JP2000318071A - Frp material and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture an FRP material having a low facility cost without impairing mechanical characteristics of a molding without dust and noise by forming a folding pattern at least on one side surface of the molding made of a fiber-reinforced composite material. SOLUTION: The FRP material 1 is a lengthy solid flat plate strip-like molding in an entirety, and is used mainly as a reinforcing material of a concrete structure. Here, the material 1 is formed with an interstice pattern made of a layer of a thermosetting resin cured material on a surface of a molding 3 of the FRP material made of reinforcing fibers 3a and a resin cured material 3b. The interstice pattern is formed on a surface of a resin or the like when a woven fabric is press bonded to a resin or the-like having flowability as a casting mold, and, after the resin or the like is cured, the pattern formed on the surface of the resin or the like is formed when the fabric is released. That is, a cloth 2' is laminated and cured on the surface of the molding 3, and the molding 3 is supplied to a job site in this state as it is, then the cloth 2' is released from the molding 3 immediately before execution, and used as the material 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an FRP material and a method of manufacturing the same, and more particularly, to an FRP material for enhancing the bonding efficiency between the FRP material and concrete in reinforcing a building, particularly in repairing / reinforcing a structure such as concrete. Is relatively easily manufactured.

[0002]

2. Description of the Related Art In the field of civil engineering and construction, as a construction method for reinforcing a building or repairing / reinforcing a concrete structure, a resin or an adhesive has conventionally been applied to a fabric made of reinforcing fibers such as carbon fiber, glass fiber, or aramid fiber. A method of applying a plurality of sheets while applying the same is performed. According to this method, when attaching a woven fabric coated with a resin or an adhesive to the repair / reinforcement portion, the woven fabric drips before the adhesive is hardened by its own weight, and thus it is difficult to perform the construction. In addition, since a plurality of sheets are required to be applied to enhance the reinforcing effect, a long time was required for construction. Further, when the repairing / reinforcing portion is a ceiling portion, the resin or adhesive impregnating the woven fabric drips onto the worker's body, causing a problem in health and safety. From these facts, in recent years, in order to enhance the working efficiency, a method of attaching and using a highly viscous adhesive to FRP material having good handleability instead of the above-mentioned application method has been adopted. Since such an FRP material is used in a long flat band-shaped molded product (hereinafter abbreviated as a molded product), it is generally manufactured by a pultrusion molding method. However, FRP molded with these
Since the surface of the material is covered with a resin rich layer, it is generally smooth and glossy. The molded body used for repair / reinforcement in the civil engineering and construction fields is designed to increase the surface area of the bonding surface to increase the bonding efficiency with concrete and enhance the anchoring effect. A blast processing method in which the cleaning material is sprayed from the injection nozzle to the bonding surface of the molded body together with the compressed air to create an uneven surface, or a liquid that forms fine irregularities by injecting fine abrasive grains together with the liquid from the injection nozzle onto the bonding surface of the molded body The honing method is common. In the blasting method using a sand blasting machine, an abrasive material is sprayed on a hardened molded body to form an uneven surface, so that generation of dust is inevitable, noise of an injection nozzle and a dust collector is large, and equipment is expensive. There are drawbacks.
In addition, when the injection pressure or the forming speed is changed, the formed body itself is extremely severely shaved, failing to maintain the thickness accuracy, and lowering the mechanical strength of the FRP material. In addition, because the particle size of the abrasive material becomes fine, it is necessary to introduce a new abrasive material at approximately regular intervals, and the life of the injection nozzle and the abrasive material supply hose is relatively short.
There is a drawback that the running cost is high because it needs to be updated periodically.

Also, in the liquid honing method, since fine abrasive grains are sprayed on a hardened molded product to form an uneven surface, chips mixed with the liquid must be continuously separated, and the noise of the injection nozzle is also reduced. It is rather large and has the disadvantage of expensive equipment. Also, since the particle size of the fine abrasive particles is small, a certain amount of new abrasive particles must be constantly mixed into the liquid, and furthermore, it is necessary to separate the chips mixed with the liquid, so that the running cost is considerably high. There is a disadvantage that.

[0004]

SUMMARY OF THE INVENTION An object of the present invention has been made in view of the above-mentioned problems, and does not generate dust or noise, does not impair the mechanical properties of a molded product, and reduces equipment costs. An object of the present invention is to provide an FRP material having an uneven surface using a manufacturing method that is inexpensive and does not require running costs, and a manufacturing method for manufacturing the same material relatively easily.

[0005]

According to the present invention, there is provided an FRP material characterized in that a textured pattern is formed on at least one surface of a molded article made of a fiber-reinforced composite material. FR wherein a fabric is coated on at least one surface of a molded body made of a fiber-reinforced composite material, and the fabric is peeled off at the time of construction and used.
P material is provided. Further, such FRP materials are particularly provided as repair / reinforcement building members for building structures. According to the present invention, as a method for producing the FRP material, a plurality of continuously reinforced fiber bundles are impregnated with a thermosetting resin, and a fabric is stuck on at least one side and heat-cured or cured in a mold. After the fabric is semi-cured, the fabric is peeled off to form a textured pattern (hereinafter referred to as "manufacturing method 1"), or at least one surface of a molded body made of a fiber-reinforced composite material is uncured. A method for producing an FRP material (hereinafter referred to as production method 2), which comprises applying a conductive resin, laminating the cloth and heat-curing or semi-curing and then peeling the cloth. Further, in the present invention, the surface of a molded body obtained by impregnating a plurality of continuously reinforced fiber bundles with a thermosetting resin, laminating a cloth on at least one surface, and performing heat curing or semi-curing in a mold. Characterized by being coated with a fabric
An uncured thermosetting resin is impregnated on at least one surface of a molded body made of a RP material manufacturing method (hereinafter referred to as manufacturing method 3) or a fiber-reinforced composite material, and the cloth is bonded and heat-cured or semi-cured. A method for producing an FRP reinforcing material, characterized in that the surface of a molded article is covered with a cloth (hereinafter referred to as production method 4).

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below with reference to the drawings.

FIGS. 1 and 2 show an example of the FRP material 1 of the present invention. The FRP material 1 is a long, solid, plate-like band-shaped molded body which is used as a reinforcing material for repair / reinforcement of civil engineering, mainly concrete structures. The FRP material 1 is composed of a molded body 3 of an FRP material composed of a reinforcing fiber 3a and a cured resin 3b, and a texture pattern 4 formed of a layer of a cured thermosetting resin on the surface of the molded body. The weave pattern in the present invention means that the woven fabric is used as a mold to perform pressure bonding or the like on a resin having fluidity, and the resin surface is removed when the woven fabric is peeled off when the resin is in a cured or semi-cured state. It is a pattern that can be formed in That is, the above steps are only given for convenience in defining the shape of the texture pattern of the present invention, and as a result, even if the shape is essentially the same, the method of forming the texture pattern of the present invention is as follows. It is not limited to a process. For the sake of simplicity, for the texture pattern of the present invention, the virtual fabric shape will be described assuming that the shape of the original fabric is supposed to be completely transferred to a molded body. Accordingly, the shape of the texture pattern of the present invention will be described in detail. Therefore, for example, a warp or a weft corresponds to a vertical or horizontal groove on the surface of a molded product, and the fiber diameter corresponds to the diameter of the groove. The texture pattern 4 has a surface roughness (Ra) of 10 to improve the adhesive strength with concrete when used as a reinforcing material for a concrete structure.
It is more preferably in the range of 120 μm and 30 to 70 μm. For the same reason, the warp and / or weft weave density is 1
The number is preferably 10 to 50 per cm, more preferably 20 to 50 per cm. Further, the fiber diameter is preferably 10 to 100 μm. This is because if the value is below the lower limit of this range, the surface roughness becomes small, and if the value exceeds the upper limit, the surface roughness becomes too large and the fiber on the surface of the molded product is bent. More preferably, it is 30 to 70 μm. When the cross section is a non-circular shape such as an ellipse, the fiber diameter is converted to a perfect circle to obtain the fiber diameter. At this time, the product of the weaving density (book / cm) and the fiber diameter (cm) should be 0.2 to 0.6 so as not to be too clogged and not too empty in relation to the weaving density. Is preferred.

[0008] As another supply form of the FRP material 1, FIG.
The cloth 2 'is bonded to the surface of the molded body 3 as shown in FIG. 1 and supplied in a hardened state, and the cloth 2' is peeled off from the molded body 3 immediately before construction at the site and used similarly as the FRP material 1. Is what you do.

The features of these two types of FRP materials 1 and 1 'are as follows.
Normally, when repairing / reinforcing concrete, dust is generated to grind the repair / reinforcement part of the concrete with a grinder etc. at the time of construction to obtain the reinforcing effect, and the dust adheres to the FRP material , The former FRP
The material 1 needs to be cleaned at the time of construction to remove the dust and dirt from the adhesive surface of the FRP material 1. However, the latter FRP material 1 ' This is effective because it becomes a covering material and the wiping step can be omitted. The FRP materials 1 and 1 ′ shown in FIGS. 1 and 2 can be manufactured by the manufacturing method 1 and the manufacturing method 2. First, the manufacturing method 1 will be described with reference to FIG. In the production line shown in FIG. 3, the uncured liquid thermosetting resin 7 and the bobbins 5a, 5b, 5c around which the strand-shaped reinforcing fibers are wound.
Tank 8 for accommodating the resin, a guide 9, a delivery bobbin 11 for delivering the fabric 2, a heating die 12, a bobbin 13 for peeling and winding the fabric 2 ′ after the thermosetting resin is cured, a take-up device 14, and a winding roll 15 are arranged in series in this order, so that the fiber bundle 6 runs continuously on this line. First, a plurality of reinforcing fiber bundles unwound from the bobbins 5a, 5b, 5c are bundled to be a thicker fiber bundle 6 and immersed in the thermosetting resin 7 of the resin tank 8. The impregnated fiber bundle 6 was then passed through a guide 9 to remove excess resin and the like adhering to the surface and shaped into a desired cross-sectional shape, and then sent out from the entire surface to a bobbin 11. The cloth 2 is bonded to the heating die 12 while being adhered to the heating die 12 while being taken up by the take-up device 14 and hardened while passing through the die. Thereafter, the cured fabric 2 ′ is peeled immediately after leaving the die 12 and wound up on a winding bobbin 13 to form a texture pattern 4 on the surface of the FRP material. Examples of the fibers used for the fabric 2 include organic fibers such as polyester fibers, polyamide fibers, aramid fibers, and vinylon fibers, and inorganic fibers such as glass fibers and boron fibers. When an organic fiber is used, it is necessary to have heat resistance at a temperature higher than the curing temperature of the thermosetting resin to be used. This is because the organic fibers are softened when the resin is cured, and a texture pattern cannot be formed on the surface of the FRP material. Further, the kind of the cloth may be any of a woven cloth, a knitted cloth, a net cloth and the like, but a woven cloth is preferable from the molding surface. The weave structure may be any of plain weave, satin weave, and twill weave, and plain weave is preferred from the viewpoint of molding stability. It is also effective to use a woven fabric that has been perforated in order to prevent misalignment of the woven fabric being formed. It is also effective in preventing damage to the texture pattern.

The surface roughness (Ra) of the woven fabric is 10 to 1
It is more preferably in the range of 20 μm and 30 to 70 μm. When the thickness is less than 10 μm, the texture is too small, and when it is more than 120 μm, the texture is too large to obtain a sufficient adhesive strength.

Further, as described above, the weaving density of the woven fabric is such that the number of warp yarns and / or weft yarns is 10 to 10 yarns / cm.
It is preferably in the range of 50, but more preferably from 20 to 50 in view of the strength of the woven fabric at the time of molding, molding stability, adhesion efficiency and the like. If a woven fabric having a warp density of less than 10 yarns / cm is used, the strength of the woven fabric itself may be reduced and the woven fabric may be broken at the time of release, and the distribution density of the weave pattern 4 formed on the surface of the FRP material may be reduced, and the bonding efficiency may be reduced. This is not preferred from the viewpoint of Further, when the number is 50 / cm or more, the texture pattern 4 formed on the surface of the FRP material 1 becomes too large, and the adhesive strength is reduced. Further, the fiber diameter is preferably 30 to 70 μm. The reason is that if the value is below the lower limit of this range, the surface roughness becomes small, and if the value exceeds the upper limit, the surface roughness becomes too large. More preferably 30
７０70 μm. When the cross section is a non-circular shape such as an ellipse, the fiber diameter is converted to a perfect circle to obtain the fiber diameter. Also,
At this time, in relation to the weaving density, the weaving density (books / cm) and the fiber diameter (cm) so that the eyes are not too clogged or too empty.
Is preferably 0.2 to 0.6.

It is sufficient that these weave characteristics are satisfied even on the side on which the molded body is coated. Therefore,
The texture of the other side of the fabric may be different.

The reinforcing fibers used as the fiber bundle here include, for example, carbon fiber, glass fiber, alumina fiber,
Fibers having high strength / high elastic modulus, such as inorganic fibers such as boron fibers and organic fibers such as aramid fibers, are arranged in one direction. Among them, carbon fiber is most preferable because of its high specific strength and specific elastic modulus.
Examples of the thermosetting resin impregnated in the fiber bundle 6 include an epoxy resin, an unsaturated polyester resin, a vinyl ester resin, and a phenol resin. Among them, vinyl ester resins and epoxy resins are most preferable because of weather resistance and adhesive performance. Of course, in a use environment, a thermoplastic resin or the like may be used in addition to the thermosetting resin. The F thus manufactured
Fiber volume content of reinforcing fiber of RP material 1 'is 40 to 80%
Is preferable. When the content is 40% or less, the material strength of the reinforcing fiber cannot be effectively exhibited. When the content is 80% or more, the reinforcing fiber moves up and down while passing through the die and bends. This is because the tensile strength decreases.

Next, a manufacturing method 2 will be described with reference to FIG.
In this production method, the above-mentioned production method 1 is carried out in two stages. First, a fiber-reinforced composite material 3 composed of a reinforcing fiber and a resin is produced in substantially the same manner as production method 1 (a fabric line is produced by a production line in FIG. 3). 2), and then the uncured thermosetting resin 1 obtained by adding a curing agent to the surface of the fiber-reinforced composite material 3
In this method, the cloth 2 ′ is applied to the fiber reinforced composite material 3 by peeling the cloth 2 ′ after applying the cloth 2 and curing it while passing it through the curing furnace 17 again while applying pressure.
In the manufacturing method 1, since the fiber bundle 6 and the fabric 2 are simultaneously cured in the heating die, the reinforcing fibers of the outermost layer bend along the texture pattern of the fabric (roughly, approximately half the diameter of the woven fiber). Therefore, the mechanical properties of the FRP material 1 decrease, but in the manufacturing method 2, since the reinforcing fibers form a composite material in the first stage, the FRP materials 1 having excellent mechanical properties without fear of bending of the reinforcing fibers. Can be manufactured. Next, Production Method 3 and Production Method 4 will be described. The production line of this production method is obtained by removing the winding bobbin 13 from the production lines of production methods 1 and 2 shown in FIGS. 3 and 4, and after being cured while passing through a heating die, the fabric 2 'is peeled off. It is manufactured without coating. FR manufactured in this manner
The P material 1 ′ is transported to the construction site while the fabric 2 is attached to the fiber-reinforced composite material 3, so that the texture pattern may be scraped off during transportation and adhesion inhibitors such as oil adhere to the P material 1 ′. There is no fear, and cloth 2 'until just before construction
Since it is covered with, there is an advantage that dust and the like do not adhere to the bonding surface and the wiping step before construction can be omitted.

[0015]

Example 1 In a production line of production method 1 shown in FIG. 3, a fiber bundle 6 composed of 38 carbon fibers ("Treca"T700SC-24K-60E; manufactured by Toray Industries, Ltd.) was treated with a curing agent and a curing accelerator. After immersing continuously in a thermosetting resin 7 containing an internal release agent added to an epoxy resin (manufactured by Yuka Shell Epoxy Co., Ltd.), a thickness of 0.1 mm, a width of 50 mm and a weaving density of 1 cm Length / width = 40 pieces / 40 pieces of polyester woven fabric was stuck into the die 12 heated to 180 ° C. and introduced at a speed of 0.6 m / min with the take-off device 14, and after curing, immediately after leaving the die 12. The polyester fabric was peeled off to form a solid FRP material having a fiber content of 67%. The surface roughness of the formed FRP material was measured with a surface roughness meter. The surface roughness (Ra) was 6 to 7 μm in both the vertical direction (length direction) and the horizontal direction (width direction). The adhesive strength was measured using this FRP material. The adhesive used was a two-part epoxy adhesive used for concrete application, and was pressed at a temperature of 15 to 18 ° C. and a surface pressure of 5 kgf /
Bonded in cm ² . The test pieces thus prepared were cured at room temperature for 3 days and then measured with a tensile tester. The adhesive strength is 210-220 Kgf / cm ² , and the fracture state is FRP
It was a mixed failure of the material and the adhesive. As a result of evaluating the material strength of the molded FRP material, the tensile strength of the FRP material was 265 k.
gf / mm ² . [Comparative Example 1] This comparative example is an example manufactured without using the fabric 2 of the present invention, except that the fabric 2 and the delivery guide 11 and the winding guide 13 in FIG. did. The surface of the molded FRP material was covered with a resin-rich layer and had a smooth and glossy appearance. As a result of measuring the surface roughness (Ra), it was 0.9 to 0.9 in both the vertical and horizontal directions.
It was 1 μm. In addition, as a result of evaluating the adhesive strength under the same conditions as in Example 1, the adhesive strength was as low as 120 to 160 kgf / cm ² ,
The breaking state was an interface breaking between the adhesive and the FRP material. Example 2 The material strength of the FRP material manufactured by the manufacturing method 2 shown in FIG. 4 was measured. This production method was the same as Example 1 except that the resin composition used for molding and the production conditions at the time of molding were changed, except that the method of attaching the polyester fabric for forming the texture pattern was changed to Production Method 2. The same amount of epoxy resin as in the example was used as the uncured resin, and the coating amount was 70 g /
m ² . As a result of evaluating the material strength of the formed FRP material, the tensile strength of the FRP material was 278 kgf / mm ² . Example 3 After curing under the same manufacturing conditions using the same polyester fabric and resin as in Example 1, the polyester fabric was molded without peeling at the high temperature at the exit of the heating die.
After leaving the molded FRP material 1 'at room temperature for 10 days and peeling it off at room temperature, the fabric base material is not broken and regular.
A "textured pattern" was obtained on the surface of the FRP material.
As a result of molding using a woven fabric substrate which had been preliminarily immersed in a silicone solution and released from a silicone solution, the releasability of the untreated substrate was better than that of the untreated substrate.

[0016]

As described above, according to the present invention,
When a texture pattern is applied to at least one surface of the FRP material, the fabric is attached and molded simultaneously at the time of molding, and then the fabric is peeled off and a texture pattern is applied, or the fabric is attached to the surface of the fiber-reinforced composite material. Therefore, no dust or noise is produced during molding, and there is no change in surface roughness which affects the adhesion efficiency, and the molding cost can be reduced.

[Brief description of the drawings]

FIG. 1 is a schematic perspective view of a textured FRP material of the present invention.

FIG. 2 is a schematic perspective view of an FRP material to which the cloth of the present invention is attached.

FIG. 3 is a schematic diagram showing an example of a production line for implementing the present invention.

FIG. 4 is a schematic diagram showing an example of another production line for implementing the present invention.

[Explanation of symbols]

 1, 1 ': FRP material 2, 2': cloth 3: fiber reinforced composite material 3a: reinforcing fiber 3b: cured resin 4: weave pattern 5a: bobbin 5b: bobbin 5c: bobbin 6: fiber bundle 7: thermosetting resin 8: Impregnation tank 9: Guide 11: Unwinding bobbin 12: Heating die 13: Winding bobbin 14: Take-up machine 15: Winding roll 16: Uncured resin 17: Curing furnace

 ──────────────────────────────────────────────────の Continuing on the front page F term (reference) 4F100 AA37A AG00A AK01A AK41 AK47A AK53 BA01 BA02 BA03 BA06 BA10B BA10C BA13 CA02 DD07A DD07B DD07C DG01A DG11B DG11C DH02A EA02 EH012 EH462 JEJB00JJB00A

Claims (11)

[Claims] An FRP material characterized in that a textured pattern is formed on at least one surface of a long molded body made of a fiber reinforced composite material. 2. An FRP material characterized in that at least one surface of a long molded body made of a fiber-reinforced composite material is covered with a fabric. 3. The FRP according to claim 1, wherein the textured pattern of the FRP or the surface roughness (Ra) of the surface on the coating side of the fabric is 10 to 100 μm.
Wood. 4. A warp and / or weft weave density of 1 cm on the textured pattern of the FRP or the surface on the coated side of the fabric.
The FRP material according to any one of claims 1 to 3, wherein the FRP material is in a range of 10 to 50 pieces. 5. The FRP material according to claim 1, wherein the fiber used for the reinforced composite material is made of carbon fiber, glass fiber or aramid fiber. 6. The fiber volume content of the reinforced composite material is 40.
The FRP material according to any one of claims 1 to 5, wherein the FRP material is 80% to 80%. 7. The FRP material according to claim 1, wherein the FRP material is attached to a building structure as a building reinforcing member. 8. A plurality of reinforcing fiber bundles which are continuously fed are impregnated with a thermosetting resin, and a fabric is stuck on at least one surface and cured or semi-cured in a mold, and then the fabric is peeled. A method for producing an FRP material. 9. An uncured thermosetting resin is applied to at least one surface of a long molded body made of a fiber-reinforced composite material, and the fabric is bonded and heat-cured or semi-cured, and then the fabric is peeled off. A method for producing an FRP material. 10. A method comprising impregnating a plurality of reinforced fiber bundles continuously fed with a thermosetting resin, laminating a cloth on at least one side, and heat-curing or semi-curing in a mold. Manufacturing method of FRP material. 11. An FRP, wherein an uncured thermosetting resin is applied to at least one surface of a long molded body made of a fiber-reinforced composite material, and the cloth is bonded and heat-cured or semi-cured. The method of manufacturing the material.