JP2888600B2 - Skeleton-like fiber structure, method for producing the same, and fiber-reinforced composite material using the same - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a skeleton-like fiber structure used as a reinforcing material such as concrete or mortar, or a reinforcing material of a synthetic resin, a method of manufacturing the same, and a method of manufacturing the same. The present invention relates to a fiber-reinforced composite material using a body.

[Conventional technology]

Conventionally, reinforcing bars and steel materials have been used as reinforcing materials for concrete and the like, but these are heavy and deteriorate due to salt corrosion or electric corrosion due to intrusion of chloride or carbon dioxide gas.

Therefore, various attempts have been made based on the recognition that the use of a fiber material for reinforcing concrete or the like can solve the above problems.

For example, it has been proposed to use a fiber material as a chop, a net, or a three-dimensional woven fabric.

However, in the case of a composite material reinforced with chopped fibers, it is difficult to obtain a material having high proof stress and deformability because the length of the fibers is limited and the amount of fibers that can be mixed is limited.

Further, the composite material using the net-shaped woven or knitted fabric was better than the chopped fibers, but cracks and interfacial peeling occurred between the nets.

On the other hand, when a three-dimensional fabric is used, the above problem is improved. However, if the texture is too dense, the three-dimensional fabric must have a coarse texture to a certain extent because the cocrete bonding force between both sides of the fabric is reduced, which may cause interfacial delamination. From such a viewpoint, conventionally, for example,
JP-A-63-159558, JP-A-1-317152, JP-A-2-
Proposals such as 38038 have been made. These are outlined below.

First, JP-A-63-159558 discloses a double Russell machine.
It is a method of knitting by comparing the shape of the finished product from the beginning.

Next, JP-A-1-317152 discloses that a continuous reinforcing fiber impregnated with a resin intersects in one direction and a direction orthogonal thereto to integrally shape a cage-shaped reinforcing bar having an axial bar and a shear reinforcing bar. After forming a plastic anchoring block at both ends of the cage reinforcing bar, the cage reinforcing bar is placed in the concrete formwork, and concrete is applied to the shaft bar with the tension applied to the shaft via the fixing block. The present invention proposes a prestressed concrete member itself manufactured by casting and curing, and a method and an apparatus for manufacturing the same.

Further, JP-A-2-38038 discloses a three-dimensional structure in which a plurality of nonwoven fabrics having a network structure are arranged in parallel, and the nonwoven fabrics having a net structure bent in a corrugated shape, a chevron shape, a U-shape, or the like are connected to each other with a layered structure. It proposes a dynamic network structure.

[Problems to be solved by the invention]

Japanese Patent Application Laid-Open No. 63-159558 discloses a double Russell machine for knitting from the beginning to the shape of a finished product, but weaving a three-dimensional woven or knitted fabric is difficult and inefficient, and the shape is not suitable for use. Since there is no compatibility between them and the degree of freedom of design, and it is not possible to prepare for mass production in advance, the production cost of reinforcing materials becomes expensive, not only the delivery time becomes long, but also the size that can be produced is limited to the machine width etc. It is naturally limited due to restrictions, and it is also difficult to bring a machine to a construction site for manufacturing.

Japanese Patent Application Laid-Open No. 1-317152 discloses that the shape of the reinforcing material is limited to only one type of cage reinforcing bar, and cannot be changed to other various shapes, and there is no design flexibility. In addition, the production cost is high.

JP-A-2-38038 is slightly superior to any of the above proposals in terms of design flexibility.
To the last, a plurality of net-structured non-woven fabrics are arranged in parallel, and a three-dimensional net-like structure formed by laminating the non-woven fabrics with a non-woven-structured non-woven fabric or a thread between them is used. Since only the number of the nonwoven fabrics to be arranged, that is, the number of layers and the layer interval, can be selected, the variation of the shape is not so rich.

The present invention has been proposed in view of the above-described problems of the conventional reinforcing material. The object of the present invention is to develop a shape and structure capable of improving productivity and mass-producing, reducing design costs at low cost. To provide a skeleton-like fibrous structure having a high degree of simplicity, miniaturization of production equipment, and factory or on-site production, a method of manufacturing the same, and a fiber-reinforced composite material using the same. It is assumed that.

[Means for solving the problem]

In order to achieve the above object, one aspect of the present invention is to provide, as a basic unit, a substantially ladder-shaped module formed by winding a binding yarn around a plurality of linear bodies arranged in parallel and fixing them with an adhesive. A plurality of blocks are fixed in a predetermined shape, wound with a binding yarn, and fixed with an adhesive to form a block, and the blocks are arranged in a plurality or a plurality of modules in a final predetermined shape. The present invention provides a skeleton-like fiber structure in which a binding yarn is wound and fixed with an adhesive to form a skeleton.

Another aspect of the present invention is a method for producing a skeleton-like fiber structure including the following steps (a), (b), or (a), (b), and (c).

(A) a step of holding a plurality of linear bodies in a side-by-side state, spirally winding a binding yarn from one end to the other end, and fixing the both with an adhesive to form a module;

(B) A step of fixing a plurality of modules in a predetermined shape, gripping both ends, winding a binding yarn around the outer periphery, and fixing both with an adhesive to form a block.

(C) arranging and configuring a plurality of blocks in a final predetermined shape;
A step of forming a skeleton by winding with a binding yarn and then fixing both with an adhesive.

Further, one aspect of the present invention is the following (a) (b) or
(A) A method for producing a skeleton-like fibrous structure comprising the steps (b) and (c).

(A) A plurality of linear bodies are held in a parallel state and run continuously, a binding yarn is wound in a direction intersecting with the running direction, then an adhesive is impregnated and cured, and cut into predetermined dimensions to obtain a desired one. Continuously manufacturing a substantially ladder-shaped module.

(B) A step of fixing a plurality of modules in a predetermined shape, gripping both ends, winding a binding yarn around the outer periphery, and fixing both with an adhesive to form a block.

(C) arranging and configuring a plurality of blocks in a final predetermined shape;
A step of forming a skeleton by winding with a binding yarn and then fixing both with an adhesive.

Still another aspect of the present invention is to provide a substantially ladder-shaped module formed by winding a binding yarn around a plurality of linear bodies arranged in parallel and fixing with an adhesive, and a plurality of such modules. It is fixed in a predetermined shape, wound with a binding yarn, fixed with an adhesive to form a block, a plurality of blocks or a plurality of the modules are arranged and arranged in a final predetermined shape, and a binding yarn is formed. It is a fiber reinforced composite material in which a skeleton fiber structure wound and fixed with an adhesive to form a skeleton is embedded as a reinforcing material in a cement-based material or a synthetic resin material.

[Action]

According to the manufacturing method of the skeleton-like fiber structure configured as described above, the module itself, the block, and the skeleton are formed by winding the binding yarn, which eliminates the need for a weaving machine, and fixing by the adhesive. In addition, production equipment can be simplified and downsized, productivity can be improved and mass production can be performed, and it can be provided at low cost. In addition, since it can be formed freely from small to large, and it is easy to maintain the required strength, the degree of freedom of design is expanded.

The skeleton-like fiber structure manufactured by the above manufacturing method and a fiber-reinforced composite material using the structure are lightweight and inexpensive, have a required shape and strength, and are deteriorated by salt corrosion, electric corrosion, and the like. There is no.

[Example] FIGS. 1 to 4 are explanatory views showing a specific example of the production method of the present invention. First, in the present invention, a plurality of continuous fibers (multifilament, monofilament, spun yarn) are used. The adhesive is impregnated with a plying yarn, a twisting yarn, and the like, and is cured to form a linear body (1).

The fibers constituting the linear body (1) may be continuous fibers, and may be in any combination state. For example, multifilaments, tows, strands, rovings, etc., twisted, aligned, braided, etc. Either state may be sufficient.

The fibers used include glass fibers, carbon fibers, aramid fibers, polyester fibers, vinylon fibers and the like.

The adhesive to be impregnated into the fiber and cured is a synthetic resin adhesive, an inorganic adhesive such as water glass, a rubber adhesive such as silicon, and the like. And unsaturated polyester.

The method for producing the linear body (1) is as follows: a heating die (4) having a supply hopper (3) for a synthetic resin (2) as shown in FIG.
It is preferable that the inside is made by a pultrusion method in which the combined body of continuous fibers (1a) is drawn out and hardened.
Other methods are also possible.

As the rigid linear body (1) created as described above, two or a plurality of two or more pieces cut to a predetermined length are arranged in parallel at a predetermined interval, and both ends thereof are arranged. As shown in FIG. 2, the filament is held by a filament winding device or the like using chuck means (5) and (5). Then, the chuck means (5) and (5) are rotated about the shafts (6) and (6), and the winding head (8) of the binding yarn (7) is stretched along the stretching direction of the linear body (1). Is installed so that can be translated. By doing so, for example, the binding yarn (7) is spirally wound around the two linear bodies (1) and (1). The same applies to the case where two or more linear bodies (1) are used. still,
For the spiral winding, the winding head (8) is fixed,
The chuck means (5) and (5) may be moved in parallel while rotating, or the chuck means (5) and (5) may be fixed and moved in parallel while rotating the winding head (8). Is also good.

The binding yarn (7) uses a combination of continuous fibers similar to the linear body (1), and is used without being impregnated with a synthetic resin or in a prepreg state. The same synthetic resin as described above is used.

The binding yarn (7) is spirally wound around two or more linear bodies (1) and (1), and then immersed in a synthetic resin tank or sprayed with a synthetic resin. By curing, two or more linear bodies (1)
The contact point between (1) and the binding yarn (7) is fixed, and the binding yarn (7) is impregnated and cured with a synthetic resin. At the same time, two or more linear bodies (1) and (1) are formed. A substantially ladder-shaped module (A) as shown in FIG. 2a is formed by attaching and curing a synthetic resin also on the surface.

When manufacturing the long module (A), in the winding step of the binding yarn (7), a spacer jig is appropriately spaced between two or more linear bodies (1) and (1). It is desirable to prevent the bending of two or more linear bodies (1) and (1).

The spacer jig uses a plastic plate or the like,
It may be removed later or left as it is.

The helical winding of the binding yarn (7) may be performed in one direction as shown in FIG. 2 or in two directions crossing the same, and either may be used. In FIG. 2 described above,
Although the case where the module (A) is manufactured by a batch method, it can also be manufactured by a continuous method.

FIG. 3 is a block diagram showing a continuous manufacturing process, in which a plurality of linear bodies (1) manufactured by continuously pulling out from a roving rack (9) by a pultrusion device (10) are bound. Bundling yarn (7) with yarn winding device (11)
Is spirally wound, impregnated with a resin by a resin processing device (12), and heat-cured by a heat-curing device (13) to produce a module (A), which is continuously pulled out by a tension device (14). The module (A) is continuously manufactured by being cut by a cutting device (15) at predetermined intervals and stored in a warehouse or the like.

The pultrusion device (10) is, for example, a plurality of devices as shown in FIG. 1 arranged side by side.

In addition, the binding yarn winding device (11) faces a shuttle accommodating a spool around which the binding yarn (7) is wound, for example, on both sides crossing the traveling direction of the plurality of linear bodies (1). The reciprocating operation and the elevating operation are combined by the alternate operation of the arranged cylinders, and the binding yarn (7) is spirally wound around the outer periphery of the plurality of linear bodies (1). In this case, the forward path and the return path of the shuttle are different from each other on the upper surface and the lower surface of the plurality of linear bodies (1), and are subjected to a so-called square motion, so that the binding yarn (7) is linear. It can be wound around the outer periphery of the body (1).

The binding yarn winding device (11) may be of a type in which a spool of the binding yarn (7) is turned around the outer periphery of the plurality of linear bodies (1).

Furthermore, the resin processing device (12)
Any type of spraying may be used. Further, instead of the resin, an inorganic adhesive such as water glass or a rubber adhesive such as silicon may be used.

The heat-curing device (13) fixes the binding point of the binding yarn (7) resin-processed by the resin processing device (12) and the contact point between the linear body (1) and the binding yarn (7) to fix the module (A). Is formed. When a prepreg-shaped material is used for the binding yarn (7), the resin processing device (12) is omitted, and the semi-cured resin is heated and cured at the heating and curing device (13), and the wire is pressed under pressure. The contact point between the state body (1) and the binding yarn (7) is securely bonded.

As described above, the module (A) may be manufactured by either a batch method or a continuous method.

A plurality of the modules (A) are prepared, arranged in parallel at appropriate intervals as shown in FIG. 4, and both ends are gripped by jigs (not shown), and a filament winding device (not shown).
And the binding yarn (7a) is spirally wound around the periphery.
This winding means is performed by the same means as in the case of the module (A).

After the binding yarn (7a) is spirally wound as described above, it is removed from the filament winding device and impregnated and cured with an adhesive to form a block (B). in this case,
Use the same binding yarn (7a) and adhesive as described above.

A plurality of the blocks (B) are used, arranged in a shape as shown in FIG. 5, and a binding yarn (not shown) is spirally wound around its outer periphery by the above-described filament winding device (not shown), The skeleton (C) is formed by removing the above-mentioned apparatus or impregnating and curing the adhesive on the machine, or spraying the adhesive on the machine. In this case, the same binding yarn and adhesive as described above are used.

The skeleton (C) can be made into various shapes. For example, as shown in FIG. 6, the modules (A) are arranged radially and a binding yarn (not shown) is formed on the outer periphery by a filament winding device. It is spirally wound and impregnated and hardened with an adhesive.

In this case, a guide tube is provided inside, and the binding yarn (7) is first spirally wound around this tube.
It also adheres to the helically wound binding yarn (7) inside.

In the case of forming a hollow square pillar-shaped skeleton (C) as shown in FIG. 7, four blocks (B) obtained by combining modules (A) in a trapezoidal shape are used as shown in FIG.

Thus, the block (B) and the skeleton (C)
Describes the case where a module (A) or a block (B) is formed into various shapes depending on the final shape. For example, a case in which a composite material made of a hollow slab (D) made of mortar as shown in FIG. 9 is described. I do.

This hollow slab (D) is 1m wide, 6m long, 130mm thick
The through hole in the longitudinal direction has a width of 70 mm and a height of 80 mm.

In this case, a block (B ₁ ) of the flange portion shown in FIG. 10 and a block (B ₂ ) of the web portion shown in FIG. 11 are formed by using the module (A) of FIG. A skeleton (C ₁ ) is formed by combining as shown in FIG.

A styrofoam rod (not shown) is inserted into the through hole of the skeleton (C ₁ ), and the styrofoam rod is fixed at a predetermined position so that the styrofoam portion becomes a hollow hole of the slab (D) after mortar hardening. . Then, the skeleton (C ₁ ) including the styrofoam rod is fixed at a predetermined position in the mold (16) as shown in FIG. 13, the mortar is poured, and after the mortar is hardened, the slab (D) is removed. And styrene foam dissolved and removed with acetone to form through holes.

The continuous fibers used in the module (A), the blocks (B ₁ ) and (B ₂ ), and the skeleton (C ₁ ) are PAN-based carbon fibers.

The volume of the skeleton (C ₁ ) is 3% of the mortar volume at the flange portion and 2% of the mortar volume at the web portion.

In the above embodiment, the shapes of the skeletons (C) and (C ₁ ) are illustrated for the hollow slab, the hollow cylinder, and the hollow quadrangular prism, but the combination of the module (A) and the block ( Combinations of B) and combinations of these can form triangular to octagonal shapes, other polygonal column shapes, elliptical column shapes, L-shaped cross-sections, H-shaped cross-sections, and other various shapes.

Further, the case where the skeleton (C) (C ₁ ) is buried in the mortar as the composite material is illustrated, but it is also possible to bury the skeleton in concrete or synthetic resin.

〔The invention's effect〕

According to the invention of claim 1, a skeleton-like fiber structure capable of opposing stress in each direction such as compression, tension, shearing, bending, and peeling of a three-dimensional fiber structure at extremely low density is provided. Since it can be provided, and particularly, the degree of freedom of design is large, various shapes can be easily obtained by combining modules or blocks.

According to the invention of claim 2, the productivity of the skeleton-like fiber structure is improved, mass production becomes possible, the production equipment can be simplified and downsized, and it can be carried out either in factory production or on-site production or in a combination of both. A skeleton-like fiber structure having the required strength and shape can be manufactured at low cost.

According to the third aspect of the present invention, the module can be manufactured continuously, so that the cost can be reduced at least equivalent to that of the second aspect.

According to the fourth aspect of the present invention, by manufacturing a composite material in which a cement-based material or a synthetic resin material is reinforced with a skeleton-like fiber structure, a construction material having the same performance as a composite material reinforced with a conventional three-dimensional woven fabric is used. Materials can be produced with high efficiency and low cost.

[Brief description of the drawings]

1 to 5 are explanatory views showing a specific example of the manufacturing method of the present invention. FIG. 1 is a sectional view of a main part of a pultrusion apparatus for producing a linear body, and FIG. Schematic diagram showing an example of a filament winding device for making,
FIG. 2a is a front view showing a module manufactured by the same apparatus, FIG. 3 is a block diagram of a continuous manufacturing process of a long module,
FIG. 4 is a perspective view showing an example of forming a block, and FIG. 5 is a perspective view showing an example of forming a skeleton. 6 is a perspective view showing another example of forming the skeleton, FIG. 7 is a perspective view showing still another example of forming the skeleton, and FIG. 8 is a perspective view of a block used when forming the skeleton of FIG. , FIG. 9 is a perspective view showing an example of the composite material, FIGS. 10 and 11 are perspective views showing two types of blocks for forming the composite material of FIG. 9, and FIG. FIG. 13 is a perspective view of a skeleton in which blocks are combined, and FIG. 13 is a perspective view showing a state where the skeleton is disposed in a mold. (1) ... linear body, (7) (7a) ... binding thread, (A) ...
… Module, (B) (B ₁ ) (B ₂ ) …… Block,
(C) (C ₁ ) ... Skeleton.

Continued on the front page. (72) Inventor, Sadatoshi Ohno, 3-1-18 Mokudori, Mihara-cho, Minamikawachi-gun, Osaka, Japan Inside the Osaka Branch of Technical Research Institute, Takenaka Corporation (72) Inventor, Kazuhiro Inoue 938 Nakatomicho, Kasai-shi, Hyogo (72) Inventor Yasuo Iwata 276-3 Nakakomori-cho, Omihachiman-shi, Shiga Prefecture (72) Inventor Hideki Sakinami 564-16 Kutoku, Taga-cho, Inoue-gun, Shiga Prefecture (56) References JP-A-2-41455 (JP, A JP-A-63-159558 (JP, A) JP-A-2-38038 (JP, A) JP-A-1-317152 (JP, A) (58) Fields investigated (Int. Cl. ⁶ , DB name) B28B 23/02 C04B 32/02

Claims (4)

(57) [Claims] 1. A substantially ladder-shaped module formed by winding a binding yarn around a plurality of linear bodies arranged in parallel and fixed with an adhesive as a basic unit, and connecting a plurality of such modules into a predetermined shape. Stop, winding this with a binding yarn, fixing with an adhesive to form a block, arranging and configuring a plurality of the blocks or a plurality of the modules in a final predetermined shape, winding the binding yarn, adhesive A skeleton-like fibrous structure characterized by being fixed to form a skeleton. (2) The following (a) (b) or (a) (b)
A method for producing a skeleton-like fiber structure, comprising the step (c). (A) a step of holding a plurality of linear bodies in a side-by-side state, spirally winding a binding yarn from one end to the other end, and fixing the both with an adhesive to form a module; (B) A step of fixing a plurality of modules in a predetermined shape, gripping both ends, winding a binding yarn around the outer periphery, and fixing both with an adhesive to form a block. (C) arranging and configuring a plurality of blocks in a final predetermined shape;
A step of forming a skeleton by winding with a binding yarn and then fixing both with an adhesive. 3. The following (a) (b) or (a) (b)
A method for producing a skeleton-like fiber structure, comprising the step (c). (A) A plurality of linear bodies are continuously run while being held in a parallel state, a binding yarn is wound in a direction crossing the running direction, then impregnated and cured with an adhesive, and cut into predetermined dimensions to obtain a desired one. Continuously manufacturing a substantially ladder-shaped module. (B) A step of fixing a plurality of modules in a predetermined shape, gripping both ends, winding a binding yarn around the outer periphery, and fixing both with an adhesive to form a block. (C) arranging and configuring a plurality of blocks in a final predetermined shape;
A step of forming a skeleton by winding with a binding yarn and then fixing both with an adhesive. 4. A substantially ladder-shaped module formed by winding a binding yarn around a plurality of linear bodies arranged in parallel and being fixed with an adhesive as a basic unit, and connecting a plurality of such modules into a predetermined shape. Stop, winding this with a binding yarn, fixing with an adhesive to form a block, arranging and configuring a plurality of the blocks or a plurality of the modules in a final predetermined shape, winding the binding yarn, adhesive A fiber-reinforced composite material, wherein a skeleton-like fiber structure fixed to form a skeleton is embedded in a cement-based material or a synthetic resin material as a reinforcing material.