JP2012076234A - Multipurpose plate material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin-made plate usable for various applications with the same laminate constitution.SOLUTION: The used multipurpose plate is a laminate made by laminating a glass fiber resin layer on a base material layer wherein the base material layer is composed of a resin plate obtained by kneading aggregate and a resin; the glass fiber resin layer is made by sequentially laminating one or a plurality of the glass fiber-made cloth sheets and a non-woven fabric or a glass mat, impregnating these with an uncured resin and integrating these by curing the uncured resin; and the outer surface of the non-woven fabric or the glass mat is covered with the resin film made by curing the uncured resin. The base material layer exhibits high load bearing performance, and the resin film-covered surface is smooth as it is, and it is hard to suppress a flow velocity when it is used for a water passage. The non-woven fabric or the glass mat existing in the vicinity of the surface shows excellent abrasion resistance and good applicability of nonslip paint or the like, and the surface property can be easily changed only by the paint.

Description

  TECHNICAL FIELD The present invention relates to a plate material that can be used for general purposes such as repairing a concrete water channel, a cover such as a groove or a manhole, and particularly relates to a plate material made of resin mortar and fiber reinforced plastic.

  As concrete waterways such as agricultural waterways and drainage channels deteriorate over time, the surface becomes rough and the flow velocity decreases and water leaks due to cracks, so repair is necessary. On the other hand, a method has been proposed in which a fiber reinforced plastic (FRP) sheet or plate prepared in advance is repaired by lining the inner bottom surface or inner surface of a concrete water channel (Patent Document 1, Non-Patent Document). 1).

  The FRP plate used for the repair is required to have lightness and strength and surface smoothness. As a material that satisfies these requirements, a material called a resin mortar (also referred to as “resin concrete”) in which a resin such as polyester and an aggregate are kneaded is used as a base material layer, and a glass cloth, a glass mat, or the like is laminated thereon. FRPM (Fiber Reinforced Plastics Motor) plate. The resin mortar layer exhibits strength and elasticity. In addition, the FRPM plate with a sheet molding compound (SMC) laminated on the surface has a smooth SMC, which makes it difficult to block the flow rate of the water flowing through the channel, and the FRP plate is lined inside the concrete channel. Even if the cross-sectional area of the water channel is reduced, the water channel can have a flow rate that is the same as or higher than that before construction.

  By the way, the FRPM board which uses glass cloth etc. for the resin mortar is utilized also as a lid | cover material, such as a manhole cover and the said water channel, from the intensity | strength and lightweight property (patent document 3).

Japanese Patent Laid-Open No. 3-247809 JP 2010-144360 A JP 11-71779 A

Easy construction / Shortening construction period / High corrosion resistance Agricultural waterway repair Agricultural waterway quick panel method workshop <URL: http://www.quickpanel.jp/>

  However, if a smooth surface RPMP plate that employs SMC on the surface is used as a cover material such as a manhole, it becomes slippery at the installation location. For this reason, FRPM plates having the same type of structure cannot be produced in a lump, and they must be manufactured as plate materials having different laminated structures for the lid member and the water channel repair member.

  Moreover, although the repair sheet of Patent Document 2 in which the intermediate layer is made of a resin film can be used for repairing water channels, the sheet is insufficient in strength to be used as a lid. Furthermore, since the fabric material is exposed on the surface of the sheet as it is, it is necessary to apply the paint to the entire surface when repairing the water channel, and it takes extra time for construction requiring quick construction.

  Accordingly, an object of the present invention is to produce a high-strength FRPM plate that can be used for general purposes without using SMC.

  This invention is a laminate in which a glass fiber resin layer is laminated on a base material layer, and the base material layer comprises a plate obtained by curing a kneaded product of an aggregate and an uncured resin, and the glass fiber resin The layer is formed by sequentially laminating one or a plurality of glass fiber cloths and a nonwoven fabric or glass mat, and the uncured resin impregnated therein is cured, and the above-described nonwoven fabric or glass is integrated. The outer surface of the mat has solved the above problems by a multipurpose plate material in which the uncured resin is covered with a solidified resin film.

  By using a resin plate in which aggregates are hardened with resin as a base material layer, the strength of the entire material is sufficiently increased compared to conventional repair sheets based on resin films, and the load applied when used as a lid It became able to endure enough. Further, by covering the nonwoven fabric or glass mat on the surface with a resin film, it is possible to provide a smooth flat surface that does not disturb the flow rate when used on the inner wall of the water channel. On the other hand, since the non-woven fabric or glass mat is near the surface through a thin resin film, it is easy for the paint to ride on the surface, and it is possible to obtain more suitable physical properties for each application by selecting and applying the paint according to the application Can do. If it is used for the inner wall of the waterway, it is better to apply a paint that improves the weather resistance such as acrylic urethane resin paint or acrylic silicone resin paint on the surface that comes into contact with water. Apply a non-slip paint such as a mixture of the body. This makes it possible to obtain an FRPM plate that is sufficiently smooth and useful for repairing waterways without using SMC, and can also be used as a cover material by changing the paint without changing the composition.

  The glass fiber resin layer may be formed only on one surface of the base material layer, or may be formed on both surfaces. If formed on both sides, both sides of the base material layer are covered, so that they are not easily damaged and durability is improved. Further, by forming the same layer on both sides, the entire material can be prevented from warping.

  It is preferable that the resin for solidifying the base material layer and the resin impregnated in the glass fiber resin layer are the same because the bondability between the layers is increased.

  As a method for producing the multipurpose board according to the present invention, the kneaded material (resin concrete) serving as a base material layer is laminated with a glass fiber cloth and a nonwoven fabric or a glass mat, and the uncured resin is cured to be integrated. It is good to make it. However, the surface must be covered with a resin film in which an uncured resin is cured, not a non-woven fabric or a glass mat. Moreover, in the case where the glass fiber resin layer is formed on both surfaces of the base material layer, that is, the base material layer is sandwiched between the glass fiber resin layers, a non-woven fabric or a glass mat in a heatable rectangular mold, At least one sheet of glass fiber cloth impregnated with uncured resin is laid in order, and then the resin concrete before curing is poured into the frame, on which at least one sheet is made of glass fiber impregnated with uncured resin. There is a method in which a cloth, a nonwoven fabric or a glass mat are placed in order, and then heated from above and pressed to cure the entire resin. The surface of the nonwoven fabric or the glass mat is covered with a resin film in which the permeated uncured resin is cured both in the upper and lower directions.

  In addition, in the case of using a plurality of glass fiber cloths, even if there is a glass fiber cloth that is not impregnated with an uncured resin (unimpregnated glass fiber cloth), the uncured resin is coated on both sides. If the impregnated glass fiber cloth is disposed, the uncured resin can be sufficiently infiltrated into the unimpregnated glass fiber cloth. On the other hand, it is preferable that the glass fiber cloth in contact with the nonwoven fabric or the glass mat is a glass fiber cloth impregnated with a resin in advance before lamination because penetration into the nonwoven fabric or the glass mat proceeds rapidly.

  By using the multipurpose plate material according to the present invention, without changing the basic structure of the plate material, as a material that is difficult to slip and has a load resistance required such as a lid material, smoothness and weather resistance such as a water channel repair material are high. Materials that can also be used as materials that require high performance and high strength can be batch-produced as the same material, and production lines and labor can be saved greatly. Further, the prepared material can be easily diverted, and the material disposal rate can be suppressed.

(A) Conceptual diagram when laying non-woven fabric and glass fiber cloth on the bottom of the frame, (b) Conceptual diagram when introducing resin concrete containing aggregate, (c) Glass fiber cloth and non-woven fabric on resin concrete (D) Conceptual diagram immediately before pressing (A) Sectional view when the resin is heat-cured, (b) Configuration diagram of the multipurpose plate taken out from the frame after curing (A) The figure which shows the example of the multipurpose board | plate material concerning this invention made into square shape, (b) Sectional drawing at the time of using the multipurpose board | plate material of (a) as a cover on a groove | channel Example when using the multipurpose plate according to the present invention as a groove or manhole cover (A) Conceptual diagram when a multipurpose plate according to the present invention is attached to a concrete groove, (b) Conceptual diagram of a concrete groove after being repaired by the multipurpose plate

  Hereinafter, a multipurpose plate material in which a base material layer 10 is sandwiched between glass fiber resin layers 11 will be described in detail as an embodiment in which the present invention is implemented. This lamination procedure is shown in FIGS.

  FIG. 1A is a conceptual diagram when a lower glass fiber resin layer 11 material is spread on a heating mold 1. The glass fiber resin layer 11 is formed by impregnating the glass fiber cloth 6 and the nonwoven fabric or the glass mat (5) with the uncured resin 7 and curing the uncured resin. In this embodiment, the nonwoven fabric or glass mat (5) is first laid on the bottom of the mold 1, and then the glass fiber cloth 6 impregnated with the uncured resin 7 (collectively, “resin impregnated glass fiber made” Cloth 6a "), glass fiber cloth 6 not impregnated with uncured resin 7 (in particular," unimpregnated glass fiber cloth "in comparison with 6a), and resin impregnated glass fiber cloth 6a in this order. Laid down.

  Among these, examples of the nonwoven fabric include those made of vinylon, nylon, polypropylene, polyethylene, aramid, acrylic, polyester, and the like. Among these, it is particularly preferable to use a polyester long fiber product because the binding force is increased and the tensile strength is improved and it is difficult to break as compared with the short fiber product. The glass mat is obtained by stacking strands of glass fibers and molding them into a mat shape with a binder, and a general glass mat can be used in the present invention. However, since the smoothness is insufficient if it is not molded into a mat, it is difficult to substitute a glass cloth.

  These nonwoven fabrics or glass mats (5) preferably have a thickness of 1 mm or less in order to allow the uncured resin 7 to permeate and cover the surface as described later. If it is too thick, it will take too much time to penetrate.

  On the other hand, as the glass fiber cloth 6, a glass fiber roving cloth, the above glass mat, or the like can be used. Among these, glass fiber roving cloth is particularly preferable because it is easy to impregnate the resin and easily integrate with the base material layer 10.

  The glass fiber cloth 6 may be a single sheet, but it is more preferable to stack a plurality of sheets in terms of strength, durability, and weather resistance.

  When the glass fiber cloth 6 is placed, as described above, the uncured resin 7 before being cured is impregnated in both end layers of the three layers. As a method of impregnation, after immersing the glass fiber cloth 6 in the uncured resin 7 before being cured, it is pressed with a roller to drop the excess uncured resin 7 and to remove an appropriate amount of the uncured resin 7. It is good to put it in an impregnated state.

  The uncured resin 7 is a resin that can be cured thereafter. When a thermosetting resin such as an unsaturated polyester resin or a polyimide resin is used, the uncured resin 7 is integrated with a resin used for the base material layer 10 described later. This is preferable.

  In this embodiment, the glass fiber cloth 6 corresponding to the second layer and the fourth layer from the bottom is impregnated with the uncured resin 7, and the glass fiber cloth 6 of the third layer from the bottom is not impregnated. This is because if all the glass fiber cloths 6 are impregnated with the uncured resin 7, if there is a lot of excess uncured resin 7 during pressing, burrs may occur.

  On the other hand, the uncured resin 7 contained in the second resin-impregnated glass fiber cloth 6a from the bottom slowly penetrates into the first-layer nonwoven fabric or glass mat (5) from the bottom. Thereby, a thin resin film can be formed on the lower surface of the nonwoven fabric or glass mat (5) (not shown).

  After laminating the nonwoven fabric or glass mat (5) and the three glass fiber cloths 6 as described above, it is a kneaded product of the aggregate 9 and the uncured resin 8 as shown in FIG. The resin concrete 8a is dropped into the mold 1. The uncured resin 8 is desirably the same resin as the uncured resin 7 impregnated in the glass fiber cloth. Further, as the aggregate 9, for example, silica sand can be used. The mixing ratio of the aggregate 9 and the resin 8 is preferably such that the content of the aggregate 9 is 60% by mass or more and 90% by mass or less. Moreover, the dropped amount of the resin concrete 8a may be determined by the thickness according to the use of the multipurpose board to be manufactured.

  After dropping the required amount of resin concrete 8a, the glass fiber cloth 6 and the nonwoven fabric or glass mat (5) constituting the upper glass fiber resin layer 11 are placed in order. This state is shown in FIG. A resin-impregnated glass fiber cloth 6a is disposed on the first and third layers from the bottom, and an unimpregnated glass fiber cloth 6 is disposed on the second layer from the bottom. Further, the nonwoven fabric or the glass mat (5) is placed on the fourth layer from the bottom, that is, the uppermost layer. That is, this configuration is a line-symmetric structure with the base material layer 10 interposed therebetween, except that the order of placing the lower glass fiber resin layer 11 is reversed. The unimpregnated glass fiber cloth 6 and the non-woven fabric or glass mat (5) of the second layer from the bottom are allowed to stand until the uncured resin 7 penetrates from the adjacent resin-impregnated glass fiber cloth 6a. Thereby, the surface of the nonwoven fabric or glass mat (5) which is the uppermost layer is also covered with a thin film of the uncured resin 7. This state is shown in FIG. Even if it does not wait until the uncured resin 7 reaches the surface, it is pushed during the press described later and penetrates to the surface. Therefore, when it is desired to shorten the working time, it is not necessary to perform the above standing.

  After the materials are laminated in this manner, the press plate 2 is inserted into the mold 1 and pressed, and the entire uncured resins 7 and 8 are cured and integrated. This state is shown in FIG. Even if the dropped resin concrete 8a does not cover the whole, it spreads evenly throughout the press and forms the base material layer 10.

  Thereby, the resin concrete 8a becomes the base material layer 10, and the nonwoven fabric or the glass mat (5) and the glass fiber cloth 6 are integrated with the uncured resin 7 to become the glass fiber resin layer 11. The surface of the glass fiber resin layer 11 is covered with a resin film 15 of an uncured resin 7 that has penetrated a nonwoven fabric or a glass mat (5), and has high smoothness.

  As another manufacturing method, not only the glass fiber cloth 6 but also the non-woven fabric or the glass mat (5) may be impregnated in advance with the uncured resin 7 when laminating. When the non-woven fabric or glass mat (5) is difficult to penetrate the uncured resin 7, it can be quickly produced by applying the same resin as the uncured resin 7 to the surface in advance.

  When the glass fiber resin layer 11 is formed on both surfaces of the base material layer 10, after the uncured resin 7 is cured on one surface, the uncured resin 7 may be cured on the other surface. However, it is preferable to cure both surfaces together from the viewpoint of work efficiency and integrity with the base material layer 10.

  Such a heat-molded multipurpose board can further enhance the performance according to the application by applying a paint to the surface. Since the glass fiber resin layer 11 is present, and there is a nonwoven fabric or glass mat (5) in the vicinity of the surface and only covered with the resin film 15, it becomes easy to apply various kinds of paint on the surface. Yes.

  As the paint, when the multipurpose plate according to the present invention is used as a lid, it is preferable to apply a paint having an anti-slip effect in order to make it difficult to slip even if the surface is wet.

  3 and 4 show examples of usage patterns when the multipurpose plate 21 thus obtained is used as a lid. When the multipurpose plates 21, 21a, 21b are attached as the lids on the grooves 22, sufficient strength by the base material layer 10 and durability of the surface of the glass fiber cloth 6 and the nonwoven fabric or glass mat (5) covered with resin Due to its properties, it exhibits sufficient performance as a lid. The shape is not particularly limited, and may be a rectangle like the multipurpose plate 21a or a circle like the multipurpose plate 21b. That is, it can be used not only as a groove but also as a manhole cover material. Furthermore, if a material coated with the above-mentioned anti-slip paint is used, even if a person or a bicycle rides on it, such as a gutter beside a road, it can be used sufficiently.

  Further, as shown in FIG. 5, when the multipurpose board 31 according to the present invention is laid without gaps on the inner wall of the concrete groove 30, and the gap is sealed with an adhesive 32 or a seal, the concrete groove 30 is repaired promptly. be able to. The groove thus repaired has a smaller cross-sectional area than the original concrete groove 30, but since the surface is smooth, the flow rate of the water 33 is less likely to be attenuated, and the flow rate per hour can be improved than before the repair. it can.

DESCRIPTION OF SYMBOLS 1 Mold 2 Press board 5 Nonwoven fabric or glass mat 6 Glass fiber cloth 6a Resin impregnated glass fiber cloth 7 Uncured resin 8 Uncured resin 8a Resin concrete 9 Aggregate 10 Base material layer 11 Glass fiber resin layer 15 Resin film 21 , 21a, 21b, 31 Multipurpose plate 22 Groove 30 Concrete groove 32 Adhesive 33 Water

Claims (5)

It is a laminate in which a glass fiber resin layer is laminated on a base material layer,
The base material layer is composed of a plate obtained by curing a kneaded product of aggregate and uncured resin,
The glass fiber resin layer is formed by sequentially laminating one or a plurality of glass fiber cloths and a nonwoven fabric or a glass mat, and the uncured resin impregnated therein is integrated by being cured,
The multipurpose board | plate material with which the outer surface of said nonwoven fabric or glass mat is covered with the resin film which said uncured resin hardened.   The multipurpose board | plate material of Claim 1 in which the said glass fiber resin layer was formed in both surfaces of the said base material layer.   The multipurpose board | plate material of Claim 1 or 2 which apply | coated the coating material which has a non-slip effect on the surface of the said resin film.   The multipurpose plate material according to any one of claims 1 to 3, wherein the uncured resin and the resin constituting the plate are the same. On a non-woven fabric or glass mat, at least one glass fiber cloth is impregnated with one or more glass fiber cloths, which are resin-impregnated glass fiber cloths impregnated with uncured resin, on which aggregates and Place a kneaded product with uncured resin, and place on it one or more glass fiber cloths, at least one of which is a resin-impregnated glass fiber cloth in which a glass fiber cloth is impregnated with uncured resin. , Put a non-woven fabric or glass mat on it,
By pressing the whole to cure the uncured resin, the kneaded product is hardened as a plate-like base material layer, and the glass fiber cloth and the nonwoven fabric or glass mat are hardened as an integral glass fiber resin layer. The manufacturing method of the multipurpose board | plate material which covered the surface of the said glass fiber resin layer with the resin film which the said uncured resin which osmose | permeated to the surface of each nonwoven fabric or glass mat hardened | cured.

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