JP2001329466A - Reinforcing fiber fabric, fiber-reinforced sheet, molded form, reinforced sheet for waterproofing work and corrugated board and method for producing the reinforcing fiber fabric - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reinforcing fiber fabric having excellent reinforcing effect through making the best use of properties including high mechanical strength and high modulus inherent in the reinforcing fiber, to provide a fiber- reinforced sheet, a molded form, a reinforced sheet for waterproofing work and a corrugated board each using the above reinforcing fiber fabric, and to provide a method for producing the above reinforcing fiber fabric. SOLUTION: This reinforcing fiber fabric to be used as a reinforcing material is characterized by that the weave construction is not leno weave one, the respective densities of warp and weft are <=11/25 mm, the porosity is 40-98%, the yarn slippage is <=50%, and a filling treatment has been made using a resin. The 2nd objective fiber-reinforced sheet, the 3rd objective molded form, the 4th objective reinforced sheet for waterproofing work, and 5th objective corrugated board each using the above reinforcing fiber fabric as a reinforcing material are provided. The 6th objective method for producing the above reinforcing fiber fabric is also provided.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reinforced fiber fabric, and more particularly, to a base fabric for various kinds of laminate coating, fiber reinforced resin (FRP), and fiber reinforced metal (FR).
M), fiber reinforced ceramics (FRC), fiber reinforced concrete, fiber reinforced fabric suitable as a reinforcement material used for fiber reinforced asphalt, and the like, and fiber reinforced sheet, molded body, and waterproofing reinforcement using the same as a reinforcing material The present invention relates to a method for producing a sheet, a corrugated sheet, and a reinforcing fiber fabric.

[0002]

2. Description of the Related Art High strength, such as glass fiber or carbon fiber,
Fabrics composed of high-elastic fibers are often used as reinforcing materials, but when fabrics are used as reinforcing materials, in order to maximize their physical properties, the warp (warp) and weft (weft) are used. ) Is required to be in a state where it is not bent as much as possible, and furthermore, the arrangement is not disturbed, and a woven fabric having a stable texture without bending and misalignment is required. However, the entangled woven fabric using a reinforcing fiber, which is well known as a reinforcing material, has a woven structure in which a pair of warp yarns are entangled with each other, and the warp yarns are bent. It has a drawback that it is not possible to make full use of the excellent properties of the elastic modulus.

Also, leno weave has the feature that the intersection of warp and weft becomes thicker. As a result, when sandwiched between sheets as a reinforcing material, irregularities appear on the surface and impair the appearance. There is also a drawback in that, when a method of use that can be applied with a resin is adopted, it is necessary to use a resin more than required in terms of strength in order to make unevenness less noticeable.

Therefore, in order to meet this demand, a plain weave, a twill weave, a satin weave, or the like, in which warp is less bent than the leno weave, is used to transfer the once wound fabric to a processing machine after weaving, and stretched by a clip or pin tenter. In addition, a method has been considered in which a resin is applied while maintaining the texture, and the warp and the weft are bound. However, this method has a problem in that, when it is wound up once after weaving, it is easy to bend and misalign the cloth.

[0005]

SUMMARY OF THE INVENTION An object of the present invention is to provide a reinforcing fiber woven fabric having an excellent reinforcing effect by making use of the inherent properties of a reinforcing fiber, such as high strength and a high elastic modulus, and a further object of the present invention. It is an object of the present invention to provide a method for producing a fiber reinforced sheet, a molded article, a reinforced sheet for waterproofing and a corrugated sheet used as a reinforcing material, and a reinforced fiber woven fabric.

[0006]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a reinforcing fiber woven fabric used as a reinforcing material, wherein the warp and the weft have a density of 11 yarns / 25 mm or less, the porosity of the woven fabric is 40 to 98%, Misalignment is 50% or less,
Reinforcing fiber woven fabric having a weaving structure excluding leno weaving, and the woven fabric is filled with resin, a fiber reinforced sheet using the reinforcing fiber woven fabric as a reinforcing material, a molded body, and waterproofing work This is achieved by reinforcing sheets and corrugated sheets.

In the production method, in producing a reinforcing fiber woven fabric used as a reinforcing material, the reinforcing fiber is woven, and a resin is applied to the woven fabric between the weaving opening and the winding section. This is achieved by a method for producing a reinforcing fiber woven fabric, which comprises solidifying the resin to bind a warp and a weft to form a filling fiber woven fabric.

According to the present invention, the warp and the weft of the reinforcing fiber woven fabric can be in a state where the warp and the weft are not bent as much as possible. . Furthermore, utilizing the properties of the reinforcing fiber such as high strength and high elastic modulus,
A fiber woven fabric having an excellent reinforcing effect and a method for producing the same can be provided. In addition, since the manufacturing process of the fiber fabric is shortened, the cost can be reduced. for that reason,
The reinforcing sheet for waterproofing and the corrugated sheet using the fiber woven fabric as a reinforcing material are inexpensive, have few air bubbles, and have a good external appearance having planar smoothness.

Here, FIG. 3 (a) schematically shows a state where the texture is bent. Next, the texture bend is shown in FIG.
This will be described with reference to FIG. Here, as shown in FIG. 3A, there are actually tufts (wefts like whiskers) on both sides of the fabric, but in FIG. 3B, this is ignored. The “bend of cloth texture” here is defined in JIS L1096-1990.
In short, a weft line AB is drawn from one ear end A of the fabric to the other ear end B along the weft thread. Next, a line perpendicular to the ear end is drawn from A, and a point intersecting with the other ear end is defined as C, and the length a (cm) of the line AC (width) is obtained. The maximum skew distance b (cm) is measured, and the cloth bend (%) is obtained by the following formula, and expressed by an average value of three different places. Texture bend (%) = (b / a) × 100 (%) where a: width (cm) b: maximum skew distance (cm)

Next, FIG. 4A shows a state of misalignment. Next, misalignment will be described with reference to FIG. Since "misalignment" is not specified in JIS,
It was decided as follows. Here, paying attention to one eye, that is, an area surrounded by two adjacent warps and wefts, how much the interval between two adjacent warps or wefts is wider than the original design value. Or
Or, it was decided to express by narrowing. FIG.
In (b), the distance c (mm) between the two wefts (warp) based on the design value corresponds to 2
The distance d (mm) between the wefts (warps) of the book is measured, and the misalignment (%) is obtained by the following equation. If it is narrow,
Since it was a negative value, it was taken as an absolute value. Misalignment (%) = | [(dc) / c] | × 100 (%) where c: interval (mm) of weft (warp) of design value d: weft (warp) of misalignment portion Interval (mm) As described above, bending of the cloth and misalignment were determined.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The preferred embodiments of the present invention will be described below in more detail. The reinforcing fiber woven fabric of the present invention is used for producing a woven fabric composed of reinforcing fibers using a loom,
The reinforcing fibers are woven into a structure other than leno weave so that the warp and weft yarns are not bent as much as possible, and furthermore, the arrangement thereof is not disturbed, and the fabric structure is a stable-textured woven structure free from bending and misalignment. In addition, the reinforcing fiber woven fabric is obtained by weaving the reinforcing fiber into a structure other than leno weaving into a woven fabric, and then applying a resin to the woven fabric between the weaving opening and the winding portion to solidify the resin. It is obtained by binding a warp and a weft.

Here, regarding the warp of the warp, as shown in FIGS. 1 and 2, the plain weave (FIG. 1) as a typical example of the present invention is compared with the conventional leno weave (FIG. 2). It can be seen that there is little bending. Here, FIG.
FIG. 2B is a diagram showing a cross section (MN) of a warp portion in FIGS. 1A and 2A, respectively. That is, in leno weaving, as shown in FIG.
Since a set of two warps is entangled between two adjacent wefts, strong bending occurs. On the other hand, in the plain weave of FIG. 1B, the bending is gentle. Although not shown here, in a structure such as a twill weave or a satin weave, the number of intersections between the warp and the weft decreases, so that the bend becomes more gentle.

Regarding the porosity of the reinforcing fiber woven fabric,
We asked as follows. First, a paper is attached to the back side of the reinforcing fiber woven fabric so that the yarn used can be easily recognized, and copying is performed by a copying machine.
For example, it is preferable to attach black paper to glass fiber woven fabric or aramid fiber woven fabric, and to attach white paper to carbon fiber woven fabric, since the used yarns are easily recognized. Next, a rectangle is written on the copied paper so that 10 or more voids of the texture are included (4 × 3, 4 × 4, etc.). Then, one side of the square is 10
Enlarge and copy until it reaches 20 cm. Thereafter, the total void area Sk of the weave is obtained by using the "single-type planimeter" manufactured by Koizumi Corporation for the void area of the weave, although the copy is enlarged. The porosity (%) = Sk / St × 100 is determined from the area of the entire square St and the total void area Sk.

The reinforcing fibers used in the present invention include glass fibers, organic high-elastic fibers (eg, aramid fibers, ultrahigh molecular weight polyethylene fibers), silicon carbide fibers, carbon fibers, graphite fibers, alumina fibers, silica fibers and the like. There are multifilament or spun yarn of high-strength, high-elasticity fiber, etc., which is selected depending on the use of the reinforcing material. When used for architectural members such as corrugated sheets, non-combustible materials such as glass fiber are preferred in terms of fire resistance.

The woven fabric woven using the reinforcing fiber woven fabric has a weave other than leno weave, and the warp and weft densities are 11 yarns / 25 mm or less. After weaving, the reinforcing fiber woven fabric is required to be fixed with a stable mesh without bending and misalignment without disturbing the arrangement. The degree of the grain bend is preferably 1.5% or less, more preferably 0.7% or less. The misalignment is preferably 50% or less, and more preferably 30% or less.

Since the reinforcing fiber woven fabric has a weak binding force at the intersection, if it is wound up as it is after weaving, there is a problem that the fabric is easily bent and misaligned beyond the above range. After that, a resin is applied to the woven fabric after the weaving between the weaving opening and the winding section to solidify the resin,
By binding the warp yarn and the weft yarn, a woven fabric having a stable texture without bending and misalignment can be obtained.

The filling resin applied to the woven reinforcing fiber fabric is, for example, an emulsion resin or a dispersion resin in which resin fine particles are dispersed in a liquid, an aqueous resin dissolved in water, or a resin dissolved in an organic solvent. Solutions, hot-melt resins and the like used by heating and melting can be mentioned,
There is no particular limitation. However, among them,
Aqueous emulsion resin or dispersion resin or water-soluble resin in which resin fine particles are dispersed in an aqueous solution, when the resin is dried and solidified, no harmful volatile components are generated,
It is not necessary to use an explosion-proof drying device, and it is preferably used because it can be dried with a simple device and the unit price of the resin is low. Emulsion resins include acrylic, vinyl chloride, polyester, E
VA (ethylene vinyl acetate), melamine, SBR
(Styrene butadiene rubber), urethane as the dispersion resin, PVA (polyvinyl alcohol), PEO (polyethylene oxide) as the water-soluble resin, etc. If there is, there is no particular limitation.

The method of applying the resin to the fabric includes, for example, a dipping method, a doctor coating method, a roll coating method, and a spraying method. However, the method is not particularly limited thereto, and may be any known method. Good. Among them, the spraying method is particularly preferable because the woven fabric in a state in which the fabric is easily bent and misaligned after weaving can apply the resin without contacting the impregnating roller or the like. The resin applied to the woven fabric can be solidified by a known appropriate method as long as the resin is dried or heat-treated.

According to the method of the present invention, the steps can be shortened,
Manufacturing costs can be reduced.

The reinforcing fiber woven fabric of the present invention includes various base materials for lamination and coating, fiber reinforced resin, fiber reinforced metal,
It is a fiber woven fabric suitable as a reinforcing material used for fiber reinforced ceramics, fiber reinforced concrete, fiber reinforced asphalt and the like.

The fiber reinforced sheet of the present invention is obtained by laminating or coating a thermoplastic resin sheet or the like on both sides or one side of the reinforcing fiber woven fabric as a reinforcing material. For example, a vinyl chloride resin sheet is laminated on both sides. And specifically, a reinforcing sheet for waterproofing work and the like.

The molded article of the present invention is obtained by molding a thermoplastic or thermosetting resin using the reinforcing fiber woven fabric obtained as described above as a reinforcing material. An unsaturated polyester resin molded article reinforced with a polyester resin, a fiber reinforced fiber woven fabric as an intermediate layer, and a sheet of vinyl chloride or the like formed on both sides thereof, and the like. And a vinyl chloride corrugated plate manufactured by a conventional method for imparting a surface roughness.

[0023]

The present invention will be specifically described below with reference to examples and comparative examples. (Example 1) As warp and weft, fiber diameter 9 μm, fineness 6
Using 7.5 tex glass fiber, an air jet loom has a basis weight of 38 g / m ² and a woven density of 7/25 m.
m, a plain weave glass fiber woven fabric is woven, and the woven fabric is woven between the weave and the winding portion by a spraying method.
The VA-based emulsion resin was applied, and the resin was solidified in a hot-air drying oven to bind the warp and the weft. The obtained glass fiber woven fabric had a small curvature and misalignment, and the warp and the weft were tightly bound in a beautifully arranged state. The porosity was 72%, the bend of the cloth was 0.5%, and the misalignment was 20%.

Comparative Example 1 A glass fiber fabric was obtained in the same manner as in Example 1 except that the emulsion resin applied between the weaving opening and the winding section was not adhered and solidified. When the obtained glass fiber fabric was subjected to a filling process with a clip tenter processing machine, a very disordered arrangement state was obtained due to a texture bend and misalignment generated at the time of winding. The porosity was 72%, and the curvature of the cloth was 1.2.
% And misalignment was 200%.

(Example 2) A 3K carbon fiber was used as the warp and the weft, and the basis weight was 17 g /
m ^2, and woven carbon fiber fabric Menuki plain weave weaving density single / 25 mm, the fabric after the weaving between the cloth fell and the winding portion, and applying the emulsion resin with spraying method, the resin Was solidified in a hot-air drying oven to bind the warp and the weft. The obtained carbon fiber woven fabric had small grain bends and misalignments, and tightly bound the warp and the weft in a beautifully arranged state. The porosity was 94%, the bend of the cloth was 1.3%, and the misalignment was 15%.

Comparative Example 2 A carbon fiber fabric was obtained in the same manner as in Example 2, except that the emulsion resin applied between the weaving opening and the winding section was not solidified. When the obtained carbon fiber woven fabric was subjected to a filling process with a clip tenter processing machine, the woven density was low, so that the carbon fiber woven fabric could not be set well on the clip tenter processing machine, and a stable cloth woven fabric could not be obtained.

Example 3 A warp and a weft have a fiber diameter of 9
Using a glass fiber of μm and a fineness of 67.5 tex, weaving a plain weave glass fiber woven fabric with a basis weight of 61 g / m ² and a weave density of 11/25 mm using an air jet loom, weaving and winding. Between the part and the woven fabric after weaving,
The EVA-based emulsion resin was applied by a spraying method, and the resin was solidified in a hot air drying furnace to bind the warp and the weft. The obtained glass fiber woven fabric had a small curvature and misalignment, and the warp and the weft were tightly bound in a beautifully arranged state. In addition, the porosity is 60%, the cloth bend is 0.3%,
The misalignment was 12%. When the obtained glass fiber fabric was laid on a primer-treated concrete and applied with urethane resin as a reinforcing material for waterproofing work, the work was carried out very well.

(Comparative Example 3) A glass fiber having a fiber diameter of 9 μm and a fineness of 33.7 tex was used as a warp, and a glass fiber having a fiber diameter of 9 μm and a fineness of 67.5 tex was used as a weft. Basis weight 62g /
m ² , weaving density warp (11 + 11) yarns / 25 mm weft 1
A single / 25 mm leno weave glass fiber fabric was woven and filled with a clip tenter to obtain a reinforcing fiber fabric. The obtained glass fiber woven fabric had a small curvature and misalignment, and the warp and the weft were tightly bound in a beautifully arranged state. The porosity was 63%, the bend of the cloth was 0.4%, and the misalignment was 11%. When the obtained glass fiber fabric was laid on the primer-treated concrete and applied with urethane resin as a reinforcing material for waterproofing work, the work was not problematic at the horizontal part, but the intersection of the leno weave at the rising corner was In order to prevent the intersection from being lifted up, the corner portion required about 30% more urethane resin than in Example 3 in order to prevent the intersection.

Example 4 A glass fiber fabric was obtained in the same manner as in Example 3. Then, a 0.4 mm vinyl chloride resin sheet was laminated on both sides of the glass fiber fabric as a reinforcing material to obtain a fiber reinforced sheet. The obtained fiber reinforced sheet had no unevenness on the surface and had flat smoothness. Using this fiber reinforced sheet as a sheet for waterproofing work,
When the work of bonding with an epoxy-based adhesive was performed, the construction was very good. Comparative Example 4 A glass fiber fabric was obtained in the same manner as in Comparative Example 3.
Next, a fiber-reinforced sheet was obtained in the same manner as in Example 4 for the fiber woven fabric. The obtained fiber reinforced sheet had irregularities on the surface. The fiber reinforced sheet was adhered with an epoxy adhesive in the same manner as in Example 4, and waterproofing was performed. However, the appearance was uneven on the surface as in the case of the fiber reinforced sheet. Example 5 A glass fiber fabric was obtained in the same manner as in Example 1.
The obtained glass fiber fabric was used as an intermediate layer, and 0.4 m on both sides.
m was molded at 150 ° C. and corrugated to produce a corrugated sheet. The resulting corrugated sheet has few bubbles,
It had high transparency, excellent smoothness and good quality.

Comparative Example 5 A glass fiber having a fiber diameter of 9 μm and a fineness of 33.7 tex was used as a warp, and a glass fiber having a fiber diameter of 9 μm and a fineness of 67.5 tex was used as a weft. 38 g / basis weight
An entangled glass fiber woven fabric having m ² and a weaving density of (7 + 7) warps / 25 mm and a weft of 7/25 mm was woven.
The obtained glass fiber fabric was filled with a clip tenter processing machine to obtain a reinforcing fiber fabric. The porosity of the obtained reinforcing fiber woven fabric is 74%, the bend of the cloth is 0.6%,
The misalignment was 20%. The reinforcing fiber woven fabric was used as an intermediate layer, and a 0.4 mm vinyl chloride sheet was molded on both sides at 150 ° C., corrugated, and a corrugated sheet was manufactured. As in Example 5, the obtained corrugated sheet was of good quality with few bubbles and high transparency, but had irregularities on the surface and was expensive to manufacture.

Tables 1 and 2 summarize the above Examples and Comparative Examples.

[0032]

[Table 1]

[0033]

[Table 2]

[0034]

As described above, the reinforcing fiber woven fabric of the present invention is a woven fabric structure in which warp and weft yarns are not bent as much as possible, and furthermore, the arrangement thereof is not disturbed, and the fabric structure is stable and has no warp or misalignment. It is excellent in that it is a reinforcing fiber woven fabric having an excellent reinforcing effect by making full use of the inherent properties of the reinforcing fiber, such as high strength and high elastic modulus. Further, according to the method of the present invention, after weaving into a woven structure other than leno weaving to form a woven fabric, a resin is applied to the woven fabric between the weaving opening and the winding section to solidify the resin. In addition, since the warp and the weft are bound, the fabric is excellent in that a woven fabric having a stable texture without bending and misalignment can be obtained. Further, the manufacturing process can be shortened and the cost is low. The reinforcing fiber sheet of the present invention has no unevenness on the surface, has flat smoothness, and has good workability. Furthermore, the molded article and corrugated sheet of the present invention are of good quality having few bubbles and high transparency, and can be manufactured at a lower cost than corrugated sheet reinforced with ordinary leno weave.

[Brief description of the drawings]

BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is an explanatory diagram of a weave structure of a plain weave of the present invention and a warp bending in the plain weave of the present invention.

FIG. 2 is an explanatory view of a weaving structure of leno weaving and warp bending in leno weaving.

FIG. 3 is an explanatory diagram of a texture bend.

FIG. 4 is an explanatory diagram of misalignment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Warp 2 Weft 3 Warp 3 'Warp 4 Weft

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Claims (10)

[Claims] 1. A reinforcing fiber woven fabric used as a reinforcing material, comprising the following (1) to (5). (1) The density of the warp and weft is 11 yarns / 25 mm or less. (2) The porosity is 40 to 98%. (3) The misalignment is 50% or less. Weave structure (5) Being filled with resin 2. The reinforcing fiber woven fabric according to claim 1, wherein the texture bend is 1.5% or less. 3. The reinforcing fiber woven fabric according to claim 1, wherein a yarn having an elongation of 10% or less and an elasticity of 5000 kgf / mm ² or more is used. 4. The reinforcing fiber woven fabric according to claim 1, wherein the reinforcing fiber woven fabric is a glass fiber woven fabric. 5. The reinforcing fiber woven fabric according to claim 1, wherein the woven structure is a plain weave, and the density of the warp and the weft is 8/25 mm or less. 6. A fiber reinforced sheet using the reinforced fiber woven fabric according to claim 1 as a reinforcing material. 7. A molded article using the reinforcing fiber woven fabric according to claim 1 as a reinforcing material. 8. A reinforcing sheet for waterproofing work, comprising the fiber reinforced sheet according to claim 6. 9. A corrugated sheet, wherein the molded article according to claim 7 is corrugated. 10. In producing a reinforcing fiber woven fabric used as a reinforcing material, after weaving the reinforcing fiber, a resin is applied to the woven fabric between the weaving opening and the winding section to solidify the resin. And a warp yarn and a weft yarn are bound to form a sealing fabric.