Reinforced fiber laminated substrate

Abstract

To provide a fiber-reinforced laminated base material which can suppress local convergence of reinforcement fibers when a reinforcement fiber resin molding is molded.SOLUTION: A fiber-reinforced laminated base material includes a plurality of fiber sheets 2 and 3 in which reinforcement fibers 5 and 6 aligned in a fixed direction are aggregated, and a filament 4 for integrally fixing the plurality of fiber sheets 2 and 3. The plurality of fiber sheets 2 and 3 are laminated so that the orientation directions of the reinforcement fibers 5 and 6 are mutually different in the fiber sheets 2 and 3 adjacent to each other in a thickness direction. The filament 4 extends in a direction different from the orientation directions of the reinforcement fibers 5 and 6 of the plurality of fiber sheets 2 and 3, and fixes the plurality of fiber sheets 2 and 3 in the state where the fiber sheets are laminated.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a reinforcing fiber laminate substrate. [Background technology]

[0002] Conventionally, when producing a resin molded product containing reinforcing fibers, a method is generally used in which a substrate made of reinforcing fibers is impregnated with a resin and then molded by pultrusion or the like to produce a molded product of a desired shape. Substrates made of reinforcing fibers used in pultrusion or the like include substrates of various forms such as rovings, cloths, and sheets.

[0003] For example, the substrates described in Patent Documents 1 and 2 have a laminate configuration that includes a plurality of fiber sheets in which reinforcing fibers oriented in a certain direction are aggregated, and the plurality of fiber sheets are stacked such that the orientation directions of the reinforcing fibers in adjacent fiber sheets in the thickness direction are different from each other (for example, the laminate of fiber sheets described in Patent Document 1 in which the reinforcing fibers are oriented at -α°, 90°, +α°, and 0° with respect to the longitudinal direction of the substrate). Such a laminate of fiber sheets is sewn together with a stitch thread (sewing thread) that extends in the 0° or 90° direction based on the longitudinal direction of the laminate. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2002-227066 A [Patent Document 2] International Publication No. 2020 / 031834 Summary of the Invention [Problem to be solved by the invention]

[0005] In the laminated substrate in which the laminate of fiber sheets is sewn together with a stitch thread extending in the 0° or 90° direction as described above, the reinforcing fibers oriented in the same direction as the stitch thread are not fixed by the stitch thread. For example, the stitch thread extending in the 0° direction cannot fix the reinforcing fibers oriented in the 0° direction (i.e., extending parallel to the stitch thread).

[0006] Therefore, when such a laminated base material is impregnated with resin and pultrusion molded, particularly when a molded body having an irregular cross-sectional shape (i.e., a cross-sectional shape that is not point-symmetric or line-symmetric) is pultrusion molded, a tension acts on the reinforcing fibers in a direction toward a corner portion (bent or curved portion) in the cross section of the molded body, causing the reinforcing fibers to locally focus at the corner portion. Due to the local focusing of the reinforcing fibers, the parts other than the corner portions of the molded body (for example, the edge portions of the molded body) become resin-rich as the reinforcing fibers decrease, and there is a risk of the resin of the molded body chipping during or after molding.

[0007] The present invention has been made to solve such problems, and has an object to provide a reinforced resin laminate substrate that can suppress local bundling of reinforcing fibers when molding a reinforced fiber resin molding. [Means for solving the problem]

[0008] The present invention Claim 1 The reinforcing fiber laminated substrate comprises a plurality of fiber sheets each having reinforcing fibers oriented in a certain direction, and a filament that fixes the plurality of fiber sheets together, the plurality of fiber sheets being laminated such that the orientation directions of the reinforcing fibers in adjacent fiber sheets in the thickness direction are different from each other, and the filament extends in a direction different from the orientation direction of the reinforcing fibers in each of the plurality of fiber sheets, and fixes the plurality of fiber sheets in a laminated state. The filamentous body extends across the entire width of the fiber sheet in a width direction perpendicular to the longitudinal direction, and extends in the longitudinal direction while bending in a zigzag pattern. It is characterized by:

[0009] According to this configuration, the filaments extend in a direction different from the orientation direction of the reinforcing fibers of each of the fiber sheets, and fix the fiber sheets in a stacked state. Therefore, even if tension is generated in the fiber sheets during molding when a molded body made of reinforced fiber resin is molded using a reinforced fiber laminate base material, the reinforcing fibers of each fiber sheet are fixed by the filaments, so that it is possible to suppress the reinforcing fibers from bundling locally. This makes it possible to reduce defects in the molded body, such as the occurrence of resin-rich parts due to uneven distribution of the reinforcing fibers. In the above configuration, the filaments extend across the entire width of the fiber sheet in a width direction perpendicular to the longitudinal direction, and extend in the longitudinal direction while bending in a zigzag pattern. This configuration makes it possible to fix all of the reinforcing fibers contained in the fiber sheet across the entire width of the fiber sheet by the filaments, and reliably suppresses local bundling of the reinforcing fibers. Claim 2 of the present invention Reinforced fiber laminated substrate the present invention comprises a plurality of fiber sheets each having reinforcing fibers oriented in a certain direction, and a filament fixing the plurality of fiber sheets together, the plurality of fiber sheets being stacked such that the orientation directions of the reinforcing fibers in adjacent fiber sheets in a thickness direction are different from each other, the filament extends in a direction different from the orientation direction of the reinforcing fibers in each of the plurality of fiber sheets and fixes the plurality of fiber sheets in a stacked state, the filament extends in the longitudinal direction while bending in a zigzag manner only at both end portions in a width direction perpendicular to the longitudinal direction of the fiber sheets, and is not present in a range between the both end portions. . In this configuration, the filaments extend in the longitudinal direction while bending in a zigzag pattern only at both ends in the width direction perpendicular to the longitudinal direction of the fiber sheet, and do not exist in the range between the ends. Therefore, the reinforcing fibers contained in the fiber sheet are fixed by the filaments at both ends in the width direction of the fiber sheet, so that when a reinforced fiber resin molding is molded using the reinforced fiber laminated substrate, it is possible to suppress the movement of the reinforcing fibers at least at both ends in the width direction of the fiber sheet. Therefore, it is possible to reduce defects such as the occurrence of resin-rich portions in the parts of the molding corresponding to both ends in the width direction of the fiber sheet. In addition, it is possible to suppress local bundling of the reinforcing fibers with a small stoppage, so that it is possible to reduce the manufacturing cost of the reinforced fiber laminated substrate.

[0010] In the above-mentioned reinforcing fiber laminated substrate, the plurality of fiber sheets preferably include a fiber sheet in which the reinforcing fibers are oriented in a width direction perpendicular to the longitudinal direction of the fiber sheet.

[0011] According to this configuration, the laminate of multiple fiber sheets includes fiber sheets in which the reinforcing fibers are oriented in a width direction perpendicular to the longitudinal direction of the fiber sheets, so that the reinforced fiber resin molding manufactured using the reinforced fiber laminate base material has improved strength against loads from a direction corresponding to the width direction of the fiber sheets.

[0012] In the above-mentioned reinforcing fiber laminated substrate, the filamentous body is preferably a sewing thread that sews the plurality of fiber sheets together.

[0013] According to this configuration, a plurality of fiber sheets can be easily and reliably integrated together by the sewing thread.

[0016] In the above-mentioned reinforcing fiber laminated substrate, it is preferable that the thread-shaped bodies fix the reinforcing fibers in a state where they cross the reinforcing fibers over the entire range of the width of the fiber sheet.

[0017] According to this configuration, the reinforcing fibers are fixed in a state in which the threads cross the reinforcing fibers over the entire width of the fiber sheet, so that local bundling of the reinforcing fibers can be more reliably suppressed. Effect of the Invention

[0020] According to the reinforcing fiber laminated base material of the present invention, it is possible to suppress local bundling of the reinforcing fibers when forming a reinforced fiber resin molding. [Brief description of the drawings]

[0021] [Figure 1] FIG. 1 is a perspective view showing the overall configuration of a two-layer reinforcing fiber laminated substrate according to a first embodiment of the present invention. [Diagram 2] FIG. 2 is an exploded perspective view of the reinforcing fiber laminate substrate of FIG. 1. [Diagram 3] FIG. 2 is an explanatory diagram showing the planar arrangement of all reinforcing fibers and stitch threads in the reinforcing fiber laminate substrate of FIG. 1. [Figure 4] FIG. 3 is a plan view showing an example of the 0° sheet of FIG. 2. [Diagram 5] FIG. 3 is a plan view showing an example of the 90° sheet of FIG. 2. [Figure 6] FIG. 2 is a diagram showing a schematic configuration of a molding device used for producing a pultrusion body by impregnating the layered base material of FIG. 1 with a resin. [Figure 7] 7 is an explanatory perspective view showing a state in which a pultrusion molded product using the layered base material of FIG. 1 is being pulled out of the mold of FIG. 6, with the reinforcing fibers of the pultrusion molded product being uniformly dispersed. FIG. [Figure 8] FIG. 7 is an explanatory perspective view showing a comparative example of the present invention, in which a pultrusion molded body using a conventional laminated base material in which stitch threads extend in the 0° direction is pulled out of the mold of FIG. 6, showing that the reinforcing fibers of the pultrusion molded body are unevenly distributed. [Figure 9] FIG. 5 is an exploded perspective view of a four-layered reinforcing fiber laminated substrate according to a second embodiment of the present invention. [Figure 10] FIG. 10 is an explanatory diagram showing the planar arrangement of all reinforcing fibers and stitch threads in the reinforcing fiber laminated substrate of FIG. 9. [Figure 11] FIG. 10 is a plan view showing an example of the 45° sheet of FIG. 9. [Figure 12] FIG. 10 is a plan view showing an example of the −45° sheet of FIG. 9. [Figure 13] FIG. 11 is a perspective view showing the overall configuration of a two-layer reinforcing fiber laminated substrate in which only both ends in the width direction are stitched, according to a third embodiment of the present invention. [Figure 14] FIG. 14 is an exploded perspective view of the reinforcing fiber laminated substrate of FIG. 13. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

[0023] (First embodiment) As shown in Fig. 1 and Fig. 2, the reinforcing fiber laminated substrate (hereinafter referred to as laminated substrate 1) according to the first embodiment is a laminated substrate having a two-layer structure, and includes a plurality of (two in this embodiment) fiber sheets 2, 3 in which reinforcing fibers 5, 6 oriented in a certain direction are assembled, and a stitch thread 4 as a filamentous body that fixes the two fiber sheets 2, 3 together. The laminated substrate 1 is used as an intermediate material when molding a resin molded body by pultrusion molding or the like, in which reinforcing fibers are impregnated with a resin. For example, when pultrusion molding of a resin molded body is performed, the molding operation is performed by aligning the longitudinal direction D1 of the fiber sheets 2, 3 with the drawing direction DE (see Figs. 7 and 8).

[0024] The two fiber sheets 2, 3 are laminated such that the orientation directions of the reinforcing fibers 5, 6 in the fiber sheets 2, 3 adjacent to each other in the thickness direction are different from each other.

[0025] In the first embodiment, the fiber sheets 2, 3 are specifically a 0° sheet 2 and a 90° sheet 3, as shown in Figs.

[0026] The 0° sheet 2 is formed by arranging and fixing, in a sheet shape, a plurality of reinforcing fibers 5 oriented in the 0° direction that coincides with the longitudinal direction D1 of the fiber sheets 2 and 3. For example, as shown in Fig. 4, the 0° sheet 2 is formed by arranging a plurality of fiber bundles B1, which are an aggregate of a plurality of reinforcing fibers 5 oriented at 0°, in parallel and holding the parallel state with threads 31.

[0027] The 90° sheet 3 is formed by arranging and fixing, in a sheet shape, a plurality of reinforcing fibers 6 oriented in a 90° direction that coincides with the width direction D2 perpendicular to the longitudinal direction D1 of the fiber sheets 2, 3. For example, the 90° sheet 3 is formed by arranging a plurality of fiber bundles B2, which are an aggregate of a plurality of reinforcing fibers 6 oriented at 90°, in parallel and holding the parallel state with threads 32, as shown in FIG.

[0028] The reinforcing fibers 5, 6 are made of a fiber material selected from carbon fiber, glass fiber, etc. That is, as the reinforcing fibers 5, 6, reinforcing fibers such as carbon fiber, glass fiber, aramid fiber, basalt fiber, ceramic fiber, etc. are used in various forms, for example, in the form of a fiber bundle (for example, a roving-like form in which fibers are lightly twisted together), but it is also possible to use an open form (i.e., a form in which the fiber bundle is separated and spread out like a strip).

[0029] The reinforcing fibers 5 and 6 may be made of different materials or have different physical properties.

[0030] In this embodiment, a stitch thread 4 is used as a filament for fixing the two fiber sheets 2 and 3 together. The stitch thread 4 is a sewing thread for sewing the two fiber sheets 2 and 3 together. A commercially available sewing thread is used as the stitch thread 4, but a thread made of a material that has the property of being fused to the fiber sheets 2 and 3 by heating, such as a thermoplastic resin or a low melting point polymer, may also be used. The thickness of the stitch thread 4 may be such that it is not broken when sewing the fiber sheets 2 and 3 together. For example, the thickness of the sewing thread used as the stitch thread 4 is preferably 20 to 100. The sewing method of the stitch thread 4 is not particularly limited in the present invention, but a sewing method such as wave sewing is adopted.

[0031] As shown in Figures 1 and 3, the stitch thread 4 extends in a direction different from the orientation directions (i.e., 0° and 90°) of the reinforcing fibers 5, 6 of each of the two fiber sheets 2, 3, and fixes the two fiber sheets 2, 3 in a stacked state.

[0032] 3 shows the planar arrangement of all the reinforcing fibers 5, 6 and the stitch thread 4 of the laminated base material 1 in FIG. 1. In this embodiment, the stitch thread 4 extends in the longitudinal direction D1 while bending in a zigzag manner over the entire width in the width direction D2 perpendicular to the longitudinal direction D1 of the fiber sheets 2, 3, as shown in FIGS. 1 to 3. The directions P1 and P2 of each section of the zigzag-extending stitch thread 4 are set to be different from the orientation direction of the reinforcing fibers 5 (0°) and the orientation direction of the reinforcing fibers 6 (90°). That is, the directions P1 and P2 of the zigzag-extending stitch thread 4 (so-called stopper directions) are set to have angles with respect to the longitudinal direction D1 that are greater than 0° and smaller than 90° (for example, about 5° to 85°).

[0033] 3, the stitch thread 4 is bent in a zigzag pattern over the entire width in the width direction D2 perpendicular to the longitudinal direction D1 of the fiber sheets 2, 3, so that the stitch thread 4 crosses the reinforcing fibers 5, 6 over the entire width of the fiber sheets 2, 3, and fixes the reinforcing fibers 5, 6 in a crossed state. This makes it possible to reliably restrict the movement of the reinforcing fibers 5, 6 during molding such as pultrusion molding of a resin molded body.

[0034] (Method of manufacturing a reinforced fiber resin molding using the laminated base material 1) Next, as an example of a method for producing a reinforced fiber resin molded body using the above-mentioned layered base material 1, a method for producing a pultrusion molded body 100 made of reinforced fiber resin by pultrusion molding will be described.

[0035] When manufacturing a pultrusion molded body 100 made of reinforced fiber resin, pultrusion is performed using a pultrusion device 50 shown in Fig. 6. The pultrusion device 50 includes a sheet delivery roller 51, an upstream guide 52, an impregnation tank 53, a downstream guide 56, a molding die 57, and a take-up machine 58.

[0036] The sheet delivery roller 51 is a roller that delivers the four laminated base materials 1 downstream. The upstream guide 52 guides the four laminated base materials 1 downstream while gathering them together to form one laminate 12.

[0037] Matrix resin 54 in an uncured state is laid in impregnation tank 53. Laminate 12 of four laminated base materials 1 passes through impregnation tank 53 while being guided by guide rollers 55, and is impregnated with matrix resin 54 in an uncured state.

[0038] The matrix resin 54 impregnated into the laminate 12 is a resin that becomes the base material of the pultrusion molded body. Various thermosetting resins are used as the matrix resin 54, such as vinyl ester resin, unsaturated polyester resin, epoxy resin, and phenolic resin. In addition, additives such as a flame retardant may be added to the matrix resin.

[0039] The forming die 57 is a metal mold that receives the impregnated laminate 12 and applies heat and pressure to it. It forms the laminate into a predetermined cross-sectional shape, for example, an L-shaped cross-sectional shape as shown in FIG. 7, and discharges it from an outlet 57a downstream in the drawing direction DE.

[0040] The take-up machine 58 has a configuration for taking up the pultrusion molded body 100 discharged from the molding die 57. Specifically, the take-up machine 58 includes multiple pairs of rollers 58a and a pair of endless belts 58b that are arranged in the vertical direction and are wound around the rollers 58a. The rollers 58a rotate while sandwiching the pultrusion molded body 100 from above and below via the endless belts 58b, thereby discharging the pultrusion molded body 100 from the molding die 57 and sending it further downstream of the molding die 57.

[0041] In this manner, the pultrusion body 100 in which four laminated base materials 1 are laminated can be continuously molded by pultrusion.

[0042] As a method for producing a reinforced fiber resin molding using the above-mentioned layered base material 1, it is also possible to produce a reinforced fiber resin molding by molding methods other than pultrusion molding, such as extrusion molding and press molding.

[0043] (Features of the first embodiment) (1) The layered base material 1 of the first embodiment includes a plurality of fiber sheets 2, 3 (i.e., a 0° sheet 2 and a 90° sheet 3) each composed of reinforcing fibers 5, 6 oriented in a certain direction, and a stitch thread 4 that fixes the plurality of fiber sheets 2, 3 together. The plurality of fiber sheets 2, 3 are layered such that the orientation directions of the reinforcing fibers 5, 6 differ from each other in the fiber sheets 2, 3 adjacent in the thickness direction. The stitch thread 4 extends in a direction different from the orientation direction of the reinforcing fibers 5, 6 of each of the plurality of fiber sheets 2, 3, and fixes the plurality of fiber sheets 2, 3 in a layered state.

[0044] According to this configuration, the stitch thread 4 extends in a direction different from the orientation direction of the reinforcing fibers 5, 6 of the plurality of fiber sheets 2, 3, and fixes the plurality of fiber sheets 2, 3 in a stacked state. Therefore, even if tension is generated in the fiber sheets 2, 3 during molding when a molded body made of a fiber-reinforced resin is molded using the layered base material 1, it is possible to suppress the reinforcing fibers 5, 6 from bundling locally, since the reinforcing fibers 5, 6 of each fiber sheet 2, 3 are fixed by the stitch thread 4. This makes it possible to reduce defects in the molded body, such as deterioration of physical properties and occurrence of resin-rich parts due to uneven distribution of the reinforcing fibers 5, 6.

[0045] For example, as shown in FIG. 6 and FIG. 7, when a pultrusion molded body 100 having an L-shaped cross section is molded by pultrusion molding, tension is generated in the fiber sheets 2, 3 (see FIG. 2 and FIG. 3) in the middle of molding in the direction of gathering at the corner portion 100a (corner portion bent into an L-shape) of the L-shaped pultrusion molded body 100. Even in this case, since the reinforcing fibers 5, 6 of each fiber sheet 2, 3 are fixed by the stitch thread 4 as shown in FIG. 1 to 3, it is possible to suppress the reinforcing fibers 5, 6 from gathering locally. Therefore, as shown in FIG. 7, the reinforcing fibers 5, 6 (particularly the reinforcing fibers 5 oriented at 0°) contained in the pultrusion molded body 100 are maintained in a uniformly dispersed state. This reduces the risk of defects such as deterioration of physical properties and generation of resin-rich portions due to uneven distribution of the reinforcing fibers 5, 6 occurring in the edge portion 100b (edge ​​portion of the L-shaped pultrusion molded body 100) of the pultrusion molded body 100.

[0046] This effect can also be achieved by molding methods other than pultrusion (such as extrusion molding and press molding).

[0047] On the other hand, as a comparative example, when the stitch thread 4 in the laminated base material 1 in FIG. 1 extends in the 0° direction like the stitch thread described in Patent Document 2, the 0°-oriented reinforcing fiber 5 is not fixed by the stitch thread 4. When a pultrusion molded body 100 having an L-shaped cross-sectional shape is molded by pultrusion molding using such a laminated base material, the reinforcing fibers 5, 6 (particularly the 0°-oriented reinforcing fiber 5) are locally concentrated around the corner portion 100a as shown in FIG. 8 due to the tension toward the corner portion 100a generated during molding. Therefore, since the reinforcing fibers 5, 6 (particularly the 0°-oriented reinforcing fiber 5) contained in the pultrusion molded body 100 are unevenly distributed, defects such as the generation of a resin-rich portion A with few reinforcing fibers 5, 6 at the edge portion 100b of the pultrusion molded body 100 away from the corner portion 100a occur. This resin-rich portion A is easily chipped during or after pultrusion molding, and the strength of the molded body cannot be maintained.

[0048] Even when looking at this comparative example, it can be seen that a configuration such as the laminated base material 1 of the present embodiment shown in Figures 1 to 3, in which the stitch thread 4 extends in a direction different from the orientation direction of the reinforcing fibers 5, 6 in each of the multiple fiber sheets 2, 3 and fixes the multiple fiber sheets 2, 3 in a stacked state, is effective in suppressing uneven distribution of the reinforcing fibers 5, 6 during molding and reducing defects such as resin-rich areas.

[0049] (2) In the layered base material 1 of the first embodiment, the multiple fiber sheets 2, 3 include fiber sheets 3 (90° sheets) in which the reinforcing fibers 6 are oriented in a width direction D2 perpendicular to the longitudinal direction D1 of the fiber sheets 2, 3. With this configuration, the reinforced fiber resin molding produced using the layered base material 1 has improved strength against a load from a direction corresponding to the width direction D2 of the fiber sheets 2, 3.

[0050] (3) In the layered base material 1 of the first embodiment, the stitch thread 4 is a sewing thread that sews together the multiple fiber sheets 2, 3. With this configuration, the multiple fiber sheets 2, 3 can be easily and reliably integrated together by the sewing thread.

[0051] (4) In the layered base material 1 of the first embodiment, the stitch threads 4 extend in the longitudinal direction D1 while bending in a zigzag pattern across the entire width in the width direction D2 perpendicular to the longitudinal direction D1 of the fiber sheets 2, 3.

[0052] According to this configuration, it becomes possible to fix all of the reinforcing fibers 5, 6 contained in the fiber sheets 2, 3 by the stitch thread 4 across the entire width of the fiber sheets 2, 3, and it is possible to reliably suppress local bundling of the reinforcing fibers 5, 6.

[0053] (5) In the layered base material 1 of the first embodiment, the stitch threads 4 fix the reinforcing fibers 5, 6 in a state where they cross the reinforcing fibers 5, 6 over the entire width range of the fiber sheets 2, 3.

[0054] According to this configuration, the stitch thread 4 fixes the reinforcing fibers 5, 6 in a state where it crosses the reinforcing fibers 5, 6 over the entire width of the fiber sheets 2, 3, so that it is possible to more reliably suppress local bundling of the reinforcing fibers 5, 6.

[0055] Second embodiment As shown in FIG. 9, the reinforcing fiber laminated substrate 11 according to the second embodiment (hereinafter referred to as the laminated substrate 11) is a laminated substrate having a four-layer structure, and includes a plurality of fiber sheets 2, 3, 7, and 8 (four in the second embodiment) each of which is an assembly of reinforcing fibers 5, 6, 9, and 10 oriented in a certain direction, and a stitch thread 4 as a filamentous body that fixes the four fiber sheets 2, 3, 7, and 8 together.

[0056] The reinforcing fibers 5, 6, 9, and 10 are made of the same material as the reinforcing fibers 5 and 6 in the first embodiment. The stitch thread 4 is also made of the same material as the stitch thread 4 in the first embodiment.

[0057] In the second embodiment, the four fiber sheets 2, 3, 7, and 8 are a 0° sheet 2, a 90° sheet 3, a 45° sheet 7, and a -45° sheet 8. Of these, the 0° sheet 2 and the 90° sheet 3 have the same configuration as in the first embodiment.

[0058] The 45° sheet 7 is formed by arranging and fixing a plurality of reinforcing fibers 9 oriented in a 45° direction in a sheet shape. For example, the 45° sheet 7, like the 0° sheet 2 and the 90° sheet 3 in Figures 4 and 5, is formed by holding fiber bundles B3, which are an aggregate of a plurality of reinforcing fibers 9 oriented at 45° (i.e., in the direction of arrow D3 in Figure 11, which is inclined 45° clockwise with respect to the longitudinal direction D1 of the laminated base material 11), in parallel with threads 33, as shown in Figure 11.

[0059] The -45° sheet 8 is formed by arranging and fixing a plurality of reinforcing fibers 10 oriented in the -45° direction in a sheet shape. For example, like the above-mentioned 45° sheet 7, the -45° sheet 8 is formed by holding a fiber bundle B4, which is an aggregate of a plurality of reinforcing fibers 10 oriented at -45° (i.e., in the direction of arrow D4 in Fig. 12, which is inclined 45° counterclockwise with respect to the longitudinal direction D1 of the laminated base material 11), in parallel with threads 34, as shown in Fig. 12.

[0060] The four fiber sheets 2, 3, 7, and 8 are laminated such that the orientation directions of the reinforcing fibers 5, 6, 9, and 10 in the fiber sheets 2, 3, 7, and 8 adjacent in the thickness direction are different from each other. Specifically, in the laminated base material 11 shown in Fig. 9, the 0° sheet 2, the 45° sheet 7, the 90° sheet 3, and the -45° sheet 10 are laminated in this order.

[0061] In the layered substrate 11 of the second embodiment, as shown in Figures 9 and 10, the stitch thread 4 extends in a direction different from the orientation direction of the reinforcing fibers 5, 6, 9, 10 of each of the four fiber sheets 2, 3, 7, 8 (i.e., 0°, 90°, 45°, -45°) to fix the four fiber sheets 2, 3, 7, 8 in a stacked state.

[0062] FIG. 10 shows the planar arrangement of all the reinforcing fibers 5, 6, 9, and 10 and the stitch thread 4 of the laminated base material 11 of FIG. 9. In this embodiment, the stitch thread 4 extends in the longitudinal direction D1 while bending in a zigzag manner over the entire width in the width direction D2 perpendicular to the longitudinal direction D1 of the fiber sheets 2 and 3, as shown in FIG. 9 and FIG. 10. The directions P1 and P2 of each section of the zigzag-extending stitch thread 4 are set to be different from the orientation directions (i.e., 0°, 90°, 45°, -45°) of all the reinforcing fibers 5, 6, 9, and 10. That is, the extending directions (stopper directions) P1 and P2 of the zigzag-extending stitch thread 4 are set to have angles with respect to the longitudinal direction D1 that are greater than 0° and smaller than 90° (for example, about 5° to 85°) and are set to angles other than 45°.

[0063] 9, similarly to the first embodiment, the stitch thread 4 zigzags across the entire width in the width direction D2 perpendicular to the longitudinal direction D1 of the laminated base material 11, fixing all of the reinforcing fibers 5, 6, 9, 10 contained in the fiber sheets 2, 3, 7, 8 in a state where the stitch thread 4 crosses the reinforcing fibers 5, 6, 9, 10. This makes it possible to reliably restrict the movement of the reinforcing fibers 5, 6, 9, 10 during molding such as pultrusion molding of a resin molded body.

[0064] The four-layered laminated base material 11 of the second embodiment configured as described above can also achieve all of the above-mentioned operational effects (1) to (5) of the first embodiment.

[0065] Furthermore, if the stitch thread extends in a direction different from the orientation direction of the reinforcing fibers of each fiber sheet of the laminated base material, the number of layers of the laminated base material can be further increased while still achieving the same effects as those of the first and second embodiments.

[0066] Third embodiment In the first and second embodiments described above, the stitch thread 4 extends in the longitudinal direction D1 while bending in a zigzag pattern across the entire width in the width direction D2 perpendicular to the longitudinal direction D1 of the fiber sheets 2 and 3, but the present invention is not limited to this, and the range in which the stitch thread is arranged in the laminated base material may be changed.

[0067] Specifically, in the third embodiment of the reinforced fiber laminated substrate 21 (hereinafter referred to as the laminated substrate 21), as shown in Figures 13 and 14, the stitch thread 24 extends in the longitudinal direction D1 while bending in a zigzag pattern at both ends (portions close to the edge 21a of the laminated substrate 21) in the width direction D2 perpendicular to the longitudinal direction D1 of the laminated substrate 21.

[0068] The rest of the configuration of the layered base material 21 is the same as that of the layered base material 1 of the first embodiment shown in Figures 1 to 3. That is, the layered base material 21 has a two-layer structure in which a fiber sheet 2 (0° sheet) having reinforcing fibers 5 oriented at 0° and a fiber sheet 3 (90° sheet) having reinforcing fibers 6 oriented at 90° are laminated together.

[0069] More specifically, the directions P3 and P4 of each section of the zigzag-extending stitch thread 24 are set to be different from the orientation direction of the reinforcing fibers 5 (0°) and the orientation direction of the reinforcing fibers 6 (90°). In other words, the directions P3 and P4 of the zigzag-extending stitch thread 24 (so-called fastening material directions) are set to have angles with respect to the longitudinal direction D1 in a range greater than 0° and less than 90° (for example, about 5° to 85°).

[0070] In the configuration of the laminated base material 21 of the third embodiment shown in Figures 13 and 14, the reinforcing fibers 5, 6 contained in the fiber sheets 2, 3 are fixed by the stitch threads 24 at both ends (parts close to the edges 21a) of the fiber sheets 2, 3 in the width direction D2, so that when a resin molded product of the reinforcing fibers 5, 6 is molded using the laminated base material 1, it is possible to suppress the movement of the reinforcing fibers 5, 6 at least at both ends of the fiber sheets 2, 3 in the width direction D2. Therefore, it is possible to reduce defects such as the occurrence of resin-rich parts in the parts of the molded product corresponding to both ends of the fiber sheets 2, 3 in the width direction D2. In addition, it is possible to suppress localized bundling of the reinforcing fibers 5, 6 with a small stoppage, so that the manufacturing cost of the laminated base material 1 can be reduced.

[0071] Moreover, the laminated base material 21 of the third embodiment configured as above can also achieve the above-mentioned operational effects (1) to (3) (features of the first embodiment).

[0072] (Modification) In the above first and third embodiments, stitch threads 4, 24 (sewing threads) are used as an example of the filament, but the present invention is not limited thereto. The filament of the present invention includes not only stitch threads but also hot melt adhesives applied linearly between fiber sheets, or strip-shaped hot melt nonwoven fabrics sandwiched between fiber sheets. Even if these hot melt adhesives or nonwoven fabrics are used as the filament, the effects of the above first to third embodiments can be achieved. [Explanation of symbols]

[0073] 1, 11, 21 Reinforced fiber laminated substrate 2 Fiber sheet (0° sheet) 3 Fiber sheet (90° sheet) 4, 24 Stitch thread (filament) 5, 6, 9, 10 Reinforced Fiber 7 Fiber sheet (45° sheet) 8 Fiber sheet (-45° sheet)

Claims

1. A plurality of fiber sheets each including reinforcing fibers oriented in a certain direction; a filament that fixes the plurality of fiber sheets together; Equipped with The plurality of fiber sheets are laminated such that the orientation directions of the reinforcing fibers in adjacent fiber sheets in the thickness direction are different from each other, The filament extends in a direction different from the orientation direction of the reinforcing fibers of each of the plurality of fiber sheets, and fixes the plurality of fiber sheets in a stacked state, The filamentous body extends across the entire width of the fiber sheet in a width direction perpendicular to the longitudinal direction, and extends in the longitudinal direction while bending in a zigzag pattern. A reinforcing fiber laminated substrate.

2. A plurality of fiber sheets each including reinforcing fibers oriented in a certain direction; a filament that fixes the plurality of fiber sheets together; Equipped with The plurality of fiber sheets are laminated such that the orientation directions of the reinforcing fibers in adjacent fiber sheets in the thickness direction are different from each other, The filament extends in a direction different from the orientation direction of the reinforcing fibers of each of the plurality of fiber sheets, and fixes the plurality of fiber sheets in a stacked state, the filaments extend in the longitudinal direction while bending in a zigzag pattern only at both ends in a width direction perpendicular to the longitudinal direction of the fiber sheet, and do not extend in a range between the both ends; A reinforcing fiber laminated substrate.

3. The reinforcing fiber laminated substrate according to claim 1 or 2, The plurality of fiber sheets include a fiber sheet in which the reinforcing fibers are oriented in a width direction perpendicular to the longitudinal direction of the fiber sheet, A reinforcing fiber laminated substrate.

4. The reinforcing fiber laminated substrate according to claim 1 or 2, The filamentous body is a sewing thread that sews the plurality of fiber sheets together. A reinforcing fiber laminated substrate.

5. The reinforcing fiber laminate substrate according to claim 1, The filamentous body fixes the reinforcing fibers in a state in which the filamentous body crosses the reinforcing fibers over the entire width of the fiber sheet. A reinforcing fiber laminated substrate.

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