JP2012092582A - Fiber-reinforced resin sheet and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fiber-reinforced resin sheet for repair and reinforcement of a concrete structure, which can be easily stuck with a barrier layer surely on the outermost surface.SOLUTION: A fiber-reinforced resin sheet 100 for the repair or reinforcement of a concrete structure includes a transparent fiber-reinforced resin sheet composed by laminating and integrating an air impermeable barrier layer formed by curing a transparent curable resin composition (A) for the barrier layer and a fiber-reinforced resin main body layer for which a transparent curable resin composition (B) for a main body compatible with the barrier layer is impregnated and cured in a mesh body 10 with a prescribed opening formed by reinforcing fibers. The fiber-reinforced resin sheet 100 for the repair or reinforcement of the concrete structure is formed by winding a continuous sheet-like object formed by laminating a first release film on the surface of the barrier layer and a second release film on the surface of the fiber-reinforced resin main body layer in a roll shape with the first release film side (barrier layer side) on the outer side.

Description

  The present invention relates to a fiber reinforced resin sheet for repairing or reinforcing concrete structures such as concrete tunnels, elevated roadways, bridges, buildings, and the like, and a method for manufacturing the same, and further to a repair or reinforcing method for concrete structures. .

  In recent years, reinforced concrete structures at or near the coast are damaged by sea salt particles, or the structures deteriorate due to corrosion and expansion of the reinforcing bars caused by salt intrusion into reinforced concrete structures in contact with seawater. Or deterioration of concrete due to weakening of the surface layer due to substances that are harmful to concrete, such as acid rain and chemicals in factories, or excessive traffic to structures due to increased vehicle traffic, increased loading capacity, speeding up, etc. A major problem is that the surface portion of the concrete structure is cracked or peeled off due to a load or the like, and the concrete structure itself is deteriorated.

  Various methods for preventing the peeling of the deteriorated concrete, various methods for repairing the cracked portion and the peeled portion, and materials thereof have been studied. Among them, in a sheet for repair or reinforcement in which a protective layer serving as a surface layer and an adhesive layer to a concrete structure are provided in advance and a reinforcing layer composed of a fiber base material is interposed between these layers, the fiber As a base material, a method using a nonwoven fabric or a woven fabric processed sheet of organic fiber or inorganic fiber has been proposed as a construction method capable of facilitating construction and stabilizing quality (Patent Document 1). reference).

On the other hand, after repairing the cracked portion of the deteriorated concrete, it is also important for the management of the concrete structure to visually observe the progress of defects such as cracks at the repaired site. However, in the conventional general repair method, since the surface is covered with a covering material such as a fiber base material, it is difficult to visually observe them.
Patent Document 2 proposes a method for forming a concrete reinforcing layer in which a reinforcing net is directly attached to a concrete surface with a visible curable vinyl ester resin having a total light transmittance of 30% or more (see Patent Document 2).

  In addition, a fiber reinforcement for repairing / reinforcing a concrete structure, comprising a mesh body in which monofilaments of sea-island type composite organic fibers are arranged in a net-like manner at intervals, and a sheet-like transparent resin enclosing the mesh body A resin sheet has been proposed (see Patent Document 3).

JP 2002-256707 A JP 2007-2514 A JP 2009-61718 A

However, the repair / reinforcing sheet described in Patent Document 1 does not take into account the visual observation of the concrete surface after construction, and it is impossible to observe the presence or absence of cracks, their degree, changes with time, and the like.
In addition, the method described in Patent Document 2 inevitably involves applying a visible light curable vinyl ester resin for fixing the reinforcing net and the reinforcing sheet at the construction site, and repairing the site with an unstable scaffold. Or the simplification and shortening of the reinforcement work have been requested.
On the other hand, the fiber reinforced resin sheet described in Patent Document 3 can be visually observed on the concrete surface, but it is considered difficult to completely eliminate pinhole-shaped through holes from the fiber reinforced resin sheet. . If there is a through-hole, uncured adhesive is likely to leak out, and when the surface is rubbed with a roller or the like during construction application, the adhesive will be spread on the surface where the adhesive has leaked. It may cause trouble in construction such as wiping off the adhesive.Furthermore, if the adhesive is not completely wiped off, dirt will easily adhere to the surface. There was. (Since the adhesive has a slime-like viscosity, it will not fall off due to its own weight, but it will squeeze with a roller when sticking the sheet, so the leaked adhesive will be spread on the surface)
Therefore, according to Japanese Patent Application No. 2009-68817 (filed on Mar. 19, 2009), the present applicant provided a barrier layer as a method for preventing a through hole, and repaired or reinforced fiber reinforcement for a concrete structure that blocked the penetration. A resin sheet was provided. However, even in this fiber reinforced resin sheet, though the through holes are blocked, it is inevitable that bubbles are generated in the transparent resin layer, and there is an appearance problem (including misunderstanding that there may be through holes). ) And other issues.

Furthermore, in the fiber reinforced resin sheet provided in this Japanese Patent Application No. 2009-68817, when a barrier layer is formed on one side, both the barrier layer and the fiber reinforced resin sheet are made of a transparent curable resin. It is difficult to identify.
And in the fiber reinforced resin sheet, the barrier layer side is considered to be used as the surface side, and the fiber reinforced resin main body layer side is used as the concrete structure side, in consideration of the expression of the reinforcing effect by the mesh body, The surface resin layer on the fiber reinforced resin main body layer side is made thinner. For this reason, if the barrier layer side is accidentally applied with the barrier layer side facing the concrete structure side, the fiber layer of the fiber reinforced resin main body layer on the surface side is subject to weathering deterioration, physical action such as rubbing and scratching. As a result, there is a concern that the fibers constituting the mesh body may be exposed, and there are concerns about problems in appearance, mechanical properties, and durability.
From these points, there has been a demand for a fiber reinforced resin sheet for repairing / reinforcing a concrete structure that can be easily attached and applied with the barrier layer as the outermost surface.
In other words, the surface of the concrete structure can be observed, and there are fewer bubbles in the sheet-like transparent resin layer that encloses the mesh body, and the barrier layer can be easily identified during construction for reinforcement or repair of the concrete structure. There has been a demand for a transparent fiber-reinforced resin sheet.

  Therefore, in the present invention, as a result of earnestly examining the fiber reinforced resin sheet for repairing or reinforcing concrete structures such as concrete tunnels, elevated carriageways, bridges, buildings, etc., which can solve the above problems, the surface of the barrier layer The first release film is a continuous sheet formed by laminating the second release film on the surface side of the fiber reinforced resin main body layer, and the first release film side (barrier layer side) is the outside. It discovered that the said subject could be solved by winding in roll shape and providing what is called a curl to a fiber reinforced resin sheet.

That is, the present invention provides the following [1] to [7].
[1] A non-breathable barrier layer obtained by curing the transparent curable resin composition for barrier layer (A);
A fiber reinforced resin body layer impregnated and cured with a transparent curable resin composition for body (B) having compatibility with the barrier layer on a mesh body in which predetermined openings are formed by reinforcing fibers is laminated and integrated. A fiber reinforced resin sheet for repairing or reinforcing a concrete structure containing a transparent fiber reinforced resin sheet,
The first release film is formed on the surface of the barrier layer, and the continuous sheet-like product in which the second release film is laminated on the surface of the fiber reinforced resin main body layer is formed on the first release film side ( A fiber-reinforced resin sheet for repairing or reinforcing a concrete structure, wherein the sheet is wound in a roll shape with the barrier layer side facing outward.
[2] In the above [1], the first release film constitutes a carrier film in the production process of the fiber reinforced resin sheet, and the second release film constitutes a cover film in the production process of the fiber reinforced resin sheet. A fiber-reinforced resin sheet for repair or reinforcement of the concrete structure described.
[3] The mesh body is a laminated fabric, and sea-island composite yarns are laminated in at least three directions of warp, oblique, and reverse oblique directions, and the sea-island composite yarns are heat-sealed. The fiber-reinforced resin sheet according to [1] or [2], which is a warp monolayer or warp bilayer triaxial laminated fabric.
[4] Any of [1] to [3], wherein the transparent curable resin composition for barrier layer (A) and the transparent curable resin composition for main body (B) are (meth) acrylic resin compositions. The fiber-reinforced resin sheet of crab.
[5] A method for producing a fiber structure reinforced resin sheet for repairing or reinforcing a concrete structure obtained by impregnating and curing a transparent curable resin composition (B) for a main body in a mesh body, the production method comprising: The manufacturing method of the fiber reinforced resin sheet characterized by including process (1)-(5).
(1) A barrier layer forming step in which the transparent curable resin composition for barrier layer (A) is applied on a carrier film, sandwiched between cover films and cured, and then the cover film is peeled off to expose the barrier layer.
(2) A liquid layer forming step of applying the main body transparent curable resin composition (B) on the barrier layer formed on the carrier film.
(3) The mesh body was made to enter the liquid layer from the upper surface of the liquid layer of the transparent curable resin composition (B) for the main body, and a cover film was placed on the upper surface to form the carrier film. An impregnation step of impregnating the transparent curable resin composition for main body (B) into a mesh body sandwiched between the barrier layer.
(4) A curing step for curing the transparent curable resin composition (B) for the main body.
(5) The fiber reinforced resin sheet cured through the step (4), the cover film as the second release film, the carrier film in contact with the barrier layer as the first release film, and the first release film side as the outside Winding process for winding into a roll.
[6] The method for producing a fiber-reinforced resin sheet according to [5], wherein the cover film peeled off in the barrier layer forming step (1) is continuously reused in the impregnation step of (3).
[7] The fiber-reinforced resin sheet according to any one of claims 1 to 4 is cut into a predetermined size and shape, the second release film is peeled off, and the adhesive layer applied to the concrete structure is confronted, Repairing a concrete structure characterized by sticking a fiber reinforced resin sheet by pressing the upper surface of the first release film, then removing the first release film and exposing the barrier layer to the surface, or Reinforcement method.

The fiber reinforced resin sheet for repairing or reinforcing a concrete structure of the present invention is formed by laminating a first release film on the surface of the barrier layer and a second release film on the surface side of the fiber reinforced resin main body layer. Since the continuous sheet material is wound in a roll shape with the first release film side (barrier layer side) outside, so-called curl is imparted to the fiber reinforced resin sheet, so it is affixed to the concrete structure. When installing, for example, a fiber reinforced resin sheet cut to a fixed size according to a construction method such as 1000 mm square or 400 mm square, and the second release film on the fiber reinforced resin main body layer side is peeled off is applied to the barrier layer. Since the first release film side in contact is warped with the outer side facing, and the four corners of the fiber reinforced resin sheet are in contact with the concrete structure side, it is easy for the barrier layer side to be the outer surface side It can be confirmed.
And since the fiber reinforced resin sheet of the present invention can surely make the barrier layer the outer surface, the appearance defect due to accidentally setting the barrier layer to the concrete structure side and the fiber reinforced resin main body layer to the outer surface side. In addition, it is possible to effectively provide a highly reliable concrete structure repair or reinforcement fiber reinforced resin sheet by solving problems such as a decrease in reinforcement efficiency and a decrease in durability.
According to the method for producing a fiber reinforced resin sheet for repair or reinforcement of a concrete structure of the present invention, the fiber reinforced resin sheet for repair or reinforcement of the present invention can be efficiently produced.
Further, according to the concrete structure repair or reinforcement method of the present invention, it is possible to effectively and reliably carry out repair or reinforcement with the barrier layer side as the outer surface.

(A) The top view of an example of the fiber reinforced resin sheet for repair or reinforcement of the concrete structure of this invention, (B) AA sectional view taken on the line. It is a cross-sectional enlarged schematic diagram which shows the layer structure of the fiber reinforced resin sheet of this invention. (A) It is explanatory drawing of the core-sheath type composite fiber which comprises the sea-island type composite yarn as an example of a reinforcing fiber, (B) It is explanatory drawing of the sea-island type composite yarn which united the sheath component. It is all process explanatory drawing of an example of the manufacturing method of this invention. (A) The schematic diagram of the winding roll of the fiber reinforced resin sheet obtained in Example 1 of this invention, (B) The expansion schematic diagram which shows the layer structure of the fiber reinforced resin sheet in a winding roll. (A) The schematic diagram of the winding roll of the fiber reinforced resin sheet obtained by the comparative example 1 of this invention, (B) The expansion schematic diagram which shows the layer structure of the fiber reinforced resin sheet in a winding roll. The direction of the barrier layer is shown when the fiber reinforced resin sheet of the present invention is unwound from a winding roll, cut to a fixed size and then placed on a flat plate, (A) the barrier layer faces outward, (B) the barrier It is explanatory drawing showing the state where a layer faces inside.

  Hereinafter, preferred embodiments of the present invention will be described. Each embodiment shown in the accompanying drawings shows an example of a typical embodiment according to the present invention, and the scope of the present invention is not interpreted narrowly.

The fiber reinforced resin sheet for repairing or reinforcing a concrete structure of the present invention has a non-breathable barrier layer formed by curing the transparent curable resin composition for barrier layer (A), and a predetermined opening by the reinforcing fiber. A transparent fiber reinforced resin obtained by laminating and integrating a fiber reinforced resin main body layer in which the formed mesh body is impregnated and cured with the transparent curable resin composition (B) for the main body having compatibility with the barrier layer. A fiber reinforced resin sheet for repairing or reinforcing a concrete structure including a sheet, wherein a first release film is laminated on the surface of the barrier layer, and a second release film is laminated on the surface of the fiber reinforced resin main body layer The continuous sheet-like material thus formed is wound into a roll shape with the first release film side (the barrier layer side) as the outside.
For roll-up winding, a fiber reinforced resin sheet is fixed to the outer periphery of either a winding core with a predetermined outer diameter attached to a rotating shaft center or a shaft core with a diameter-reducing shaft core expanded. The fiber reinforced resin sheet is continuously wound by rotating the rotating shaft in a predetermined direction. At this time, in the process diagram of FIG. 4, the winder 61 is set in the arrow direction, that is, in the clockwise direction, In the process diagram of FIG. 4, the barrier layer 101 formed on the cure rear film 21 is wound up outward as shown in FIG.

By winding in this way, a winding wrinkle is generated in combination with the diameter D of the winding core 30, winding tension, characteristics of the transparent curable resin, etc., rewinding, cutting into a predetermined dimension, and concrete structure It is convenient for construction to adhere to an object with an adhesive.
That is, when the fiber reinforced resin sheet is placed on the flat surface L (concrete structure surface) as shown in FIG. For example, the four corners of the fiber-reinforced resin sheet cut into a rectangular shape come into contact with the flat surface first.
Then, when adhering to the surface of the concrete structure with an adhesive, the four corners and end surfaces with a high degree of freedom are formed as shown in FIG. 7B, in which the barrier layer has a downwardly curved shape. Since there is no warping, the sticking work can be carried out smoothly and the construction efficiency is improved.
The winding diameter D (the outer diameter of the core) in the case of winding in a roll shape is preferably about 100 mm to 600 mm in terms of the relationship with the curl and the handling in the roll shape.

In the present invention, the non-breathable barrier layer is a layer for preventing the uncured adhesive applied to the concrete surface from leaking out if a pinhole is present in the fiber reinforced resin main body layer. It is. The non-breathable barrier layer preferably has an ability to suppress the water vapor permeability to 10 g / m ² · 24 h or less in measurement according to JIS Z0208.

In the fiber reinforced resin sheet of the present invention, the thickness of the barrier layer is preferably 50 to 60 μm, and if it is in the range of 50 to 60 μm, the adhesive applied during repair or reinforcement work on the concrete structure penetrates. The phenomenon of leakage due to swelling does not occur, and the function as a barrier layer for preventing leakage can be expressed.
The thickness of the fiber reinforced resin sheet obtained by laminating and integrating a fiber reinforced resin main body layer impregnated and cured with a transparent curable resin having compatibility with the barrier layer in the mesh body with the barrier layer is 400 to 500 μm. It has flexibility that allows it to follow the surface of a concrete structure, and is preferable from the viewpoints of handleability, workability, lightness, reinforcing effect, economy, and the like.
The fiber reinforced resin sheet of the present invention contains almost no bubbles with a diameter of 2 mm or more when the number of bubbles having a diameter of 2 mm or more is 1 / m ² or less. This is preferable because the effect of repair or reinforcement of the concrete structure by the mesh body can be maximized.

In the present invention, the mesh body in which the predetermined openings are formed by the reinforcing fibers can be selected from one or a combination of two or more of woven fabric, net, knitted fabric, and laminated fabric, and laminated fabric is preferably used. be able to.
The laminated fabric is also referred to as a braided fabric, and a three-axis fabric laminated in at least three directions of warp direction, oblique direction, and reverse oblique direction can be generally used. Since the laminated fabric has low cost as a mesh body, there is also an economic merit. The laminated fabric can be produced, for example, by the method described in JP-A-11-20059.
The opening portion preferably has an opening ratio of 30% or more. When the opening ratio is less than 30%, it is difficult to observe the concrete surface layer.

The mesh body is a one-layer or two-ply triaxial laminated fabric obtained by laminating reinforcing fibers in at least three directions of warp direction, oblique direction, and reverse oblique direction, and heat-sealing the laminated sea-island type composite yarns. It can be.
FIG. 1A is a top view of an example of a fiber reinforced resin sheet for repairing or reinforcing a concrete structure of the present invention, and shows a state in which the mesh body 10 is visible through a transparent resin layer. In the mesh body shown in the figure, the reinforcing fiber 1 is used as a constituent yarn, and the oblique layer 13, the reverse oblique layer 14, and the upper warp layer 12 are laminated on the lower warp layer 11, and the intersection of each layer is thermally fused by heating. It is what I wore.
After the mesh body 10 is formed, the whole mesh body 10 may be thinned by further heating and pressing. Thereby, the softness | flexibility and flexibility of the mesh body 10 can be improved further. The heating temperature at that time is preferably close to the melting point of the thermoplastic resin constituting the sea. The pressurization can be performed by a method such as roller pressing.

The reinforcing fiber used in the mesh body is vinylon fiber, polyester fiber, polyamide fiber, polyolefin fiber, aromatic polyamide fiber, as long as the physical properties such as fiber strength and elongation have a reinforcing effect as a constituent thread of the mesh body. It doesn't matter what kind.
In particular, the mesh body has a core-sheath type composite comprising: (a) a core component made of a polyolefin resin; and (b) a sheath component made of a polyolefin resin having a melting point 20 ° C. lower than the melting point of the core component. It is preferable to use a sea-island type composite yarn in which fiber sheath components are fused and to form a mesh body, particularly a triaxial laminated fabric, obtained by heat-sealing the intersection of the composite yarn.
Examples of the polyolefin-based resin that can be used for the sea-island composite yarn of the present invention include binary copolymers of olefins such as polyethylene, polypropylene, ethylene, propylene, and butene-1, and ternary copolymers.
Suitable combinations of the core component and the sheath component include, for example, a combination using isotactic polypropylene (mp = 163 ° C.) as the core component and linear low density polyethylene (mp = 110 ° C.) as the sheath component.
Such a sea-island type composite yarn is spun to have a predetermined sheath / core cross-section ratio by using, for example, a spin draw method, using a conventional composite spinning equipment and a core-sheath type composite spinning nozzle, and led to a drawing apparatus that is directly connected. It can be obtained by stretching under saturated water vapor pressure and fusing a plurality of fibers with a sheath component together with stretching. Moreover, it can manufacture by the method as described in Unexamined-Japanese-Patent No. 2003-326609.

In the sea-island type composite yarn, the mass ratio of the island part to the sea part is preferably 20:80 to 80:20. If the mass ratio of the island part to the total mass of the island part and the sea part is less than 20% by mass, the reinforcing effect by the mesh body tends to be small, and if it exceeds 80% by mass, the thermal bond strength tends to be low. From the same viewpoint, the mass ratio between the island and the sea is more preferably 40:60 to 70:30.
The fineness of the sea-island type composite yarn is preferably 100 to 5000 dtex. If it is less than 100 dtex, the intended physical properties tend to be difficult to obtain, and if it exceeds 5000 dtex, flexibility and followability tend to be impaired. A fineness of 500 to 3000 dtex is more preferable.

FIG. 3 is an explanatory view showing an embodiment of a sea-island type composite yarn.
In the embodiment of FIG. 3, the core-sheath type composite single fiber is formed by converging a plurality of core-sheath type composite single fibers 9 composed of a single core part (island part) 3 and a sheath part 5a covering the outer peripheral surface thereof. A sea-island type composite yarn having a form (FIG. 3B) in which the sheath 5a is melted while stretching the bundle 15 (FIG. 3A), and the sheath 5a is fused to form the sea 5 containing the plurality of islands 3. is there.

  As the transparent curable resin composition for barrier layer (A) and the transparent curable resin composition for main body (B), the transparent curable resin composition for barrier layer (A) and the transparent curable resin composition for main body (B ) Has compatibility (including adhesiveness after curing), and is selected from transparent resins having a function as a constituent material of the fiber-reinforced resin sheet in mechanical properties. As this type of resin composition, a resin composition containing a (meth) acrylic resin or vinyl ester resin as a main component is preferable.

The method for producing a fiber reinforced resin sheet for repairing or reinforcing a concrete structure according to the present invention includes the following steps (1) to (5).
(1) A barrier layer forming step in which a transparent curable resin composition for barrier layer (A) is applied on a carrier film, and is sandwiched and cured by a cover film, and then the cover film is peeled to expose the barrier layer;
(2) A liquid layer forming step of applying the transparent curable resin composition for main body (B) on the barrier layer formed on the carrier film,
(3) The mesh body was made to enter the liquid layer from the upper surface of the liquid layer of the transparent curable resin composition (B) for the main body, and a cover film was placed on the upper surface to form the carrier film. An impregnation step of impregnating the transparent curable resin composition (B) for the main body into the mesh body sandwiched between the barrier layers;
(4) a curing step for curing the transparent curable resin composition (B) for the main body, and (5) a fiber reinforced resin sheet cured through the step (4), a cover film as a second release film, and a barrier. A winding process in which the carrier film in contact with the layer is used as a first release film, and the first release film side is taken out as a roll.

  For application of the transparent curable resin composition for barrier layer (A) on the carrier film or the transparent curable resin composition for main body (B) on the cured barrier layer, a general coating apparatus is used. For example, gravure reverse, gravure direct, triple reverse, and die coat can be selected and used.

  FIG. 4 is a process explanatory view showing an example of the production method of the present invention. In the manufacturing method according to FIG. 4, the transparent curable resin composition (A) 20a for the barrier layer is applied on the carrier film 21, and is sandwiched and cured by the cover film 22 to form the barrier layer 101. Through the barrier layer forming step (1) in which the barrier layer is exposed by peeling 22, the main body transparent curable resin composition (B) 20 b is supplied from the pump 43 through the nozzle 48 onto the barrier layer.

In the barrier layer forming step (1), first, a transparent curable resin composition for a barrier layer (A) containing a polymerizable monomer for forming a barrier layer having a predetermined thickness on the carrier film 21 [in this embodiment, a barrier layer] The transparent curable resin composition for use (A) and the transparent curable resin composition for main body (B) are the same. ] 20a is prepared in the preparation tank 40a, put into the reserve tank 40, and applied to the carrier film 21 from the nozzle 42 by the pump 41 to form the liquid layer 20a ', and the cover film 22 is placed on the upper surface thereof. The first squeeze roller 52 is adjusted to a predetermined coating thickness, inserted into the heating furnace 70, and after curing, the cover film 22 is peeled off to form the barrier layer 101 made of the transparent curable resin composition for barrier layer (A). Form.
Next, a transparent curable resin composition (B) 20b for main body for forming a fiber reinforced resin main body layer (102) having a predetermined thickness on the barrier layer 101 is supplied (applied) to form a liquid layer (resin pool) 20b ′. The mesh body 10 was entered from the upper surface of the liquid layer 20b ′, impregnated / defoamed and adjusted in thickness with the impregnation roller 55, and further peeled off on the upper surface in the barrier layer forming step (1). The cover film 22 is placed, and the mesh body 10 sandwiched between the barrier layers by the squeeze roller 56 is impregnated with the liquid layer 20b ′ of the transparent curable resin composition for main body (B).
Next, the liquid layer 20 b ′ of the transparent curable resin composition for main body (B) impregnated in the mesh body 10 sandwiched between the cover film 22 and the carrier film 21 is cured in the curing furnace 71 and required. Then, it is wound up through the heat treatment in the heat treatment furnace 72. In this winding, as described above, the winding is continuously performed so that the barrier layer is on the outside.
In this embodiment, the cover film 22 is peeled off at the portion of the roller 53a after the barrier layer is cured in the barrier layer forming step, and again at the portion of the second squeeze roller 56 through the guide rollers 53b to 53c. 22 is reused. A tension roller (not shown) is provided between the guide rollers 53b to 53c to adjust the tension of the cover film 22 and adjust the speed balance with the carrier film 21 side.

The mesh body 10 is pre-impregnated with the transparent curable resin composition for pre-impregnation (C) (hereinafter, this step may be referred to as “pre-impregnation step”), and then the pre-impregnated mesh is used. When the body 10 is guided to the upper surface of the liquid layer 20b ′ of the transparent curable resin composition for main body (B), the generation of bubbles due to poor impregnation can be reduced. Such a pre-impregnating transparent curable resin composition (C) is preferably selected from those having a compatibility with the transparent curable resin composition for main body (B) and a viscosity of 50 to 15000 cP.
The transparent curable resin composition (C) for pre-impregnation includes, for example, a solvent such as a styrene monomer (viscosity 50 cP or less, 25 ° C.) and a thermosetting resin (viscosity 100 to 6000 cP, 25 ° C.) such as vinyl ester or unsaturated polyester. ), Which is compatible with the transparent curable resin composition for main body (B) (urethane acrylate). The lower the viscosity of the pre-impregnating transparent curable resin composition (C), the higher the deaeration effect. Therefore, the transparent curable resin composition for body (B) may be heated to lower the viscosity. . However, the thermosetting resin needs to be at a temperature at which no curing reaction occurs. Until the pre-impregnated mesh body 10a enters the liquid layer 20b 'of the main body transparent curable resin composition (B), the mesh body 10a is sent to the transparent curable resin for pre-impregnation. Since it is important to wet with the composition (C), when a solvent is used, it is necessary to promptly send it to the impregnation step (3) before volatilization.

  As the carrier film 21 and the cover film 22, for example, a polyester film such as polyethylene terephthalate or polyethylene naphthalate can be used. In FIG. 4, the cover film is peeled off after curing the cover film 22 used for forming the barrier layer, and this is introduced again from the site of the second squeeze roller 56 and used after the impregnation and curing steps. Yes. The carrier film 21 and the cover film 22 may be used as they are as the first release film 21 and the second release film 22. The release film protects the surface of the fiber reinforced resin sheet in the work and construction such as inspection, storage, transportation, and cutting after the fiber reinforced resin sheet is manufactured, and is removed after the completion of construction. is there.

Furthermore, the transparent curable resin composition for main body (B) [when the preliminary impregnation step is included, the transparent curable resin composition for preliminary impregnation (C) is also included. ] May contain an adhesive component. By including a pressure-sensitive adhesive component (for example, a tackifier), it becomes easy to adhere to the adhesive layer on the concrete structure side during construction, and effects such as rapid construction can be expected.
Moreover, a fiber reinforced resin sheet can be effectively protected by adhesion with a protective film.

A transparent curable resin composition for barrier layer (A) 20a, a transparent curable resin composition for main body (B) 20b, and a transparent curable resin composition for pre-impregnation (C) when a pre-impregnation step is included. As the transparent curable resin, for example, a composition containing a (meth) acrylic resin and a polymerizable monomer having an acryl group or a methacryl group can be used. Examples of the polymerizable monomer include urethane (meth) acrylate and (meth) acrylic acid ester.
The said transparent curable resin composition (A)-(C) may further contain a ultraviolet absorber, antioxidant, etc. within the range from which desired transparency is acquired. The viscosity of the transparent curable resin composition for main body (B) and the transparent curable resin composition for barrier layer (A) other than the above-described transparent curable resin composition for pre-impregnation (C) is 50 to 15000 cP. Preferably, it is 800-1000 cP.
When the viscosity of the transparent curable resin composition for barrier layer (A) and the transparent curable resin composition for main body (B) is low, dripping tends to occur, and the viscosity of the curable resin composition is high. There is a tendency that bubbles are easily generated in the formed transparent resin layer due to poor impregnation.

The transparent curable resin compositions (A) to (C) may be of a radiation curable type, and in this case, they can be cured by irradiation with radiation after coating.
As the radiation curable resin, a prepolymer (or oligomer) that cures by causing a crosslinking or polymerization reaction by radiation, a monomer, or a mixture of both is used. As such a prepolymer, urethane (meth) acrylate, epoxy (meth) acrylate, (meth) acrylate compounds such as polyester (meth) acrylate, unsaturated polyester, epoxy compounds and the like are used. Examples of the monomer include (meth) acrylate compounds such as diethylene glycol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, dipentaerythritol hexa (meth) acrylate, and 3,4-epoxycyclohexenylmethyl-3. Alicyclic epoxides such as', 4'-epoxycyclohexenecarboxylate, glycidyl ethers such as bisphenol A diglycidyl ether, vinyl ethers such as 4-hydroxybutyl vinyl ether, oxetanes such as 3-ethyl-3-hydroxymethyloxetane, etc. Used. Here, (meth) acrylate is a notation that means acrylate or methacrylate. As the radiation, particle beams such as electron beams, or electromagnetic waves such as ultraviolet rays, visible rays, and X-rays are used. In particular, when curing with ultraviolet rays or visible rays, benzophenone, acetophenone, aromatic iodonium, metallocene compounds and the like are usually added as photoinitiators.

  The mesh body 10 preferably adjusts the wettability of the surface as necessary in order to improve the adhesiveness with each resin that comes into contact with the fiber-reinforced resin sheet. The wettability of the surface may be appropriately adjusted according to each of the resins, but it is generally preferable to adjust the wettability index to a range of 55 to 75 mN / m. In particular, when the sea part 5 of the monofilament constituting the mesh body 10 is made of polyolefin, the surface activity is low, so that the adhesion between the monofilament and the transparent cured resin 20 is lowered, and the reinforcing effect by the fiber reinforced resin sheet 100 is reduced. Since there is a tendency or when the protective film 21 or 22 is peeled off, a part of the transparent resin 20 tends to be peeled off to the protective film side, and thus the mesh body 10 whose surface wettability is adjusted by the hydrophilization treatment. It is effective to use. Examples of the hydrophilic treatment include corona discharge treatment and plasma treatment.

  The cross-sectional enlarged view of the fiber reinforced resin sheet obtained by the manufacturing method of this invention is shown in FIG. In the figure, the constituent fibers of the mesh body are also embedded in the barrier layer 101 side. This is because the surface of the barrier layer 101 once cured is uncured transparent curable resin composition for body (B ) Swells due to the compatibility with each other, so that the mesh body 10 is affected by the impregnation roller 55, the second squeeze roller 56, and the like, and a part of the mesh body 10 is also embedded on the barrier layer side. Such an interface state with the barrier layer is preferable as the fiber reinforced resin sheet hardly causes interface peeling. In addition, in the same figure, the 1st mold release film 21 and the 2nd mold release 22 also serve as the carrier film 21 and the cover film 22 at the time of manufacture, and are peeled off at the time of construction or after construction as a fiber reinforced resin sheet. The

  Hereinafter, although an example and a comparative example explain the present invention, the present invention is not limited to these examples.

(Preparation of mesh body)
Isotactic polypropylene (mp = 163 ° C) for the core component, linear low-density polyethylene (mp = 110 ° C) with a metallocene catalyst for the sheath component, and a total fineness of 1. A sea-island type composite yarn having 850 dtex and 240 filaments was obtained (spin draw method). The sea-island type composite yarn had a tensile strength of 6.5 cN / dtex, an elongation of 15%, a Young's modulus of 92.0 cN / dtex, and a heat shrinkage measured at 140 ° C. of 6.8%. .

The obtained sea-island type composite yarn is placed in a laminated fabric manufacturing apparatus, and warp yarns, oblique yarns and reverse oblique yarns are laminated at a pitch of 10 mm in three directions of warp direction, oblique direction and reverse direction, and then the surface temperature By contact heating with a 150 ° C. heating roller, the sea part resin of the composite yarn was melted to obtain a triaxial mesh body in which the composite yarn of each layer was bonded. The mesh was 10 mm, and the mass per unit area was 65 g / m ² .

(Formation of barrier layer)
UV curing for forming a non-breathable barrier layer made of a transparent resin by adding 4 parts by weight of a photocuring initiator to 100 parts by weight of a mixed solution of urethane acrylate and methacrylate (viscosity 1000 cP, 25 ° C.) Liquid composition (A) was prepared.
This liquid composition is applied onto a polyethylene terephthalate film (thickness 50 μm) as a carrier film, and the upper surface thereof is sandwiched between cover films (thickness 25 μm). The total thickness including both films is 125 μm. Adjusted.
Next, both surfaces were irradiated with black light in an ultraviolet curing furnace for 1 minute (irradiation energy: 300 mJ / cm ² ) and photocured, and then thermally cured at 100 ° C. for 10 minutes, the cover film was peeled off, and the carrier A non-breathable barrier layer having a thickness of 50 μm supported by the film was formed.

(Lamination integration of barrier layer and fiber reinforced resin main body layer)
Next, according to the process shown in FIG. 4, the carrier film 21 and the non-breathable barrier layer 101 formed thereon are continuously supplied, and the ultraviolet curable liquid composition (A) is used for the main body. The curable resin composition (B) is supplied to form the liquid layer 20 b ′, the mesh body 10 is supplied to the upper surface of the coating liquid layer 20 b ′ having a predetermined thickness by the coating roller 55, and the liquid resin is fed by the impregnation roller 55. After impregnating the composition (A), the film is sandwiched between the previously peeled cover film 22 (polyethylene terephthalate film (thickness 25 μm)) and squeeze roller 56 so that the total thickness including both films becomes 400 μm. And the mesh body was impregnated with the liquid composition (A).
Thereafter, both surfaces were photocured for 5 minutes with a black light in an ultraviolet curing furnace as the curing furnace 71 of FIG. 4 and then thermally cured by heating at 100 ° C. for 10 minutes in a heat treatment furnace 72 to obtain a fiber reinforced resin sheet. Got.

Example 1
The obtained fiber reinforced resin sheet 100 is taken up through a roller-type take-up machine 60, and the core 30 having an outer diameter D of 140, 220, 300, 400, and 500 mm is prepared, and a torque-controlled take-up machine Was wound with the first release film 21 and the barrier layer 101 outside (see FIGS. 5A and 5B).
Next, the second release (PET) film 22 on the fiber reinforced resin main body side 102 (the anti-barrier layer side) is cut into 1000 mm square and 400 mm square from scrolls having different core diameters D so that the barrier layer 101 faces the outside. And the floating state of the four corners of the square sample was observed when it was placed on the flat plate L as shown in FIG. Samples of any winding diameter were curved as shown in FIG. 7A, and no floating at the four corners was observed on the flat plate L. The results are shown in Table 1.
For each sample, when the barrier layer side was the upper surface and an epoxy adhesive (made by Japan-US resin: XL-1902) was applied to the fiber reinforced resin main body layer 102 side and pasted on the concrete piece, none of them stuck It was confirmed that it can be attached.

Comparative Example 1
The winding direction of Example 1 is adjusted so that the rotation direction of the winder and the position of the winding shaft are as shown in FIG. 30 m of each was wound up using the core 30. Like Example 1, it cuts into 1000 mm square and 400 mm square from a roll, peels the 2nd mold release (PET) film 22 by the side of the main body layer 102 so that a barrier layer may become an outer side, and it mounts on the flat plate L as shown in FIG. When the sample was placed, the floating state of the four corners of the square sample was observed. As shown in FIG. 7B, the samples having any winding diameter were convexly curved downward (flat plate side), and on the flat plate L, the four corners were in a state of being completely lifted (warped). The results are shown in Table 1.
As in Example 1, when an epoxy adhesive (XL-1902: made from Japan-US resin) was applied and pasted on a concrete piece, four corners floated immediately after pasting, and could not be pasted neatly. It was.

The fiber reinforced resin sheet for repairing or reinforcing a concrete structure according to the present invention is wound in a roll shape with the first release film side (barrier layer side) outside, so that a so-called curl is imparted to the fiber reinforced resin sheet. Therefore, at the time of construction, the four corners of the fiber reinforced resin sheet cut to a predetermined size are in contact with the concrete structure side, and it can be easily confirmed that the barrier layer side is the outer surface side, which is efficient. It can be used as a fiber reinforced resin sheet capable of repairing or reinforcing concrete structures.
Further, since the fiber reinforced resin sheet of the present invention can reliably make the barrier layer the outer surface, the appearance defect due to accidentally setting the barrier layer to the concrete structure side and the fiber reinforced resin main body layer to the outer surface side. In addition, it is possible to effectively use a highly reliable concrete structure repair or reinforcement fiber-reinforced resin sheet that can eliminate problems such as a decrease in reinforcement efficiency and a decrease in durability.
The method for producing a fiber reinforced resin sheet for repair or reinforcement of a concrete structure of the present invention can be used as a method for efficiently producing the fiber reinforced resin sheet for repair or reinforcement of the present invention.
Furthermore, the repair or reinforcement method for a concrete structure of the present invention can be effectively used as a repair or reinforcement method that allows the barrier layer side to be the outer surface easily and reliably.

1 Reinforcing fiber (Umijima type composite yarn)
3 core (island)
5a sheath part 5 sea part 9 core-sheath type composite monofilament 10 mesh body 10a pre-impregnated mesh body 11 lower warp (layer)
12 Upper warp (layer)
13 Oblique yarn (layer)
14 Reverse diagonal thread (layer)
15 Core-sheath type composite single fiber bundle 20a Transparent curable resin composition for barrier layer (A)
20b Transparent curable resin composition for main body (B)
20a ′ Liquid layer of transparent curable resin composition for barrier layer (A) 20b ′ Liquid layer of transparent curable resin composition for main body (B) 21 Carrier film (first release film)
22 Cover film (second release film)
30 core 40 reserve tank 40a preparation tank 41, 43 pump (resin composition supply pump)
42, 48 Nozzle 50, 54 Application roller 51, 52 First squeeze roller 53a, 53b, 53c Guide roller 55 Impregnation roller 56 Second squeeze roller 60 Picker 61 Winder 70, 71 Curing furnace 72 Heat treatment furnace 100 Fiber reinforced resin Sheet 101 Barrier layer 102 Fiber reinforced resin main body layer D Core diameter L Flat plate

Claims (7)

A non-breathable barrier layer obtained by curing the transparent curable resin composition (A) for the barrier layer;
A fiber reinforced resin main body layer obtained by impregnating and curing a transparent curable resin composition for main body (B) having compatibility with the barrier layer in a mesh body in which predetermined openings are formed by reinforcing fibers;
A fiber reinforced resin sheet for repairing or reinforcing a concrete structure including a transparent fiber reinforced resin sheet that is laminated and integrated,
The first release film is formed on the surface of the barrier layer, and the continuous sheet-like product in which the second release film is laminated on the surface of the fiber reinforced resin main body layer is formed on the first release film side ( A fiber-reinforced resin sheet for repairing or reinforcing a concrete structure, wherein the sheet is wound in a roll shape with the barrier layer side facing outward.   2. The concrete structure according to claim 1, wherein the first release film constitutes a carrier film in a production process of a fiber reinforced resin sheet, and the second release film constitutes a cover in the production process of the fiber reinforced resin sheet. A fiber-reinforced resin sheet for repair or reinforcement.   The mesh body is a laminated fabric, and the sea-island type composite yarn is laminated in at least three directions of warp direction, oblique direction, and reverse oblique direction, and the sea-island type composite yarns are heat-sealed to each other or The fiber-reinforced resin sheet according to claim 1 or 2, wherein the fiber-reinforced resin sheet is a bilayer triaxial laminated fabric.   The fiber reinforced according to any one of claims 1 to 3, wherein the transparent curable resin composition for barrier layer (A) and the transparent curable resin composition for main body (B) are (meth) acrylic resin compositions. Resin sheet. It is a fiber reinforced resin sheet for repairing or reinforcing a concrete structure obtained by impregnating and curing a transparent curable resin composition (B) for a main body in a mesh body, and the production method includes the following steps (1) to ( 5) The manufacturing method of the fiber reinforced resin sheet characterized by including.
(1) A barrier layer forming step in which the transparent curable resin composition for barrier layer (A) is applied on a carrier film, sandwiched between cover films and cured, and then the cover film is peeled off to expose the barrier layer.
(2) A liquid layer forming step of applying the main body transparent curable resin composition (B) on the barrier layer formed on the carrier film.
(3) The mesh body was made to enter the liquid layer from the upper surface of the liquid layer of the transparent curable resin composition (B) for the main body, and a cover film was placed on the upper surface to form the carrier film. An impregnation step of impregnating the transparent curable resin composition for main body (B) into a mesh body sandwiched between the barrier layer.
(4) A curing step for curing the transparent curable resin composition (B) for the main body.
(5) The fiber reinforced resin sheet cured through the step (4), the cover film as the second release film, the carrier film in contact with the barrier layer as the first release film, and the first release film side as the outside Winding process for winding into a roll.   The method for producing a fiber-reinforced resin sheet according to claim 5, wherein the cover film peeled off in the barrier layer forming step (1) is continuously reused in the impregnation step of (3).   The fiber reinforced resin sheet according to any one of claims 1 to 4 is cut into a predetermined size and shape, the second release film is peeled off, and the adhesive layer applied to the concrete structure is opposed to the first release. A method for repairing or reinforcing a concrete structure, comprising: sticking a fiber reinforced resin sheet by pressing the upper surface of a mold film; then peeling and removing the first release film to expose a barrier layer on the surface.

Images