JP2022077324A - Method for manufacturing continuous fiber reinforcing material - Google Patents

Abstract

To provide a method for manufacturing a continuous fiber reinforcing material capable of satisfactorily obtaining the continuous fiber reinforcing material having a bumps and dips shape on an outer surface.SOLUTION: A method for manufacturing a continuous fiber reinforcing material is provided with: a core material that contains a cured product of a thermosetting resin and a reinforcing fiber; and a covering layer for covering an outer surface of the core material. The method comprises: an arrangement step for arranging a material for the covering layer containing a thermosetting resin and an inorganic filler on an outer surface of the core material to obtain a structural body provided with the core material and the material for the covering layer; and a heating step for heating the structural body using a mold which can move in an axial direction of the structural body by a moving mechanism and which has bumps and dips on the surface.SELECTED DRAWING: Figure 2

Description

The present invention relates to a method for producing a continuous fiber reinforcing material.

A concrete structure in which a concrete reinforcing member such as a continuous fiber reinforcing material is embedded in concrete is widely known. The concrete reinforcing member is generally manufactured by impregnating a fiber such as glass fiber with a resin. The concrete reinforcing member is lighter in weight than the reinforcing bar, and has excellent corrosion resistance and workability.

Conventionally, in order to increase the adhesive force between the continuous fiber reinforcing material and concrete, a continuous fiber reinforcing material having an uneven shape on the outer surface has been used.

The continuous fiber reinforcing material having an uneven shape on the outer surface is manufactured by, for example, the following methods (1), (2) or (3). (1) A method of forming unevenness by cutting the outer surface of a rod-shaped molded product using a cutting tool or the like. (2) As described in Patent Document 1 below, a method of winding a string-like object, creating a groove shape by pressing or the like, and removing the string-like object after curing to form irregularities. (3) As described in Patent Document 2 below, a method in which a mold is pressed against an uncured portion, a coating material is allowed to flow, and then the coating material is cured to form irregularities.

Japanese Unexamined Patent Publication No. 04-12828 Japanese Unexamined Patent Publication No. 07-139093

In the method of forming unevenness by cutting as described in (1) above, it takes time and effort to cut a rod-shaped molded product having high hardness, and the cutting tool is quickly worn and replacement cost is incurred. The manufacturing cost due to processing increases. In the method of forming unevenness using a string-like object as described in (2) above, it takes time and effort to prepare and form the string-like object, and it takes time and effort to remove the string-like object, and waste. Will increase. In the method of pressing the mold to form the unevenness as in (3) above, the uncured resin adheres to the uneven shape portion of the continuous fiber reinforcing material, and the appearance of the uneven shape is spoiled, or the amount of protrusion is reduced. It is difficult to control and the uneven shape becomes uneven, or the viscosity of the resin in the covering portion decreases when curing is performed later, and the uneven shape cannot be maintained.

An object of the present invention is to provide a method for manufacturing a continuous fiber reinforcing material capable of satisfactorily obtaining a continuous fiber reinforcing material having an uneven shape on an outer surface.

According to a broad aspect of the present invention, there is a method for manufacturing a continuous fiber reinforcing material including a core material containing a cured product of a thermosetting resin and reinforcing fibers, and a coating layer covering the outer surface of the core material. An arrangement step of arranging a coating layer material containing a thermosetting resin and an inorganic filler on the outer surface of the core material to obtain a structure including the core material and the coating layer material, and moving. Provided is a method for manufacturing a continuous fiber reinforcing material, which comprises a heating step of heating the structure by using a mold which is movable in the axial direction of the structure by a mechanism and has irregularities on the surface.

In certain aspects of the method of manufacturing a continuous fiber reinforcing material according to the present invention, the mold can be moved in the axial direction of the structure by a rack and pinion mechanism.

In a specific aspect of the method for producing a continuous fiber reinforcing material according to the present invention, the mold includes a first mold portion having irregularities on the surface and a second mold portion having irregularities on the surface. It is an upper and lower split mold.

In a specific aspect of the method for producing a continuous fiber reinforcing material according to the present invention, the inorganic filler contained in the material of the coating layer has an average particle size of 1 μm or more and 100 μm or less and a Mohs hardness of 3 or more and 10 or less. Is an inorganic filler.

INDUSTRIAL APPLICABILITY According to the present invention, it is possible to provide a method for manufacturing a continuous fiber reinforcing material capable of satisfactorily obtaining a continuous fiber reinforcing material having an uneven shape on an outer surface.

FIG. 1 is a diagram for explaining a step of obtaining a core material in the method for manufacturing a continuous fiber reinforcing material according to an embodiment of the present invention. FIG. 2 is a diagram for explaining an arrangement step and a heating step in the method for manufacturing a continuous fiber reinforcing material according to an embodiment of the present invention. FIG. 3A is a front view schematically showing the mold, and FIG. 3B is a side view schematically showing the mold. FIG. 4A is a plan view schematically showing a first mold portion having irregularities on the surface, and FIG. 4B schematically shows a second mold portion having irregularities on the surface. It is a plan view which shows.

Hereinafter, the present invention will be described in detail.

The method for producing a continuous fiber reinforcing material according to the present invention is a method for producing a continuous fiber reinforcing material including a core material containing a cured product of a thermosetting resin and reinforcing fibers and a coating layer covering the outer surface of the core material. Is. In the method for producing a continuous fiber reinforcing material according to the present invention, a coating layer material containing a thermosetting resin and an inorganic filler is arranged on the outer surface of the core material, and the core material and the coating layer are formed. It includes an arrangement step of obtaining a structure including a material, and a heating step of heating the structure by using a mold that can be moved in the axial direction of the structure by a moving mechanism and has irregularities on the surface.

Since the method for producing a continuous fiber reinforcing material according to the present invention has the above-mentioned configuration, a continuous fiber reinforcing material having an uneven shape on the outer surface can be satisfactorily obtained.

In the method for producing a continuous fiber reinforcing material according to the present invention, the process from the placement of the coating layer material on the outer surface of the core material to the molding of the coating layer can be performed in a continuous process.

Further, in the method for producing a continuous fiber reinforcing material according to the present invention, the hardness of the coating layer of the obtained continuous fiber reinforcing material can be increased. Therefore, the adhesive force between the continuous fiber reinforcing material and the concrete can be enhanced. Further, by providing the coating layer, the alkali resistance of the obtained continuous fiber reinforcing material can be enhanced.

Hereinafter, the present invention will be clarified by explaining specific embodiments of the present invention with reference to the drawings. In the drawings below, the size, thickness, shape, etc. may differ from the actual size, thickness, shape, etc. for convenience of illustration.

(Process to obtain core material)
The method for producing a continuous fiber reinforcing material according to the present invention preferably includes a step of obtaining a cured product of a thermosetting resin and a core material containing reinforcing fibers. The method for manufacturing the core material is not particularly limited. The core material can be produced by a conventionally known method.

FIG. 1 is a diagram for explaining a step of obtaining a core material in the method for manufacturing a continuous fiber reinforcing material according to an embodiment of the present invention.

The thermosetting resin 12 is stored in the thermosetting resin impregnation tank 16. The continuous fiber 11 unwound from the glass roving 15 is brought into contact with the thermosetting resin 12 in the thermosetting resin impregnation tank 16 to obtain the continuous fiber 11 impregnated with the thermosetting resin 12. Next, using the drawing die 17, excess thermosetting resin is removed from the continuous fiber 11 impregnated with the thermosetting resin 12, and the shape is adjusted to some extent. Next, heat molding is performed using the drawing die 18, and the core material 1 containing the cured product of the thermosetting resin 12 and the continuous fibers 11 is obtained by taking it up with the take-up machine 19. In this embodiment, a columnar core material is obtained.

The heating in the heat molding using the drawing die may be heating by a heater or the like.

The core material may be surface-treated, if necessary. In the step of obtaining the core material, a surface-treated core material may be obtained. Examples of the method for treating the surface of the core material include a treatment method using a plasma discharge device, a treatment method using a file, and a heat treatment method. By surface-treating the core material taken up by the take-up machine, the surface-treated core material can be obtained.

(Arrangement process and heating process)
FIG. 2 is a diagram for explaining an arrangement step and a heating step in the method for manufacturing a continuous fiber reinforcing material according to an embodiment of the present invention.

In FIG. 2, the core material 1 obtained in FIG. 1 is used. 1 and 2 are performed in a continuous process and are performed on the same production line. That is, the core material 1 obtained in FIG. 1 is used in FIG. 2 without being cut to a predetermined length.

In the arrangement step and the heating step, a core material cut to a predetermined length may be used. The production line in which the step of obtaining the core material is performed and the production line in which the arrangement process and the heating step are performed may be different from each other. Further, in the arrangement step and the heating step, the surface-treated core material may be used.

<Placement process>
The thermosetting resin 2XA is housed in the first tank 21. The second tank 22 contains the inorganic filler 2XB. After driving the pump to mix the thermosetting resin 2XA and the inorganic filler 2XB with the static mixer 23, the material of the coating layer as a mixture is introduced into the resin coating mold 20. Using the resin-coated mold 20, the material 2X of the coating layer containing the thermosetting resin 2XA and the inorganic filler 2XB is arranged on the outer surface of the core material 1. In the present embodiment, the material 2X of the coating layer is coated on the outer surface of the core material 1 by using the resin-coated mold 20. In this way, a structure 3X including the core material 1 and the material 2X of the coating layer (structure 3X in which the material 2X of the coating layer is arranged on the outer surface (on the outer peripheral surface) of the core material 1) is obtained. ..

The thermosetting resin and the inorganic filler may be stored in the first tank without using the second tank. Further, the thermosetting resin and the inorganic filler may be stored in the first tank, and the curing agent of the thermosetting resin may be stored in the second tank. Further, the thermosetting resin and the inorganic filler may be stored in the first tank, and the thermosetting resin curing agent and the inorganic filler may be stored in the second tank. Further, the material of the coating layer may be arranged on the outer surface of the core material by an extrusion process. When a plurality of coating layer materials are used, it is preferable to sufficiently mix them using a static mixer or the like.

<Heating process>
Next, the obtained structure 3X is introduced into the mold 50. In the present embodiment, the mold 50 is a vertically divided mold including a first mold portion 51 having an uneven surface and a second mold portion 52 having an uneven surface. Further, in the present embodiment, four molds 50 are connected along the axial direction of the structure 3X. Further, in the present embodiment, the length of one mold 50 (the length along the axial direction of the structure 3X) is 500 mm. Of the four molds 50, the mold 50 located on the most upstream side and the mold 50 located on the most downstream side are closed with the first mold portion 51 and the second mold portion 52. Not. Of the four molds 50, the first mold portion 51 and the second mold portion 52 of the two molds 50 located in the central portion are closed.

The mold will be further described with reference to FIGS. 3 and 4.

In FIGS. 3 and 4, one mold is illustrated. FIG. 3A is a front view schematically showing the mold, and FIG. 3B is a side view schematically showing the mold. FIG. 3A is a mold 50 observed from the axial direction of the structure 3X. FIG. 4A is a plan view schematically showing a first mold portion having irregularities on the surface, and FIG. 4B schematically shows a second mold portion having irregularities on the surface. It is a plan view which shows. In addition to the mold, FIG. 3 also shows a mold mounting plate and a rack. Further, FIG. 3 illustrates a mold in which the first mold portion and the second mold portion are not closed.

The mold 50 has a first mold portion 51 having irregularities on the surface and a second mold portion 52 having irregularities on the surface. The upper and lower split molds are formed by the first mold portion 51 and the second mold portion 52. In the present embodiment, the first mold portion 51 is located on the lower side of the upper and lower split molds, and the second mold portion 52 is located on the upper side of the upper and lower split molds. .. By using the upper and lower split molds, it is possible to form uneven shapes with good reproducibility.

As shown in FIG. 3, the first mold portion 51 has a pin hole 511. The second mold portion 52 has a protrusion pin 521. By fitting and fastening the pin hole 511 and the protruding pin 521, the first mold portion 51 and the second mold portion 52 can be satisfactorily closed. Therefore, even when the rack and pinion mechanism described later is provided only on the side of the first mold portion 51, the first mold portion 51 and the second mold portion 52 move without being separated. It is possible.

As shown in FIG. 4, the first mold portion 51 has a concave portion 51A for forming a convex portion of the obtained continuous fiber reinforcing material and a convex portion 51B for forming a concave portion of the obtained continuous fiber reinforcing material. And have. The first mold portion 51 has irregularities on the surface due to the concave portion 51A and the convex portion 51B. The second mold portion 52 has a concave portion 52A for forming a convex portion of the obtained continuous fiber reinforcing material and a convex portion 52B for forming a concave portion of the obtained continuous fiber reinforcing material. The second mold portion 52 has irregularities on the surface due to the concave portion 52A and the convex portion 52B.

In FIG. 4, A1 corresponds to the radial dimension of the convex portion of the obtained continuous fiber reinforcing material, and A2 corresponds to the radial dimension of the concave portion of the obtained continuous fiber reinforcing material. A1 is larger than A2, and A2 is larger than the radial dimension of the core material.

As shown in FIGS. 2 and 3, the first mold portion 51 and the second mold portion 52 are attached to the mold mounting plate 55, respectively. A rack 56 is also attached to the mold mounting plate 55 to which the first mold portion 51 is attached.

A rack and pinion is composed of a rack 56 and a pinion 57 connected to a power source such as a motor. The rack and pinion mechanism allows the mold 50 to move in the axial direction of the structure 3X.

The outer surface of the first mold portion may have a shape that meshes with the pinion. That is, the rack and pinion may be configured by the first mold portion and the pinion. However, it is preferable to use a mold mounting plate for mounting the first mold portion. By using the above-mentioned mold mounting plate, when the mold is placed on the molding device and moved in the axial direction of the structure, rails, bearings and tires are attached to the molding device, and the mold slides on the mounting smooth surface of the mold mounting plate. It becomes easy to attach a mechanism to make it.

As shown in FIG. 2, when the structure 3X is introduced inside the mold 50, the first mold portion 51 and the second mold portion 52 are closed. The closed mold 50 is moved in the axial direction of the structure 3X by the rack and pinion mechanism. Due to the rack and pinion mechanism, a plurality of molds 50 are connected in a row and move at a constant speed in the axial direction of the structure 3X. In the region where the mold 50 is moving by the rack and pinion mechanism, the mold 50 is heated by using the radiant heating device 30 while being pressurized by the pressurizing roller 60. That is, thermal pressure molding is performed in the region where the mold 50 is moving by the rack and pinion mechanism.

The temperature and pressure at the time of thermal pressure molding can be appropriately changed depending on the composition of the material of the coating layer.

The mold may be heated by using a heater or the like instead of the radiant heating device 30. The method for heating the mold may be radiant heating or contact heating.

As shown in FIG. 2, the moving speed (moving speed with respect to the ground) of the structure 3X by the pick _- up machine or the like is defined as V1. As shown in FIG. 2, the moving speed (moving speed with respect to the ground) of the mold 50 by the rack and pinion mechanism is V ₂ . When the thermosetting resin in the material of the coating layer is not cured in the mold in which molding is started, the velocity ratio of V ₂ to V ₁ (V ₂ / V ₁ ) is preferably 0.8. As mentioned above, it is more preferably 0.95 or more, still more preferably 0.99 or more. The closer the speed ratio (V ₂ / V ₁ ) is to 1.00, that is, the closer the relative speed between the structure 3X and the mold is to zero, the more the continuous fiber reinforcing material having a good uneven shape on the outer surface is formed. Obtainable. Further, the closer the speed ratio (V ₂ / V ₁ ) is to 1.00, that is, the closer the relative speed between the structure 3X and the mold is to zero, the more the core material 2X of the coating layer is cured. The shearing force (vibration) generated at the interface between the coating layer and the material 2X of the coating layer can be reduced, and the adhesive strength between the core material and the coating layer can be increased. However, the velocity ratio of V ₂ to V ₁ (V ₂ / V ₁ ) may be 0.99 or less, or may be 0.8 or less. Since the speeds of the rack and pinion mechanism and the pick-up machine match after the continuous curing starts, for example, the pick-up machine may be stopped from moving and operated only by the rack and pinion mechanism.

By appropriately adjusting the tooth size (module) of the rack 56 and the pinion 57, the load of the usable core material and the moving speed of the mold can be appropriately adjusted.

The material 2X of the coating layer is cured while moving the mold 50 by the rack and pinion mechanism. That is, the material 2X of the coating layer is cured by performing thermal pressure molding on the structure 3X sandwiched between the molds 50. In this way, the continuous fiber reinforcing material 3 including the core material 1 and the coating layer 2 can be obtained. Further, by cutting the obtained continuous fiber reinforcing material 3 with a cutting machine or the like, a continuous fiber reinforcing material 3 having a predetermined length can be obtained.

After the material 2X of the coating layer is cured, the mold 50 is separated into a first mold portion 51 and a second mold portion 52, and is conveyed upstream by a belt conveyor (dotted arrow in FIG. 2). .. As a result, the first mold portion 51 and the second mold portion 52 can be circulated. Therefore, as long as the core material is continuously supplied, the continuous fiber reinforcing material can be continuously manufactured.

The length of one mold (the length along the axial direction of the structure 3X) is preferably 200 mm or more, preferably 500 mm or less.

The number of molds used is preferably 4 or more, and more preferably 6 or more. As shown in FIG. 2, the number of molds existing in the production line including the mold separated into the first mold portion and the second mold portion and the closed mold. Is preferably 4 or more. The number of molds existing in the production line, including the mold separated into the first mold portion and the second mold portion and the closed mold, may be 6 or more. More preferred. The upper limit of the number of molds used is not particularly limited. The number of molds used may be 20 or less, 15 or less, or 7 or less. As the number of the molds increases, the material 2X of the coating layer in the structure 3X can be continuously cured in the molds.

By applying pressure in the area where the mold is moving by the rack and pinion mechanism, the mold clamping force can be increased. The pressurization may be pressurization using an air cylinder. It is not necessary to pressurize.

In the rack and pinion mechanism, a brake mechanism may be provided at the final stage of the pinion. In this case, the mold clamping pressure in the axial direction of the structure can be increased, the material of the coating layer can be suppressed from dripping from between the molds, and continuous molding can be performed satisfactorily.

Hereinafter, the details of the core material, the coating layer and the continuous fiber reinforcing material will be further described.

The core material can be manufactured by pultrusion or the like. The shape of the core material may be columnar or polygonal. Further, the core material itself may have a concave portion and a convex portion on the outer surface.

The coating layer is arranged on the outer peripheral surface of the core material. Of the 100% surface area of the outer peripheral surface of the core material, the area of the portion where the coating layer is arranged is preferably 95% or more, more preferably 99% or more, and most preferably 100%. When the area of the portion where the coating layer is arranged is at least the above lower limit, the alkali resistance can be further improved.

Further, in the method for producing a continuous fiber reinforcing material according to the present invention, by appropriately selecting the material of the coating layer, a continuous fiber reinforcing material having high durability and hardness can be obtained, and continuous fiber reinforcing material having non-magnetic performance can be obtained. A fiber reinforcing material can be obtained.

(Thermosetting resin)
The core material contains a cured product of a thermosetting resin. The material of the coating layer contains a thermosetting resin. The coating layer contains a cured product of a thermosetting resin. As the thermosetting resin contained in the material of the coating layer, only one kind may be used, or two or more kinds may be used in combination. As the cured product of the thermosetting resin contained in the core material and the coating layer, only one type may be used, or two or more types may be used in combination.

The cured product of the thermosetting resin contained in the core material and the cured product of the thermosetting resin contained in the coating layer may be the same or different.

Examples of the thermosetting resin include epoxy resin, vinyl ester resin, and unsaturated polyester resin.

Examples of the epoxy resin include bisphenol A type epoxy resin, bisphenol F type epoxy resin, bisphenol S type epoxy resin, phenol novolac type epoxy resin, biphenyl type epoxy resin, biphenyl novolac type epoxy resin, biphenol type epoxy resin, and naphthalene type epoxy resin. , Fluolene type epoxy resin, phenol aralkyl type epoxy resin, naphthol aralkyl type epoxy resin, dicyclopentadiene type epoxy resin, anthracene type epoxy resin, adamantan skeleton epoxy resin, tricyclodecane skeleton epoxy resin, and triazine nucleus. Examples thereof include an epoxy resin having a skeleton.

Examples of the vinyl ester resin include bis-based vinyl ester resin and novolak-based vinyl ester resin.

Examples of the unsaturated polyester resin include α, β-unsaturated dicarboxylic acid or a resin obtained by polycondensation of an acid anhydride thereof and glycols.

From the viewpoint of further increasing the strength of the continuous fiber reinforcing material, the thermosetting resin contained in the core material is preferably an epoxy resin, a vinyl ester resin, or an unsaturated polyester resin. From the viewpoint of further increasing the strength of the continuous fiber reinforcing material, the cured product of the thermosetting resin contained in the core material is a cured product of epoxy resin, a cured product of vinyl ester resin, or a cured product of unsaturated polyester resin. Is preferable.

From the viewpoint of further enhancing the adhesive force with concrete and further enhancing the alkali resistance, the thermosetting resin contained in the material of the coating layer shall be an epoxy resin, a vinyl ester resin, or an unsaturated polyester resin. Is preferable, and an epoxy resin is more preferable. From the viewpoint of further enhancing the adhesive force with concrete and further enhancing the alkali resistance, the cured product of the thermosetting resin contained in the coating layer is a cured product of an epoxy resin, a cured product of a vinyl ester resin, or a cured product. It is preferably a cured product of unsaturated polyester resin, and more preferably a cured product of epoxy resin. In particular, when the cured product of the thermosetting resin contained in the coating layer is a cured product of the epoxy resin, the alkali resistance can be further enhanced, so that the strength of the continuous fiber reinforcing material decreases with time. Can be effectively suppressed.

The content of the cured product of the thermosetting resin (content of the cured product of the thermosetting resin contained in the core material) is preferably 20% by volume or more, more preferably 25 in 100% by volume of the core material. By volume or more, preferably 70% by volume or less, more preferably 45% by volume or less. When the content of the cured product of the thermosetting resin is not less than the above lower limit and not more than the above upper limit, the strength of the continuous fiber reinforcing material can be further increased.

The content of the thermosetting resin in 100% by weight of the material of the coating layer is preferably 20% by weight or more, more preferably 30% by weight or more, preferably 80% by weight or less, and more preferably 70% by weight or less. be. When the content of the thermosetting resin is at least the above lower limit and at least the above upper limit, the adhesive force with concrete can be further enhanced, and the alkali resistance can be further enhanced.

(Inorganic filler)
The material of the coating layer includes an inorganic filler. The coating layer contains an inorganic filler. As the inorganic filler, only one kind may be used, or two or more kinds may be used in combination.

From the viewpoint of increasing the adhesive force with concrete and increasing the alkali resistance, the average particle size of the inorganic filler is preferably 1 μm or more, more preferably 5 μm or more, preferably 100 μm or less, and more preferably 50 μm or less. When the average particle size of the inorganic filler is at least the above lower limit and at least the above upper limit, the adhesive force with concrete can be further enhanced, and the alkali resistance can be further enhanced.

The average particle size of the inorganic filler indicates a number average particle size. The average particle size of the inorganic filler can be obtained, for example, by performing a laser diffraction type particle size distribution measurement.

From the viewpoint of increasing the adhesive force with concrete and increasing the alkali resistance, the Mohs hardness of the inorganic filler is preferably 3 or more, more preferably 4 or more, and preferably 10 or less. When the Mohs hardness of the inorganic filler is at least the above lower limit and at least the above upper limit, the adhesive force with concrete can be further enhanced, and the alkali resistance can be further enhanced. Further, when the Mohs hardness of the inorganic filler is at least the above lower limit, even if the speed ratio (V ₂ / V ₁ ) exceeds 1.00 or is less than 1.00, the outer surface is exposed to the outer surface. A continuous fiber reinforcing material having a good uneven shape can be obtained.

It is particularly preferable that the inorganic filler has an average particle size of 1 μm or more and 100 μm or less and a Mohs hardness of 3 or more and 10 or less. In this case, the adhesive force with concrete can be further enhanced and the alkali resistance can be further enhanced.

Examples of the inorganic filler include silicon carbide, nitrogen carbide, alumina, aluminum hydroxide, calcium carbonate, silica, fly ash, carbon black and the like.

From the viewpoint of further enhancing the adhesive force with concrete and further enhancing the alkali resistance, the inorganic filler shall be silicon carbide, nitrogen carbide, alumina, aluminum hydroxide, calcium carbonate, silica, or fly ash. Is preferable, and silicon carbide or alumina is more preferable. Further, by using these preferable inorganic fillers, the hardness of the coating layer can be further increased, the coating layer can be prevented from being scraped or damaged in the concrete, and the concrete can be used. The adhesive force can be further increased.

The content of the inorganic filler in 100% by weight of the material of the coating layer is preferably 25% by weight or more, more preferably 30% by weight or more, preferably 80% by weight or less, more preferably 75% by weight or less, and further. It is preferably 70% by weight or less. When the content of the inorganic filler is at least the above lower limit, the adhesive force with concrete can be further enhanced. When the content of the inorganic filler is not more than the above upper limit, the alkali resistance can be further improved.

The content of the inorganic filler in 100% by weight of the coating layer is preferably 25% by weight or more, more preferably 30% by weight or more, preferably 80% by weight or less, more preferably 75% by weight or less, still more preferably. It is 70% by weight or less. When the content of the inorganic filler is at least the above lower limit, the adhesive force with concrete can be further enhanced. When the content of the inorganic filler is not more than the above upper limit, the alkali resistance can be further improved.

(Reinforcing fiber)
The core material contains reinforcing fibers. Only one type of the reinforcing fiber may be used, or two or more types may be used in combination.

Examples of the reinforcing fiber include glass fiber, carbon fiber, aramid fiber, basalt fiber and the like.

From the viewpoint of further increasing the strength of the continuous fiber reinforcing material, the reinforcing fiber is preferably glass fiber, carbon fiber, aramid fiber, or basalt fiber, and more preferably glass fiber or basalt fiber. In the conventional continuous fiber reinforcing material using glass fiber or basalt fiber as the reinforcing fiber, the alkali resistance is low, so that the reinforcing fiber tends to deteriorate, and as a result, the strength of the continuous fiber reinforcing material tends to decrease with time. On the other hand, in the present invention, even when glass fiber or basalt fiber is used as the reinforcing fiber, the strength of the continuous fiber reinforcing material can be maintained high.

The reinforcing fiber is preferably a roved fiber (reinforcing fiber bundle).

The reinforcing fibers are preferably oriented along the axial direction of the continuous fiber reinforcing material. It is preferable that the reinforcing fibers are aligned in the axial direction of the continuous fiber reinforcing material.

The content of the reinforcing fiber in 100% by volume of the core material is preferably 30% by volume or more, more preferably 50% by volume or more, preferably 80% by volume or less, and more preferably 75% by volume or less. When the content of the reinforcing fiber is not less than the above lower limit and not more than the above upper limit, the strength of the continuous fiber reinforcing material can be further increased.

(Other ingredients)
The core material, the coating layer material, and the coating layer may each contain various additives, if necessary. Examples of the additive include a compatibilizer, a stabilizer, a stabilizing aid, a lubricant, a processing aid, a heat improving agent, an antioxidant, an ultraviolet absorber, a light stabilizer, a pigment, a plasticizer and the like. Only one kind of the above-mentioned additive may be used, or two or more kinds thereof may be used in combination.

1 ... Core material 2 ... Coating layer 2X ... Coating layer material 2XA ... Thermocurable resin 2XB ... Inorganic filler 3 ... Continuous fiber reinforcing material 3X ... Structure 11 ... Continuous fiber 12 ... Thermocurable resin 15 ... Glass roving 16 … Thermo-curable resin impregnation tank 17… Squeezing die 18… Extraction die 19… Take-up machine 20… Resin-coated die 21… First tank 22… Second tank 23… Static mixer 30… Width-fire heating device 50 ... Mold 51 ... First mold part 51A ... Concave 51B ... Convex part 52 ... Second mold part 52A ... Concave 52B ... Convex part 55 ... Mold mounting plate 56 ... Rack 57 ... Pinion 60 ... Pressurized roller 511 ... Pin hole 521 ... Protruding pin

Claims (4)

A method for producing a continuous fiber reinforcing material including a core material containing a cured product of a thermosetting resin and reinforcing fibers, and a coating layer covering the outer surface of the core material.
An arrangement step of arranging a coating layer material containing a thermosetting resin and an inorganic filler on the outer surface of the core material to obtain a structure including the core material and the coating layer material.
A method for producing a continuous fiber reinforcing material, comprising a heating step of heating the structure by using a mold that can be moved in the axial direction of the structure by a moving mechanism and has irregularities on the surface. The method for manufacturing a continuous fiber reinforcing material according to claim 1, wherein the mold is movable in the axial direction of the structure by a rack and pinion mechanism. The continuous fiber reinforcement according to claim 1 or 2, wherein the mold is a vertically divided mold including a first mold portion having an uneven surface and a second mold portion having an uneven surface. Material manufacturing method. Any one of claims 1 to 3, wherein the inorganic filler contained in the material of the coating layer is an inorganic filler having an average particle diameter of 1 μm or more and 100 μm or less and a Mohs hardness of 3 or more and 10 or less. The method for manufacturing a continuous fiber reinforcing material according to.

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