JP2947504B2 - Textile substrate for reinforcement - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reinforcing woven fabric substrate capable of exhibiting excellent properties for use in a fiber-reinforced composite material, and more particularly to a reinforcing woven fabric substrate most suitable for hand lay-up molding.

[0002]

2. Description of the Related Art Recently, the weakening of cement-based structures and the decrease in durability have become problems, such as the generation of rust on reinforcing bars due to the neutralization of concrete and the fatigue of reinforcing bars due to a sudden increase in traffic volume. I have. As a countermeasure, for example, in the case of a floor slab of a road bridge, a reinforcing method of bonding a fiber reinforced plastic including a reinforcing fiber base material (for example, a carbon fiber base material) to a lower surface of the floor slab has been adopted. This method has a high reinforcing effect, excellent durability, and is easy to reinforce,
It is becoming widely adopted.

[0003] In this reinforcing method, for example, first, after smoothing the lower surface of a floor slab, a primer is applied, a resin serving as an adhesive is applied thereon, and a reinforcing base material is attached, and the resin is applied to the reinforcing base material. It is bonded while impregnating. In most cases, the reinforcing base material is a reinforcing material for a portion where a tensile force acts in the length direction. Therefore, a unidirectional woven fabric or sheet material in which reinforcing fiber yarns (for example, carbon fiber yarns) are arranged in one direction is used. It is heavily used.

In the case where such a unidirectional woven fabric or sheet material is to be stuck on the lower surface of the floor slab while impregnating the resin, the resin must be impregnated while holding the entire surface of the substrate in an upward state with an impregnating roller. The operator is very tired. Further, it is difficult to impregnate the resin uniformly, and the operation is upward, so that the resin may drool on the face of the worker, which is even more troublesome. Further, since the reinforcing base material is weak and easily deformed even by a slight external force, there is a problem that it is difficult to apply the reinforcing fiber yarn while orienting the reinforcing fiber yarn straight in the length direction.

To solve the above problem, a unidirectionally arrayed fiber reinforced sheet material in which reinforcing fiber yarns are arranged in one direction and in parallel with each other and integrated by bonding the sheet to the entire surface of the paper with an adhesive is disclosed in Japanese Patent Application Laid-Open Publication No. HEI 10-163,887. It has been proposed in Japanese Patent Application Laid-Open No. 3-222732.
According to this method, since the paper is adhered, the sheet material is stuck to the floor surface coated with the resin, and the resin is impregnated with a resin roller from above the paper, so that the resin can be prevented from dripping and the base material can be prevented. It can be attached to a predetermined position without being shifted.

However, since the reinforcing fiber yarn itself is adhered with an adhesive and is adhered to paper (support sheet) with the adhesive and held together, the impregnating property of the matrix resin becomes low. In addition to the decrease, when air is included, there is no escape route of air, so that air is dispersed in the resin, resulting in generation of many voids. In particular, if the adhesive is an epoxy resin containing no curing agent,
Since the curing agent does not spread to that portion, the matrix resin is present without being cured, and the high strength of the reinforcing fiber cannot be sufficiently exhibited.

Further, if the amount of the adhesive is reduced in order to increase the impregnation of the resin, the adhesive strength with the paper is weakened, the adhesive is easily peeled off during the attaching operation, and the reinforcing fibers are disintegrated. Problems arise. Conversely, if the amount of the adhesive is increased to increase the adhesive strength with paper, when the paper is peeled off after impregnation with the resin, there is a problem that the paper is peeled off together with the reinforcing fiber base material.

[0008]

SUMMARY OF THE INVENTION It is an object of the present invention to solve the above-mentioned conventional problems as a reinforcing woven fabric base material such as a floor slab, to efficiently and easily construct the slab, and to suppress the generation of voids. An object of the present invention is to provide a reinforcing woven fabric base material that can be used for reinforcing concrete structures such as floor slabs and has high long-term reliability.

[0009]

In order to achieve the above object, a reinforcing woven fabric substrate according to the present invention comprises a reinforcing fiber yarn for at least one of a warp yarn and a weft yarn, and a low melting polymer for the warp yarn and / or the weft yarn. Is a woven fabric that is arranged in a line or a dot shape, and is characterized in that a sheet-like support is adhered to the woven fabric surface with the low-melting polymer.

As a more specific embodiment, the reinforcing woven fabric base material according to the present invention comprises a warp yarn or a weft yarn composed of reinforcing fiber yarns arranged in one direction in parallel with each other in a sheet form. And / or an auxiliary yarn parallel to the reinforcing fiber yarn and an auxiliary yarn orthogonal thereto cross each other to hold the reinforcing fiber yarn integrally, and the reinforcing fiber yarn or /
And a woven fabric in which the low-melting polymer is arranged in a line or a dot on the auxiliary yarn, and a sheet-like support is adhered to the woven fabric surface with the low-melting polymer. Become.

As the sheet-like support, for example,
Paper or film can be used. Further, a non-woven fabric can be used as the sheet-like support.

The reinforcing woven fabric base material according to the present invention is particularly suitable for reinforcing concrete structures such as floor slabs and beams of road bridges.

Hereinafter, the reinforcing woven fabric substrate of the present invention will be described in detail with reference to the drawings. FIG. 1 shows a reinforcing textile substrate according to one embodiment of the present invention. The reinforcing woven fabric substrate 1 is composed of a warp yarn 3 made of reinforcing fiber yarns arranged in a direction parallel to each other and in a sheet shape, and a weft yarn 4 made of an auxiliary yarn orthogonal to the warp yarns 3 intersecting with each other in a plain weave structure. And has a unidirectional reinforcing fabric. The warp yarns 3 and the weft yarns 4 are laid out by low-melting polymers 4 arranged linearly or in a dot shape in the weft yarn direction.

The above embodiment is a unidirectional reinforcing fabric in which a warp yarn 3 made of a reinforcing fiber yarn and a weft yarn 4 as an auxiliary yarn are crossed with each other. In the present invention, as shown in FIG. A group of warp yarns 3 composed of reinforcing fiber yarns are arranged in one direction in parallel with each other and in a sheet shape, and an auxiliary yarn 6 parallel to the warp yarn group 3, an auxiliary yarn 7 arranged on the warp yarn sheet surface and orthogonal to the warp yarn 3, A so-called non-crimp fabric may be used in which the reinforcing fiber yarns 3 are integrally held by intersecting the eight groups. Since such a woven fabric has a non-crimp structure, stress concentration does not occur even when it is solidified with a resin, and the tensile strength and the tensile elastic modulus when molded into a fiber reinforced plastic plate are increased.

Further, the present invention is not limited to the above-described unidirectional reinforcing fabric or non-crimped fabric, but includes a plain weave structure, a twill weave structure, and a satin weave in which a warp and a weft composed of reinforcing fiber yarns intersect each other. It also includes bidirectional fabrics such as tissues.

The reinforcing fiber yarn may have an elliptical cross section, but is preferably flat. By doing so, the thickness of the yarn can be reduced throughout, and the resin around the yarn can be easily impregnated even if it has a high viscosity. For example, if the cross section of the reinforcing fiber yarn is elliptical, resin impregnation proceeds at the thin portions at both ends,
In the thick part at the center, the impregnation path of the resin to the center of the yarn becomes longer, so that an unimpregnated part where the resin does not reach is easily formed. By making the yarn cross section flat, there is no portion where the resin impregnation path becomes long, so that the resin impregnation can be performed easily and satisfactorily.

Furthermore, by providing a gap between the parallel reinforcing fiber yarns, the impregnation property of the resin can be further improved. The range of the gap is 0.1 to 1.0 m
m is preferred. If the gap is less than 0.1 mm, it becomes difficult for the resin to move, and when air is contained, the escape route is small and may remain as a void. on the other hand,
If the gap exceeds 1 mm, it has a sufficient effect on the movement of resin and the escape of air, but on the actual surface, the bonding area between the reinforcing fiber yarn and the concrete surface such as a floor slab is reduced. The reinforcing effect may be reduced.

When the fiber weight of the reinforcing fiber yarns is increased, flat reinforcing fiber yarns 3 can be stacked and woven as in the embodiment shown in FIG. FIG. 3 shows an example in which two layers are stacked, but three or more layers can be stacked as necessary. Since the reinforcing fiber yarns 3 are flat, the yarn spacing can be ensured even if the fiber weight is increased.

The flatness (= width of yarn / thickness of yarn) of the flat reinforcing fiber yarn is preferably about 30 to 80. When the flatness is less than 30, the impregnating property of the resin becomes poor in a reinforcing base material having a large fiber weight, and when the flatness exceeds 80, it is difficult to secure the yarn interval.

As the reinforcing fiber used for the reinforcing fiber yarn of the present invention, a fiber having a high strength and a high elastic modulus is preferable, and for example, carbon fiber, glass fiber, polyaramid fiber and the like can be used. Among them, a carbon fiber multifilament yarn in which a large number of filaments are bundled is a high-strength, high-modulus fiber and is not liable to be attacked by an alkali. In particular, it is a multifilament yarn in which 5,000 to 50,000 carbon fibers having a single fiber diameter of about 5 to 8 microns are bundled, and has a tensile strength of 2,000 to 50,000.
7,000 MPa, tensile modulus of 200 to 700 GPa
Are preferred. Further, it is preferable that the fiber reinforcing material has a higher tensile strength and a higher tensile elastic modulus because a small amount of reinforcing fibers can efficiently reinforce a floor slab or the like.

The auxiliary yarn does not essentially bear the mechanical properties of the fiber-reinforced plastic, but maintains the shape of the reinforcing fiber yarn.
Fine denier yarns are preferred, and particularly preferably 1/5 or less the thickness of the carbon fiber multifilament yarn used. 1/5 of the thickness of carbon fiber multifilament yarn
If the auxiliary yarn is too thick, the space between the reinforcing fiber yarns provided at the angle is filled with the auxiliary yarn, and the resin cannot be defoamed. The auxiliary yarn in the warp direction is preferably twisted at about 10 to 200 turns / m and converged in order to secure an interval between the carbon fiber multifilament yarns. The auxiliary yarn is not particularly limited to glass fiber, polyester fiber, polyaramid fiber, nylon fiber, ABS fiber, polyethylene fiber, polypropylene fiber, vinylon fiber, etc. Is small, the dimensional stability of the reinforcing base material is good, and the density of the reinforcing fiber yarn does not change due to the contraction of the weft direction auxiliary yarn. In addition, since reinforcing fiber yarns of carbon fiber, polyaramid fiber and glass fiber in the warp direction hardly shrink, when the warp direction auxiliary yarn shrinks, the reinforcing fiber yarns meander, but glass fiber, polyaramid fiber and vinylon. These problems can be solved by using a warp-direction assisting yarn having a small heat shrinkage such as a fiber.

The weight of the carbon fiber multifilament yarn in the reinforcing fabric is from 250 g / m ^{2 to} 500 g / m ^2.
g / m ² is preferred. If it is less than 250 g / m ² , the number of laminating operations increases in order to obtain a predetermined amount of reinforcing fibers for reinforcing the slab or the like, so that it takes time to reinforce or repair the slab or the like. On the other hand, when it exceeds 500 g / m ² , the impregnating property of the resin becomes poor.

The reinforcing fiber yarns and / or auxiliary yarns of the reinforcing woven fabric according to the present invention are blinded with low-melting polymers arranged in a linear or dot-like manner. As the low melting point polymer, nylon, copolymerized nylon, polyester, vinylidene chloride, vinyl chloride, polyurethane and the like can be used. Among them, copolymerized nylon, for example, nylon 6,
66 and 610 copolymerized nylon, nylon 6, 1
Copolymer nylons 2, 66 and 610 are preferred because of their good adhesion to thermosetting resins.

In addition, as a sighting method, when a weft yarn is inserted, a reinforcing fiber yarn or an auxiliary yarn and a low-melting nylon yarn are aligned and woven, and the low-melting nylon yarn is melted by a heater in a woven state. It is possible to easily achieve the target eye stoppage. By performing the eye-stopping in this way, even when the resin is impregnated with the impregnating roller, it is possible to maintain a predetermined fiber orientation without causing misalignment even if the resin is strongly squeezed.

Further, when the low-melting nylon yarn is melted by heat, the low-melting nylon melted on the surface of the reinforcing woven fabric becomes an adhesive by supplying the woven fabric together with the sheet-like support. The body can be easily adhered to the reinforcing fabric.

The adhesive strength of the sheet-like support can be controlled by adjusting the amount of the low-melting polymer yarn to be supplied during weaving. The means for changing the supply amount of the low-melting polymer yarn may be freely selected depending on the thickness of the low-melting polymer yarn to be used, the weaving density to be inserted, and the like.

The optimum amount of the low melting point polymer varies depending on the structure of the woven fabric, but is preferably ² to 30 g / m ² . 2g
/ M ² , a sufficient adhesive strength cannot be obtained. Conversely 3
If it exceeds 0 g / m ² , there arises a problem that the adhesive strength is too strong to easily peel off the sheet-like support and a problem that the impregnating property of the resin is alienated.

The low-melting polymer yarn may be arranged and supplied so as to be always arranged on the reinforcing fiber yarn,
It may be supplied together with the auxiliary yarn. In particular, weaving in parallel with the weft direction auxiliary yarn is preferable because it is not necessary to prepare for the number of warp yarns.

According to the above-mentioned method, the staple material is present in a linear or dot form on the surface of the reinforcing fabric, and adheres to the sheet-like support in that state. As described above, since the sheet-like support is bonded by the low-melting polymer arranged in a linear or dot-like manner, the resin can easily move even if the sheet-like support is impregnated with the resin in a bonded state, and Since air can escape even when air is contained, voids and unimpregnated portions are not generated.

Since the sheet-like support is to be discarded after use, inexpensive paper or film may be used. If the adhesive strength of the staple material is too strong, the sheet-like support is preliminarily demolded with silicone or the like. It is advisable to apply an agent.

As the paper used for the sheet-like support, wrapping paper such as kraft paper or roll paper, or processed paper such as art paper, coated paper, cast-coated paper, etc., having a heat resistance of 120 ° C. or more can be used. It is sufficient if the thickness is such that it does not break during the pasting work,
10 to 100 μm is preferred.

In the present invention, the sheet-like support is not limited to paper, but may be a sheet-like material such as a synthetic resin film or a non-woven fabric. When a film is used, a heat-resistant polyester film, polyphenylene sulfide, nylon, polyimide film or the like having a thickness of 10 to 50 μm is preferable.

As the nonwoven fabric, glass fiber, carbon fiber,
A nonwoven fabric made of a heat-resistant fiber such as a polyaramid fiber or a polyester fiber, which has a large amount of binder and is excellent in dimensional stability of the mesh is preferable. Further, in the case of a nonwoven fabric, the resin is generally penetrated, so that the dimensional stability of the base material is exhibited more than prevention of dripping. A preferred basis weight is 20 to 200 g / m ² . Weight 2
With a nonwoven fabric that is too low, such as less than 0 g / m ² , the form is unstable and the desired stabilization of the textile substrate cannot be achieved. On the other hand, if the basis weight exceeds 200 g / m ² , there is a problem that the total weight increases and handling becomes poor.

When a film or a non-woven fabric is attached,
After being impregnated with the resin, it may be left attached without being peeled off. By doing so, the surface is smooth and the appearance is good.

[0035]

EXAMPLES Examples of the present invention will be described below together with comparative examples. Example As a warp yarn composed of a reinforcing fiber, the tensile strength was 4,800.
MPa, tensile modulus 230 GPa, elongation at break 2.1
%, The filament diameter is 7 μm, and the number of filaments is 1
2,000 flat carbon fiber yarns with a fineness of 7,200 denier are arranged in parallel in one direction at a density of 1.875 yarns / cm × 2 layers, and glass fibers are used as auxiliary yarns in the warp direction. Yarn (filament diameter 7 μm, number of filaments 400, fineness 405 denier), glass fiber yarn (filament diameter 7 μm) as an auxiliary yarn in the weft direction
m, the number of filaments is 200, and the fineness is 202 denier), and as shown in FIG. 2, a non-crimp woven fabric structure in which reinforcing fiber yarns are arranged straight in one direction.
A low-melting polymer yarn (copolymer nylon yarn) was aligned with a weft direction auxiliary yarn glass fiber yarn and woven.

Next, the woven fabric is passed through the surface of a heating cylinder provided between a surface roller and a take-up roll of a loom together with release paper supplied from another place, so that the low-melting polymer yarn is melted. The release paper was adhered while pressing with a roller to obtain a reinforcing woven fabric substrate of the present invention.

Next, assuming the actual floor slab reinforcement of the bridge, using the obtained woven fabric substrate for reinforcement and an epoxy resin cured at room temperature, an upward sticking experiment was performed using a slate plate. . As a result, since the release paper was adhered to the base material and was stable, the base material could be stuck at a predetermined position. In addition, although the resin was impregnated by pressing strongly on the release paper with a roller, the fibers could be straightened without disorder and the resin could be easily attached without dripping.

Further, in order to evaluate the impregnating property of the resin, a test piece was prepared using the base material of the present invention by the same impregnation method as the above-mentioned bonding, and the cross section thereof was observed. And no voids were generated. Further, as a result of performing a tensile test on the test piece based on JIS-K7073, as shown in Table 1, the test piece exhibited high tensile strength and tensile elastic modulus.

Comparative Example For comparison, a sheet using the same yarn as in the above example and arranged in one direction at a density of 3.75 yarns / cm was used as a release paper coated with an epoxy resin containing no curing agent. Superposition,
The carbon fiber sheet and the release paper were adhered while being crushed by a calender roller. At this time, the adhesive was integrated without penetrating into the carbon fibers and separating the carbon fibers themselves.

When an experiment was conducted by attaching this base material to a slate plate under the same conditions as in the example, there was a problem that air did not escape when air was contained. This is thought to be because the carbon fibers are uniformly dispersed and are integrally held by the resin, so there is no escape route for air. You need to be careful not to do this.

A test piece was prepared from the comparative substrate in the same manner as in the example, and the cross section was observed. As a result, a large amount of air contained during molding was generated in the test piece as voids. In addition, the results of a tensile test of the test piece based on JIS-K7073 are shown together with the results of the examples in Table 1.

[0042]

[Table 1]

As can be seen from Table 1, in the examples, there are gaps between the yarns, and since the bonding between the base material and the release paper is made of a linear or dot-like low-melting polymer, the air escape route is provided. It can move even if it contains air during molding,
Further, since the resin itself can be easily moved, it can be completely impregnated with the resin and exhibits high tensile strength and tensile modulus.

[0044]

As described above, according to the reinforcing woven fabric substrate of the present invention, the reinforcing fiber yarns are organized as a woven fabric, and the warp yarns and the weft yarns are blinded by the low melting point polymer. Since the form is stable, and a sheet-like support such as release paper is adhered to the woven fabric surface, it can be molded without disturbing the fiber orientation during resin impregnation, resulting in a highly reliable fiber reinforced resin material. . Further, even after the sheet-like support is peeled off, the reinforcing fiber yarn maintains the woven structure, so that the fiber orientation is not disturbed. Therefore, as a reinforcing woven fabric base material such as a bridge slab, when applied upward and impregnated with a resin, the resin can be uniformly impregnated by strongly pressing the sheet-shaped support with an impregnating roller, and Since the resin does not drip on the face of the worker, the molding can be performed efficiently and easily. Of course, the same molding can be performed in downward molding such as ordinary hand lay-up molding, and problems such as contamination with resin are eliminated.

Further, since the reinforcing fiber yarn has a woven structure, there are slight gaps between the woven yarns, and the sheet-like support is a low-melting polymer disposed on the warp or / and the weft of the woven fabric. It is adhered to the fabric surface in a shape or a dot, and an appropriate gap is created between the fabric surface and the sheet surface, so that air and resin can easily move, the resin reaches the entire fabric base material, without causing voids It can be completely impregnated with resin.

Further, in the production of the reinforcing woven fabric base material of the present invention, the sheet-like support heat-melts the low-melting polymer woven together with the woven fabric and adheres it to the woven fabric surface.
There is no need to prepare a sheet-like support to which an adhesive has been applied in advance, and it is possible to easily bond the support on a loom.

[Brief description of the drawings]

FIG. 1 is a perspective view of a reinforcing textile substrate according to an embodiment of the present invention.

FIG. 2 is a perspective view of a reinforcing textile substrate according to another embodiment of the present invention.

FIG. 3 is a partial cross-sectional view according to another embodiment in which reinforcing fiber yarns are stacked in two layers to form a woven structure in order to increase the weight of the reinforcing fibers.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Reinforcement textile base material 2 Sheet-like support 3 Warp yarn made of reinforcing fiber yarn 4 Weft direction auxiliary yarn 5 Low melting point polymer 6 Warp yarn direction auxiliary yarn 7, 8 Weft direction auxiliary yarn

──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Kazuo Eguchi 1-12-20 Uemachi, Ageo City, Saitama Prefecture 105, Kobayashi Heights 105 (72) Inventor Katsumi Hino 5-8-17-205, Ochiai, Tama City, Tokyo (58) Field surveyed (Int.Cl. ⁶ , DB name) B32B 1/00-35/00 E01D 1/00-23/00 E04G 23/00-23/08

Claims (6)

(57) [Claims] 1. A woven fabric in which at least one of a warp yarn and a weft yarn is a reinforcing fiber yarn, and a low-melting-point polymer is linearly or dottedly arranged on the warp yarn and / or the weft yarn, and the woven fabric surface is A woven fabric substrate for reinforcement, wherein a sheet-like support is bonded with the low-melting polymer. 2. A warp yarn or a weft yarn composed of reinforcing fiber yarns is arranged in one direction in parallel with each other and in a sheet shape, and said reinforcing fiber yarn and / or an auxiliary yarn parallel to said reinforcing fiber yarn and an auxiliary yarn orthogonal thereto. Are crossed with each other to hold the reinforcing fiber yarns integrally, and the reinforcing fiber yarns and / or auxiliary yarns are provided with a low-melting-point polymer in a linear or dot-like pattern and are laid down. A woven fabric substrate for reinforcement, wherein a sheet-like support is adhered with the low-melting polymer. 3. The reinforcing woven fabric substrate according to claim 1, wherein said sheet-like support is paper or film. 4. The reinforcing woven fabric substrate according to claim 1, wherein the sheet-like support is a nonwoven fabric. 5. A concrete structure reinforcing base material, wherein the concrete structure is reinforced by using the reinforcing textile base material according to claim 1. 6. A substrate for reinforcing a concrete structure, wherein the substrate is reinforced by using the textile substrate for reinforcement according to claim 2.