JP5324788B2 - Fiber reinforced plastic, method for producing the same, and kit for producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a fiber reinforced plastics to be adhered to an adherent such as a concrete or the like by a simple step in an operating site as a desired design. <P>SOLUTION: The invention relates to a method of manufacturing a fiber reinforced plastic 20 adhered to the adherend 1 made by curing a two liquid curing type resin in the presence of reinforcing fibers. The method includes a step for laminating a first sheet 11 containing one component of a two-liquid curing resin on the adherend 1 and a second sheet 12 containing another component of the two-liquid curing resin in the order, and a step for generating a curing reaction by contacting both components of the two-liquid curing resin by pressing laminated body obtained 1, 11 and 12 and at least one of the first sheet 11 and the second sheet 12 is made by impregnating a cloth layer comprising a reinforcing fiber with each component of the two-liquid curing type resin. <P>COPYRIGHT: (C)2009,JPO&amp;INPIT

Description

  The present invention relates to a fiber reinforced plastic, a method for manufacturing a fiber reinforced plastic, and a fiber reinforced plastic manufacturing kit. The present invention is particularly suitable as a method for producing a fiber reinforced plastic that is molded on the surface of a structure on which concrete, metal, plastic, FRP, ceramic, etc. that require repair and reinforcement are present.

  (1) The most widely used known technology repairs reinforcing fibers such as carbon fibers, aramid fibers, and glass fibers with an impregnating adhesive such as an epoxy adhesive, an unsaturated polyester adhesive, an acrylic adhesive, After affixing to the adherend that needs reinforcement, the adhesive is carefully impregnated with a defoaming roller, a spatula, etc. so that air bubbles do not enter the reinforcing fiber, and the impregnated adhesive cured It was made of reinforced plastic.

  (2) Specific stimuli such as photo-curing type impregnating adhesive, moisture-curing type impregnating adhesive, thermosetting type impregnating adhesive for the purpose of reducing or eliminating the impregnation work of the reinforcing fiber with the impregnating adhesive in the field. By impregnating a reinforcing fiber in advance with an impregnating adhesive that can be post-cured in advance, pasting the adherend, curing the impregnating adhesive by applying a specific stimulus, and integrating with the adherend, Obtained fiber reinforced plastic.

  (3) According to Patent Document 1, a second component of a two-component curable resin is applied to a prepreg formed by impregnating a reinforcing substrate mainly composed of reinforcing fibers with a first component of a two-component curable resin. The fiber reinforced plastic was set by pasting on the surface of the structural element to be reinforced and curing it.

  (4) According to Patent Document 2, after applying one liquid (agent A) of a two-component room-temperature curable adhesive to an adherend, a sheet-like material composed of reinforcing fibers is pasted, and from the pasted reinforcing fibers The other liquid (B agent) of the two-component room temperature curable adhesive is applied to the surface of the sheet-like material, and the A solution is further applied to the B-liquid application surface to cure the two-component curable adhesive. Had set fiber reinforced plastic.

  (5) According to Patent Document 3, an epoxy-impregnated adhesive, an acrylic-based impregnated adhesive, and an unsaturated polyester-based impregnated adhesive are applied to a sheet-like substrate made of reinforcing fibers such as carbon fiber, vinylon fiber, aramid fiber, and glass fiber. A pressure-sensitive adhesive layer is provided on at least one side of a curable fiber reinforced plastic formed by impregnating a resin-impregnated adhesive such as an adhesive, and the pressure-sensitive adhesive layer is applied to an adherend that requires repair and reinforcement. After the curable fiber reinforced plastic is pasted, the curable fiber reinforced plastic is cured by a curing method such as room temperature curing, heat curing, light (ultraviolet ray, visible light, etc.), and the fiber reinforced plastic It was set.

(6) According to Patent Document 4, a composite panel in which reinforcing fibers are impregnated and bonded to one side of an incombustible flame retardant board with an impregnating adhesive is fixed with a gap so that the reinforcing fiber side faces the adherend. The periphery of the composite panel and the adherend are glued with a putty-like adhesive, then an injection hole is provided in the composite panel, the adhesive is injected into the gap between the composite panel and the adherend, and cured. The panel was set as an adherend.
JP-A-8-253604 JP-A-10-110536 JP 2002-47809 A Japanese Patent No. 3839446

  Regarding the technique (1), the work of adhering and impregnating the reinforcing fiber to the adherend without impregnation with the impregnated adhesive is labor intensive and varies depending on the skill level of the operator. Therefore, there is a problem that the quality and the amount of adhesive used are not stable. In addition, when the place where fiber reinforced plastic is set is a wall surface or ceiling surface, if the impregnated adhesive is applied to the surface, the impregnated adhesive will fall depending on the cohesive force and adhesive force when the impregnated adhesive is uncured. There is a risk of contaminating third parties. In addition, when applying a paint on the set fiber reinforced plastic, since the impregnated adhesive is cured, the paint is usually applied at intervals of one day or more. For convenience, when the coating is applied immediately, an impregnated adhesive having a high curing rate is used. However, there is a problem that the impregnated adhesive is completely cured before impregnating the reinforcing fibers, and does not become a fiber-reinforced plastic. Further, when the working environment is high temperature, the curing reaction of the impregnated adhesive is promoted, and there is a problem that the resin is cured before being completely impregnated and does not become a fiber reinforced plastic. In some cases, reinforcing fibers may be cut in advance according to the shape of the adherend. However, depending on the fiber type, cutting may be difficult. It may irritate the skin and respiratory organs of neighbors, which may cause sanitary problems.

  With regard to the technique (2), a technique in which a reinforcing fiber impregnated with an impregnating adhesive that can be post-cured in advance is applied to an adherend and given a specific stimulus to be adhesively cured is a skill of an operator. It is a high-quality construction method because it does not depend on the degree, but since many of the stimulation methods are based on light, moisture, and heat, the problem of hardening before construction is due to its storage and handling methods If it is used in a certain environment, the quality and quantity of the stimulus can be specified, but when applied to civil engineering structures, it can be used in various ways such as high and low humidity, outdoors, indoors, and high and low temperatures. There is a problem that quality is not stable due to various environmental conditions. In addition, after applying to the adherend, in order to give a stimulus from the opposite side of the adherend and reach the interface with the adherend by a radical reaction and cure it, it cures in the vicinity of the stimulated surface. However, there is a problem that confirmation is difficult because it may be uncured at the interface with the adherend. In the case of a photo-curing and impregnating adhesive, carbon fiber, aramid fiber, PBO fiber, etc., which have the highest reinforcing effect as reinforcing fibers, have a problem that they cannot be used because they do not transmit light.

  Regarding the technique (3), that is, the technique of Patent Document 1, the first component of the two-component curable resin is impregnated in advance into a reinforcing base mainly composed of reinforcing fibers to form a prepreg, and the second component is converted into a prepreg immediately before reinforcement. Since it is applied and attached to the structure and fiber reinforced plastic is set, the quality is stable regardless of the translucency, environmental temperature, humidity, etc. of the reinforcing substrate, but applying the second component to the prepreg In addition, it is difficult to apply uniformly from the viewpoint of visibility, and there may be a portion that is not applied, and a curing reaction starts at the time of application, and there is a risk of curing before adhering to the adherend. Cause poor curing and poor adhesion. Also, for the purpose of improving them and when applying multiple layers of reinforcing base material, apply the second component to the prepreg, successively stack and mold, then apply the second component to the adherend surface, It has been proposed to apply the first component to the adherend side of the fiber reinforced plastic molded into a layer, and to make it adhere and harden, but the adherend surface may be flat and smooth, but it may be curved When there are fine irregularities, the fiber reinforced plastic cannot be in close contact with the adherend surface, which may impair the reinforcing and repairing effects.

  Regarding the technique (4) above, that is, the technique of Patent Document 2, after applying one liquid (agent A) of a two-component room temperature curable adhesive to an adherend, a sheet-like material made of reinforcing fibers is pasted, Since the liquid (B agent) is applied to the sheet and the A agent is further applied, the curing reaction is quick and the working time is shortened. The adhesive used in Patent Document 2 that cures only by contacting with the base material is applied to the adherend because the radical polymerization reaction causes a rapid curing reaction regardless of the amount of agent A or agent B. The curing reaction of the prepared A agent and B agent proceeds rapidly, and the B agent that reacts with the A agent to be applied is deficient, and the surface may not be cured.

  With regard to the above (5), that is, the technique of Patent Document 3, a pressure-sensitive adhesive layer is preliminarily laminated on a continuous reinforcing fiber impregnated with a curable resin and adhered to an adherend through the pressure-sensitive adhesive layer. After that, in order to cure the curable resin, it does not contain bubbles and the quality is stable, but the pressure-sensitive adhesive layer is not suitable for applications that adhere strongly due to the adhesive. In addition, curable resins pre-impregnated into continuous fibers are cured by temperature and light, but the surrounding environment of structures that require repair and reinforcement varies, and their storage and handling There is a difficult problem. Further, in the case of room temperature curing, there is a problem that the material is cured before being adhered to the adherend depending on the curing speed.

  Regarding the technique of (6) above, that is, Patent Document 4, the reinforcing fiber laminated on the composite panel is fixed to an incombustible flame retardant board by an impregnating adhesive in advance to become a fiber reinforced plastic, and this is used as an adherend. Temporarily fixed and adhesive is injected into the gap between the adherend and the composite panel to fix them, so that the quality is stable and construction is simple, without including bubbles in the impregnated adhesive. Because the flame retardant board is laminated, the composite panel is hard, and if the adherend is finely uneven or the adherend is curved, it is impossible to follow the shape. Therefore, the distance between the composite panels becomes uncontrollable, and it is difficult to set the amount of adhesive used, and there is a variation problem in the reinforcing effect. Moreover, since it is necessary to provide the bolt hole and injection hole which penetrate the composite panel, there exists a problem by which the continuity of a reinforcement fiber is impaired. In addition, the adhesive is injected into the gap between the composite panel and the adherend after pre-sealing in the gap around the composite panel and the adherend. There is a problem that the adhesive flows out.

  In view of the above, the present invention can be applied easily and reliably to a structure (adhered body) that requires repair and reinforcement of concrete, metal, plastic, FRP, ceramic, etc., depending on environmental conditions. An object of the present invention is to provide a fiber-reinforced plastic having a stable quality, a method for producing the same, and a production kit.

As a result of intensive studies by the inventor, the present invention as described below has been completed.
(1) A method for producing a fiber reinforced plastic adhered to an adherend,
The fiber reinforced plastic is obtained by curing a two-component curable resin in the presence of reinforcing fibers.
Laminating a first sheet containing one component of the two-component curable resin and a second sheet containing the other component of the two-component curable resin in this order on the adherend; and
A step of pressurizing the obtained laminate and bringing both components of the two-component curable resin into contact with each other to cause a curing reaction,
At least one of Der those one or other of the components of the two-component curable resin cloth-like layer made of reinforcing fibers, which are impregnated with the first and second sheets is,
A separation layer that prevents permeation of each component of the two-component curable resin is provided on one main surface of the second sheet before lamination, and the separation layer is on the side opposite to the first sheet. In a direction, the first and second sheets are laminated on the adherend, and the first and second sheets are laminated again on the separation layer and pressed, so that 2 Forming a layer of fiber reinforced plastic over the layer ,
The above manufacturing method.
(2) The first sheet is formed by impregnating one component of a two-component curable resin into a cloth-like layer composed of reinforcing fibers, and the second sheet is two-component cured into a cloth-like layer composed of reinforcing fibers. The production method according to (1), wherein the other component of the mold resin is impregnated.
(3) The manufacturing method according to (1), wherein one of the first and second sheets is a sheet made of a gel-like material containing one or the other component of the two-component curable resin and containing no reinforcing fiber.
(4) The production method according to any one of (1) to (3), wherein the two-component curable resin is a two-component main component type acrylic adhesive.
(5) The production method according to any one of (1) to (3), wherein the two-component curable resin is a two-component curable epoxy adhesive.
( 6 ) The production method according to any one of (1) to ( 5 ), wherein the adherend is a concrete body.
( 7 ) A fiber reinforced plastic produced by the production method according to any one of (1) to ( 6 ).

  According to the present invention, on-site adhesive weighing work, application work, and impregnation work are not required, no skill in work is required, quality variation is unlikely to occur, adhesive is scattered, or adhesive is used. The inconvenience of falling and contaminating a third party is unlikely to occur. Since each component of the two-component curable resin is preliminarily molded as each sheet, it is not necessary to manage the amount of resin at the site, and the amount used can be easily managed. Since the curing reaction starts from the contact interface between the first and second sheets, if it is confirmed that the surface opposite to the contact surface of each sheet (especially the second sheet) is cured, the overall It can be easily determined that it is cured. Since the curing reaction is started after the lamination work of the sheets is completed, the work failure and the quality variation are less likely to occur. Since the amount of the reinforcing fiber and the amount of the cured resin component can be set by preparing the first and second sheets, a fiber-reinforced plastic having an excellent reinforcing effect can be obtained without depending on the skill level of the operator. .

  A sheet in which a component of a two-component curable resin is impregnated in a cloth-like layer made of reinforcing fibers has a high liquid-retaining ability of the resin component, and the liquid agent is biased in the vertical direction and difficult to separate during storage. The cloth-like layer can be selected from various fiber base materials and can be adapted to various adherend materials, repair and reinforcement conditions, and target quality.

Hereinafter, the present invention will be described in detail with reference to the drawings. However, the present invention is not limited to the illustrated embodiment.
FIG. 1 is a conceptual diagram of the production of fiber reinforced plastic according to the present invention. FIG. 1A shows a state in which the first and second sheets are laminated on the adherend, and FIG. 1B shows a fiber reinforced plastic obtained by curing a two-part curable resin on the adherend. It shows the state of bonding. The main point of the present invention is that each component of the two-component curable resin is contained in a plurality of independent sheets 11 and 12, and the sheets 11 and 12 are stacked and then pressed to generate a curing reaction. There is. According to the present invention, the fiber reinforced plastic 20 bonded to the adherend 1 can be suitably manufactured. In the present specification, when the sheets 11 and 12 are stacked on the adherend 1, they are referred to as a first sheet and a second sheet in order from the side closer to the adherend 1. According to the present invention, in order to obtain a fiber reinforced plastic, at least one of the first sheet 11 and the second sheet 12 is impregnated with a predetermined component of a two-component curable resin in a cloth-like layer made of reinforcing fibers. It is the form which becomes.

  FIG. 2 is a cross-sectional view of the sheet 10 in a form in which a cloth-like layer made of reinforcing fibers is impregnated with a predetermined component of a two-component curable resin. Such a sheet is typically called a prepreg. The sheet having such a form may be used as the first sheet or the second sheet. Both the first sheet and the second sheet may be formed by impregnating a predetermined layer of a two-component curable resin into a cloth layer made of reinforcing fibers. In the sheet of FIG. 2, a cloth-like layer made of reinforcing fibers is impregnated with one or the other component of a two-component curable resin. When impregnating, it is better that there are fewer bubbles, and a release film 2 may optionally be provided as shown.

The cloth-like layer is made of woven fabric, knitted fabric, braided fabric, non-woven fabric, laminated fabric, or the like. The unit cross-sectional area S ₁ of the cloth layer and the cross-sectional area S ₂ of the fibers existing in the unit cross-sectional area are preferably S ₂ / S ₁ × 100% ≦ 5%. If it is in the said range, it will be easy to hold | maintain each component of 2 liquid curable resin, and storage and handling will be easy.

  As a method for obtaining the sheet in the form of FIG. 2, a liquid agent containing one or the other component of a two-component curable resin and having a viscosity in an environment of 20 ° C. preferably in the range of 500 to 8000 mPa · s is prepared. In addition, a method of impregnating a cloth layer with this liquid agent can be mentioned. If it is the said viscosity range, it will become easy to fully impregnate a liquid agent without a bubble in a cloth-like layer. If the viscosity of the liquid agent is low, the liquid agent once impregnated in the cloth layer tends to flow out of the cloth layer, and if the viscosity of the liquid agent is high, the liquid agent tends not to be impregnated in the cloth layer. Bubbles and air pockets remain in the cloth-like layer, and the fiber-reinforced plastic finally obtained tends to be less integrated. The liquid agent may contain a substance other than one or the other component of the two-component curable resin.

  Here, the reinforcing fibers can be selected without particular limitation from those used as fibers in fiber-reinforced plastics, and preferably carbon fibers, aramid fibers, acrylic fibers, PBO fibers, polyester fibers, vinylon fibers, and cellulose-based fibers. It is at least one selected from the group consisting of fiber, nylon fiber, olefin fiber, glass fiber, mineral fiber and metal fiber. The form of the cloth-like layer made of reinforcing fibers is not particularly limited, and is preferably at least one substrate selected from the group consisting of woven cloth, knitted cloth, braided cloth, non-woven cloth and laminated cloth. Preferably, the cloth-like layer is a multiaxial laminated cloth in which the fiber base material is laminated by crossing two or more thread shapes in a mesh shape. The concrete piece is highly effective in preventing flaking.

  A release film (separator) may be provided on the sheet before lamination, in which case removal of the film immediately before lamination facilitates storage and transportation, and contaminates surroundings and workers in the lamination work. It is preferable at the point which becomes difficult to do. The release film may be provided on both main surfaces of each of the first and second sheets, or may be provided only on one main surface. Preferably, a release film is provided on a main surface of the first sheet that contacts the adherend, and a release film is provided on a main surface of the second sheet that contacts the first sheet. These release films are peeled off during lamination.

According to the present invention, the cloth-like layer may be present on both the first and second sheets, or the cloth-like layer may not be present on either one of them.
As a sheet | seat which does not have a cloth-like layer, the sheet | seat which consists of a gel-like material containing the one or other component of 2 liquid curable resin is mentioned. In consideration of moldability as a sheet and releasability when a release film is present, it is necessary to improve the cohesive force and viscosity of the gel-like material. At that time, it is possible to employ a technique for improving the cohesive force and viscosity of a known adhesive, such as adding an elastomer or a thickener to the gel. A release film may be provided on the sheet made of the gel material, and in that case, preferably F <W between the adhesion force F between the sheet and the release film and the cohesion force W of the gel material. A relationship is established. If such a relationship is established, the release film can be easily removed from the sheet, and cohesive failure of the gel-like material to the film hardly occurs during the removal of the release film.

  According to the present invention, the fiber reinforced plastic can be obtained by curing the two-component curable resin in the presence of the above-described reinforcing fiber. The two-component curable resin is a resin that cures when two predetermined components, that is, “one component” and “the other component” are in contact with each other. In the present invention, one component and the other component are separated from each other. It is characterized by being contained in the sheet. Here, each component of the two-component curable resin may be a single compound or a mixture of a plurality of compounds.

  Preferably, the two-component curable resin is a two-component main component type acrylic resin. The two-component main component type acrylic resin is an acrylic resin that includes a resin component in both one component and the other component, and both the components come into contact with each other and are cured. The two-component main component type acrylic resin is cured by radical reaction. According to the two-component main component type acrylic resin, if the first and second sheets are brought into contact with each other, the entire sheet is quickly cured and the construction period can be shortened. One main component (component) of the two-component main component type acrylic resin includes at least an acrylic monomer, an elastomer, and a polymerization initiator, and the other main component (component) includes at least an acrylic monomer, an elastomer, and a reducing agent. By having such a main agent structure and containing each main agent separately in the first sheet and the second sheet, undesired curing and alteration during storage can be prevented.

According to the present invention, the two-component curable resin is not limited to an acrylic resin, and various resins can be used. Examples of the two-component curable resin include an acrylic resin and an epoxy resin.
When a two-component mixed resin such as an epoxy resin is used as the two-component curable resin, the entire structure may be difficult to be cured only by bringing both components of the two-component curable resin into contact with each other. It is preferable to rub with a roller or the like having protrusions at the time of pressurization after the sheets are laminated.

  A protective layer is preferably provided on the second sheet before lamination. The protective layer is, for example, a layer having weather resistance, for example, a layer made of one or more synthetic resins selected from the group of fluorine resins, acrylic resins, urethane resins, vinyl chloride resins, and the like. is there. Such a protective layer can be suitably used for civil engineering structures that are exposed to ultraviolet rays for a long time outdoors. These protective layers may be provided on the main surface on one side of the second sheet before lamination, and laminated in such a direction that the protective layer is opposite to the first sheet when used. Since a protective layer can be provided in advance at the stage of manufacturing the second sheet, there is no need to perform repair and reinforcement work such as providing a protective layer at the work site, and the work can be greatly simplified and shortened. Is possible.

  In another preferred embodiment, the second sheet before lamination is preferably provided with a separation layer. The separation layer is a layer that prevents permeation of each component of the two-component curable resin. The separation layer is preferably a coated metal foil or a synthetic resin film, and the coating is made of a fiber substrate or paper. Examples of the synthetic resin film include a polyester film, a nylon film, and an olefin film. Examples of the fiber base material include non-woven fabrics. These separation layers may be provided on the main surface on one side of the second sheet before lamination, and laminated in such a direction that the separation layer is opposite to the first sheet when used. When the separation layer is provided in this manner, when a plurality of fiber reinforced plastics must be laminated, the components of the two-component curable resin in each layer are difficult to contact undesirably. Hard to occur. Another advantage of providing a separation layer is that even if it is necessary to apply paint to fiber-reinforced plastic immediately after implementation, there is no need to wait for the two-part curable resin to cure, greatly reducing the work. Is possible. Further, in the construction on the vertical surface or ceiling surface, it is difficult to cause inconvenience that the resin and paint in the second and subsequent layers sag and the quality varies.

  The thickness of the sheet is preferably 10 mm or less so that each component of the two-component curable resin can penetrate into the entire first and second sheets during curing and pressurization to cure the entire sheet. In particular, when the two-component curable resin is cured by a sequential reaction, it is important that the two components are sufficiently mixed, and the thinner the sheet, the better. On the other hand, the lower limit of the thickness of the sheet is not particularly defined, but is about 0.1 mm from the viewpoint of ease of handling and manufacturing process.

  The manufacturing method of the first and second sheets is not particularly limited. FIG. 3 is a configuration diagram of an example of an apparatus for manufacturing the first or second sheet. In this apparatus, a sheet formed by impregnating one or the other component of a two-component curable resin into a cloth-like layer made of reinforcing fibers can be obtained.

  The cloth layer is fed from the feed roll 31 and supplied to the liquid agent storage tank 37 filled with the liquid agent 40 containing one or the other component of the two-component curable resin. At this time, the liquid agent 40 is impregnated in the cloth layer. Next, the impregnated cloth-like layer is delivered to the pinch roll 32. In the pinch roll 32, an excess liquid agent is squeezed out by adjusting the interval between the pair of rolls, and the amount of impregnation of the liquid agent is adjusted. As a result, the basic configuration of the first or second sheet is established. A release film (separator) may be sent from a delivery roll 33 different from the cloth layer and laminated on the cloth layer by a nip roll 35, and finally collected by a take-up roll 36. If necessary, a protective layer, a reinforcing layer, a separation layer, and the like can be laminated on the sheet from another feeding roll 34. When laminating the protective layer and the reinforcing layer, both of them may be laminated in advance and sent out from one delivery roll, or one delivery roll may be added and each may be delivered and laminated. Is possible.

  The production of the first and second sheets is not limited to the apparatus shown in FIG. 3. For example, an adhesive coater (not shown) is used instead of the liquid agent storage tank 37 in the above example, and the cloth layer is delivered. It is also possible to adjust the amount of one or the other component of the two-component curable resin with respect to the reinforcing fiber by controlling the speed and the amount of the liquid agent from the coater. It can also be formed by technology. Furthermore, in order to more reliably impregnate one or the other component of the two-component curable resin into a cloth-like layer made of reinforcing fibers, the impregnated sheet may be left in a vacuum container.

  When producing a sheet having no cloth-like layer, for example, a release film is fed from a feeding roll, and one or the other component of the two-component curable resin is added onto the film using an adhesive coater. You may apply | coat the liquid agent to contain uniformly. By drying after application, a sheet made of the liquid material gel can be obtained.

  According to the present invention, the first sheet 11 and the second sheet 12 described above are stacked on the adherend 1 and pressed. Here, at the time of lamination, the first sheet 11 and the second sheet 12 are usually laminated so that both components of the two-component curable resin are mixed to produce an effective reaction. The degree of pressurization may be such that both components of the two-component curable resin are in contact with each other. For example, pressurization by pressing with a tool such as a roller or a spatula at a concrete repair site may be mentioned. By such pressurization, both components of the two-component curable resin come into contact with each other to cause a curing reaction. At this time, since at least one sheet has a cloth-like layer of reinforcing fibers, A fiber reinforced plastic 20 is obtained. The fiber reinforced plastic thus obtained is also within the scope of the present invention.

  When a release film is provided on the first and second sheets, preferably, the release sheet of the first sheet is laminated with the exposed surface facing the adherend, and the second sheet. The release film is peeled and the exposed surface is laminated toward the first sheet.

  Examples of the adherend include concrete, metal, plastic, fiber reinforced plastic, ceramic, and wood, and are not particularly limited. In general, adhesion is difficult when the surface of the adherend is wet, mirror-finished, or in a state where liquid is absorbed. In such a case, a good adhesion surface is formed by a known technique such as drying the adhesion surface of the adherend, roughening the surface, or creating a surface by applying a primer. It is preferable to keep it.

  If possible, it is preferable to check the adhesion between the adherend 1 and the first sheet 11 before lamination. When the first sheet 11 is easily peeled off from the adherend 1 or when it is difficult to obtain good adhesion between the adherend 1 and the first sheet 11, primer application, roughening, and chemical conversion treatment are performed. It is preferable to apply a known surface treatment technique such as flame treatment, corona discharge treatment, plasma treatment or the like.

  For the laminate of the adherend 1, the first sheet 11 and the second sheet 12, a roller, a spatula, or the like is preferably used so as to reduce bubbles remaining at the interface in each sheet as much as possible. If the bubbles remain, there is a possibility that a problem occurs in the integrity as a fiber reinforced plastic, or the curing reaction of the two-component curable resin may be hindered.

  The first and second sheets preferably have the same shape. If they do not have the same shape, there is a possibility that one component of the two-component curable resin may not come into contact with the other component of the pair, resulting in problems such as poor curing and occurrence of an uncured part. In order to reduce such problems, a measure may be taken so that each sheet can be cured later by an external stimulus. Such measures include, for example, adding in advance to the first and / or second sheet a substance that can be cured by an external stimulus such as ultraviolet rays.

  According to the present invention, it is preferable that the entire first and second sheets are completely cured. The possibility of incomplete curing at the part far from the contact interface of both sheets cannot be denied, but even in that case, fiber reinforced plastic as a cured product is obtained near the contact point of both sheets Belongs to the scope of the present invention.

  According to the present invention, the first and second sheets are manufactured by carefully adjusting the type and amount of each component at a factory or the like, and simply laminating and pressing both sheets at the site of use. Through this process, a fiber reinforced plastic close to the intended design can be obtained. Therefore, it is also possible to grasp the first and second sheets as a fiber reinforced plastic manufacturing kit. That is, the fiber-reinforced plastic manufacturing kit having the first and second sheets described above is also within the scope of the present invention. In addition to the first and second sheets, the manufacturing kit includes, for example, an explanatory document that states that these sheets should be laminated and pressed, and a pressing spatula or roller. Also good.

  The adherend to which the fiber reinforced plastic according to the present invention is bonded is not particularly limited. Since concrete bodies (structures) are expected to have various qualities in various environments, the advantages of repair and reinforcement according to the present invention can be enjoyed effectively. Depending on the material of the adherend, the purpose of repair, reinforcement, and the like, the type and amount of the reinforcing fiber can be appropriately adjusted. The sheet can be cut in advance according to the shape of the adherend, and if it is cut in this way, the work at the construction site is easy.

  EXAMPLES Hereinafter, although an Example demonstrates this invention further in detail, this invention is not limited to these.

< Reference Example 1>
< Reinforcement of concrete structures>
・ Substrate: Concrete ・ First sheet Cloth layer: Polyester non-woven fabric (Kuniko Paper Reflon EP-40)
Two-component main component acrylic adhesive A agent (acrylic monomer, elastomer, polymerization initiator included) viscosity 4000 mPa · s
Release film (both sides): 25 μm thick polyester base silicone coating film Production of first sheet:
With the apparatus shown in FIG. 3, a first sheet was manufactured using the above material. The amount of the agent A impregnated into the cloth layer was 400 g / m ² . FIG. 4 is a cross-sectional view of the sheet thus obtained, and the release film 2 is provided on both main surfaces of the sheet 10.
-Second sheet cloth layer: Carbon fiber (TU Cross HT300 manufactured by Mitsubishi Nisseki)
2 component main component type acrylic adhesive agent B (containing acrylic monomer, elastomer and reducing agent) viscosity 4000 mPa · s
Release film (both sides): 25 μm thick polyester base silicone coating film Production of second sheet:
With the apparatus shown in FIG. 3, a second sheet was manufactured using the above material. The amount of agent B impregnated into the cloth-like impregnation layer was 400 g / m ² . The cross section of the second sheet is also expressed as shown in FIG.

The weak part of the concrete surface was removed by sanding. One of the release films provided on both sides of the first sheet was removed, and the sheet was attached to a position where concrete fiber reinforced plastic should be set. A roller and a spatula were used to press from above the release film remaining on the first sheet so that no air bubbles remained at the interface between the concrete and the first sheet. Thereafter, the release film remaining on the first sheet was removed. One of the release films provided on both surfaces of the second sheet was removed, and the second sheet was laminated on the first sheet. A roller and a spatula were used to press from above the laminate so that bubbles and the like did not remain at the interface.
When left for 30 minutes in an environment of 20 ° C. as it was, it was confirmed that the resins of both sheets were completely cured, became fiber reinforced plastic, and were set to concrete.

Various strengths of the obtained fiber reinforced plastic were confirmed.
(1) Tensile test with Kenken-type adhesive strength tester Concrete cohesive failure was observed in all tests 3 (1.9, 3.5, 1.9 N / mm ² ).
(2) Bending strength test (conforms to JIS A1106)
In all the tests of test number 3 (15.6, 14.1, 15.1 N / mm ² ), no breakage was observed at the fiber-reinforced plastic setting point.
From the above results, the reinforcing effect of the adherend was recognized.

< Reference Example 2>
< FRP small ship repair>
・ Substrate: FRP
・ First sheet (see Fig. 4)
Cloth-like layer: Glass cloth (manufactured by Nittobo WR570 C-100)
Two-component main component acrylic adhesive A agent (acrylic monomer, elastomer, polymerization initiator included) viscosity 4000 mPa · s
Release film (both sides): 25 μm thick polyester base silicone coating film Production of first sheet:
With the apparatus shown in FIG. 3, a first sheet was manufactured using the above material. The amount of the agent A impregnated into the cloth layer was 400 g / m ² .
・ Second sheet (see Fig. 4)
Cloth-like immersion: Glass cloth (WR570 C-100, manufactured by Nittobo)
2 component main component type acrylic adhesive agent B (containing acrylic monomer, elastomer and reducing agent) viscosity 4000 mPa · s
Release film (both sides): 25 μm thick polyester base silicone coating film Production of second sheet:
With the apparatus shown in FIG. 3, a second sheet was manufactured using the above material. The amount of the agent B impregnated into the cloth layer was 400 g / m ² .

The damaged FRP portion was removed from the small ship, and the removed portion was filled with a putty-like adhesive and leveled so as to be smooth with the surroundings. One of the release films provided on both sides of the first sheet was removed, and the sheet was attached to a position to be repaired with fiber reinforced plastic. A roller and a spatula were used to press against the release film remaining on the first sheet so as not to leave bubbles at the interface between the site to be repaired and the sheet. Thereafter, the release film remaining on the first sheet was removed. One of the release films provided on both surfaces of the second sheet was removed, and the second sheet was laminated on the first sheet. A roller and a spatula were used to press from above the laminate so that bubbles and the like did not remain at the interface.
As it was left outdoors in a 15 ° C. environment for 60 minutes, it was confirmed that the resins of both sheets were completely cured and turned into fiber reinforced plastic, and the repair was completed. After that, the similar paint used in the surrounding area was applied to the repair site.

< Reference Example 3>
< FRP waterproof repair>
・ Substrate: FRP
・ First sheet (see Fig. 4)
Cloth-like layer: non-woven glass (manufactured by Nittobo MC380A-100)
Two-component main component acrylic adhesive A agent (acrylic monomer, elastomer, polymerization initiator included) viscosity 4000 mPa · s
Release film (both sides): 25 μm thick polyester base silicone coating film Production of first sheet:
With the apparatus shown in FIG. 3, an adherend-side adhesive layer was formed from the above material. The amount of the agent A impregnated into the cloth layer was 550 g / m ² .
・ Second sheet (see Fig. 4)
Cloth-like layer: non-woven glass (manufactured by Nittobo MC380A-100)
2 component main component type acrylic adhesive agent B (containing acrylic monomer, elastomer and reducing agent) viscosity 4000 mPa · s
Release film (both sides): 25 μm thick polyester base silicone coating film Production of second sheet:
With the apparatus shown in FIG. 3, a coating adhesive layer was made of the above material. The amount of the agent B impregnated into the cloth layer was 550 g / m ² .

  We repaired the FRP used for water tank floor wall waterproofing. The waterproof FRP layer adhered to the damaged concrete slab was removed. A primer was applied to the slab, and the primer was dried by touch. One of the release films provided on both sides of the first sheet was removed, and the sheet was affixed at a position where the fiber reinforced plastic of the slab should be set. A roller and a spatula were used to press from above the release film remaining on the first sheet so that no air bubbles remained at the interface between the primer and the sheet. Thereafter, the release film remaining on the first sheet was removed. One of the release films provided on both surfaces of the second sheet was removed, and the second sheet was laminated on the first sheet. A roller and a spatula were used to press from above the laminate so that bubbles and the like did not remain at the interface. When left for 60 minutes in an environment of 20 ° C. as it was, it was confirmed that the resins of both sheets were completely cured and turned into fiber reinforced plastic, and the repair was completed. After that, the similar paint used in the surrounding area was applied to the repair site.

< Reference Example 4>
< Concrete repair>
・ Substrate: Concrete ・ First sheet (see Fig. 4)
Release film (both sides): 25 μm thick polyester base silicone coating film Production of first sheet:
No cloth layer was used on the first sheet. A liquid agent having a viscosity of 25000 mPa · s containing a curing agent of a two-component curable epoxy adhesive was applied to the release film using an adhesive coater, and then dried to obtain a gel. Thereafter, a release film was provided on the gel. The weight of the liquid agent per unit area was 450 g / m ² .
-2nd sheet | seat cloth-like layer: Polyester nonwoven fabric (Kuniko Paper Manufacturing Reflon EP-40)
Two-component curable epoxy adhesive (main agent) viscosity 4000 mPa · s
Release film (single side): 25 μm thick polyester base silicone coating film Protective layer: PVF film (38 μm thick Tedlar film made by DuPont)
Reinforcing layer: Vinylon mesh (Vinylon triaxial mesh TSS1810Y manufactured by Unitika)
Production of the second sheet:
The cloth layer, the reinforcing layer, and the protective layer were laminated by a dry laminating method. Then, the 2nd sheet | seat was manufactured with the said material with the apparatus shown in FIG. The amount of the main agent impregnated into the cloth layer was 400 g / m ² . FIG. 5 is a schematic cross-sectional view of the obtained second sheet. A release film 2, a polyester nonwoven fabric 10 impregnated with a two-component curable epoxy adhesive, a reinforcing layer 3, and a protective layer 4 are laminated in this order.

Repairs were carried out as follows to prevent the concrete pieces falling off the concrete from falling and to protect the concrete. The concrete repair area was ground-treated and a primer was applied. One of the release films provided on both surfaces of the first sheet was removed, and the sheet was stuck on the primer. A roller and a spatula were used to press from above the release film remaining on the first sheet so that no air bubbles remained at the interface between the primer and the sheet. Thereafter, the release film remaining on the first sheet was removed. The release film provided on the second sheet was removed, and the second sheet was laminated on the first sheet. In order not to leave bubbles or the like at the interface, the roller having protrusions was sufficiently pressed from above the laminate.
When left as it was for 300 minutes in an 18 ° C. environment, it was confirmed that both sheets were completely cured, became fiber reinforced plastic, and were set to concrete.

<Example>
< Reinforcement of concrete poles>
・ Substrate: Concrete ・ First sheet (see Fig. 4)
Two-component main component acrylic adhesive agent A (containing acrylic monomer, elastomer, polymerization initiator, thickener) viscosity 25000 mPa · s
Release film (both sides): 25 μm thick polyester base silicone coating film Production of first sheet:
No cloth layer was used on the first sheet. A two-part curable epoxy adhesive agent A was applied to the release film using an adhesive coater, and then dried to obtain a gel-like product. Thereafter, a release film was provided on the gel. The weight of the liquid agent per unit area was 450 g / m ² .
-Second sheet cloth layer: Carbon fiber (TU Cross HT300 manufactured by Mitsubishi Nisseki)
Two-component main component acrylic adhesive agent B (acrylic monomer, elastomer, reducing agent-containing main agent) viscosity 4000 mPa · s
Release film (single side): 25 μm thick polyester base silicone coating film Separation layer: 16 μm thick polyester film and non-woven fabric OL150 made by Nippon Vilene were dry-laminated to obtain a non-woven laminate film.
Production of the second sheet:
The cloth layer and the separation layer were laminated by a dry laminating method. Then, the 2nd sheet | seat was manufactured with the said material with the apparatus shown in FIG. The amount of the B agent impregnated into the cloth layer was 400 g / m ² .

  In many cases, the fibers contained in the carbon fiber are aligned in one direction, and reinforcement in only that direction is possible. However, reinforcement of the concrete electric pole may require reinforcement in two directions, the height direction and the trunk circumferential direction. In this case, after setting the fiber reinforced plastic in one direction, the fiber reinforced plastic is set while covering in another direction. Therefore, the reinforcing fiber has two layers. FIG. 6 is a cross-sectional view schematically showing two-layer reinforcement on a concrete utility pole. A first layer of fiber reinforced plastic 21 is provided on the utility pole 6, and a second layer of fiber reinforced plastic 22 is provided via the separation layer 5. Therefore, in the following manner, two layers of reinforcement were performed in the two directions of the height direction and the trunk circumferential direction using the first and second sheets.

  A primer was applied to the repaired part of the utility pole 6 and dried by touch. One of the release films provided on both surfaces of the first sheet was removed, and the sheet was stuck on the primer. A roller and a spatula were used to press from above the release film remaining on the first sheet so that no air bubbles remained at the interface between the primer and the sheet. Thereafter, the release film remaining on the first sheet was removed. The release film provided on the second sheet was removed, and the second sheet was laminated on the first sheet. At this time, the reinforcing fibers of the second sheet were laminated in such a direction as to be in the height direction of the utility pole 6. In order not to leave bubbles or the like at the interface, the roller having protrusions was sufficiently pressed from above the laminate. In this way, the two-component curable resin was cured to reinforce the first-layer fiber-reinforced plastic 21.

  Immediately thereafter, a first sheet was separately attached on the separation layer 5 appearing on the surface of the first-layer fiber-reinforced plastic 21. Prior to sticking, the release film on one side of the first sheet was removed. A roller and a spatula were used to press from above the release film remaining on the first sheet so that no bubbles remained at the interface between the separation layer 5 and the first sheet. Thereafter, the release film remaining on the first sheet was removed. The release film provided on the second sheet was removed, and the second sheet was laminated on the first sheet. At this time, the second sheet was laminated in such a direction that the reinforcing fibers of the second sheet were in the trunk circumferential direction. In order not to leave bubbles or the like at the interface, the roller having protrusions was sufficiently pressed from above the laminate. Furthermore, a known weather-resistant paint (fluororesin paint, not shown) was applied on the separation layer to complete the coating. The first layer of fiber reinforced plastic 21 and the second layer of fiber reinforced plastic 22 were found to be completely separated by the separation layer 5, and there were no problems such as poor curing or abnormal curing. Since the separation layer is a non-woven laminate film, when the first sheet is laminated or when the weather resistant paint is applied, the separation layer does not sag even on the vertical surface and exhibits good adhesion.

  As a result, in addition to concrete utility poles, reinforcement with only one layer of reinforcing fiber is not enough, reinforcing structures that need to be laminated in two, three, or multiple layers, or applying paint to fiber-reinforced plastic. It can be easily estimated that it can be suitably used in repair and reinforcement that must be performed.

  According to the present invention, a method for producing a fiber-reinforced plastic bonded to an adherend such as concrete and a production kit thereof are provided, and application to repair work such as concrete is expected.

It is a conceptual diagram of manufacture of the fiber reinforced plastic by this invention. Sectional drawing of the 1st and 2nd sheet | seat used in this invention. It is a block diagram of an example of the apparatus which manufactures the 1st or 2nd sheet | seat. It is sectional drawing of the sheet | seat in which the release film was provided in both main surfaces. It is sectional drawing of the sheet | seat in which the protective layer, the reinforcement layer, and the release film were provided. It is sectional drawing which represents the reinforcement of 2 layers to a concrete electric pole.

DESCRIPTION OF SYMBOLS 1 Adhering body 2 Release film 3 Reinforcing layer 4 Protective layer 5 Separating layer 6 Concrete utility pole 10 Sheet 11 First sheet 12 Second sheet 20, 21, 22 Fiber reinforced plastic 31, 33, 34 Feed roll 32 Pinch Roll 35 Nip roll 36 Winding roll 36
37 Liquid storage tank 40 Liquid

Claims (7)

A method for producing a fiber reinforced plastic adhered to an adherend,
The fiber reinforced plastic is obtained by curing a two-component curable resin in the presence of reinforcing fibers.
Laminating a first sheet containing one component of the two-component curable resin and a second sheet containing the other component of the two-component curable resin in this order on the adherend; and
A step of pressurizing the obtained laminate and bringing both components of the two-component curable resin into contact with each other to cause a curing reaction,
At least one of Der those one or other of the components of the two-component curable resin cloth-like layer made of reinforcing fibers, which are impregnated with the first and second sheets is,
A separation layer that prevents permeation of each component of the two-component curable resin is provided on one main surface of the second sheet before lamination, and the separation layer is on the side opposite to the first sheet. In a direction, the first and second sheets are laminated on the adherend, and the first and second sheets are laminated again on the separation layer and pressed, so that 2 Forming a layer of fiber reinforced plastic over the layer ,
The above manufacturing method.   The first sheet is formed by impregnating one component of a two-component curable resin with a cloth-like layer made of reinforcing fibers, and the second sheet is made of a two-component curable resin with a cloth-like layer made of reinforcing fibers. The production method according to claim 1, wherein the other component is impregnated.   The manufacturing method according to claim 1, wherein one of the first and second sheets is a sheet made of a gel-like material containing one or the other component of the two-component curable resin and containing no reinforcing fiber.   The production method according to any one of claims 1 to 3, wherein the two-component curable resin is a two-component main component type acrylic adhesive.   The production method according to claim 1, wherein the two-component curable resin is a two-component curable epoxy adhesive. The production method according to any one of claims 1 to 5 , wherein the adherend is a concrete body. The fiber reinforced plastic manufactured by the manufacturing method in any one of Claims 1-6 .

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