Three-dimensional structural member

Abstract

A three-dimensional structural member adapted for wide use as an industrial composite structural member such as an aircraft or other vehicle interior part. A reinforcing substrate fabric has a plurality of planar structural sections. The reinforcing substrate fabric serving as a core material is impregnated or covered with a shape retention agent such as synthetic resin or ceramic material and then solidifed to form a predetermined three-dimensional structure or, alternatively, the reinforcing substrate fabric is unfolded to form a predetermined three-dimensional structure and then impregnated or covered with the shape retention agent. The three-dimensional structural member is characterized in that the reinforcing substrate fabric is formed of lengthwise continuously arrayed yarns. Fabric areas defined by a plurality of surfaces using a plurality of groups of yarns are integrally formed. At least one group of yarns are arrayed so that they are continuous in the direction of the length, with continuity between widthwise and/or obliquely extending linear portions in the fabric areas and curved or bent portions in the ends of the fabric areas. Alternatively, at least one group of yarns are arrayed so that they are continuous in the direction of the length while continuously forming loops, the yarns being interlaced with each other and/or with the other groups of yarns which are arrayed so that they are continuous in the direction of the length. The yarns are thus connected together.