JP2010084372A - Woven fiber-reinforced sheet and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a woven fiber-reinforced sheet formed as a continuous flat woven fabric, and a method of manufacturing such a woven fiber-reinforced sheet with high work efficiency by a loom method. <P>SOLUTION: The woven fiber-reinforced sheet formed as a sheet-like woven fabric is formed by (a) arranging a plurality of continuous fiber-reinforced plastic wires 2 in parallel with predetermined gaps (g) as warp and arranging auxiliary warp 5 between the fiber-reinforced plastic wires 2 arranged in parallel, and (b) arranging weft 3 at predetermined spaces P along the longitudinal direction of the fiber-reinforced plastic wires 2 so as to be located on either side of the sheet-like fiber-reinforced plastic wires formed of a plurality of fiber-reinforced plastic wires 2 arranged in parallel, and weaving the weft 3 in the warp 2 and the auxiliary warp 5 to fix the plurality of fiber-reinforced plastic wires 2 arranged in parallel, into sheet shape. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a fiber reinforced sheet of a woven fabric having a predetermined width that is produced by arranging thin fiber reinforced plastic wires in a sheet shape, that is, a “woven fiber reinforced sheet” and a method for producing the same. It is about. The woven fiber reinforced sheet of the present invention is, for example, a concrete structure or a steel structure which is a civil engineering building structure (in the present specification, including a concrete structure and a steel structure is simply referred to as “structure”). It can be used effectively for adhesion and reinforcement.

  As a method for reinforcing a structure, in recent years, a bonding method has been developed in which a continuous fiber reinforced sheet is attached to or wound around the surface of an existing or newly installed structure.

  However, the above-mentioned bonding method is only simple bonding, and the effect of reinforcing the ultimate strength is limited due to the early destruction of the structure due to peeling of the FRP (fiber reinforced plastic) reinforcing material. There is a limit to the suppression effect. In addition, the high performance of the FRP reinforcement is often not utilized effectively. In addition, it is impossible to recover from crack damage of existing structures or to reinforce dead loads.

  In order to improve such problems, a tension bonding method is being used in which a load is applied to a sheet-shaped reinforcing material and the sheet-shaped reinforcing material is tensioned, and the sheet-shaped reinforcing material is bonded to the structure surface in a tensioned state. The sheet-like reinforcing material used in this tension bonding method is currently a sheet in which fibers not impregnated with resin are aligned in one direction, a so-called reinforcing fiber sheet, or a flat plate of fiber reinforced plastic having a width of 50 mm or more. Is used.

  However, in a fiber reinforced sheet using fibers that are not impregnated with resin, reinforcing fibers are not always uniformly aligned in one direction due to problems in manufacturing or handling. For this reason, in order to introduce tension, partial thread breakage may occur when a tension is applied to the reinforcing fiber sheet to cause tension, and sufficient tension may not be introduced. That is, the reinforcing fiber sheet may not exhibit sufficient force necessary for tension. Usually, the tension is reduced by about 50% to 30% of the final breaking load.

  Further, when a fiber reinforced plastic flat plate is used, since the plate width is wide, there is a problem that when adhering, voids are mixed into the bonding surface and it is difficult to obtain a sufficient bonding force. In order to avoid the generation of voids, it is conceivable to make a hole in the fiber-reinforced plastic flat plate. However, in this case, the reinforcing fiber of the fiber-reinforced plastic flat plate is cut, which is not preferable.

  Therefore, as described in Patent Document 1, the inventors of the present invention have a fiber reinforced sheet in which a plurality of continuous fiber reinforced plastic wires that have been cured by impregnating a matrix resin into a reinforced fiber and are cured are slender in the longitudinal direction. A fiber reinforced sheet was proposed in which the wires were fixed to each other with a fixing fiber material.

Such a fiber reinforced sheet can solve the problem of thread breakage during tension, and can also avoid generation of voids during construction to obtain a sufficient adhesion force to the reinforced surface. Reinforcement of concrete structures based on the bonding method can be performed with extremely good workability.
JP 2004-197325 A

  As described in Patent Document 1, the above-mentioned fiber reinforced sheet is composed of a plurality of continuous fiber reinforced plastic wires that are impregnated with a matrix resin in a reinforced fiber and cured in a longitudinal manner, and then the wires are joined to each other. Although fixing with a fixing fiber material has been proposed, a more specific and more efficient manufacturing method has been desired.

  Thereafter, the inventors of the present application conducted further research experiments and found that a fiber reinforced sheet having a very good workability and a flat woven shape can be produced by a loom system. The present invention has been made on the basis of novel findings obtained as a result of many research experiments by the present inventors.

  An object of the present invention is to produce a woven fiber reinforced sheet made into a continuous, flat woven fabric, and a woven fiber reinforced sheet by a loom system capable of producing such a woven fiber reinforced sheet with good workability. Is to provide a method.

The above object is achieved by the woven fiber reinforced sheet and the method for producing the same according to the present invention. In summary, according to the first aspect of the present invention, in the fiber reinforced sheet having a plurality of fiber reinforced plastic wires aligned in the longitudinal direction,
(A) A plurality of continuous fiber reinforced plastic wires as warp yarns are arranged in parallel with a predetermined gap between them, and auxiliary warps are arranged in parallel between the fiber reinforced plastic wire materials arranged in parallel. Arranged in parallel at
(B) Along the longitudinal direction of the fiber-reinforced plastic wire so as to be located on either side of the sheet-like fiber-reinforced plastic wire formed by the plurality of fiber-reinforced plastic wires arranged in parallel The wefts are arranged at a predetermined interval, and the wefts are woven into the warp yarns and the auxiliary warp yarns, thereby fixing the plurality of fiber-reinforced plastic wires arranged in parallel in a sheet shape.
There is provided a woven fiber reinforced sheet that is a sheet-like woven fabric.

According to the second aspect of the present invention, in the method for producing a fiber reinforced sheet having a plurality of fiber reinforced plastic wires aligned in the longitudinal direction,
(A) A plurality of continuous fiber reinforced plastic wires as warp yarns are arranged in parallel with a predetermined gap between them, and auxiliary warps are arranged in parallel between the fiber reinforced plastic wire materials arranged in parallel. Arranged in parallel at
(B) Along the longitudinal direction of the fiber-reinforced plastic wire so as to be located on either side of the sheet-like fiber-reinforced plastic wire formed by the plurality of fiber-reinforced plastic wires arranged in parallel Weft yarns are arranged at predetermined intervals, and the weft yarns are woven into the warp yarns and the auxiliary warp yarns to weave a sheet-like woven fabric.
A method for producing a woven fiber reinforced sheet is provided.

  According to one embodiment of the present invention, the weft is a hot-melt resin-coated fiber in which the surface of the core wire is coated with a thermoplastic resin having a melting point in the range of 50 ° C to 230 ° C.

  According to another embodiment of the present invention, the core of the weft is a fiber made of carbon fiber, glass fiber, cotton, or aramid fiber, polyester fiber, polyamide fiber, polyvinyl alcohol fiber or polyethylene terephthalate fiber. The thermoplastic resin is polyamide resin, polyester resin, polyurethane resin, polyethylene resin, polypropylene resin, ionomer resin, polyvinyl acetate resin, polystyrene resin, ABS resin, methacrylic resin, polyvinyl chloride resin, polyvinyl alcohol resin, heat It is a plastic elastomer resin or a polyvinyl butyral resin, and the coating amount of the thermoplastic resin is 10 to 1000% by weight of the core wire.

  According to another embodiment of the present invention, the outer diameter of the core wire of the weft is 0.01 to 2.0 times the average diameter of the fiber reinforced plastic wire.

  According to another embodiment of the present invention, the auxiliary warp yarn is a yarn made of carbon fiber, glass fiber, cotton, or aramid fiber, polyester fiber, polyamide fiber, polyvinyl alcohol fiber or polyethylene terephthalate fiber.

  According to another embodiment of the present invention, the wefts are arranged at an interval of 1 mm to 250 mm along the longitudinal direction of the fiber reinforced plastic wire.

  According to another embodiment of the present invention, the auxiliary warp yarns are arranged in parallel with each other in the width direction perpendicular to the longitudinal direction of the plurality of fiber reinforced plastic wires 1 to 1 of the fiber reinforced plastic wires. They are arranged at intervals of 150.

  According to another embodiment of the present invention, the fabric structure of the warp, the auxiliary warp, and the weft is a plain weave, twill, or satin weave structure.

According to another embodiment of the present invention, the fiber-reinforced plastic wire has a reinforcing fiber impregnated with a matrix resin,
The reinforcing fiber is a carbon fiber; glass fiber: boron fiber; organic fiber such as aramid, PBO (polyparaphenylene benzbisoxazole), polyamide, polyarylate, polyester, etc. Used,
The matrix resin is a thermosetting resin such as a room temperature curable or thermosetting epoxy resin, vinyl ester resin, urethane acrylate resin, MMA resin, unsaturated polyester resin or phenol resin, or polyamide resin, polyester resin, A thermoplastic resin such as polyurethane resin, polyethylene resin, polypropylene resin, ionomer resin, polyvinyl acetate resin, polystyrene resin, ABS resin, methacrylic resin, polyvinyl chloride resin, polyvinyl alcohol resin, thermoplastic elastomer resin or polyvinyl butyral resin. is there.

  According to another embodiment of the present invention, the fiber reinforced plastic wire has a circular cross-sectional shape with a diameter of 0.5 mm to 5 mm, or a width of 1 mm to 20 mm and a thickness of 0.1 mm to 10 mm. It has a rectangular cross-sectional shape.

  According to another embodiment of the present invention, the fiber reinforced plastic wires in the woven fiber reinforced sheet as a product are separated from each other by 0.1 mm to 3.0 mm.

  According to another embodiment of the present invention, the product woven fiber reinforced sheet has a width of 10 mm to 3000 mm.

  The woven fiber reinforced sheet of the present invention is the flatness of the entire fiber reinforced sheet, the flatness of the warp yarns, the smoothness of the weft yarn, the flexibility (small winding property), the shape stability, the width accuracy, the warp yarn / weft yarn alignment accuracy. Is excellent in terms of.

  Further, according to the present invention, it is possible to produce a fiber reinforced sheet that is made into a continuous, flat woven fabric, that is, a woven fiber reinforced sheet with extremely good workability.

  Hereinafter, the woven fiber reinforced sheet and the manufacturing method thereof according to the present invention will be described in more detail with reference to the drawings.

Example 1
(Fiber reinforced sheet)
1 and 2 show an embodiment of the woven fiber reinforced sheet 1 of the present invention. The fiber reinforced sheet 1 includes a plurality of continuous fiber reinforced plastic wire rods 2 as warp yarns, aligned in the longitudinal direction and arranged in parallel to each other, and each wire rod 2 is a weft yarn 3 which is a fixing fiber material, and auxiliary warp yarns 5 (weaving).

  That is, the woven fiber reinforced sheet 1 as a product obtained in the present invention is a woven fabric in which a warp fiber reinforced plastic wire 2 is fixed by a woven fabric woven using auxiliary warps 5 and wefts 3. . The woven structure may be a plain weave, twill weave, satin weave, or the like.

  The fiber reinforced plastic wire 2 has an elongated shape (small diameter) in which a matrix resin R is impregnated with a plurality of continuous reinforcing fibers f oriented in one direction and cured, and has elasticity. Accordingly, the elastic fiber-reinforced plastic wire 2 is fixed in a sheet shape by being slid, that is, the wires 2 are close to each other in parallel and separated in one direction, and the auxiliary warp 5 and the weft 3 are woven. The fiber reinforced sheet 1 has elasticity in the longitudinal direction. Therefore, for example, the fiber reinforced sheet 1 can be carried in a state of being wound at a predetermined radius during conveyance, and is extremely portable.

  Further, since the fiber reinforced sheet 1 is composed of the fiber reinforced plastic wire 2, the orientation of the reinforced fibers is disturbed at the time of conveyance, as in a conventional unimpregnated reinforced fiber sheet, or when tension is introduced. There is no concern that thread breakage may occur due to disordered orientation of the reinforcing fibers.

  More specifically, the thin fiber reinforced plastic wire 2 has a substantially circular cross-sectional shape (Fig. 3 (a)) with a diameter (d) of 0.5 to 5 mm, or a width (w) of 1 to 20 mm. , And a substantially rectangular cross-sectional shape (FIG. 3B) having a thickness (t) of 0.1 to 10 mm. Of course, other various cross-sectional shapes can be used as necessary.

That is, in the specification and claims of the present application, it is understood that “small diameter” is not limited to a circular cross-sectional shape of the wire, but includes cases of a rectangular shape or other shapes. I want to be. Usually, “small diameter” means that the cross-sectional area of the wire is about 0.1 to ²⁰ mm ² . If it is too thin, the reinforcing effect is small, and if it is too thick, it is difficult to ensure the strength of the lap joint of the fiber reinforced sheet.

  Moreover, in order to improve the adhesive force at the time of use, the fiber reinforced plastic wire 2 is preferably roughened by roughening the surface using shot blasting, a gold brush, or the like.

  As described above, in the fiber reinforced sheet 1 that is aligned and slender in one direction, the wires 2 are close to and separated from each other by a gap (g) = 0.1 to 3.0 mm, and the auxiliary warp 5 and the weft 3 is fixed with a woven fabric structure. Further, the length (L) and the width (W) of the woven fiber reinforced sheet 1 formed in this way are appropriately determined according to the size and shape of the structure to be reinforced, but there are problems in handling. Therefore, generally, the total width (W) is 10 to 3000 mm. Moreover, although a length (L) can manufacture a thing of 100 m or more, in use, it cuts and uses it suitably.

  As the reinforcing fiber f, carbon fiber; glass fiber; boron fiber; and organic fibers such as aramid, PBO (polyparaphenylene benzbisoxazole), polyamide, polyarylate, polyester, etc. are used alone or in combination of plural kinds. And can be used in a hybrid.

  The matrix resin R impregnated in the fiber reinforced plastic wire 2 can be a thermosetting resin or a thermoplastic resin. As the thermosetting resin, a room temperature curing type or a thermosetting type epoxy resin, vinyl ester can be used. Resin, urethane acrylate resin, MMA resin, unsaturated polyester resin, phenol resin, etc. are preferably used. As the thermoplastic resin, polyamide resin, polyester resin, polyurethane resin, polyethylene resin, polypropylene resin, ionomer resin, A polyvinyl acetate resin, a polystyrene resin, an ABS resin, a methacrylic resin, a polyvinyl chloride resin, a polyvinyl alcohol resin, a thermoplastic elastomer resin, a polyvinyl butyral resin, or the like can be suitably used. The resin impregnation amount is 30 to 70% by weight, preferably 40 to 60% by weight.

  Further, as a method for fixing each wire 2 with the weft 3 and auxiliary warp 5 which are fixing fiber materials, as shown in FIG. 1, the wire 2 is composed of a plurality of wires 2 arranged in a unidirectional manner. The weft yarns 3 are alternately arranged at predetermined intervals P along the longitudinal direction of the fiber reinforced plastic wire rod so as to be located on either side of the wire rod in the sheet form, that is, the continuous wire rod sheet, and the weft yarn 3 adopts a method of weaving the wire 2 as the warp and the auxiliary warp 5. 1 and 2 show a mode in which the wefts 3 are alternately arranged on the upper side and the lower side of the wire sheet every other line, but the weft yarns are limited to this. is not. For example, a mode is also possible in which a plurality of wefts are arranged at a predetermined interval below the wire sheet, and then a plurality of wefts are arranged at a predetermined interval above the wire sheet.

  In other words, according to the present invention, the plurality of fiber reinforced plastic wires 2 arranged in a sled shape in one direction are fixed by a woven fabric structure composed of weft yarns 3 and auxiliary warp yarns 5 as fixing fiber materials.

  The interval P between the wefts 3 is not limited to this, but in the case of an equal interval, it is in the range of 1 to 250 mm. If too close, the flexibility of the sheet is lost. If it opens too much, a problem occurs in the shape stability of the sheet, such as deformation at an angle. Usually, it is about 50 mm. The auxiliary warp yarns 5 are arranged at intervals of 1 to 150 fiber-reinforced plastic wires in the width direction perpendicular to the longitudinal direction of a plurality of fiber-reinforced plastic wires arranged in parallel to each other.

  As the weft 3, various hot melt resin-coated fibers can be used to fix the continuous wire 2. That is, the weft 3 is a hot melt resin-coated fiber having a surface coated with a thermoplastic resin (hot melt resin) having a melting point in the range of 50 to 230 ° C.

  As the core wire of the weft 3, a yarn made of carbon fiber, glass fiber, cotton, aramid fiber, polyester fiber, polyamide fiber, polyvinyl alcohol fiber, polyethylene terephthalate fiber, or the like can be suitably used. As the melt resin, polyamide resin, polyester resin, polyurethane resin, polyethylene resin, polypropylene resin, ionomer resin, polyvinyl acetate resin, polystyrene resin, ABS resin, methacrylic resin, polyvinyl chloride resin, polyvinyl alcohol resin, thermoplastic elastomer Resin or polyvinyl butyral resin can be used.

  The coating amount of the hot melt resin is 10 to 1000% by weight of the core wire. If it is too small, the fixing force is insufficient, and if it is too large, the flexibility of the sheet is lost.

Moreover, the outer diameter of the core wire of the weft 3 is preferably 0.01 to 2.0 times the average diameter d of the wire 2. If it is too thin, the fixing force will be insufficient, and if it is too thick, the wire spacing P will become large and the reinforcing effect will be insufficient. The average diameter d of the wire 2 is d = (4S / π) ^1/2 where S is the cross-sectional area of the wire. When the cross section of the wire 2 is circular, the outer diameter of the core wire is about 0.1 mm to 2.1 mm.

  As the auxiliary warp yarn 5, a yarn made of carbon fiber, glass fiber, cotton, aramid fiber, polyester fiber, polyamide fiber, polyvinyl alcohol fiber or polyethylene terephthalate fiber can be suitably used. As described above, the auxiliary warp yarns 5 are arranged at intervals of 1 to 150 of the fiber reinforced plastic wire 2, but are usually arranged at intervals of 10 to 50, that is, 16 to 80 mm. The outer diameter of the auxiliary warp is 0.1 mm to 0.5 mm.

  Next, the manufacturing method of the fiber reinforced sheet | seat of the textile fabric based on this invention, ie, the woven fiber reinforced sheet | seat 1, is demonstrated.

(Production method of fiber reinforced sheet)
The fiber reinforced sheet 1 can be produced (woven) by a fly shuttle loom or a shuttleless loom. In this example, a shuttleless loom was used.

  FIG. 4 shows a schematic configuration of the loom 100, but the detailed structure of the loom is well known to those skilled in the art, and a detailed description thereof will be omitted.

  In this embodiment, a plurality of fiber reinforced plastic wires 2 as warp yarns of a fiber reinforced sheet are continuously supplied to the loom 100 by 250 to 350 wires 2 in this embodiment. . At the same time, in this embodiment, auxiliary warp yarns 5 are arranged every 30 to 50 wires 2 and are continuously supplied to the loom 100.

  In the loom 100, each wire 2 and the auxiliary warp 5 are passed through the holes of the hooks 103 (103a, 103b) for moving the warp up and down, and then the hook 104 is a guide bar for determining the interval between the warps. Passed through. This state is shown in FIG.

  In addition, as shown by a one-dot chain line in FIG. 4, the delivery device 101 may include a back tension applying mechanism 102. By applying a back tension to the wire 2 by the back tension applying mechanism 102, the arrangement accuracy of the wire 2 and the auxiliary warp yarn 5 can be controlled.

  In addition, a plurality of wire rods 2 and auxiliary warp yarns 5 arranged at a predetermined interval, that is, ear yarns fe and fe on the right side and the left side in FIG. It arrange | positions and is continuously supplied to the loom 100 with each wire 2 and the auxiliary warp 5 at a predetermined speed.

  As the ear thread fe, for example, a plurality of yarns made of fibers such as polyester fiber, polyamide fiber, polyvinyl alcohol fiber, cotton, etc., for example, ten or more yarns, can be used together.

  In FIG. 5 (a), it is divided into a wire group fg1 composed of a plurality of aligned wire rods 2 and a plurality of auxiliary warp yarn groups fg2, which can be moved up and down by hooks 103a and 103b, respectively.

  As shown in FIG. 5B, with respect to the reference plane H, the wire group fg1 is moved upward by the hook 103a, the auxiliary warp group fg2 is moved downward by the hook 103b, and the wire group fg1 and the auxiliary warp yarn are moved. A predetermined gap S is formed between the group fg2.

  Next, as shown in FIG. 5 (c), the weft 3 passes through the right ear thread fe, passes between the wire group fg1 and the auxiliary warp group fg2 that are defined as the gap S, and then passes through the left ear thread fe. Inserted through. In this embodiment, the weft 3 does not use a shuttle, but adopts a method of flying on a jet of air.

  The weft yarn 3 passed between the wire group fg1 and the auxiliary warp yarn group fg2 and the both-side ear yarn fe is entangled with the right and left ear yarns fe to form an ear part Fe. The weft 3 is cut at an outer portion than the both ears Fe. In other words, the weft 3 is held by the ear threads fe located on both sides of the plurality of fiber reinforced plastic wires arranged in parallel to each other, located on the outermost side in the width direction perpendicular to the longitudinal direction.

  The steps shown in FIGS. 5A, 5B, and 5C are performed continuously.

  After the process of FIG. 5 (c) has been completed and a predetermined time has elapsed, that is, at a position separated from the weft 3 knitted between the wire group fg1 and the auxiliary warp group fg2 by a predetermined distance (P). As shown in FIG. 5D, the wire group fg1 is moved downward and the auxiliary warp group fg2 is moved upward with respect to the reference plane H by the hooks 103a and 103b.

  Next, as shown in FIG. 5 (e), the weft thread 3 passes through the right ear thread fe, passes between the wire group fg1 and the auxiliary warp thread group fg2 defined as the gap S, and then passes through the left ear thread fe. Inserted through. The weft 3 is entangled with the right and left ear threads fe to form an ear part Fe, and the weft 3 is cut at the outer part from both ear parts Fe.

  Next, after the process of FIG. 5 (e) is completed, after a predetermined time has elapsed, that is, the weft 3 knitted between the wire group fg1 and the auxiliary warp group fg2 is separated by a predetermined distance (P). At the position, as shown in FIG. 5B, the wire group fg1 is moved upward and the auxiliary warp group fg2 is moved downward with respect to the reference plane H by the hooks 103a and 103b.

  Thereafter, by repeatedly performing the above-described FIGS. 5C to 5E, the weft yarn is formed on a plurality of fiber-reinforced plastic wires arranged in parallel on either side of the sheet-like fiber-reinforced plastic wire. Are arranged alternately and at predetermined intervals along the longitudinal direction of the fiber-reinforced plastic wire, and at the same time, the wire 2 as the warp constituting the wire group fg1 and the auxiliary warp constituting the auxiliary warp group fg2 5 and the weft 3 form a woven fabric, for example, a plain weave structure. That is, the weft 3 is woven into the warp 2 and the auxiliary warp 5, thereby fixing the sheet-like fiber reinforced plastic wire, and the so-called plain weave reinforced fiber sheet 1 is woven.

  The woven fiber reinforced sheet 1, which is a woven product, is wound up by a winding device 105 having a caterpillar device 106.

In addition, according to the present embodiment, as understood with reference to FIG. 4, a heating facility, for example, a remote device, is provided between the caterpillar device 106 and the basket 104, that is, in the vicinity of the downstream side of the basket 104. An infrared heater 105 is provided, and a cooling facility such as a cooling roll 106 is provided immediately thereafter, and the reinforcing fiber sheet is heated and pressurized at a temperature of 100 to 150 ° C. and a pressure of 0.5 to 3 kgf / cm ² . Thereby, the reinforced fiber sheet 1 of the woven fabric produced by repeating the steps shown in FIGS. 5A to 5E can further increase the flatness while slightly narrowing the sheet width, and is an extremely flat woven fabric. Thus, a woven fiber reinforced sheet can be obtained.

  In particular, it is preferable to use an organic high-strength fiber such as an aramid yarn for the weft and melt the hot melt resin of the weft before pressing. Glass fibers and normal fibers with low strength may break during pressing. Moreover, the sheet | seat excellent in flatness can be obtained by the space | interval of adjacent wefts being 10-50 mm especially.

  In the above description, the wire 2 as the warp, the auxiliary warp 5 and the weft 3 are woven in a plain weave. However, the present invention is not limited to this. Also good.

  As described above, according to the present invention, the tissue is fixed by various hot melt resin-coated fibers. Moreover, the woven fiber reinforced sheet which is a product is excellent in handling property and structure | strength strength by adjusting the fiber arrangement | sequence using the hot melt resin coating fiber of predetermined thickness.

Production Example 1
In this production example, the fiber reinforced plastic wire 2 in the fiber reinforced sheet 1 uses PAN-based carbon fiber strands having an average diameter of 7 μm and a convergent number of 12,000 as the reinforcing fibers f, and impregnated with a room temperature curing type epoxy resin as the matrix resin R. And cured. The resin impregnation amount was 40% by weight, and the fiber-reinforced plastic wire 2 after curing had a circular cross section with a diameter d = 1.0 mm.

  The fiber-reinforced plastic wire 2 obtained in this way was supplied to the loom 100 after being pulled in one direction by the feeding device 101 with 180 pieces / width 300 mm (weight per unit 600 g). That is, the interval between the wires 2 in the collar portion 104 of the loom 100 was 16 mm.

  As the auxiliary warp yarn 5, an aramid fiber (counter 1100d) was used. Moreover, the auxiliary warp 5 was made into every 30 fiber-reinforced plastic wires 2, that is, the interval P0 was 50 mm.

  Further, polyester fiber was used as the ear thread fe.

  As the weft 3, a hot melt coated fiber (manufactured by Unitika Co., Ltd.) in which a core resin aramid fiber (1100d) was coated with a polyester resin was used. The coating amount of the hot melt resin was 60% by weight of the core wire.

  The interval P between the wefts 3 was 50 mm.

In Production Example 1, as shown in FIG. 4, a far infrared heater 107 and a cooling roll 106 are installed between the loom 100 and the caterpillar device 106, and the fabric is heated to 120 ° C. with the far infrared heater 107, and then The cooling roll 106 was pressurized at 2 kgf / cm ² .

  The woven fiber reinforced sheet 1 produced in this way had a width (W) of 300 mm and a gap (g) between the wires 2 of 0.3 to 0.4 mm.

  In addition, the overall flatness of the fiber reinforced sheet, the flatness of the warp yarns, the smoothness of the weft yarns, the flexibility (small winding), the shape stability, the width accuracy, and the warp / weft alignment accuracy were evaluated. there were. In particular, it was found that the flatness between the warp yarns and the smoothness of the weft yarns were particularly improved by performing heat treatment and cooling press using the far-infrared heater 107 and the cooling roll 106.

  As the weft, instead of the aramid fiber, a cotton yarn was used and a polyester-coated one was used. In this case as well, good results could be obtained.

  Next, experimental examples of the woven fiber reinforced sheet of the present invention obtained as described above will be described.

Experimental Example Using the fiber reinforced sheet 1 of the present invention, a concrete beam was reinforced in accordance with a tension bonding method.

  As described above, the woven fiber reinforced sheet 1 used has a width (W) of 300 mm, a gap (g) between the wires 2 of 0.3 to 0.4 mm, and a length (L) of 100 m. Met.

  Next, concrete beams were reinforced by the tension bonding method using the fiber reinforced sheet 1 as follows.

First, in this experimental example, a tension force of 10,000 kg / mm ² was introduced into the fiber reinforced sheet 1 prior to bonding the fiber reinforced sheet 1 to the concrete beam. When the tension force was introduced, no thread breakage occurred, and a sufficient tension force could be introduced to near the breaking strength of the carbon fiber.

  In a state where the fiber reinforced sheet 1 is maintained in a tension state, a matrix resin is applied to the fiber reinforced sheet 1 from the side facing the concrete beam sheet bonding surface, and then the fiber reinforced sheet 1 is applied to the concrete beam bonding surface. Glued. At this time, in order to increase the adhesive strength, the entire fiber reinforced sheet was covered with a bag film, the air in the bag film was evacuated with a vacuum pump, and bonded while pressing against the beam with vacuum pressure. It was possible to adhere to the concrete beam very well without generating any voids on the sticking surface of the fiber reinforced sheet 1.

  In this experimental example, the reinforcement of the concrete structure has been described. However, the woven fiber reinforced sheet 1 of the present invention can be similarly applied to the reinforcement of the steel structure, and the same operational effects can be achieved.

  The woven fiber reinforced sheet 1 of the present invention can also be suitably used for a reinforcing method for simply adhering and reinforcing a structure other than the tension bonding method described in the experimental example.

It is a perspective view which shows one Example of the woven fiber reinforcement sheet | seat manufactured by this invention. It is the elements on larger scale of a woven fiber reinforcement sheet. It is sectional drawing of a fiber reinforced plastic wire. It is a perspective view which shows schematic structure of the loom for enforcing the manufacturing method of the fiber reinforced sheet which concerns on this invention. It is process drawing for demonstrating the manufacturing method of the woven fiber reinforcement sheet | seat which concerns on this invention.

Explanation of symbols

1 Fiber reinforced sheet 2 Fiber reinforced plastic wire (warp)
3 Weft (Fiber material for fixing)
5 Auxiliary warp yarn (fiber material for fixing)
DESCRIPTION OF SYMBOLS 100 Loom 101 Feeding device 102 Back tension mechanism 103 (103a, 103b) １０４ 104 筬 105 Winding device 106 Caterpillar device 107 Far-infrared heater (heating equipment)
108 Cooling roll (cooling equipment)

Claims (24)

In the fiber reinforced sheet having a plurality of fiber reinforced plastic wires aligned in the longitudinal direction,
(A) A plurality of continuous fiber reinforced plastic wires as warp yarns are arranged in parallel with a predetermined gap between them, and auxiliary warps are arranged in parallel between the fiber reinforced plastic wire materials arranged in parallel. Arranged in parallel at
(B) Along the longitudinal direction of the fiber-reinforced plastic wire so as to be located on either side of the sheet-like fiber-reinforced plastic wire formed by the plurality of fiber-reinforced plastic wires arranged in parallel The wefts are arranged at a predetermined interval, and the wefts are woven into the warp yarns and the auxiliary warp yarns, thereby fixing the plurality of fiber-reinforced plastic wires arranged in parallel in a sheet shape.
A woven fiber reinforced sheet formed into a sheet-like woven fabric.   The woven fiber reinforced sheet according to claim 1, wherein the weft is a hot-melt resin-coated fiber in which a surface of a core wire is coated with a thermoplastic resin having a melting point in a range of 50 to 230 ° C.   The core wire of the weft is a fiber made of carbon fiber, glass fiber, cotton, or aramid fiber, polyester fiber, polyamide fiber, polyvinyl alcohol fiber or polyethylene terephthalate fiber, and the thermoplastic resin is a polyamide resin, Polyester resin, polyurethane resin, polyethylene resin, polypropylene resin, ionomer resin, polyvinyl acetate resin, polystyrene resin, ABS resin, methacrylic resin, polyvinyl chloride resin, polyvinyl alcohol resin, thermoplastic elastomer resin or polyvinyl butyral resin, The woven fiber reinforced sheet according to claim 2, wherein a coating amount of the thermoplastic resin is 10 to 1000% by weight of the core wire.   The woven fiber reinforced sheet according to claim 3, wherein an outer diameter of the core wire of the weft is 0.01 to 2.0 times an average diameter of the fiber reinforced plastic wire.   The auxiliary warp yarn is a yarn made of carbon fiber, glass fiber, cotton, or aramid fiber, polyester fiber, polyamide fiber, polyvinyl alcohol fiber, or polyethylene terephthalate fiber. A woven fiber reinforced sheet according to any one of the above items.   The woven fiber reinforced sheet according to any one of claims 1 to 5, wherein the wefts are arranged at an interval of 1 to 250 mm along a longitudinal direction of the fiber reinforced plastic wire.   The auxiliary warp yarns are arranged at an interval of 1 to 150 of the fiber reinforced plastic wires in the width direction perpendicular to the longitudinal direction of the plurality of fiber reinforced plastic wires arranged in parallel to each other. The woven fiber reinforced sheet according to any one of claims 1 to 6.   The woven fiber reinforced sheet according to any one of claims 1 to 7, wherein a woven fabric structure of the warp, the auxiliary warp, and the weft is a plain weave, a twill weave, or a satin weave structure. . The fiber reinforced plastic wire is impregnated with a matrix resin in a reinforced fiber,
The reinforcing fiber is a carbon fiber; glass fiber: boron fiber; organic fiber such as aramid, PBO (polyparaphenylene benzbisoxazole), polyamide, polyarylate, polyester, etc. Used,
The matrix resin is a thermosetting resin such as a room temperature curable or thermosetting epoxy resin, vinyl ester resin, urethane acrylate resin, MMA resin, unsaturated polyester resin or phenol resin, or polyamide resin, polyester resin, A thermoplastic resin such as polyurethane resin, polyethylene resin, polypropylene resin, ionomer resin, polyvinyl acetate resin, polystyrene resin, ABS resin, methacrylic resin, polyvinyl chloride resin, polyvinyl alcohol resin, thermoplastic elastomer resin or polyvinyl butyral resin. is there,
The woven fiber reinforced sheet according to any one of claims 1 to 8.   The fiber-reinforced plastic wire has a circular cross-sectional shape having a diameter of 0.5 to 5 mm, or a rectangular cross-sectional shape having a width of 1 to 20 mm and a thickness of 0.1 to 10 mm. The woven fiber reinforced sheet according to any one of claims 1 to 9.   The woven fabric according to any one of claims 1 to 10, wherein the fiber reinforced plastic wires in the woven fiber reinforced sheet as a product are separated from each other by 0.1 to 3.0 mm. Fiber reinforced sheet.   The woven fiber reinforced sheet according to any one of claims 1 to 11, wherein the woven fiber reinforced sheet as a product has a width of 10 to 3000 mm. In the method for producing a fiber reinforced sheet having a plurality of fiber reinforced plastic wires aligned in the longitudinal direction,
(A) A plurality of continuous fiber reinforced plastic wires as warp yarns are arranged in parallel with a predetermined gap between them, and auxiliary warps are arranged in parallel between the fiber reinforced plastic wire materials arranged in parallel. Arranged in parallel at
(B) Along the longitudinal direction of the fiber-reinforced plastic wire so as to be located on either side of the sheet-like fiber-reinforced plastic wire formed by the plurality of fiber-reinforced plastic wires arranged in parallel Weft yarns are arranged at predetermined intervals, and the weft yarns are woven into the warp yarns and the auxiliary warp yarns to weave a sheet-like woven fabric.
A method for producing a woven fiber reinforced sheet characterized by the above.   The method for producing a woven fiber reinforced sheet according to claim 13, wherein the weft is a hot-melt resin-coated fiber in which a surface of a core wire is coated with a thermoplastic resin having a melting point in a range of 50 to 230 ° C. .   The core wire of the weft is a fiber made of carbon fiber, glass fiber, cotton, or aramid fiber, polyester fiber, polyamide fiber, polyvinyl alcohol fiber or polyethylene terephthalate fiber, and the thermoplastic resin is a polyamide resin, Polyester resin, polyurethane resin, polyethylene resin, polypropylene resin, ionomer resin, polyvinyl acetate resin, polystyrene resin, ABS resin, methacrylic resin, polyvinyl chloride resin, polyvinyl alcohol resin, thermoplastic elastomer resin or polyvinyl butyral resin, The method for producing a woven fiber reinforced sheet according to claim 14, wherein the coating amount of the thermoplastic resin is 10 to 1000% by weight of the core wire.   The method for producing a woven fiber reinforced sheet according to claim 15, wherein the outer diameter of the core wire of the weft is 0.01 to 2.0 times the average diameter of the fiber reinforced plastic wire.   The auxiliary warp yarn is a yarn made of carbon fiber, glass fiber, cotton, or aramid fiber, polyester fiber, polyamide fiber, polyvinyl alcohol fiber, or polyethylene terephthalate fiber. A method for producing a woven fiber reinforced sheet according to any one of the above items.   The method for producing a woven fiber reinforced sheet according to any one of claims 13 to 17, wherein the weft is woven at an interval of 1 to 250 mm along a longitudinal direction of the fiber reinforced plastic wire. .   The auxiliary warp yarns are arranged at an interval of 1 to 150 of the fiber reinforced plastic wires in the width direction orthogonal to the longitudinal direction of the plurality of fiber reinforced plastic wires arranged in parallel to each other. The method for producing a woven fiber reinforced sheet according to any one of claims 13 to 18.   The method for producing a woven fiber reinforced sheet according to any one of claims 13 to 19, wherein a woven fabric structure of the warp and the weft is a plain weave, a twill weave, or a satin weave structure. The fiber reinforced plastic wire is impregnated with a matrix resin in a reinforced fiber,
The reinforcing fiber is a carbon fiber; glass fiber: boron fiber; organic fiber such as aramid, PBO (polyparaphenylene benzbisoxazole), polyamide, polyarylate, polyester, etc. Used,
The matrix resin is a thermosetting resin such as a room temperature curable or thermosetting epoxy resin, vinyl ester resin, urethane acrylate resin, MMA resin, unsaturated polyester resin or phenol resin, or polyamide resin, polyester resin, A thermoplastic resin such as polyurethane resin, polyethylene resin, polypropylene resin, ionomer resin, polyvinyl acetate resin, polystyrene resin, ABS resin, methacrylic resin, polyvinyl chloride resin, polyvinyl alcohol resin, thermoplastic elastomer resin or polyvinyl butyral resin. is there,
The method for producing a woven fiber reinforced sheet according to any one of claims 13 to 20.   The fiber-reinforced plastic wire has a circular cross-sectional shape having a diameter of 0.5 to 5 mm, or a rectangular cross-sectional shape having a width of 1 to 20 mm and a thickness of 0.1 to 10 mm. The method for producing a woven fiber reinforced sheet according to any one of claims 13 to 21.   The woven fabric according to any one of claims 13 to 22, wherein the fiber reinforced plastic wires in the woven fiber reinforced sheet as a product are separated from each other by 0.1 to 3.0 mm. A method for producing a fiber reinforced sheet.   The method for producing a woven fiber reinforced sheet according to any one of claims 13 to 23, wherein the woven fiber reinforced sheet as a product has a width of 10 to 3000 mm.

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