, a knitted fabric base material 1 in which a pattern of a character "G" is expressed based on a difference in appearance of the knitting stitch of the knitting yarn 3 is exemplified. Note that, in the present embodiment, the outline of the character "G" is drawn in white lines so as to make the pattern conspicuous for easy observation of the pattern. Hereinafter, a region of the knitted fabric base material 1 other than the pattern (outside of the character "G") is referred to as a first region Rl, and a region of the pattern is referred to as a second region R2.

[0055] As shown in FIG. 2, in the first region Rl, the knitting yarn 3 forms the knitted fabric only by loop stitches. On the other hand, as shown in FIG. 3, in the second region R2, the knitted fabric is formed by partially using tuck stitches. Figure 2 Figure 3 As shown in FIG. 2, in the first region Rl, the knitting yarn 3 forms the knitted fabric only by loop stitches. On the other hand, as shown in FIG. 3, in the second region R2, the knitted fabric is formed by partially using tuck stitches. Figure 2 Figure 4 As shown in FIG. 2, in the first region Rl, the knitting yarn 3 forms the knitted fabric only by loop stitches. On the other hand, as shown in FIG. 3, in the second region R2, the knitted fabric is formed by partially using tuck stitches.

[0056] As shown in FIG. 2, in the first region Rl, the knitting yarn 3 forms the knitted fabric only by loop stitches. On the other hand, as shown in FIG. 3, in the second region R2, the knitted fabric is formed by partially using tuck stitches. Figure 6 As shown in FIG. 2, in the first region Rl, the knitting yarn 3 forms the knitted fabric only by loop stitches. On the other hand, as shown in FIG. 3, in the second region R2, the knitted fabric is formed by partially using tuck stitches.

[0057] Figure 4 By thus partially using the tuck stitches in the second region R2 as shown in FIG. 3, the knitting stitch of the second region R2 becomes a knitting stitch having an appearance different from that of the first region Rl as shown in FIG. 2 (refer to FIG. 4 and FIG. 5). Figure 3 Figure 1 Figure 2 ​​​​​). In the present embodiment, as described above, the weave pattern of the character "G" is expressed by using different weaves in the prescribed pattern portion (second region R2) and the portion other than this (first region R1).

[0058] Thus, in the present embodiment, by appropriately changing the weave of the knitting yarn 3, appropriate expression of the weave pattern is possible in the knitted fabric base material 1. At this time, it is not necessary to locally deform the reinforcing fiber yarns such as the first base yarn 10 and the second base yarn 20 in order to express the weave pattern. Thus, it is possible to express the weave pattern without causing uneven strength.

[0059] Next, an example of the knitting method of the knitted fabric base material 1 described above will be described.

[0060] The knitted fabric base material 1 can be knitted using a flat knitting machine. Specifically, a plurality of the first base yarns 10 are supplied to the teeth of the flat knitting machine in a state of being arranged left and right. The second base yarns 20 are inserted into the teeth of the flat knitting machine using the yarn guides that move on the front side of the yarn supply path of the first base yarns 10. Note that, in the knitting of the knitted fabric base material 1, the first base yarns 10 and the second base yarns 20 are knitted by being inserted into the teeth of the flat knitting machine using the yarn guides that move on the front side of the yarn supply path of the first base yarns 10. Figure 5 In the case of the knitted fabric base material 1 of six layers shown in FIG. 6, a plurality of the first base yarns 10 are supplied to the teeth of the flat knitting machine in a state of being arranged in three columns extending in the left-right direction, and three second base yarns 20 are inserted using three yarn guides that pass through the front side of the arrangement of each of the first base yarns 10. Then, the knitting yarn 3 is supplied to the knitting needles of the front needle bed using the yarn guide that is disposed on the back side of the arrangement of the last first base yarn 10, and the knitted fabric is knitted with the first base yarns 10 and the second base yarns 20 that are overlapped in multiple layers. By repeating the above knitting, the knitted fabric base material 1 can be knitted by fixing the first base yarns 10 and the second base yarns 20 using the knitting yarn 3. However, the knitting method of this knitted fabric base material 1 is an example, and the knitting is not limited to this method, and can be knitted by any method.

[0061] In addition, as shown in FIG. 1, in the present embodiment, the second base yarns 20 (weft yarns) are inserted once at a time when knitting based on the knitting yarn 3 is performed for two courses at a time to form the knitted fabric base material 1, but the present application is not limited to this, and the interval at which the second base yarns 20 are inserted can be arbitrarily set. For example, the second base yarns 20 can also be inserted at a time when knitting based on the knitting yarn 3 is performed for one course at a time. Figure 3 In addition, as shown in FIG. 1, in the present embodiment, the second base yarns 20 (weft yarns) are inserted once at a time when knitting based on the knitting yarn 3 is performed for two courses at a time to form the knitted fabric base material 1, but the present application is not limited to this, and the interval at which the second base yarns 20 are inserted can be arbitrarily set. For example, the second base yarns 20 can also be inserted at a time when knitting based on the knitting yarn 3 is performed for one course at a time. Figure 3 In addition, as shown in FIG. 1, in the present embodiment, the second base yarns 20 (weft yarns) are inserted once at a time when knitting based on the knitting yarn 3 is performed for two courses at a time to form the knitted fabric base material 1, but the present application is not limited to this, and the interval at which the second base yarns 20 are inserted can be arbitrarily set. For example, the second base yarns 20 can also be inserted at a time when knitting based on the knitting yarn 3 is performed for one course at a time.

[0062] By impregnating the woven fabric base material 1 woven in this way with a resin and performing heat compression, an FRP can be formed. Note that, as a method of supplying the resin, in addition to a method of applying the resin to the woven fabric base material 1 that is woven, there is a method of applying the resin to each yarn (the first base yarn 10, the second base yarn 20, or the woven yarn 3) in advance, and the like.

[0063] Next, using Figure 7 The structure of the woven fabric base material 1 of the second embodiment of the present application will be described.

[0064] The woven fabric base material 1 of the second embodiment differs from the woven fabric base material 1 (refer to Figure 4 and the like) of the first embodiment in that, instead of using a single kind of woven yarn 3, two kinds of woven yarns (the first woven yarn 4 and the second woven yarn 5) are used, and one of them is made into a transparent woven yarn. Hereinafter, this difference will be described.

[0065] In the second embodiment, the first woven yarn 4 and the second woven yarn 5 are used alternately per 1 course. As the first woven yarn 4, for example, the same yarn as the woven yarn 3 of the first embodiment is used. In contrast to this, as the second woven yarn 5, a transparent (or translucent) yarn is used. Note that the transparency of the second woven yarn 5 is not particularly limited, but a woven yarn having a higher transparency than the other fixed yarn (the first woven yarn 4) is used. In Figure 7 In the second embodiment, the first woven yarn 4 and the second woven yarn 5 are used alternately per 1 course. As the first woven yarn 4, for example, the same yarn as the woven yarn 3 of the first embodiment is used. In contrast to this, as the second woven yarn 5, a transparent (or translucent) yarn is used. Note that the transparency of the second woven yarn 5 is not particularly limited, but a woven yarn having a higher transparency than the other fixed yarn (the first woven yarn 4) is used. In

[0066] By making the second woven yarn 5 a woven yarn having a high transparency in this way, the presence of the other first woven yarn 4 is emphasized (stands out) when an FRP is formed by impregnating a resin, and various pattern expressions can be performed. For example, a visual effect in which the first woven yarn 4 floats in the resin can be obtained.

[0067] Note that the second woven yarn 5 is not limited to a transparent (or translucent) yarn, and, for example, a yarn that is transparentized (or translucentized) when impregnated with a resin can also be used. As such a yarn, for example, there are a white polyester yarn, a nylon yarn, and the like. These yarns are translucentized when impregnated with a resin, and thus, as with the example of Figure 7 the presence of the first woven yarn 4 can be emphasized.

[0068] Next, using Figure 7 The structure of the woven fabric base material 1 of the third embodiment of the present application will be described.

[0069] The knitted fabric base material 1 of the third embodiment differs from the knitted fabric base material 1 of the second embodiment in that, as the second knitted yarn 5, a yarn of the same color family as the first base yarn 10 and the second base yarn 20 is not used, but a yarn of the same color family as the reinforcing fiber yarn is used. Hereinafter, this difference will be described.

[0070] In the third embodiment, as the second knitted yarn 5, a yarn of the same color family as the first base yarn 10 and the second base yarn 20 (reinforcing fiber yarn) is used. For example, in the case where carbon fiber is used as the reinforcing fiber, a black (or a color of the same color family close to black) yarn is used as the second knitted yarn 5. Also, in the case where aramid fiber is used as the reinforcing fiber, a yellow (or a color of the same color family close to yellow) yarn is used as the second knitted yarn 5.

[0071] Note that the color of the second knitted yarn 5 is preferably the same color (the same color) as the color of the reinforcing fiber, but it is not necessarily the same color, and a color of the same color family as the reinforcing fiber can also be used. For example, as the color of the second knitted yarn 5, a color similar to the color of the reinforcing fiber (a color adjacent to or in the vicinity on a color wheel), a color of the same color and only a different tone, a color of the same base color, and the like can be used.

[0072] By thus making the second knitted yarn 5 a knitted yarn of the same color family as the reinforcing fiber, the presence of the other first knitted yarn 4 is emphasized (stands out) when the resin is impregnated to form the FRP, and various pattern expressions can be performed (see Figure 7 ). For example, a visual effect in which the first knitted yarn 4 floats in the resin can be obtained. Note that in order to emphasize the presence of the first knitted yarn 4, the color of the second knitted yarn 5 is preferably made to be at least closer to the color of the reinforcing fiber than the first knitted yarn 4.

[0073] Next, the structure of the knitted fabric base material 1 of the fourth embodiment of the present application will be described.

[0074] The knitted fabric base material 1 of the fourth embodiment differs from the knitted fabric base material 1 of the second embodiment in that a thin metal yarn (wire) is used as the second knitted yarn 5 (see Figure 7 ). Hereinafter, this difference will be described.

[0075] In the fourth embodiment, as the second knitted yarn 5, a metal yarn (wire) thinner than the first knitted yarn 4 is not used, but a yarn thinner than the first knitted yarn 4 is used. The thickness and the raw material of the second knitted yarn 5 are not particularly limited, but at least a yarn thinner than the first knitted yarn 4 is used.

[0076] By thus making the second knitted yarn 5 a thin metal yarn, the second knitted yarn 5 becomes unobtrusive. Thus, as in the second embodiment, the presence of the other first knitted yarn 4 is relatively emphasized (stands out), and various pattern expressions can be performed.

[0077] Note that the second woven yarn 5 is not limited to a metal yarn, but can be any yarn as long as the presence of the first woven yarn 4 is emphasized. For example, if a yarn thinner than the first woven yarn 4 is used, the presence of the first woven yarn 4 can be emphasized, and thus in this case, a yarn of the same raw material as the first woven yarn 4 can be used.

[0078] Next, the structure of the woven fabric base material 1 of the fifth embodiment of the present application will be described. Figure 8 The structure of the woven fabric base material 1 of the fifth embodiment of the present application will be described.

[0079] The woven fabric base material 1 of the fifth embodiment differs from the woven fabric base material 1 (refer to FIG. 1) of the first embodiment in that, instead of using a single kind of woven yarn 3, two kinds of woven yarns (the first woven yarn 4 and the second woven yarn 5) are used, and the yarn of one kind contains a pigment capable of coloring a resin. Hereinafter, this difference will be described. Figure 4

[0080] An FRP 100 formed by impregnating a resin in the woven fabric base material 1 of the fifth embodiment is exemplified. As the first woven yarn 4 of the first woven yarn 4 and the second woven yarn 5 of the fifth embodiment, a colored yarn is used. As the pigment of the first woven yarn 4, a dye or a pigment that is transferred to a resin is used in the case where the resin is impregnated in the woven fabric base material 1. The second woven yarn 5 does not contain a pigment that is transferred to a resin. Figure 8 By using such a first woven yarn 4, as shown in FIG. 10, in the case where a resin is impregnated in the woven fabric base material 1, the pigment of the first woven yarn 4 is transferred to the resin, and the resin around the first woven yarn 4 is colored. Note that in FIG. 10, the colored portion is schematically shown by hatching. In this way, the woven fabric base material 1 of the fifth embodiment can perform pattern expression using a pigment in addition to pattern expression based on the weave of the first woven yarn 4 and the second woven yarn 5, and can perform various pattern expressions.

[0081] Figure 8 Note that not only the first woven yarn 4 but also the second woven yarn 5 can contain a pigment (the same pigment or a different pigment). Figure 8 Next, the structure of the woven fabric base material 1 of the sixth embodiment of the present application will be described.

[0082] The woven fabric base material 1 of the sixth embodiment differs from the woven fabric base material 1 (refer to FIG. 1) of the first embodiment in that, instead of using a single kind of woven yarn 3, two kinds of woven yarns (the first woven yarn 4 and the second woven yarn 5) are used, and the yarn of one kind contains a pigment capable of coloring a resin. Hereinafter, this difference will be described.

[0083] Figure 9 Next, the structure of the woven fabric base material 1 of the sixth embodiment of the present application will be described.

[0084] The woven fabric base material 1 of the sixth embodiment differs from the woven fabric base material 1 (refer to FIG. 1) of the first embodiment in that, instead of using a single kind of woven yarn 3, two kinds of woven yarns (the first woven yarn 4 and the second woven yarn 5) are used, and the yarn of one kind contains a pigment capable of coloring a resin. Hereinafter, this difference will be described. Figure 4 ​​The difference is that a colored yarn 6 is arranged between the upper and lower parallel second base yarns 20. This difference will be explained below.

[0085] The colored yarn 6 is arranged between the second base yarns 20 in a manner substantially parallel to the second base yarn 20. For example, a portion of the second base yarns 20 of the woven fabric substrate 1 of the first embodiment can be pulled apart, and the colored yarn 6 can be arranged in that portion. The colored yarn 6 and the first woven yarn 4 of the fifth embodiment (see reference) Figure 8 Similarly, coloring is achieved by using dyes or pigments that are transferred to the resin when the resin is impregnated in the woven substrate 1.

[0086] By using such colored yarn 6, such as Figure 9 As shown, when resin is impregnated in the woven fabric substrate 1, the pigment of the colored yarn 6 transfers to the resin, and the resin surrounding the colored yarn 6 is colored. Thus, the woven fabric substrate 1 of the sixth embodiment can exhibit patterns not only based on the weave structure of the first woven yarn 4 and the second woven yarn 5, but also patterns using pigments, enabling a variety of pattern representations. For example, in... Figure 9 In the example shown, in addition to patterns based on the woven structure, patterns such as stripes based on pigments can also be created. Furthermore, unlike the fifth embodiment, pigments can be transferred to the resin regardless of the arrangement of the woven yarns 3, thus enabling a variety of pattern creations.

[0087] It should be noted that, for convenience, in Figure 9 The example shown is a colored yarn 6 arranged between two parallel second base yarns 20, but the number and arrangement of the colored yarns 6 are not limited to this. For example, the second base yarns 20 and the colored yarns 6 can be arranged alternately or in a random order.

[0088] Next, use Figure 10 The structure of the woven fabric substrate 1 according to the seventh embodiment of the present invention will be described.

[0089] The woven fabric substrate 1 of the seventh embodiment and the woven fabric substrate 1 of the sixth embodiment (see reference) Figure 9 The difference is that, instead of placing the colored yarn 6 between the second base yarns 20, the colored yarn 6 is aligned with the second base yarns 20. By aligning the colored yarn 6 with the second base yarns 20 in this way, the resin surrounding the colored yarn 6 (second base yarn 20) can be colored, enabling various pattern representations.

[0090] The embodiments of the present invention have been described above, but the present invention is not limited to the above embodiments, and appropriate modifications can be made within the scope of the technical concept of the invention as described in the claims.

[0091] For example, in the above embodiments, carbon fiber is shown as an example of using carbon fiber as a reinforcing fiber, but the present invention is not limited thereto, and various other reinforcing fibers (such as glass fiber, aramid fiber, etc.) can also be used.

[0092] In addition, in the second and third embodiments (see...) Figure 7 ) and the fourth embodiment (refer to Figure 8 The example shown in the paper is an example of using two types of woven yarn as the fixing yarn, but the invention is not limited to this. For example, more than three types of woven yarn can also be used.

[0093] Additionally, in the sixth embodiment (see...) Figure 9 ) and the seventh implementation method (refer to) Figure 10 In this process, the colored yarn 6 is arranged parallel to the second base yarn 20, but the present invention is not limited thereto and can be arranged in any direction. For example, it can also be arranged parallel to the first base yarn 10 (arranged between the first base yarns 10 or aligned with the first base yarns 10).

[0094] Furthermore, in the above embodiment, by using tufting in the second region R2, the weave structure of the second region R2 differs from that of the first region R1, but the present invention is not limited to this. That is, it is not limited to tufting; other weaving methods (intarsia, jacquard, etc.) can also be used. The weave structure in the present invention preferably includes at least one of tufting, intarsia, and jacquard.

[0095] The following uses Figure 11 Specific examples of patterns using inlay are explained.

[0096] Figure 11 This is a schematic diagram showing a woven fabric substrate 1 formed by multiple woven yarns (fixed yarns) of different colors to create an intarsia pattern. In the diagram, symbol A (hollow circle) indicates, for example, a loop of yellow woven yarn visible on the substrate surface. Symbol B (grid-shaded circle) indicates, for example, a loop of red woven yarn visible on the substrate surface. Symbol C (black circle) indicates, for example, a loop of black woven yarn visible on the substrate surface. Symbol T (inverted V-shaped symbol) indicates a section where the two types of woven yarns are joined together in a loop.

[0097] Figure 11 (a) shows an example of a woven fabric substrate 1 with a color-separated intarsia pattern formed using two types of yarns, yellow and red. The two types of yarns are joined together at the boundary. It should be noted that the specific weaving method of the intarsia, the method of joining the yarns, etc., are not limited to the example shown, and any known method can be used.

[0098] exist Figure 11In the example shown in (a), at the boundary between the two types of yarn (the part marked T), the size of the loops decreases due to the tucked loops, so the appearance of the loops differs at this boundary and elsewhere. This makes the boundary of the yarn more prominent.

[0099] It should be noted that, in Figure 11 In the woven substrate 1 of (a), by not connecting the two types of yarns together, the size of the loops at the boundary is the same (uniform) as the size of the loops in the other parts, thus enabling the boundary to have a neat appearance. However, in this case, since the two types of yarns are not connected to each other, cracks may easily occur at the boundary when forming FRP using this woven substrate 1.

[0100] on the other hand, Figure 11 (b) shows an example of a woven substrate 1 in which black woven yarn is used in addition to yellow and red woven yarn to form an intarsia pattern. Specifically, in Figure 11 In the woven substrate 1 of (b), black woven yarn is woven between rows of loops formed by yellow and red woven yarns. In the illustration, a second base yarn 20 is inserted once every two rows of loops, and black woven yarn is placed at the insertion position of the second base yarn 20.

[0101] exist Figure 11 In the example shown in (b), it is possible to obtain a pattern where the red and yellow coils are arranged in a dotted pattern. Additionally, in Figure 11 In the example shown in (b), with Figure 11 Unlike the example shown in (a), the red and yellow yarns are not looped together at the boundary. However, in Figure 11 In example (b), with Figure 11 Unlike example (a), the black braided yarn is continuous throughout the entire braid width. Therefore, even when using this braided substrate 1 to form FRP, cracks are less likely to occur at the boundary between the red and yellow braided yarns. In addition, since the red and yellow braided yarns are not looped together, the coil size can be made uniform.

[0102] It should be noted that, in Figure 11 In the example shown in (b), the boundary section can also be made more noticeable by looping the red and yellow woven yarns together.

[0103] exist Figure 11The illustration shows an example of using intarsia as a weave structure, but jacquard can also be used. When using jacquard, the weaving yarn is supplied from two yarn guides, and the yarn is looped only on one side while the other side is floated, thus weaving the yarn. Here, in a section where only one of the two weaving yarns (fixed yarns) is continuously looped, the other yarn continuously floats. When the weaving yarn is not connected to the fabric substrate 1 for a long distance on the back surface, weaving defects may occur. Therefore, considering ease of weaving, the yarn on the side where the floats are formed can be looped together with the yarn on the other side at predetermined intervals. Furthermore, by looping in this way, the size of the loops on the surface of the fabric substrate 1 changes, thus allowing for pattern creation. Additionally, by switching the looping yarns at predetermined intervals, striped or checkered patterns can be formed. In this case, even without looping, the length of the floated portion can be suppressed.

[0104] Industrial availability

[0105] This invention can be applied to the weaving method of woven fabric substrates and the woven fabric substrates themselves.

[0106] Explanation of reference numerals in the attached figures

[0107] 1. Woven fabric substrate

[0108] 2. Substrate

[0109] 3. Woven yarn

[0110] 4 First weaving yarn

[0111] 5 Second weave yarn

[0112] 6. Colored yarn

[0113] 10 First base yarn

[0114] 20 Second base yarn

[0115] 100 FRP

Claims

1. A method for weaving a woven fabric substrate, the method comprising a substrate and fixing yarns, wherein the substrate is provided in multiple layers with warp and weft yarns composed of reinforcing fiber yarns interlacing each other, and the fixing yarns fix the multiple layers of substrate through the woven fabric, wherein... When forming the woven fabric, the fixing yarn is used to create patterns on the surface of the woven fabric substrate. The fixing yarn uses at least two types of woven yarns. At least one of the braided yarns functions to make the other braided yarns stand out. The at least one woven yarn is a non-transparent yarn, which has the property of becoming transparent or semi-transparent when resin is impregnated in the woven substrate.

2. The weaving method for the woven fabric substrate according to claim 1, wherein, The at least one type of braided yarn uses thread with a diameter finer than that of other braided yarns.

3. The weaving method for the woven fabric substrate according to claim 1, wherein, The at least one type of woven yarn is in the same color family as the reinforcing fiber yarn.

4. The weaving method for the woven fabric substrate according to any one of claims 1 to 3, wherein, The pattern is created using at least one of the following: scalloped, inlaid, and jacquard.

5. A woven fabric substrate, wherein, The woven substrate is formed by the weaving method of any one of claims 1 to 4.

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