JP2019034486A - Method for molding cured body - Google Patents

Abstract

To provide a method for molding a cured body capable of forming even a cubic object with a complicated shape whose realization is impossible in conventional methods.SOLUTION: A method for molding a cured body including a fiber bundle F0 obtained by converging a plurality of single fibers, comprises: impregnating the continuous fiber bundle F0 with an inorganic hydraulic matrix M to form an impregnated fiber bundle F; and continuously feeding the impregnated fiber bundle F is through a feed nozzle 10 and an impregnated fiber bundle feed part 40 composing fiber bundle feed means to form a molded body and to cure the same.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for forming a cured body.

Conventionally, alkali-resistant glass fibers containing ZrO ₂ have been widely used as reinforcing materials for glass fiber reinforced concrete (GRC) because they are hardly corroded by alkali components contained in cement. It plays the role of improving strength and impact strength.
Here, the GRC molding method mainly includes a premix method and a spray method.

  The premix method is a method in which chopped strands in which glass fibers are cut to a length of 5 to 40 mm are mixed with mortar composed of cement, aggregate, water, admixture, and the like, and then molded into a predetermined shape. The molding method is used in combination with a mechanical molding method such as a casting method, an extrusion method, a pressing method, and a press dewatering method.

On the other hand, in the spray method, mortar pumped by a mortar pump and glass fibers having a length of 10 to 50 mm cut by a roving cutter are simultaneously blown by air pressure from different outlets of the spray gun to reach the mold surface, and then removed. This is a method of compacting with a foam roller.
According to this molding method, since the glass fibers are randomly oriented without being damaged, a thin GRC having high bending strength can be obtained.

By the way, in recent years, a so-called 3D printer, which is a three-dimensional modeling apparatus that forms solid objects by laminating arbitrary materials such as resin and metal little by little, has been attracting attention.
By using such a 3D printer, it is possible to form a three-dimensional object having a complicated shape that cannot be realized by a normal method by stacking arbitrary materials.
Note that 3D printer systems that are currently in practical use include, for example, a binder injection type, a material extrusion type, and a liquid tank photopolymerization type.

  Among these, the 3D printer based on the material extrusion type is a three-dimensional object (three-dimensional object) based on a computer-aided design (CAD) model by extruding a fluid material from a nozzle provided in the extrusion head. Is used to build a layer.

In this system (sometimes referred to as “Fused Deposition Modeling” or “FDM”), the material is inserted into the extrusion head as a filament of thermoplastic resin (eg, ABS resin). , Continuously extruding on the XY plane substrate in the chamber from the nozzle provided in the extrusion head while heating and melting, and depositing and fusing the extruded resin on the already deposited resin laminate, A configuration of cooling and solidifying integrally is widely used.
In the FDM method, a three-dimensional object based on a CAD model is usually constructed by repeating the extrusion process while the nozzle position with respect to the substrate rises in the Z-axis direction that is perpendicular to the XY plane. (See, for example, “Patent Document 1”).

Japanese translation of PCT publication No. 2003-502184

  Here, also in the molding method of GRC, a method for obtaining a complicated shape that cannot be realized by a normal method such as a spray method or a premix method is required. In particular, when continuous fibers are used, there is no method other than the filament winding method. Therefore, a method for realizing a complicated shape using continuous fibers is required.

  The present invention has been made in view of such current problems, and provides a method for forming a cured body that can be formed even with a three-dimensional object having a complicated shape that cannot be realized by a normal method. This is the issue.

  The problem to be solved by the present invention is as described above. Next, means for solving the problem will be described.

  The method for forming a cured body according to the present invention is a method for forming a cured body containing a fiber bundle formed by bundling a plurality of single fibers, and impregnating the fiber bundle by impregnating a continuous fiber bundle with an inorganic hydraulic matrix. Is formed, and the impregnated fiber bundle is continuously fed out by a fiber bundle supply means to form a molded body and harden it.

  According to such a configuration, it is possible to provide a method for forming a cured body that can be formed even with a three-dimensional object having a complicated shape that cannot be realized by a normal method.

Further, in the method for molding a cured body according to the present invention, the fiber bundle is composed of 12% by mass or more of ZrO ₂ and 10% by mass of R ₂ O (R is at least one selected from Li, Na and K). A glass fiber bundle in which the glass single fibers contained above are bundled is preferable.

  According to such a configuration, since the fiber bundle has high alkali resistance, the shape of the cured body can be maintained over a long period of time.

  In the method for molding a cured body according to the present invention, the inorganic hydraulic matrix is preferably a cement-based matrix.

  According to such a configuration, a cured body having a desired rigidity can be obtained by appropriately adjusting the components of the cement-based matrix.

  Further, in the method for forming a cured body according to the present invention, the diameter of the glass single fiber is preferably 9 to 30 μm, and the number of focused glass single fibers in the glass fiber bundle is preferably 50 to 6000. .

  According to such a configuration, a cured body with sufficient mechanical strength can be obtained.

  In the method for molding a cured body according to the present invention, it is preferable that the glass fiber bundle has a film made of at least one water-soluble polymer component.

  According to such a configuration, the affinity of the inorganic hydraulic matrix for the glass fiber bundle is increased, and the glass fiber bundle is easily impregnated with the inorganic hydraulic matrix. Specifically, polyvinyl alcohol, polyvinyl pyrrolidone, polyoxyethylene polyoxypropylene glycol, bisphenol A epoxy EO, PO adduct, bisphenol A epoxy urethane-modified glycol adduct, and the like may be included. Moreover, said effect is expressed more by including surfactant with a molecular weight of 500 or less.

  Moreover, as for the molding method of the hardening body which concerns on this invention, it is preferable that a fiber bundle content rate is 1-50 wt%.

  That is, if the fiber bundle content is 1% or more, a cured product having minimum bending strength or prevention of cracking in the inorganic hydraulic matrix can be obtained, and if the fiber bundle content is 50% or less. The fiber is impregnated with the maximum amount of the inorganic hydraulic matrix, the shape can be maintained during lamination, and a cured body having sufficient mechanical strength can be obtained. More preferably, it is 5 to 30%, and it is possible to realize the above-mentioned effect efficiently in terms of cost.

  As effects of the present invention, the following effects can be obtained.

  According to the present invention, it is possible to provide a method for forming a cured body that can be formed even with a three-dimensional object having a complicated shape that cannot be realized by a normal method.

It is a schematic diagram which shows the modeling part of the three-dimensional modeling apparatus which implement | achieves the shaping | molding method of the hardening body which concerns on one Embodiment of this invention. It is a schematic diagram which shows the whole structure of the three-dimensional modeling apparatus which implement | achieves the shaping | molding method of the hardening body which concerns on one Embodiment of this invention. It is a perspective view which shows a cylindrical body. It is a figure which shows an orientation pattern.

Next, an embodiment of the invention will be described with reference to FIGS.
In addition, regarding the following description, the up-down direction of the modeling apparatus 1 is prescribed | regulated and described with the direction of the arrow shown in FIG. 1 for convenience.
Moreover, the conveyance direction of a fiber bundle is prescribed | regulated and described with the direction of the arrow A shown in FIG.

[Overall configuration of 3D modeling equipment by material extrusion]
First, the overall configuration of a three-dimensional modeling apparatus 1 (hereinafter simply referred to as “modeling apparatus 1”) of a cured body H that embodies a method for molding a cured body H containing a fiber bundle according to an embodiment of the present invention. Will be described with reference to FIGS. 1, 2, and 3.

As shown in FIGS. 1 and 2, the modeling apparatus 1 is a material extrusion type 3D printer, and uses a impregnated fiber bundle F impregnated with a predetermined inorganic hydraulic matrix M to form a cured body H (see FIG. 3). ).
The modeling apparatus 1 includes a supply nozzle 10, a mounting table 20 on which a three-dimensional object to be modeled (for example, a cylindrical body 200) is stacked, a position changing mechanism 30 that moves the supply nozzle 10 relative to the mounting table 20, and impregnation. An impregnated fiber bundle supply unit 40 that supplies the fiber bundle F to the supply nozzle 10, a modeling unit 70 that includes the base 50, and an impregnation unit 80 that is disposed on the upstream side of the modeling unit 70. Yes.

The supply nozzle 10 has a supply port for supplying the impregnated fiber bundle F to the mounting table 20 at the lower end, and the impregnated fiber bundle F is extruded from the supply nozzle 10 and the extruded impregnated fiber bundle F is placed on the mounting table 20. Supply as if pressed against.
In the present embodiment, it is assumed that the impregnated fiber bundle F is supplied downward from the tip of the supply nozzle 10, but the direction in which the impregnated fiber bundle F is supplied from the supply nozzle 10 is limited to the downward direction. It may be any direction such as upward or lateral direction. Further, the impregnated fiber bundle F may be extruded while the inorganic hydraulic matrix is introduced into this portion, or the fiber bundle impregnated with the inorganic hydraulic matrix may be mechanically extruded by a movable roller or the like.

  The position changing mechanism 30 includes a guide rail 31 that extends in the X-axis direction (the left-right direction in the present embodiment), and drive means (not shown) that slides the supply nozzle 10 in the X-axis direction with respect to the guide rail 31. Driving means (not shown) for sliding the mounting table 20 in the Y-axis direction (in this embodiment, the front-rear direction) with respect to the base 50, and the Z-axis direction (in this embodiment, from the base 50) A support column 32 erected in the vertical direction) and driving means (not shown) for sliding the guide rail 31 in the Z-axis direction with respect to the support column 32 are provided.

As each driving means of the position changing mechanism 30, for example, a belt mechanism driven by a stepping motor can be adopted.
In addition, pulse power can be used for the operation of the stepping motor.

That is, the computer calculates the moving path and moving speed of the supply nozzle 10 based on the three-dimensional data (3DCG, 3DCAD, etc.) of the shape of the cylindrical body 200 to be molded, and creates command data.
This command data is transferred to a pulse power control unit (not shown) of the modeling apparatus 1.
Then, based on the command data, the pulse power control unit of the modeling apparatus 1 may be configured to operate the supply nozzle 10 by applying pulse power to the stepping motor.

  A ball screw mechanism that is driven by a stepping motor may be employed instead of the belt mechanism.

Here, although details will be described later, in FIG. 2, the impregnation unit 80 includes an impregnation device 100 in which the inorganic hydraulic matrix M is stored, and allows the fiber bundle F0 to pass through the impregnation device 100 while being immersed therein. The impregnated fiber bundle F, which is the fiber bundle F0 impregnated with the inorganic hydraulic matrix M, is formed.
The impregnated fiber bundle F impregnated with the inorganic hydraulic matrix M is sent to the impregnated fiber bundle supply unit 40 (see FIG. 1) of the modeling unit 70.

[Method of forming cured body]
Next, the shaping | molding method which shape | molds the cylindrical body 200 which is an example of the hardening body H using the modeling apparatus 1 is demonstrated using FIG.1, FIG.2 and FIG.3.

  In the method for forming the cured body H according to the present embodiment, the impregnated fiber forming step of impregnating the fiber bundle F0 with the inorganic hydraulic matrix M to form the impregnated fiber bundle F and the supply nozzle 10 relative to the mounting table 20 are performed. A shaping step of forming and curing a molded body by continuously feeding the impregnated fiber bundle F from the supply port onto the mounting table 20 while moving the substrate.

In the impregnated fiber forming step, as shown in FIG. 2, the fiber bundle F0 is first drawn from the inner layer (inner peripheral surface) of the prepared roving R by being taken up by the take-up machine 110 provided in the downstream part of the step. The fiber bundle F0 is sent to a fiber opening device 90 including a plurality of tension bars 91, 91.
Note that the opening device 90 is not an essential configuration and can be used as necessary.

Here, the roving R is configured as a hollow cylindrical wound body in which continuous string-like fiber bundles F0 are wound so as to overlap each other.
Further, the fiber bundle F0 constituting the roving R is composed of a plurality of bundled single fibers.

Examples of the single fiber include glass single fiber, carbon single fiber, aramid single fiber, polypropylene single fiber, polyethylene single fiber, polyester single fiber, nylon single fiber, vinylon single fiber, and the like. Examples of the glass single fiber include E glass, AR glass, C glass, D glass, and S glass.
E glass is preferable because it is inexpensive and easily obtains a cured product H having excellent mechanical strength. Moreover, S glass is preferable because it is easy to obtain a cured product H that is more excellent in mechanical strength than E glass. AR glass is particularly preferable because it has high alkali resistance and is inexpensive.
When carbon fibers and aramid fibers are required to have higher tensile strength, organic fibers such as polypropylene fibers, polyethylene fibers, polyester fibers, nylon fibers and vinylon fibers are broken and stretched. Taking advantage of the degree, it can be used for the purpose of preventing the inorganic hydraulic matrix from falling off after the occurrence of cracks. Moreover, it is good also as a fiber bundle which mixed these fibers.

The fiber bundle F0 of the present embodiment has a glass composition containing ZrO ₂ of 12% by mass or more and R ₂ O (R is at least one selected from Li, Na and K) of 10% by mass or more. It is a glass fiber bundle in which continuous glass single fibers are bundled.
Moreover, the moisture content of the fiber bundle F0 is 0.5 mass% or less.

The surface of the fiber bundle F0 may be covered with a film.
For example, as a constituent component of the material of the film, for example, a polypropylene resin, a modified polypropylene resin, a nylon resin, a polyphenylene sulfide resin, and a polyurethane resin, which are thermoplastic resins, polyvinyl acetate, polyester, which are thermosetting resins, and the like And epoxy resin can be selected.
Examples of the modified polypropylene resin include maleic acid-modified polypropylene resin.

Fiber bundle F0 of the present embodiment, as a glass composition, because it contains glass filaments containing a ZrO ₂ or 12 wt%, is excellent in alkali resistance.
Therefore, even when used as a reinforcing material for the cured body H made of a cement-based material, the fiber bundle F0 is hardly eroded by the alkaline substance in the cement.
Therefore, it is possible to prevent the mechanical strength of the fiber bundle F0 from being lowered by the alkaline substance. In addition, the specific gravity is close to that of a cement-based matrix and is easy to mold because it is heavy.

Furthermore, glass containing 12% by mass or more of ZrO ₂ is difficult to melt, but the glass single fiber of the present embodiment contains 10% by mass or more of R ₂ O, and thus contains 12% by mass or more of ZrO _2. Even if it is, it is excellent in meltability.
Note that the _{R 2} O is 10 wt% or more, _Li 2 O in the glass filaments in, the total content of Na ₂ O and _{K 2} O, refers to at least 10 mass%.

  Moreover, it is preferable that the fiber bundle F0 has a film composed of at least one water-soluble polymer component.

  By having such a configuration, for example, in the later step, when the fiber bundle F0 is impregnated with the inorganic hydraulic matrix M to form the impregnated fiber bundle F, the affinity of the inorganic hydraulic matrix M with respect to the fiber bundle F0. It becomes easy to impregnate the inorganic hydraulic matrix M.

  In addition, as a component of water-soluble polymer, polyethylene oxide, polypropylene oxide, polyvinyl alcohol, etc. can be suitably selected, for example.

  In the fiber bundle F0 configured as described above, the count is not particularly limited, but is preferably 100 tex or more, and more preferably 1200 tex or more.

The fiber bundle F0 sent to the opening device 90 is repeatedly bent and gradually opened by passing through a plurality of tension bars 91, 91.
Thereby, the fiber bundle F0 will be in the state which the uncured inorganic hydraulic matrix M mentioned later is easy to be impregnated to the inside.

Then, the fiber bundle F0 opened by the fiber opening device 90 is subsequently sent to the impregnation device 100.
Here, in the impregnation apparatus 100, the uncured inorganic hydraulic matrix M is stored in advance.
The uncured inorganic hydraulic matrix M is charged into the impregnation apparatus 100 through the charging port 101 and replenished.

The fiber bundle F0 sent to the impregnation apparatus 100 is drawn into the impregnation apparatus 100 provided in the impregnation apparatus 100, and then conveyed while being immersed in an uncured inorganic hydraulic matrix M.
Thereby, the fiber bundle F0 is sufficiently impregnated with the uncured inorganic hydraulic matrix M.

The fiber bundle F0 impregnated with the uncured inorganic hydraulic matrix M is drawn out of the impregnation apparatus 100 by the impregnation apparatus 100.
Thereby, the impregnated fiber bundle F in which the fiber bundle F0 is impregnated with the inorganic hydraulic matrix M is formed.

Examples of the inorganic hydraulic matrix M include a cement matrix.
Moreover, when using a cement-type matrix, the hardening body which has desired rigidity can be obtained by adjusting the component suitably.
Furthermore, examples of the cement-based matrix include mortar obtained by mixing cement, aggregate, water, an admixture, an admixture, and the like. As the admixture, if the particle size can be controlled, such as silica fume having a small particle size, blast furnace slag fine powder, fly ash, etc., it is easy to ensure the thixotropic property of the matrix. It is also easy to ensure thixotropy by introducing a polymer. The mixing ratio of cement, aggregate, water, admixture, admixture, etc. may be adjusted as appropriate according to the size of the cured product H or the like.

  The impregnated fiber bundle F formed by the impregnated fiber forming step is then sent to the modeling unit 70 of the modeling apparatus 1.

Subsequently, as shown in FIG. 1, in the modeling step, the impregnated fiber bundle F sent to the impregnated fiber bundle supply unit 40 of the modeling unit 70 is moved while moving the supply nozzle 10 relative to the mounting table 20. A solid object (cylindrical body 200) is formed by supplying the supply nozzle 10 so as to be pushed out onto the mounting table 20 from the supply port.
The supply nozzle 10 and the impregnated fiber bundle supply unit 40 constitute fiber bundle supply means that can continuously feed the impregnated fiber bundle F.

What is necessary is just to set the quantity per unit time of the impregnated fiber bundle F supplied from the supply port of the supply nozzle 10 according to the size of the hardening body H, the required precision, etc.
Here, in the entire process of manufacturing the cured body H, the supply amount per unit time may be constant or may be appropriately changed.
For example, when forming a portion that appears on the surface of the cured body H, the supply amount per unit time is reduced, and when forming a portion that does not appear on the surface (internal structure), the supply amount per unit time is increased. May be.
In addition, during manufacture of the hardening body H, the distance from a supply port to the hardening body H should just be about 0.05-5.0 cm.

  The fiber bundle F0 (see FIG. 2) is composed of a plurality of glass single fibers, and in this embodiment, the diameters of the plurality of glass single fibers are set to 9 μm or more and 30 μm or less, respectively. The number of glass single fibers is set to be 50 or more and 6000 or less.

  In this way, by forming the fiber bundle F0 with a plurality of glass single fibers having a diameter of 9 μm or more and 30 μm or less and a number of glass single fibers of 50 μm or more and 6000 or less, the surface area is sufficiently increased A cured body H having a sufficient mechanical strength can be obtained, the shape of the matrix can be maintained during lamination, and a glass fiber bundle can be selected according to the thickness dimension of the cured body.

  Moreover, it is preferable that the content rate of the fiber bundle F0 to the inorganic hydraulic matrix M is 1-50 wt%.

  That is, if the content rate of the fiber bundle F0 is 1% or more, a cured product H in which the minimum bending strength or the prevention of cracking of the hydraulic matrix can be obtained can be obtained, and the content rate of the fiber bundle F0 is 50%. If it is below, it will be in the state which the fiber bundle was impregnated to the maximum with the inorganic hydraulic matrix M, and the surface appearance of a molding can be ensured, and the hardening body H which has sufficient mechanical strength can be obtained. In the molded body of the present invention, the fibers are oriented in the uniaxial direction, so that a particularly remarkable reinforcing effect can be obtained with respect to the bending strength even in the vertical direction. For this reason, it can be used particularly in places where bending stress is required, such as a cast formwork of a concrete structure.

  In the modeling apparatus 1 described above, the modeling unit 70 and the impregnation unit 80 are provided respectively. For example, an impregnation unit that stores the inorganic hydraulic matrix M is provided in the impregnated fiber bundle supply unit 40 of the modeling unit 70. In the impregnated fiber bundle supply unit 40, the fiber bundle F0 may be impregnated with the inorganic hydraulic matrix M.

  Further, according to the modeling apparatus 1, for example, as shown in FIG. 4, the impregnated fiber bundle F can be sent out in various orientation patterns, and a single layer or a laminated molded body having a desired shape and a desired mechanical strength. The cured product H can be obtained.

According to the configuration as described above, it is possible to provide a cured body H that maintains the shape of the molded body formed in a single layer or a laminate and has sufficient strength after the molded body is cured.
Further, since the continuous fiber bundle F0 is impregnated with the inorganic hydraulic matrix M to form the impregnated fiber bundle F, it can be oriented in various directions as shown in FIG. 4 and can be laminated. is there.
Furthermore, for example, compared with the case where the inorganic hydraulic matrix M contains a chopped glass strand as a reinforcing material, the fibers can be arranged only in a necessary direction and the fiber content can be increased, so that the bending strength is increased. It is possible to improve the mechanical strength.

DESCRIPTION OF SYMBOLS 1 Three-dimensional modeling apparatus 10 Supply nozzle 40 Impregnation fiber bundle supply part F0 Fiber bundle F Impregnation fiber bundle H Hardened body M Inorganic hydraulic matrix

Claims (6)

A method of forming a cured body containing a fiber bundle formed by bundling a plurality of single fibers,
Impregnating a continuous fiber bundle with an inorganic hydraulic matrix to form an impregnated fiber bundle,
By continuously feeding the impregnated fiber bundle by a fiber bundle supply means, a molded body is formed and cured,
A method for forming a cured body. The fiber bundle is a glass fiber bundle in which glass single fibers containing 12% by mass or more of ZrO ₂ and 10% by mass or more of R ₂ O (R is at least one selected from Li, Na and K) are bundled. Is,
The molding method of the hardening body of Claim 1 characterized by the above-mentioned. The inorganic hydraulic matrix is a cementitious matrix;
The method for forming a cured body according to claim 1 or 2, wherein The diameter of the glass single fiber is 9-30 μm, and
The number of bundles of the glass single fibers in the glass fiber bundle is 50 to 6000,
The method for forming a cured body according to claim 2, wherein: The glass fiber bundle is
Having a coating composed of at least one water-soluble polymer component;
The method for forming a cured body according to claim 2 or 4, wherein The fiber bundle content is 1 to 50 wt%.
The method for forming a cured body according to any one of claims 1 to 5, wherein

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