JP7732264B2 - Manufacturing method of reinforcing mesh - Google Patents

Description

The present invention relates to a method for manufacturing a reinforcing mesh and a reinforcing mesh wound body.

Mortar used in cement products and building exterior walls is prone to cracking due to drying shrinkage, and if such cracks are left unattended for a long period of time, water can seep in and cause leaks, or the strength of the mortar can decrease, causing it to deteriorate. For this reason, attempts have been made to embed reinforcing mesh in the mortar or concrete to prevent cracks from expanding.

As an example of such a reinforcing mesh, Patent Document 1 below discloses a crack suppression material for hardened cement paste, which is a net-like structure made up of first threads and second threads that are shorter than the first threads. Patent Document 1 states that the ratio of (tensile stiffness of first threads)/(tensile stiffness of second threads) in the net-like structure is 1.5 to 30.

JP 2009-126730 A

Reinforcing mesh such as that described in Patent Document 1 is intended to be inserted directly into mortar, and the larger the mesh openings, the less susceptible it is to the effects of aggregate in the matrix, making it easier to install. Furthermore, since mortar is poured using equipment such as a vibrator, a strong sealing process is required to prevent the warp and weft threads in the mesh from coming loose, even in such an environment. It is also necessary to protect the fibers themselves so that they do not unravel and reduce tensile strength.

To solve these problems, one common approach is to increase the amount of secondary binder applied during the sealing process. However, applying too much secondary binder can make the mesh itself hard, or when used in a wound state, it can cause a tendency to curl, making application difficult. Another approach is to soften the composition of the secondary binder itself, but this can make the secondary binder film sticky, which can cause blocking when used in a wound state and make it difficult to unwind from the wound state.

Furthermore, in the secondary binder application process for meshes with large openings and a large amount of fibers arranged in one axis direction, as in Patent Document 1, the mesh may become unstable, causing the warp and weft threads to meander and become blocked, making it impossible to achieve the desired tensile strength.

The object of the present invention is to provide a method for manufacturing a reinforcing mesh that is less likely to develop curls when wound and has excellent workability, as well as a reinforcing mesh wound body made from the reinforcing mesh.

The reinforcing mesh manufacturing method of the present invention is a method for manufacturing a biaxial reinforcing mesh composed of warp and weft threads, and is characterized by comprising the steps of: obtaining a mesh fabric by weaving the fabric so that heat-sealing yarns containing thermoplastic resin fibers are entangled with at least one of the warp and weft threads; subjecting the mesh fabric to heat and pressure treatment to pressurize the warp and weft threads; and applying a secondary binder to the pressed mesh fabric to obtain a reinforcing mesh.

In the present invention, in the process of obtaining the reinforcing mesh, it is preferable to apply the secondary binder so that the ignition loss of the reinforcing mesh is 0.5% to 10.0% by mass.

In the present invention, in the process of obtaining the mesh fabric, it is preferable to entangle a first heat-sealed yarn containing a first thermoplastic resin fiber along at least one of the warp and weft yarns, and to entangle a second heat-sealed yarn containing a second thermoplastic resin fiber by winding it around at least one of the warp, weft, and first heat-sealed yarns. It is preferable that the second heat-sealed yarn further contains inorganic fibers. It is more preferable that the ratio of the content of the second thermoplastic resin fiber to the content of the inorganic fiber in the second heat-sealed yarn is 3:7 to 7:3 by mass.

In the present invention, in the process of obtaining the mesh fabric, it is preferable to weave the warp and weft yarns by plain weaving, and to entangle the second heat-sealed yarn at the intersection of the warp and weft yarns from one main surface of the mesh fabric toward the other main surface, and from the other main surface of the mesh fabric back to the one main surface.

The reinforcing mesh wound body of the present invention is a reinforcing mesh wound body formed by winding a biaxial reinforcing mesh composed of warp and weft threads, and the reinforcing mesh contains a secondary binder. When the reinforcing mesh is cut out 500 mm in the winding direction from the reinforcing mesh wound body and placed on a flat surface, the shortest distance connecting both ends of the reinforcing mesh in the winding direction is 400 mm or more.

In the present invention, it is preferable that the ignition loss of the reinforcing mesh be 0.5% to 10.0% by mass.

In the present invention, it is preferable that the maximum spacing between rows of warp or weft yarns is 20 mm or more and 60 mm or less.

In the present invention, it is preferable that the tensile strength of one row of the warp or weft yarns is 800 N/row or more.

The present invention provides a method for manufacturing a reinforcing mesh that is less likely to develop a curl when wound and has excellent workability, as well as a reinforcing mesh wound body made from the reinforcing mesh.

FIG. 1 is a schematic plan view showing a mesh fabric used in a method for manufacturing a reinforcing mesh according to a first embodiment of the present invention. FIG. 2 is a schematic plan view showing an enlarged portion of a mesh fabric used in the method for producing a reinforcing mesh according to the first embodiment of the present invention. FIG. 3 is a schematic plan view showing an enlarged portion of a mesh fabric used in a method for manufacturing a reinforcing mesh according to a second embodiment of the present invention. FIG. 4 is a schematic plan view showing an enlarged portion of a mesh fabric used in a method for manufacturing a reinforcing mesh according to a third embodiment of the present invention. FIG. 5 is a schematic plan view showing a mesh fabric used in a method for manufacturing a reinforcing mesh according to a fourth embodiment of the present invention. FIG. 6 is a schematic plan view showing an enlarged portion of a mesh fabric used in a method for manufacturing a reinforcing mesh according to a fourth embodiment of the present invention. FIG. 7 is a schematic diagram showing a reinforcing mesh wound body according to one embodiment of the present invention. FIG. 8 is a schematic plan view showing a reinforcing mesh constituting a reinforcing mesh wound body according to one embodiment of the present invention. FIG. 9 is a diagram for explaining a method for evaluating the curling tendency of a reinforcing mesh. FIG. 10 is a diagram for explaining a method for evaluating the sealing strength of a reinforcing mesh. FIG. 11 is a schematic diagram illustrating the structure of the mesh fabrics produced in Examples 1 and 2. FIG. 12 is a schematic diagram illustrating the structure of the mesh fabrics produced in Examples 3 and 5. FIG. 13 is a schematic diagram illustrating the structure of the mesh fabric produced in Example 4. FIG. 14 is a schematic plan view showing an enlarged portion of a mesh fabric used in the manufacturing method of a reinforcing mesh in Comparative Example 1. FIG. 15 is a schematic plan view showing an enlarged portion of a mesh fabric used in the manufacturing method of a reinforcing mesh in Comparative Example 2. FIG. 16 is a schematic plan view showing an enlarged portion of a mesh fabric used in the manufacturing method of the reinforcing mesh in Comparative Examples 3 and 4.

Preferred embodiments are described below. However, the following embodiments are merely examples, and the present invention is not limited to the following embodiments. Furthermore, in each drawing, components having substantially the same functions may be referred to by the same reference numerals.

[Method for manufacturing reinforcing mesh]
In the method for manufacturing a reinforcing mesh of the present invention, a mesh fabric is first obtained by weaving a fabric so that a heat-sealed yarn containing a thermoplastic resin fiber is entangled with at least one of the warp and weft yarns (mesh fabric formation process). The mesh fabric is then heated and pressurized to crimp the warp and weft yarns (crimping process). A secondary binder is then applied to the crimped mesh fabric (secondary binder application process). This results in a biaxial reinforcing mesh composed of the warp and weft yarns.

In the reinforcing mesh manufacturing method of the present invention, heat-sealing yarns containing thermoplastic resin fibers are entangled with at least one of the warp and weft threads during weaving, followed by heating and pressure treatment. This increases the sealing strength of the warp and weft threads and improves mechanical strength. Furthermore, because the sealing strength of the warp and weft threads is increased, the amount of secondary binder required in subsequent processes can be reduced. This increases the flexibility of the reinforcing mesh and makes it less likely to become curled. Therefore, even when using a uniaxially reinforced mesh with large openings and high tensile strength per row, workability can be improved. Furthermore, applying a secondary binder prevents damage to the fibers themselves during concrete pouring, allowing the desired tensile strength to be achieved.

(First embodiment)
Fig. 1 is a schematic plan view showing a mesh fabric used in a manufacturing method of a reinforcing mesh according to a first embodiment of the present invention, and Fig. 2 is a schematic plan view showing an enlarged portion of the mesh fabric of Fig. 1.

<Mesh fabric forming process>
In the process of forming the mesh fabric 1, first, warp threads 4 and weft threads 5 are prepared. In this embodiment, the fiber bundles constituting the warp threads 4 and weft threads 5 are both glass fiber bundles. The glass fiber bundles can be obtained by bundling several tens to several thousands of glass fiber monofilaments.

More specifically, glass fiber bundles can be obtained by the following method. First, glass raw materials fed into a glass melting furnace are melted to form molten glass, and after the molten glass is made homogeneous, the molten glass is drawn out from a heat-resistant nozzle attached to a bushing. The drawn molten glass is then cooled to form glass fiber monofilaments (glass fibers).

Next, a sizing agent is applied to the surface of the glass fibers. With the sizing agent evenly applied, the glass fibers are aligned and bundled together in groups of tens to thousands, and then dried to obtain a glass fiber bundle.

The glass fiber monofilaments constituting the glass fiber bundle preferably contain, as their glass composition, 12 mass% or more of _ZrO2 and 10 mass% or more of _R2O (R is at least one selected from Li, Na, and K). In this case, alkali resistance and rigidity can be further improved. Note that "10 mass% or more of _R2O " means that the total content of _Li2O , _Na2O , and _K2O in the glass fiber monofilament is 10 mass% or more.

Such glass fiber monofilaments may contain, for example, the following glass composition in mass %: SiO ₂ 54-65%, ZrO ₂ 12-25%, Li ₂ O 0-5%, Na ₂ O 10-17%, K ₂ O 0-8%, R'O (where R' represents Mg, Ca, Sr, Ba, or Zn) 0-10%, TiO ₂ 0-10%, and Al ₂ O ₃ 0-2%; and preferably, the following compositions in mass %: SiO ₂ 57-64%, ZrO ₂ 14-24%, Li ₂ O 0-3%, Na ₂ O 10-17%, K ₂ O 0-5%, R'O (where R' represents Mg, Ca, Sr, Ba, or Zn) 0.2-8%, TiO ₂ It is possible to use one containing 0.5 to 9% of Al and 0 to 1% of Al ₂ O ₃ .

The average diameter of the glass fiber monofilaments is preferably 10 μm or more, more preferably 15 μm or more, and preferably 30 μm or less, more preferably 25 μm or less. If the average diameter of the glass fiber monofilaments is equal to or greater than the above-mentioned lower limit, the rigidity can be further increased. If the average diameter of the glass fiber monofilaments is equal to or less than the above-mentioned upper limit, the surface area can be further increased, and the adhesiveness to cement, etc. can be further improved.

Examples of sizing agents used when bundling glass fiber monofilaments include polyester resins. The polyester resin may be saturated polyester resin or unsaturated polyester resin. It may also be vinyl acetate resin, urethane resin, epoxy resin, or acrylic resin. These may be used alone or in combination.

In addition to the above components, the sizing agent preferably also contains a silane coupling agent. Examples of silane coupling agents that can be used include aminosilane, epoxysilane, vinylsilane, acrylicsilane, chlorosilane, mercaptosilane, and ureidosilane. Adding a silane coupling agent can further enhance adhesion to the matrix, such as cement.

In addition to the silane coupling agent, the sizing agent may contain other components such as a lubricant, a nonionic surfactant, a water-soluble polymer, and an antistatic agent, and the blending ratio of each component can be determined as needed. Examples of water-soluble polymers that can be used include polyvinyl alcohol, polyoxyethylene polyoxypropylene glycol, and polyvinylpyrrolidone.

The amount of sizing agent applied is preferably adjusted so that the ignition loss of the glass fiber bundle is 0.5% to 2.0% by mass. Ignition loss can be measured in accordance with JIS R3420 (2013).

However, the fiber bundles that make up the warp threads 4 and weft threads 5 are not limited to glass fiber bundles, and may also be synthetic fiber bundles. Furthermore, the warp threads 4 and weft threads 5 may be made of the same fiber bundles as in this embodiment, or may be made of different fiber bundles. They may also be made of a combination of multiple fibers. For example, the warp threads 4 may be glass fiber bundles and the weft threads 5 may be synthetic fiber bundles. Alternatively, the warp threads 4 may be synthetic fiber bundles and the weft threads 5 may be glass fiber bundles. However, from the perspective of further increasing rigidity, it is preferable that at least one of the warp threads 4 and the weft threads 5 contains glass fiber bundles.

Examples of fibers that make up the synthetic fiber bundle include carbon fiber, aramid fiber, vinylon fiber, polyester fiber, and polyolefin fiber. These fibers may be used alone or in combination. Of these, carbon fiber, aramid fiber, vinylon fiber, and polyolefin fiber are preferred. From the perspective of further improving heat resistance, polyolefin fiber is preferably polypropylene fiber.

The count of the fiber bundles that make up the warp threads 4 and weft threads 5 is not particularly limited, but is preferably 100 tex or more and 3000 tex or less. If the count of the fiber bundles is within the above range, the rigidity of the resulting reinforcing mesh can be further increased.

Next, the obtained fiber bundles are used as warp yarns 4 and weft yarns 5 to form a plain weave. In this process, as shown in FIGS. 1 and 2, two warp yarns 4a and 4b are used to form a warp row 2, and one weft yarn 5 is used to form a weft row 3. Then, as shown in FIG. 2, a first heat-sealed yarn 6 is aligned so as to extend parallel to the warp yarns 4a and 4b , and entangled with the weft yarn 5. Furthermore, a second heat-sealed yarn 7 is entangled with the two warp yarns 4a and 4b that make up the warp yarns 4, so as to be wrapped around the warp yarns 4a and 4b in the direction of extension of the warp yarns 4, thereby forming the weaving fabric. In this manner, a mesh fabric 1 can be obtained. Note that the first heat-sealed yarn 6 and the second heat-sealed yarn 7 are omitted from FIG. 1.

It is preferable that the second heat-sealed yarn 7 be entangled at the intersection 8 of the warp yarns 4 and weft yarns 5 so that it moves from one main surface of the mesh fabric 1 to the other main surface, and from the other main surface of the mesh fabric 1 back to one main surface. This allows the second heat-sealed yarn 7 to be wound regularly around the warp yarns 4a, 4b, and increases the contact area between the weft yarn 5 and the second heat-sealed yarn 7, further improving the sealing strength of the warp and weft yarns.

The first heat-sealing yarn 6 and the second heat-sealing yarn 7 are yarns that fuse when heated. While it is sufficient to provide either the first heat-sealing yarn 6 or the second heat-sealing yarn 7, it is preferable to provide both. In this case, the amount of secondary binder required in subsequent processes can be further reduced.

The melting points of the first heat-sealing yarn 6 and the second heat-sealing yarn 7 are preferably 70°C or higher and 160°C or lower, respectively. If the melting points of the first heat-sealing yarn 6 and the second heat-sealing yarn 7 are above the lower limit mentioned above, sealing can be performed at a relatively low temperature. Furthermore, if the melting points of the first heat-sealing yarn 6 and the second heat-sealing yarn 7 are below the upper limit mentioned above, the flexibility of the mesh fabric 1 can be more reliably ensured.

The first heat-sealing yarn 6 and the second heat-sealing yarn 7 each contain thermoplastic resin fibers. The first heat-sealing yarn 6 and the second heat-sealing yarn 7 may be made of the same thermoplastic resin fibers, or may be made of different thermoplastic resin fibers.

Thermoplastic resin fibers can be made of, for example, polyester, polyamide, polyacrylonitrile, polyvinyl alcohol, polyolefin, etc. Among these, polyester, polyamide, or polyolefin is preferred because they have an even lower melting point. These resins may be used alone or in combination.

The counts of the first heat-sealing yarn 6 and the second heat-sealing yarn 7 are not particularly limited, but are preferably 10 dtex or more, more preferably 50 dtex or more, and preferably 600 dtex or less, more preferably 350 dtex or less. When the counts of the first heat-sealing yarn 6 and the second heat-sealing yarn 7 are within the above-mentioned ranges, the amount of secondary binder required in subsequent processes can be further reduced.

It is preferable that the second heat-sealing yarn 7 further contains inorganic fibers. While there are no particular limitations on the inorganic fibers, they are preferably fibers that do not melt at the heating temperature of the second heat-sealing yarn 7. Such inorganic fibers are not particularly limited, and examples include glass fibers, carbon fibers, and mineral fibers, with glass fibers being preferred. In this case, the sealing strength of the warp yarns 4 and weft yarns 5 can be further increased. Furthermore, inorganic fibers have a lower elongation (0.1% or more and 5% or less) than thermoplastic resin fibers, and are therefore more likely to become entangled with the warp yarns 4 and weft yarns 5.

In addition, when the second thermally fused yarn 7 also contains inorganic fibers, the inorganic fibers and thermoplastic resin fibers may be double-twisted yarns, or the inorganic fibers and thermoplastic resin fibers may simply be aligned.

Furthermore, the ratio of the thermoplastic resin fiber content to the inorganic fiber content in the second heat-sealing yarn 7 is preferably 3:7 to 7:3 by mass. In this case, the sealing strength of the warp yarns 4 and weft yarns 5 can be further improved.

The mesh fabric 1 may be woven so that the area of the openings 9 is, for example, 250 ^mm2 or more and 2500 ^mm2 or less. The maximum spacing between the warp rows 2 may be, for example, 20 mm or more and 60 mm or less. The maximum spacing between the weft rows 3 may be, for example, 20 mm or more and 60 mm or less. The thickness of the mesh fabric 1 is not particularly limited, but may be, for example, 0.2 mm or more and 1 mm or less.

<Crimping process>
Next, the mesh fabric 1 is subjected to a heat and pressure treatment to thermocompress the warp threads 4 and the weft threads 5 .

The heating and pressure treatment can be carried out using a hot press such as a hot roll press or a hot mold press. The hot press is preferably carried out at a temperature that does not soften the fiber bundles (warp threads 4 and weft threads 5) that make up the mesh fabric 1. Note that "a temperature that does not soften" refers to a temperature lower than the softening point for materials that have a softening point, and a temperature equal to or lower than the softening point for materials that do not have a softening point.

The temperature of the heat press varies depending on the type of material constituting the fiber bundle, but is preferably 80° C. or higher, more preferably 100° C. or higher, and preferably 250° C. or lower, more preferably 160° C. or lower. The pressure of the heat press is preferably 5 N/cm ² or higher, more preferably 7 N/cm ² or higher, and preferably 40 N/cm ² or lower, more preferably 15 N/cm ² or lower.

<Secondary binder coating process>
Next, a secondary binder is applied to the compressed mesh fabric 1 to obtain a reinforcing mesh. Examples of the secondary binder that can be used include acrylic resin, urethane resin, epoxy resin, vinyl acetate resin, urea resin, and PVC resin. One type of secondary binder may be used alone, or multiple types may be used in combination.

The glass transition temperature (Tg) of the secondary binder is not particularly limited, but is preferably -12°C or higher, more preferably -10°C or higher, and preferably 35°C or lower, more preferably 15°C or lower. In this case, curling can be made even less likely when the film is wound. It is preferable to use multiple types of compounds with different glass transition temperatures as the secondary binder.

The secondary binder is preferably applied so that the ignition loss of the resulting reinforcing mesh is 0.5% to 10.0% by mass. In this case, the flexibility of the resulting reinforcing mesh can be further increased, making it even less likely to curl. Furthermore, applying a small amount of secondary binder can prevent damage to the fibers themselves when the concrete is poured, and more reliably achieve the desired tensile strength.

The ignition loss of the secondary binder is preferably adjusted to be 1.0% by mass or more, more preferably 3.0% by mass or more, and preferably 8.0% by mass or less, more preferably 6.0% by mass or less. Ignition loss can be measured in accordance with JIS R3420 (2013).

In this embodiment, the first thermal fusion yarn 6 and the second thermal fusion yarn 7 are entangled with the warp yarns 4 and weft yarns 5 after weaving, followed by heating and pressure treatment. This increases the sealing strength of the warp yarns 4 and weft yarns 5, thereby improving mechanical strength. Furthermore, because the sealing strength of the warp yarns 4 and weft yarns 5 is increased, the amount of secondary binder required in subsequent processes can be reduced. This increases the flexibility of the resulting reinforcing mesh and reduces the likelihood of curling. Therefore, even when a uniaxially reinforced mesh with large openings 9 and high tensile strength per row is used, workability can be improved. Furthermore, applying a secondary binder can prevent damage to the fibers themselves during concrete pouring, achieving the desired tensile strength.

In addition, the first heat-sealed yarn 6 and the second heat-sealed yarn 7 may be entangled with the warp yarn 4 during weaving, and the first heat-sealed yarn 6 and the second heat-sealed yarn 7 may be entangled with the weft yarn 5 during weaving.

More specifically, the first heat-sealed yarn 6 may be entangled along at least one of the warp yarns 4 and weft yarns 5, and the second heat-sealed yarn 7 may be entangled with at least one of the warp yarns 4, weft yarns 5, and first heat-sealed yarn 6.

In the present invention, it is not necessary to provide either the first heat-sealing thread 6 or the second heat-sealing thread 7; it is sufficient to provide at least one heat-sealing thread. Even in this case, the effects of the present invention can be enjoyed.

Second Embodiment
FIG. 3 is a schematic plan view showing an enlarged portion of a mesh fabric used in a method for manufacturing a reinforcing mesh according to a second embodiment of the present invention.

In the manufacturing method of the second embodiment, in the mesh fabric forming step, as shown in Fig. 3, six warp threads 4a, 4b form one warp row 2 and one weft thread 5 forms one weft row 3 to weave the mesh fabric 21. Also, as shown in Fig. 3, the first heat-sealed yarn 6 is made to extend parallel to the warp threads 4a, 4b and entangled with the weft thread 5 , and then the warp threads 4a, 4b and the weft thread 5 are woven by plain weaving while the second heat-sealed yarn 7 is wound around and entangled with the warp threads 4a, 4b. Therefore, in this embodiment, the warp row 2 is formed by providing three pairs of warp threads 4a, 4b entangled with the second heat-sealed yarn 7. Other points are the same as those in the first embodiment.

In the second embodiment, the first heat-sealed yarn 6 and the second heat-sealed yarn 7 are entangled with the warp yarns 4 and the weft yarns 5 in weaving, and then the weft yarns are heated and pressurized. Therefore, the reinforcing mesh obtained is less likely to develop a curl when wound, has excellent workability, and is also excellent in mechanical strength.

Therefore, as in the second embodiment, the warp row 2 may be formed by providing multiple sets of warp threads 4a, 4b entangled with the second heat-sealed thread 7. In this way, by almost simultaneously weaving the warp threads 4a, 4b and the weft thread 5 and winding the second heat-sealed thread 7, the time required for the mesh fabric formation process can be shortened.

(Third embodiment)
FIG. 4 is a schematic plan view showing an enlarged portion of a mesh fabric used in a method for manufacturing a reinforcing mesh according to a third embodiment of the present invention.

In the manufacturing method of the third embodiment, in the mesh fabric forming step, as shown in Fig. 4, one warp thread 4 forms one warp row 2 and one weft thread 5 forms one weft row 3 to weave a mesh fabric 31. Also, as shown in Fig. 4, the first heat-sealed thread 6 extends parallel to the warp thread 4 and is entangled with the weft thread 5 , and the second heat-sealed thread 7 is entangled so as to be wound around the warp thread 4 to weave the mesh fabric. Other points are the same as those of the first embodiment.

In the third embodiment, the first heat-sealed yarn 6 and the second heat-sealed yarn 7 are entangled with the warp yarns 4 and the weft yarns 5 in weaving, and then the weft yarns are heated and pressurized. Therefore, the reinforcing mesh obtained is less likely to develop a curl when wound, has excellent workability, and is also excellent in mechanical strength.

Therefore, as in the third embodiment, the warp row 2 may be constructed by entangling a second heat-sealed thread 7 with one warp thread 4 and arranging a first heat-sealed thread 6 so that it extends parallel to the warp thread 4 .

(Fourth embodiment)
Fig. 5 is a schematic plan view showing a mesh fabric used in a manufacturing method of a reinforcing mesh according to a fourth embodiment of the present invention. Fig. 6 is a schematic plan view showing an enlarged portion of the mesh fabric used in the manufacturing method of a reinforcing mesh according to the fourth embodiment of the present invention.

In the fourth embodiment, in the mesh fabric forming process, glass fiber bundles prepared in the same manner as in the first embodiment are used, and a mesh fabric 41 is obtained by weaving using a leno weave, as shown in FIG. 5 . In this process, as shown in FIGS. 5 and 6 , first strands 44a and second strands 44b are intertwined to form warp threads 44, and weft threads 45 are woven into the warp threads 44. Also, as shown in FIG. 6 , a first heat-sealing yarn 46 is pulled along the first strand 44a and intertwined with the second strand 44b and the weft thread 45 , and a second heat-sealing yarn 47 is pulled along the second strand 44b and intertwined with the first strand 44a and the weft thread 45. The remaining aspects are the same as those of the first embodiment. Note that the first heat-sealing yarn 46 and the second heat-sealing yarn 47 are omitted from FIG. 5 .

In the fourth embodiment, the first heat-sealed yarn 46 and the second heat-sealed yarn 47 are entangled with the warp yarns 44 (first strands 44a and second strands 44b) and the weft yarns 45 after weaving, and are then subjected to heat and pressure treatment. Therefore, the reinforcing mesh obtained is less likely to develop a curl when wound, has excellent workability, and is also excellent in mechanical strength.

Therefore, as in the fourth embodiment, the mesh fabric 41 may be obtained by weaving using a leno weave. However, since this allows for an even larger surface area to be bonded using heat-sealing yarns, it is preferable to obtain the mesh fabric by weaving using a plain weave, as in the first to third embodiments.

[Reinforcing mesh wound body]
Fig. 7 is a schematic diagram showing a reinforcing mesh wound body according to one embodiment of the present invention, and Fig. 8 is a schematic plan view showing a reinforcing mesh constituting the reinforcing mesh wound body according to one embodiment of the present invention.

The reinforcing mesh wound body 10 shown in Figure 7 is formed by winding the reinforcing mesh 11 shown in Figure 8. The reinforcing mesh 11 can be manufactured, for example, by the reinforcing mesh manufacturing method of the present invention described above. Therefore, the reinforcing mesh 11 contains a secondary binder. Note that the reinforcing mesh 11 can be constructed using the materials described in the section on the reinforcing mesh manufacturing method, as appropriate. Note that the first heat-sealed yarn 6 and the second heat-sealed yarn 7 are omitted from Figure 8.

When the reinforcing mesh 11 of the reinforcing mesh roll 10 is cut out 500 mm in the winding direction and placed on a flat surface, the shortest distance connecting both ends of the reinforcing mesh 11 in the winding direction is 400 mm or more.

Specifically, as shown in Figure 9, when the reinforcing mesh 11 is placed on a flat surface 50, it is preferable that the distance L connecting both ends of the main surface 11a of the reinforcing mesh 11 on the flat surface 50 side in the winding direction X is 400 mm or more. In this case, when the reinforcing mesh 11 is wound, it is even less likely to develop a curl, further improving workability.

To further reduce the likelihood of curling when wound and to further improve workability, the distance L is more preferably 420 mm or more, and even more preferably 470 mm or more. However, the distance L may be as large as 500 mm.

The ignition loss of the reinforcing mesh 11 is preferably 0.5% by mass or more, more preferably 3.0% by mass or more, and preferably 10.0% by mass or less, more preferably 8.0% by mass or less, and even more preferably 6.0% by mass or less. If the ignition loss of the reinforcing mesh 11 is within the above-mentioned range, it is even less likely to become curled when wound, further improving workability. It can also further improve mechanical strength.

Furthermore, the maximum spacing W between the rows formed by the warp row 2 or the weft row 3 is preferably 20 mm or more, more preferably 25 mm or more, and preferably 60 mm or less, more preferably 55 mm or less. In this case, the workability of the reinforcing mesh 11 can be further improved.

The tensile strength of one row formed by the warp row 2 or the weft row 3 is preferably 800 N/row or more, more preferably 1000 N/row or more, and preferably 1500 N/row or less. In this case, the mechanical strength of the reinforcing mesh 11 can be further improved. The tensile strength can be measured in accordance with JIS L1015 (2010).

The reinforcing mesh wound body 10 of this embodiment can provide a reinforcing mesh 11 that is less likely to curl, has excellent workability, and has excellent mechanical strength.

Furthermore, the reinforcing mesh roll 10 and reinforcing mesh 11 are preferably embedded in concrete or mortar, and can be suitably used as cement reinforcing mesh.

The present invention will now be described in more detail based on specific examples. The present invention is not limited to the following examples, and can be modified and implemented as appropriate without departing from the spirit and scope of the invention.

Example 1
First, raw materials were _prepared to obtain glass having a composition of 58.6 mass% SiO ₂ , 17.3 mass% ZrO ₂ , 0.1 mass% Li ₂ O , 15.2 mass% Na ₂ O , 0.4 mass% K 2 O , 0.6 mass% CaO, 7.6 mass% TiO ₂ , and 0.2 mass% Al ₂ O _{3 ,} and the molten glass was drawn out as glass fiber monofilaments from a bushing having several hundred to several thousand nozzles.

Next, a sizing agent made by dispersing aminosilane, epoxy resin, and lubricant in water was applied to the surface of the obtained glass fiber monofilaments using an applicator, adjusted so that the loss on ignition was 0.7% by mass. After bundling the glass fibers, the sizing agent was dried to produce a glass fiber bundle.

Next, a mesh woven fabric having the structure shown in Fig. 11 was produced. Specifically, as shown in Fig. 6, a first strand 44a and a second strand 44b made of the glass fiber bundle obtained by the above method were intertwined to form warp threads 44, and three sets of these warp threads 44 were provided to form one warp row 2 shown in Fig. 11. Furthermore, one weft thread 45 was formed into one weft row 3 shown in Fig. 11, and this weft row 3 was woven into the warp row 2 by leno weaving. Note that, as shown in Fig. 6, a first heat-sealed yarn 46 was pulled along the first strand 44a and entangled with the second strand 44b and the weft thread 45 , and a second heat-sealed yarn 47 was pulled along the second strand 44b and entangled with the first strand 44a and the weft thread 45 to form the weaving.

The first heat-sealed yarn 46 and the second heat-sealed yarn 47 were made of heat-sealed nylon fiber (count: 330 dtex) as a thermoplastic resin fiber.

The count of the warp yarns 44 and weft yarns 45 was 1100 tex. The warp yarn density was 5.0 threads/inch, and the weft yarn density was 0.83 threads/inch. The number of heat-sealed yarns (warp heat-sealed yarns) in warp row 2 was 2 threads/row, and the number of heat-sealed yarns (weft heat-sealed yarns) in weft row 3 was 0 threads/row. The spacing a between the rows in warp row 2 and weft row 3 was 30 mm, and the width b of the mesh fabric was 210 mm.

Next, the obtained mesh fabric was hot-pressed with a heated roller at a temperature of 120°C and a pressure of 10 N/ ^cm2 for thermocompression bonding. The obtained mesh fabric was then immersed in a secondary binder. The secondary binder used was a mixture of an acrylic resin with a glass transition temperature of 14°C and an acrylic resin with a glass transition temperature of -10°C. After immersion, the mesh fabric was dried to obtain a reinforcing mesh. The secondary binder was applied so that the ignition loss of the reinforcing mesh was 3.0% by mass. The ignition loss was measured using the method described in JIS R3420 (2013). The basis weight of the obtained reinforcing mesh was 307 g/ ^m2 .

Example 2
In Example 2, a mesh fabric having the structure shown in Fig. 11 was produced using glass fiber bundles obtained in the same manner as in Example 1. Specifically, as shown in Fig. 3, three sets of warp threads 4 each consisting of two warp threads 4a and 4b were provided to form one warp thread row 2, and one weft thread 5 was provided to form one weft thread row 3, and the fabric was woven by plain weaving. Also, as shown in Fig. 3, a first heat-fusion yarn 6 was made to extend parallel to each of the warp threads 4a and 4b and be entangled with the weft thread 5 , and a second heat-fusion yarn 7 was made to be wound around each of the warp threads 4 and be entangled with it.

The first heat-sealing yarn 6 was a heat-sealing yarn (count: 330 dtex) made of nylon resin as a thermoplastic resin fiber. The second heat-sealing yarn 7 was a heat-sealing yarn (count: 555 dtex) containing 69% by mass of nylon resin as a thermoplastic resin fiber and 31% by mass of glass fiber as an inorganic fiber.

The number of heat-sealed yarns (warp heat-sealed yarns) in warp row 2 was three, and the number of heat-sealed yarns (weft heat-sealed yarns) in weft row 3 was zero. The secondary binder was applied so that the ignition loss of the reinforcing mesh was 2.0% by mass. A reinforcing mesh was obtained in the same manner as in Example 1 except for the above. The basis weight of the obtained reinforcing mesh was 298 g/ ^m² .

The count of the warp thread 4 and the count of the weft thread 5 are the same as the count of the warp thread 44 and the count of the weft thread 45 in Example 1.

Example 3
In Example 3, a mesh woven fabric having the structure shown in Fig. 12 was produced using glass fiber bundles obtained in the same manner as in Example 1. Specifically, as shown in Figs. 1 and 2, a warp row 2 was formed using warp threads 4 consisting of two warp threads 4a and 4b, and a weft row 3 was formed using one weft thread 5, and the fabric was woven by plain weaving. As shown in Fig. 2, the first heat-fusion yarns 6 were aligned so as to extend parallel to the warp threads 4a and 4b, and entangled with the weft thread 5 , and the second heat-fusion yarns 7 were entangled so as to be wrapped around the warp threads 4 constituting the warp row 2.

The first heat-sealing yarn 6 and the second heat-sealing yarn 7 were the same as the first heat-sealing yarn 6 and the second heat-sealing yarn 7 in Example 2.

The warp yarn 4 had a count of 155 tex, and the weft yarn 5 had a count of 320 tex. The warp yarn density was 10 yarns/inch, and the weft yarn density was 5 yarns/inch. The number of heat-sealed yarns (warp heat-sealed yarns) in warp row 2 was 3 yarns/row, and the number of heat-sealed yarns (weft heat-sealed yarns) in weft row 3 was 0 yarns/row. The spacing a between the rows in warp row 2 and weft row 3 was 5 mm, and the width of the mesh fabric was 210 mm. The secondary binder was applied so that the ignition loss of the reinforcing mesh was 5.0% by mass. A reinforcing mesh was obtained in the same manner as in Example 1, except for the above. The basis weight of the obtained reinforcing mesh was 135 g/ ^m² .

Example 4
In Example 4, a mesh fabric having the structure shown in Fig. 13 was produced using glass fiber bundles obtained in the same manner as in Example 1. Specifically, as shown in Fig. 4, one warp thread 4 was used as one warp thread row 2, and one weft thread 5 was used as one weft thread row 3, and the fabric was woven by plain weaving. Also, as shown in Fig. 4, the first heat-fusion yarns 6 were aligned so as to extend parallel to the warp threads 4 and entangled with the weft threads 5 , and the second heat-fusion yarns 7 were entangled so as to be wrapped around the warp threads 4, and the fabric was woven.

The first heat-sealing yarn 6 and the second heat-sealing yarn 7 were the same as the first heat-sealing yarn 6 and the second heat-sealing yarn 7 in Example 2.

The warp yarns 4 and weft yarns 5 had a count of 320 tex. The warp yarn density and weft yarn density were 5 yarns/inch. The number of heat-sealed yarns (warp heat-sealed yarns) in warp row 2 was 2 yarns/row, and the number of heat-sealed yarns (weft heat-sealed yarns) in weft row 3 was 0 yarns/row. The spacing a between the rows in warp row 2 and weft row 3 was 5 mm, and the width of the mesh fabric was 210 mm. The secondary binder was applied so that the ignition loss of the reinforcing mesh was 4.0% by mass. A reinforcing mesh was obtained in the same manner as in Example 1 except for the above. The basis weight of the obtained reinforcing mesh was 130 g/ ^m2 .

Example 5
In Example 5, a mesh woven fabric having the structure shown in Fig. 12 was produced using glass fiber bundles obtained in the same manner as in Example 1. Specifically, as shown in Figs. 1 and 2, a warp row 2 was formed using two warp threads 4a and 4b, and a weft row 3 was formed using one weft thread 5, and the fabric was woven by plain weaving. As shown in Fig. 2, the first heat-fusion yarns 6 were aligned so as to extend parallel to the warp threads 4a and 4b, and entangled with the weft thread 5 , and the second heat-fusion yarns 7 were entangled so as to be wrapped around the warp threads 4 constituting the warp row 2.

The first heat-sealing yarn 6 and the second heat-sealing yarn 7 were the same as the first heat-sealing yarn 6 and the second heat-sealing yarn 7 in Example 2.

The warp yarn 4 had a count of 640 tex. The weft yarn 5 had a count of 1400 tex. The warp yarn density was 2.4 yarns/inch. The weft yarn density was 1.2 yarns/inch. The number of heat-sealed yarns (warp heat-sealed yarns) in warp row 2 was 3 yarns/row, and the number of heat-sealed yarns (weft heat-sealed yarns) in weft row 3 was 1 yarn/row. The spacing a between the rows in warp row 2 and weft row 3 was 20 mm, and the width of the mesh fabric was 210 mm. The secondary binder was applied so that the ignition loss of the reinforcing mesh was 8.0% by mass. A reinforcing mesh was obtained in the same manner as in Example 1 except for the above. The basis weight of the obtained reinforcing mesh was 132 g/ ^m² .

(Comparative Example 1)
In Comparative Example 1, a mesh fabric 71 shown in Fig. 14 was produced using glass fiber bundles obtained in the same manner as in Example 1. Specifically, a single warp thread 74 was used as one warp row, and a single weft thread 75 was used as one weft row, and the fabric was woven by plain weaving. Furthermore, as shown in Fig. 14, cotton thread 76 was entangled around the warp thread 74.

The warp density was 2.25 threads/inch and the weft density was 1.88 threads/inch. The spacing between the warp and weft rows was 11 mm x 13 mm, and the width of the mesh fabric was 210 mm. The secondary binder was applied so that the ignition loss of the reinforcing mesh was 21.0 mass%. In Comparative Example 1, no heating or pressure treatment was performed. Otherwise, a reinforcing mesh was obtained in the same manner as in Example 1. The basis weight of the obtained reinforcing mesh was 220 g/ ^m2 .

(Comparative Example 2)
In Comparative Example 2, a mesh fabric 81 shown in Fig. 15 was produced using glass fiber bundles obtained in the same manner as in Example 1. Specifically, a plain weave was used to weave the fabric, with three warp threads 84 forming one warp row and one weft thread 85 forming one weft row. Furthermore, as shown in Fig. 15, cotton threads 86 were entangled and wound around each warp thread 84.

The warp density was 5.0 threads/inch, and the weft density was 0.83 threads/inch. The spacing between the warp and weft rows was 30 mm, and the width of the mesh fabric was 210 mm. The secondary binder was applied so that the ignition loss of the reinforcing mesh was 20.0 mass%. In Comparative Example 2, no heating or pressure treatment was performed. Otherwise, a reinforcing mesh was obtained in the same manner as in Example 1. The basis weight of the obtained reinforcing mesh was 332 g/ ^m2 .

(Comparative Example 3)
In Comparative Example 3, a mesh fabric 91 shown in Fig. 16 was produced using glass fiber bundles obtained in the same manner as in Example 1. Specifically, a first strand 94a and a second strand 94b made of the glass fiber bundles obtained as described above were entangled to form warp threads 94, and a weft thread 95 made of the glass fiber bundles obtained as described above was woven into the warp threads 94 by leno weaving. In addition, no thermally fused yarns or cotton yarns were used.

The warp yarn 94 had a count of 155 tex, and the weft yarn 95 had a count of 320 tex. The warp yarn density was 10 yarns/inch, and the weft yarn density was 5 yarns/inch. The spacing between the warp and weft yarn rows was 5 mm, and the width of the mesh fabric was 210 mm. The secondary binder was applied so that the ignition loss of the reinforcing mesh was 20.0 mass%. In Comparative Example 3, no heating or pressure treatment was performed. A reinforcing mesh was obtained in the same manner as in Example 1 except for the above. The basis weight of the obtained reinforcing mesh was 153 g/ ^m2 .

(Comparative Example 4)
In Comparative Example 4, a reinforcing mesh was obtained in the same manner as in Comparative Example 3, except that a secondary binder was applied so that the ignition loss of the reinforcing mesh was 8.7% by mass. The basis weight of the obtained reinforcing mesh was 137 g/ ^m2 .

[evaluation]
(Evaluation of tensile strength)
The tensile strength of one row composed of warp yarns and weft yarns (one row of warp yarns and one row of weft yarns) was measured for each of the reinforcing meshes obtained in Examples 1 to 5 and Comparative Examples 1 to 4. The tensile strength was measured in accordance with JIS L1015 (2010).

(Evaluation of curling tendency)
The reinforcing meshes obtained in Examples 1 to 5 and Comparative Examples 1 to 4 were wound to a diameter of 150 mm to obtain mesh wound bodies. The obtained reinforcing mesh wound bodies were stored at 40°C for one month. A piece 200 mm wide and 500 mm long was cut out from the outer layer of the stored reinforcing mesh wound body. The cut-out sample was designated the reinforcing mesh 11 shown in Figure 9 and placed on a flat surface 50. After placement, the distance L connecting both ends of the main surface 11a of the reinforcing mesh 11 on the flat surface 50 side in the winding direction X was measured.

(Evaluation of sealing strength)
From the reinforcing meshes obtained in Examples 1 to 5 and Comparative Examples 1 to 4, pieces were cut out so as to include intersections 8 of the warp row 2 and the weft row 3 as shown in FIG. 10 , and the warp row 2 and the weft row 3 were fixed to a backing paper 60 with an adhesive 61, and the adhesive strength at the intersections 8 was measured.

The results are shown in Table 1 below.

As is clear from Table 1, the reinforcing mesh of Examples 1 to 5 was confirmed to be less prone to curling and to have superior workability compared to Comparative Examples 1 to 4. It was also confirmed that the reinforcing mesh of Examples 1 to 5 also had high sealing strength. Furthermore, when Examples 1 and 2 were compared with Comparative Example 2, which had approximately the same warp count and density, weft count and density, and basis weight, Examples 1 and 2 had higher tensile strength than Comparative Example 2. Furthermore, when Example 3 was compared with Comparative Example 3, which had approximately the same warp count and density, weft count and density, and basis weight, Example 3 had higher tensile strength.

DESCRIPTION OF SYMBOLS 1, 21, 31, 41...Mesh fabric 2...Warp row 3...Weft row 4, 4a, 4b, 44...Warp threads 5, 45...Weft threads 6, 46...First heat-sealed yarns 7, 47...Second heat-sealed yarns 8...Intersection points 9...Openings 10...Reinforcing mesh wound body 11...Reinforcing mesh 11a...Main surface 44a...First strand 44b...Second strand 50...Flat surface 60...Backing paper 61...Adhesive

Claims (5)

A method for manufacturing a biaxial reinforcing mesh composed of warp yarns and weft yarns,
A step of weaving a mesh fabric by entangling a heat-sealing yarn containing a thermoplastic resin fiber with at least one of a warp yarn and a weft yarn;
a step of heating and pressurizing the mesh fabric to crimp the warp and weft yarns;
Applying a secondary binder to the compressed mesh fabric to obtain a reinforcing mesh;
Equipped with
In the step of obtaining the mesh fabric,
a first heat-sealing yarn containing a first thermoplastic resin fiber is arranged so as to extend along at least one of the warp yarns and the weft yarns;
A method for manufacturing a reinforcing mesh, comprising weaving a second heat-sealed yarn containing a second thermoplastic resin fiber by wrapping it around at least one of the warp yarn, the weft yarn, and the first heat- sealed yarn to entangle them. In the step of obtaining the reinforcing mesh,
The method for producing a reinforcing mesh according to claim 1, wherein the secondary binder is applied so that the ignition loss of the reinforcing mesh is 0.5% by mass to 10.0% by mass. The method for producing a reinforcing mesh according to claim 1 or 2 , wherein the second thermal adhesive yarn further contains inorganic fibers. 4. The method for manufacturing a reinforcing mesh according to claim 3 , wherein the ratio of the content of the second thermoplastic resin fiber to the content of the inorganic fiber in the second heat-fused yarn is 3:7 to 7:3 by mass. In the step of obtaining the mesh fabric,
The warp and weft yarns are woven by plain weaving,
5. A method for manufacturing a reinforcing mesh according to claim 1, wherein at the intersection of the warp and weft threads, the second heat-sealed yarn is entangled from one main surface of the mesh fabric toward the other main surface, and from the other main surface of the mesh fabric back to the one main surface.