JP5525412B2 - Manufacturing method of fiber reinforced resin sheet and fiber reinforced resin sheet - Google Patents
Manufacturing method of fiber reinforced resin sheet and fiber reinforced resin sheet Download PDFInfo
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- JP5525412B2 JP5525412B2 JP2010241219A JP2010241219A JP5525412B2 JP 5525412 B2 JP5525412 B2 JP 5525412B2 JP 2010241219 A JP2010241219 A JP 2010241219A JP 2010241219 A JP2010241219 A JP 2010241219A JP 5525412 B2 JP5525412 B2 JP 5525412B2
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- 229920005989 resin Polymers 0.000 title claims description 133
- 239000011347 resin Substances 0.000 title claims description 133
- 239000000835 fiber Substances 0.000 title claims description 81
- 238000004519 manufacturing process Methods 0.000 title claims description 35
- 239000011342 resin composition Substances 0.000 claims description 104
- 230000004888 barrier function Effects 0.000 claims description 76
- 238000005470 impregnation Methods 0.000 claims description 75
- 239000010408 film Substances 0.000 claims description 58
- 239000007788 liquid Substances 0.000 claims description 41
- 239000004567 concrete Substances 0.000 claims description 39
- 239000013039 cover film Substances 0.000 claims description 36
- 239000002131 composite material Substances 0.000 claims description 31
- 238000000034 method Methods 0.000 claims description 26
- 230000003014 reinforcing effect Effects 0.000 claims description 26
- 239000000203 mixture Substances 0.000 claims description 20
- 239000004744 fabric Substances 0.000 claims description 16
- 239000004925 Acrylic resin Substances 0.000 claims description 11
- 229920000178 Acrylic resin Polymers 0.000 claims description 11
- 230000008569 process Effects 0.000 claims description 11
- 239000012783 reinforcing fiber Substances 0.000 claims description 11
- 230000002441 reversible effect Effects 0.000 claims description 9
- 238000010030 laminating Methods 0.000 claims description 5
- 230000015572 biosynthetic process Effects 0.000 claims description 3
- 238000010998 test method Methods 0.000 claims description 3
- 239000013306 transparent fiber Substances 0.000 claims description 3
- 239000010410 layer Substances 0.000 description 118
- 238000001723 curing Methods 0.000 description 27
- 238000010438 heat treatment Methods 0.000 description 17
- 239000000306 component Substances 0.000 description 13
- 239000000853 adhesive Substances 0.000 description 12
- 230000001070 adhesive effect Effects 0.000 description 12
- 238000010276 construction Methods 0.000 description 12
- -1 polyethylene Polymers 0.000 description 12
- 239000000178 monomer Substances 0.000 description 10
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 9
- 230000000052 comparative effect Effects 0.000 description 8
- 230000002787 reinforcement Effects 0.000 description 7
- 239000000463 material Substances 0.000 description 6
- 230000001681 protective effect Effects 0.000 description 6
- 230000005855 radiation Effects 0.000 description 6
- 229920001567 vinyl ester resin Polymers 0.000 description 6
- 239000008358 core component Substances 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- 230000008439 repair process Effects 0.000 description 5
- 238000009987 spinning Methods 0.000 description 5
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical group C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 4
- 239000000470 constituent Substances 0.000 description 4
- UHESRSKEBRADOO-UHFFFAOYSA-N ethyl carbamate;prop-2-enoic acid Chemical compound OC(=O)C=C.CCOC(N)=O UHESRSKEBRADOO-UHFFFAOYSA-N 0.000 description 4
- 229920000139 polyethylene terephthalate Polymers 0.000 description 4
- 239000005020 polyethylene terephthalate Substances 0.000 description 4
- 238000002360 preparation method Methods 0.000 description 4
- 238000003825 pressing Methods 0.000 description 4
- 239000004743 Polypropylene Substances 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 3
- 239000003085 diluting agent Substances 0.000 description 3
- 229920000092 linear low density polyethylene Polymers 0.000 description 3
- 239000004707 linear low-density polyethylene Substances 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 230000000704 physical effect Effects 0.000 description 3
- 238000006116 polymerization reaction Methods 0.000 description 3
- 229920005672 polyolefin resin Polymers 0.000 description 3
- 229920001155 polypropylene Polymers 0.000 description 3
- 230000002829 reductive effect Effects 0.000 description 3
- 239000002344 surface layer Substances 0.000 description 3
- 230000037303 wrinkles Effects 0.000 description 3
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 2
- KWOLFJPFCHCOCG-UHFFFAOYSA-N Acetophenone Chemical compound CC(=O)C1=CC=CC=C1 KWOLFJPFCHCOCG-UHFFFAOYSA-N 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 2
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 2
- 150000001252 acrylic acid derivatives Chemical class 0.000 description 2
- 239000012790 adhesive layer Substances 0.000 description 2
- CJDPJFRMHVXWPT-UHFFFAOYSA-N barium sulfide Chemical compound [S-2].[Ba+2] CJDPJFRMHVXWPT-UHFFFAOYSA-N 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000003851 corona treatment Methods 0.000 description 2
- 150000001451 organic peroxides Chemical class 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 229920000098 polyolefin Polymers 0.000 description 2
- 239000011241 protective layer Substances 0.000 description 2
- 239000011150 reinforced concrete Substances 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 235000002639 sodium chloride Nutrition 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- 229920006305 unsaturated polyester Polymers 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical class O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 239000002759 woven fabric Substances 0.000 description 2
- UNMJLQGKEDTEKJ-UHFFFAOYSA-N (3-ethyloxetan-3-yl)methanol Chemical compound CCC1(CO)COC1 UNMJLQGKEDTEKJ-UHFFFAOYSA-N 0.000 description 1
- TXBCBTDQIULDIA-UHFFFAOYSA-N 2-[[3-hydroxy-2,2-bis(hydroxymethyl)propoxy]methyl]-2-(hydroxymethyl)propane-1,3-diol Chemical compound OCC(CO)(CO)COCC(CO)(CO)CO TXBCBTDQIULDIA-UHFFFAOYSA-N 0.000 description 1
- HMBNQNDUEFFFNZ-UHFFFAOYSA-N 4-ethenoxybutan-1-ol Chemical compound OCCCCOC=C HMBNQNDUEFFFNZ-UHFFFAOYSA-N 0.000 description 1
- LCFVJGUPQDGYKZ-UHFFFAOYSA-N Bisphenol A diglycidyl ether Chemical compound C=1C=C(OCC2OC2)C=CC=1C(C)(C)C(C=C1)=CC=C1OCC1CO1 LCFVJGUPQDGYKZ-UHFFFAOYSA-N 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 1
- 241001482237 Pica Species 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004820 Pressure-sensitive adhesive Substances 0.000 description 1
- 229920000297 Rayon Polymers 0.000 description 1
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 1
- ZJCCRDAZUWHFQH-UHFFFAOYSA-N Trimethylolpropane Chemical compound CCC(CO)(CO)CO ZJCCRDAZUWHFQH-UHFFFAOYSA-N 0.000 description 1
- QYKIQEUNHZKYBP-UHFFFAOYSA-N Vinyl ether Chemical class C=COC=C QYKIQEUNHZKYBP-UHFFFAOYSA-N 0.000 description 1
- 229920002978 Vinylon Polymers 0.000 description 1
- 238000003916 acid precipitation Methods 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 230000003078 antioxidant effect Effects 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
- 229920003235 aromatic polyamide Polymers 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- RWCCWEUUXYIKHB-UHFFFAOYSA-N benzophenone Chemical compound C=1C=CC=CC=1C(=O)C1=CC=CC=C1 RWCCWEUUXYIKHB-UHFFFAOYSA-N 0.000 description 1
- 239000012965 benzophenone Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- GYZLOYUZLJXAJU-UHFFFAOYSA-N diglycidyl ether Chemical class C1OC1COCC1CO1 GYZLOYUZLJXAJU-UHFFFAOYSA-N 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 238000013007 heat curing Methods 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 239000012784 inorganic fiber Substances 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- MGFYSGNNHQQTJW-UHFFFAOYSA-N iodonium Chemical compound [IH2+] MGFYSGNNHQQTJW-UHFFFAOYSA-N 0.000 description 1
- 230000001678 irradiating effect Effects 0.000 description 1
- 239000011344 liquid material Substances 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 239000012968 metallocene catalyst Substances 0.000 description 1
- 125000005641 methacryl group Chemical group 0.000 description 1
- 125000005397 methacrylic acid ester group Chemical group 0.000 description 1
- 125000005395 methacrylic acid group Chemical group 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 150000002921 oxetanes Chemical class 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 238000009832 plasma treatment Methods 0.000 description 1
- 229920003207 poly(ethylene-2,6-naphthalate) Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920006267 polyester film Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 239000011112 polyethylene naphthalate Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000013535 sea water Substances 0.000 description 1
- 238000004904 shortening Methods 0.000 description 1
- 239000011780 sodium chloride Substances 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 229920006027 ternary co-polymer Polymers 0.000 description 1
- 238000001029 thermal curing Methods 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 238000002834 transmittance Methods 0.000 description 1
- 239000006097 ultraviolet radiation absorber Substances 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 230000003313 weakening effect Effects 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
Landscapes
- Working Measures On Existing Buildindgs (AREA)
- Reinforced Plastic Materials (AREA)
- Laminated Bodies (AREA)
- Moulding By Coating Moulds (AREA)
- Nonwoven Fabrics (AREA)
- Woven Fabrics (AREA)
Description
本発明は、コンクリート製のトンネル、高架車道、橋梁、建築物などのコンクリート構造物の補修又は補強用繊維強化樹脂シートの製造方法、及び該製造方法で得られる繊維強化樹脂シートに関するものである。 TECHNICAL FIELD The present invention relates to a method for manufacturing a fiber reinforced resin sheet for repairing or reinforcing concrete structures such as concrete tunnels, elevated carriageways, bridges, and buildings, and a fiber reinforced resin sheet obtained by the manufacturing method.
近年、海岸又はその付近にある鉄筋コンクリート構造物が海塩粒子によって塩害を受けたり、海水と接触する鉄筋コンクリート構造物に塩分が侵入したりすることによる鉄筋の腐食、膨張によりそれらの構造物が劣化することや、酸性雨や工場の薬品等コンクリートに有害な物質により表層が脆弱化することなどによるコンクリートの劣化、あるいは、車両通行量の増大、積載量の増大、高速化等による構造物への過負荷などから、コンクリート構造物の表面部分がひび割れたり、剥落したり、また、コンクリート構造物自体が劣化してきていることが大きな問題となっている。 In recent years, reinforced concrete structures at or near the coast are damaged by sea salt particles, or the structures deteriorate due to corrosion and expansion of the reinforcing bars caused by salt intrusion into reinforced concrete structures in contact with seawater. Or deterioration of concrete due to weakening of the surface layer due to substances that are harmful to concrete, such as acid rain and chemicals in factories, or excessive traffic to structures due to increased vehicle traffic, increased loading capacity, speeding up, etc. A major problem is that the surface portion of the concrete structure is cracked or peeled off due to a load or the like, and the concrete structure itself is deteriorated.
その劣化したコンクリートの剥落を防止する工法や、ひび割れた部分や、剥落した部分を補修する各種工法やその材料等が種々検討されている。その中で、予め表面層となる保護層とコンクリート構造物への貼着層とを有する積層体とし、これらの層間に繊維基材からなる補強層を介在させた補修又は補強用シートにおいて、繊維基材として、有機繊維や無機繊維等を不織布、織布加工したシート状物を用いたものが、施工の容易化、品質の安定化を図ることができる工法として提案されている（特許文献１参照）。 Various methods for preventing the peeling of the deteriorated concrete, various methods for repairing the cracked portion and the peeled portion, and materials thereof have been studied. Among them, in a sheet for repair or reinforcement in which a protective layer serving as a surface layer and an adhesive layer to a concrete structure are provided in advance and a reinforcing layer composed of a fiber base material is interposed between these layers, the fiber As a base material, a method using a nonwoven fabric or a woven fabric processed sheet of organic fiber or inorganic fiber has been proposed as a construction method capable of facilitating construction and stabilizing quality (Patent Document 1). reference).
一方、その劣化したコンクリートのひび割れ部分を補修したのち、その後当該補修部位のひび割れ等の欠陥の進展の有無を目視観察することも、コンクリート構造物の管理上重要である。しかし、従来の一般的な補修方法では、表面が繊維基材などの被覆材で覆われているため、それらの目視観察が困難であった。
特許文献２には、コンクリート表面に、補強ネットを全光線透過率が３０％以上の可視硬化型ビニルエステル樹脂により直貼りするコンクリート補強層の形成方法が提案されている（特許文献２参照）。
On the other hand, after repairing the cracked portion of the deteriorated concrete, it is also important for the management of the concrete structure to visually observe the progress of defects such as cracks at the repaired site. However, in the conventional general repair method, since the surface is covered with a covering material such as a fiber base material, it is difficult to visually observe them.
Patent Document 2 proposes a method for forming a concrete reinforcing layer in which a reinforcing net is directly attached to a concrete surface with a visible curable vinyl ester resin having a total light transmittance of 30% or more (see Patent Document 2).
また、海島型の複合有機繊維のモノフィラメントが間隔を空けて網状に配されているメッシュ体と、該メッシュ体を内包するシート状の透明樹脂とを備える、コンクリート構造物の補修・補強用繊維強化樹脂シートが提案されている（特許文献３参照）。 In addition, a fiber reinforcement for repairing / reinforcing a concrete structure, comprising a mesh body in which monofilaments of sea-island type composite organic fibers are arranged in a net-like manner at intervals, and a sheet-like transparent resin enclosing the mesh body A resin sheet has been proposed (see Patent Document 3).
しかしながら、特許文献１に記載の補修・補強用シートは施工後のコンクリート表面の目視観察についての考慮はされておらず、ひび割れの発生の有無やその程度、経時変化等を観察することができない。
また、特許文献２に記載の方法は、施工現場において、補強ネット及び補強シートを固着するための可視光硬化型ビニルエステル樹脂を塗布する作業は避けられず、不安定な足場での現場における補修又は補強作業の簡略化、短縮化が要請されていた。
一方、特許文献３に記載の繊維強化樹脂シートは、コンクリート面の目視観察は可能であるが、前記繊維強化樹脂シートからピンホール状の貫通した穴を完全に無くすことは困難であると考えられる。その貫通した穴が存在すると未硬化の接着剤が漏出しやすく、施工の貼り付け作業で表面をローラー等でしごく場合に、接着剤が漏洩した表面ではその接着剤が塗り広げてられてしまうため、その接着剤の拭取りなどの施工上の手間が発生することがあり、さらに接着剤を完全に拭き取りきれないと表面に汚れが付着しやすいので外観を重要視する施工現場等では問題となることがあった。（接着剤はスライム状に粘性を持たせてあるので自重で落ちてくることは無いが、シートを貼り付ける際にローラーでしごくので、漏出した接着剤を表面に塗り広げてしまう。）
そこで、本出願人は、特願２００９−６８８１７（平成２１年３月１９日出願）によって、貫通穴を防ぐ方法としてバリア層を設けて、貫通を遮断したコンクリート構造物の補修又は補強用繊維強化樹脂シートを提供した。しかしながらこの繊維強化樹脂シートにおいても、貫通穴は遮断されたものの透明樹脂層に、気泡が発生することは避けられず、外観上の問題（貫通穴があるかもしれないという誤解が生じることも含む）などの課題があった。
つまり、コンクリート構造物表面の観察が可能であって、メッシュ体を内包するシート状の透明樹脂層に気泡のより少ない補強又は補修用の透明性繊維強化樹脂シートが求められていた。
However, the repair / reinforcing sheet described in Patent Document 1 does not take into account the visual observation of the concrete surface after construction, and it is impossible to observe the presence or absence of cracks, their degree, changes with time, and the like.
In addition, the method described in Patent Document 2 inevitably involves applying a visible light curable vinyl ester resin for fixing the reinforcing net and the reinforcing sheet at the construction site, and repairing the site with an unstable scaffold. Or the simplification and shortening of the reinforcement work have been requested.
On the other hand, the fiber reinforced resin sheet described in Patent Document 3 can be visually observed on the concrete surface, but it is considered difficult to completely eliminate pinhole-shaped through holes from the fiber reinforced resin sheet. . If there is a through-hole, uncured adhesive is likely to leak out, and when the surface is rubbed with a roller or the like during construction application, the adhesive will be spread on the surface where the adhesive has leaked. This may cause trouble in construction such as wiping off the adhesive, and if the adhesive is not completely wiped off, dirt will easily adhere to the surface. There was a thing. (Since the adhesive has a slime-like viscosity, it does not fall off due to its own weight, but when the sheet is attached, it is squeezed with a roller, and the leaked adhesive is spread on the surface.)
Therefore, according to Japanese Patent Application No. 2009-68817 (filed on Mar. 19, 2009), the present applicant provided a barrier layer as a method for preventing a through hole, and repaired or reinforced fiber reinforcement for a concrete structure that blocked the penetration. A resin sheet was provided. However, even in this fiber reinforced resin sheet, though the through holes are blocked, it is inevitable that bubbles are generated in the transparent resin layer, and there is an appearance problem (including misunderstanding that there may be through holes). ) And other issues.
That is, there has been a demand for a transparent fiber-reinforced resin sheet that can observe the surface of a concrete structure and that has less bubbles in the sheet-like transparent resin layer that encloses the mesh body.
そこで、本発明では、上記の問題が解決できる、コンクリート製のトンネル、高架車道、橋梁、建築物などのコンクリート構造物の補修又は補強用繊維強化樹脂シートの製造方法について鋭意検討した結果、メッシュ体にキャリアフィルム上に塗布された本体用透明硬化性樹脂組成物（Ａ）を含浸する（本含浸）前に、予備含浸用透明硬化性樹脂組成物（Ｂ）が注入された予備含浸槽と含浸ローラーで含浸・加圧を行うことで、メッシュ体に含まれる気泡を脱泡することができ、その後本含浸することで気泡の少ないメッシュ状補強繊維入り樹脂シートを得ることができ、上記課題を解決できることを見出した。 Therefore, in the present invention, as a result of earnestly examining the method for repairing concrete structures such as concrete tunnels, elevated roadways, bridges, buildings, or the like, which can solve the above problems, or manufacturing a reinforcing fiber reinforced resin sheet, the mesh body A pre-impregnation tank and impregnated with a transparent curable resin composition (B) for pre-impregnation before impregnating (main impregnation) with the transparent curable resin composition (A) for main body coated on the carrier film. By impregnating and pressurizing with a roller, the bubbles contained in the mesh body can be degassed, and then by the main impregnation, a resin sheet with mesh-like reinforcing fibers with few bubbles can be obtained. I found that it can be solved.
すなわち、本発明は、以下の〔１〕〜〔８〕を提供する。
〔１〕メッシュ体に透明硬化性樹脂組成物を含浸・硬化してなるコンクリート構造物の補修又は補強用繊維強化樹脂シートの製造方法であって、該製造方法は下記の工程（１）〜（４）を含むことを特徴とする繊維強化樹脂シートの製造方法。
（１）キャリアフィルム上、又は該キャリアフィルム上に形成されたバリア層上に、本体用透明硬化性樹脂組成物（Ａ）を塗布する液層形成工程、
（２）メッシュ体を、前記本体用透明硬化性樹脂組成物（Ａ）と相溶性を有し、かつ粘度５０〜１５０００ｃＰの予備含浸用透明硬化性樹脂組成物（Ｂ）が注入された含浸槽に浸漬させつつ走行させ、次いで樹脂液を保持したメッシュ体を含浸ローラー間に通して、ローラー線圧５〜３０Ｎ／ｃｍで含浸・脱泡する予備含浸工程、
（３）前記本体用透明硬化性樹脂組成物（Ａ）の液層上面から前記予備含浸用透明硬化性樹脂組成物（Ｂ）が含浸されたメッシュ体を前記液層中に進入させ、さらにその上面に第１のカバーフィルムを載置して、キャリアフィルム上又は該キャリアフィルム上に形成されたバリア層との間に挟み込んだメッシュ体に本体用透明硬化性樹脂組成物（Ａ）を含浸する本含浸工程、及び
（４）前記予備含浸用透明硬化性樹脂組成物（Ｂ）及び本体用透明硬化性樹脂組成物（Ａ）を硬化する硬化工程。
〔２〕さらに、前記液層形成工程（１）の前に、キャリアフィルムの上部にバリア層を形成するための、下記のバリア層の形成工程（５）を含む前記〔１〕に記載の繊維強化樹脂シートの製造方法。
（５）キャリアフィルム上にバリア層用透明硬化性樹脂組成物（Ｃ）を塗布し第２のカバーフィルムで挟み込んで硬化してバリア層を形成した後、該第２のカバーフィルムを剥離して該バリア層を前記液層形成工程（１）に供するバリア層形成工程。
〔３〕前記メッシュ体が積層布であって、海島型複合糸を、経方向、斜方向、逆斜方向の少なくとも３方向に積層し、積層した海島型複合糸同士を熱融着してなる経一層又は経二層の３軸積層布である前記〔１〕又は〔２〕に記載の繊維強化樹脂シートの製造方法。
〔４〕前記本体用透明硬化性樹脂組成物（Ａ）及び予備含浸用透明硬化性樹脂組成物（Ｂ）が（メタ）アクリル系樹脂組成物である前記〔１〕〜〔３〕のいずれかに記載の繊維強化樹脂シートの製造方法。
〔５〕前記バリア層用透明硬化性樹脂組成物（Ｃ）が（メタ）アクリル系樹脂組成物である前記〔２〕〜〔４〕のいずれかに記載の繊維強化樹脂シートの製造方法。
〔６〕前記メッシュ体のＪＩＳ Ｋ６７６８に準じる濡れ性試験方法による表面濡れ性が５５〜７５ｍＮ／ｍの範囲である前記〔１〕〜〔５〕のいずれかに記載の繊維強化樹脂シートの製造方法。
〔７〕前記第１のカバーフィルムがバリア層形成工程（５）に用いた第２のカバーフィルムを剥離したフィルムを連続的に再利用したものである前記〔２〕〜〔６〕のいずれかに記載の繊維強化樹脂シートの製造方法。
〔８〕透明硬化樹脂からなる非通気性のバリア層と、補強繊維によって所定の開口部が形成されたメッシュ体に該バリア層と相溶性を有する透明硬化性樹脂組成物を含浸・硬化させた繊維強化樹脂本体層とを積層一体化させてなる透明性繊維強化樹脂シートであって、該繊維強化樹脂本体層中における直径２ｍｍ以上の気泡含有数が、１個／ｍ2以下である、ことを特徴とするコンクリート構造物の補修又は補強用繊維強化樹脂シート。
That is, the present invention provides the following [1] to [8].
[1] A method for producing a fiber reinforced resin sheet for repairing or reinforcing a concrete structure obtained by impregnating and curing a transparent curable resin composition in a mesh body, the production method comprising the following steps (1) to ( 4) The manufacturing method of the fiber reinforced resin sheet characterized by including.
(1) A liquid layer forming step of applying the transparent curable resin composition for main body (A) on the carrier film or on the barrier layer formed on the carrier film,
(2) The impregnation tank in which the mesh body is compatible with the transparent curable resin composition for main body (A) and the transparent curable resin composition for pre-impregnation (B) having a viscosity of 50 to 15000 cP is injected. Pre-impregnation step in which the mesh body holding the resin liquid is passed between the impregnation rollers, and impregnated and defoamed at a roller linear pressure of 5 to 30 N / cm,
(3) The mesh body impregnated with the transparent curable resin composition for pre-impregnation (B) is introduced into the liquid layer from the upper surface of the liquid layer of the transparent curable resin composition for main body (A), and further The first cover film is placed on the upper surface, and the mesh body sandwiched between the carrier film or the barrier layer formed on the carrier film is impregnated with the transparent curable resin composition for main body (A). A main impregnation step, and (4) a curing step of curing the pre-impregnation transparent curable resin composition (B) and the main body transparent curable resin composition (A).
[2] The fiber according to [1], further including the following barrier layer forming step (5) for forming a barrier layer on the carrier film before the liquid layer forming step (1). A method for producing a reinforced resin sheet.
(5) After applying the transparent curable resin composition (C) for the barrier layer on the carrier film and sandwiching and curing with the second cover film to form the barrier layer, the second cover film is peeled off. A barrier layer forming step of subjecting the barrier layer to the liquid layer forming step (1);
[3] The mesh body is a laminated fabric, and sea-island composite yarns are laminated in at least three directions of warp, oblique, and reverse oblique directions, and the sea-island composite yarns are heat-sealed. The method for producing a fiber-reinforced resin sheet according to the above [1] or [2], which is a warp or bilayer triaxial laminated fabric.
[4] Any of [1] to [3], wherein the transparent curable resin composition for main body (A) and the transparent curable resin composition for pre-impregnation (B) are (meth) acrylic resin compositions. The manufacturing method of the fiber reinforced resin sheet of description.
[5] The method for producing a fiber-reinforced resin sheet according to any one of [2] to [4], wherein the transparent curable resin composition (C) for the barrier layer is a (meth) acrylic resin composition.
[6] The method for producing a fiber-reinforced resin sheet according to any one of [1] to [5], wherein the mesh body has a surface wettability in a range of 55 to 75 mN / m according to a wettability test method according to JIS K6768. .
[7] Any one of [2] to [6], wherein the first cover film is a film obtained by continuously reusing the second cover film used in the barrier layer forming step (5). The manufacturing method of the fiber reinforced resin sheet of description.
[8] A non-breathable barrier layer made of a transparent curable resin and a mesh body having predetermined openings formed by reinforcing fibers were impregnated and cured with a transparent curable resin composition compatible with the barrier layer. A transparent fiber reinforced resin sheet obtained by laminating and integrating a fiber reinforced resin main body layer, and the number of bubbles having a diameter of 2 mm or more in the fiber reinforced resin main body layer is 1 / m 2 or less. A fiber-reinforced resin sheet for repairing or reinforcing concrete structures.
本発明の繊維強化樹脂シートの製造方法によれば、メッシュ体を一度樹脂に浸漬し、樹脂が含浸したメッシュ体を含浸ローラーにて適切な圧力で加圧することでメッシュの内部まで樹脂含浸を行うと同時に気泡を除去する予備含浸工程を経て、予備含浸されたメッシュ体をキャリアフィルムに塗布された液層（樹脂プール）上面から進入させて本含浸を行うので、メッシュ体による気泡の持ち込みや、キャリアフィルムとの接触時の気泡の発生を排除できるので、結果として気泡が少なく、特に直径２ｍｍ以上の大きさの気泡がほとんどない繊維強化樹脂シートを得ることができる。
本発明の繊維強化樹脂シートは、気泡の少ない繊維強化樹脂シートなので、コンクリート構造物表面の観察が可能な補強又は補修用繊維強化樹脂シートとして有効に提供できる。
According to the method for producing a fiber-reinforced resin sheet of the present invention, the mesh body is once immersed in the resin, and the mesh body impregnated with the resin is pressurized with an appropriate pressure with an impregnation roller to impregnate the inside of the mesh. At the same time, through the pre-impregnation step of removing bubbles, the pre-impregnated mesh body is entered from the upper surface of the liquid layer (resin pool) applied to the carrier film to perform the main impregnation. Since the generation of bubbles at the time of contact with the carrier film can be eliminated, as a result, a fiber reinforced resin sheet having few bubbles and particularly having almost no bubbles having a diameter of 2 mm or more can be obtained.
Since the fiber reinforced resin sheet of the present invention is a fiber reinforced resin sheet with few bubbles, it can be effectively provided as a reinforcing or repairing fiber reinforced resin sheet capable of observing the surface of a concrete structure.
以下、本発明の好適な実施形態について説明する。なお、添付図面に示された各実施形態は、本発明に係わる代表的な実施形態の一例を示したものであり、これにより本発明の範囲が狭く解釈されることはない。 Hereinafter, preferred embodiments of the present invention will be described. Each embodiment shown in the accompanying drawings shows an example of a typical embodiment according to the present invention, and the scope of the present invention is not interpreted narrowly.
本発明のコンクリート構造物の補修又は補強用繊維強化樹脂シートの製造方法は、（１）キャリアフィルム上、又は該キャリアフィルム上に形成されたバリア層上に、本体用透明硬化性樹脂組成物（Ａ）を塗布する液層形成工程、
（２）メッシュ体を、前記本体用透明硬化性樹脂組成物（Ａ）と相溶性を有し、かつ粘度５０〜１５０００ｃＰの予備含浸用透明硬化性樹脂組成物（Ｂ）が注入された含浸槽に浸漬させつつ走行させ、次いで樹脂液を保持したメッシュ体を含浸ローラー間に通して、ローラー線圧５〜３０Ｎ／ｃｍで含浸・脱泡する予備含浸工程、（３）前記本体用透明硬化性樹脂組成物（Ａ）の液層上面から前記予備含浸用透明硬化性樹脂組成物（Ｂ）が含浸されたメッシュ体を前記液層中に進入させ、さらにその上面に第１のカバーフィルムを載置して、キャリアフィルム上又は該キャリアフィルム上に形成されたバリア層との間に挟み込んだメッシュ体に本体用透明硬化性樹脂組成物（Ａ）を含浸する本含浸工程、及び（４）前記予備含浸用透明硬化性樹脂組成物（Ｂ）及び本体用透明硬化性樹脂組成物（Ａ）を硬化する硬化工程、を含み、特に上記予備含浸工程（２）に特徴を有する。
The method for producing a fiber reinforced resin sheet for repairing or reinforcing a concrete structure according to the present invention comprises: (1) a transparent curable resin composition for a main body on a carrier film or a barrier layer formed on the carrier film ( A liquid layer forming step of applying A),
(2) The impregnation tank in which the mesh body is compatible with the transparent curable resin composition for main body (A) and the transparent curable resin composition for pre-impregnation (B) having a viscosity of 50 to 15000 cP is injected. Pre-impregnation step in which the mesh body holding the resin liquid is passed between the impregnating rollers and impregnating and defoaming at a roller linear pressure of 5 to 30 N / cm, (3) Transparent curability for the main body A mesh body impregnated with the transparent curable resin composition for pre-impregnation (B) is introduced into the liquid layer from the upper surface of the liquid layer of the resin composition (A), and a first cover film is placed on the upper surface. The impregnation step of impregnating the transparent curable resin composition for main body (A) into the mesh body sandwiched between the carrier film or the barrier layer formed on the carrier film, and (4) Transparent curing for pre-impregnation Curing step of curing the fat composition (B) and transparent curable resin composition for body and (A), include, in particular, has a feature in the pre-impregnation step (2).
本発明において、補強繊維によって所定の開口部が形成されたメッシュ体としては、織布、網、編布、および積層布からなる１種又は２種以上の組み合わせから選択でき、積層布が好ましく用いることができる。
積層布は、組布とも称されるもので、経方向、斜方向、逆斜方向の少なくとも３方向に積層した３軸のものを一般的に使用できる。積層布は、メッシュ体としての低コスト性を有しているので、経済的なメリットもある。積層布の製造は、例えば特開平１１−２００５９号公報に記載の方法により製造できる。
開口部は開口率が３０％以上であることが好ましく、開口率が３０％未満では、コンクリート表面層の観察もし難い。
In the present invention, the mesh body in which the predetermined openings are formed by the reinforcing fibers can be selected from one or a combination of two or more of woven fabric, net, knitted fabric, and laminated fabric, and laminated fabric is preferably used. be able to.
The laminated fabric is also referred to as a braided fabric, and a three-axis fabric laminated in at least three directions of warp direction, oblique direction, and reverse oblique direction can be generally used. Since the laminated fabric has low cost as a mesh body, there is also an economic merit. The laminated fabric can be produced, for example, by the method described in JP-A-11-20059.
The opening portion preferably has an opening ratio of 30% or more. When the opening ratio is less than 30%, it is difficult to observe the concrete surface layer.
メッシュ体は、補強繊維を、経方向、斜方向、逆斜方向の少なくとも３方向に積層し、積層した海島型複合糸同士を熱融着してなる経一層又は経二層の３軸積層布とすることができる。
図１（Ａ）は、本発明のコンクリート構造物の補修又は補強用繊維強化樹脂シートの一例の上面図であり、メッシュ体１０は透明樹脂層を介して見えている状態を示している。同図に示すメッシュ体は、補強繊維１を構成糸として、下経糸層１１上に、斜交層１３及び逆斜交層１４、上経糸層１２を積層し、各層の交点を加熱により熱融着したものである。
メッシュ体１０を形成した後、さらに加熱加圧してメッシュ体１０全体を薄肉化してもよい。これによりメッシュ体１０の柔軟性や可撓性を更に向上させることができる。その際の加熱温度は、海部を構成する熱可塑性樹脂の融点近傍がよい。加圧はローラー押圧などの方法で行うことができる。
The mesh body is a one-layer or two-ply triaxial laminated fabric obtained by laminating reinforcing fibers in at least three directions of warp direction, oblique direction, and reverse oblique direction, and heat-sealing the laminated sea-island type composite yarns. It can be.
FIG. 1A is a top view of an example of a fiber reinforced resin sheet for repairing or reinforcing a concrete structure of the present invention, and shows a state in which the mesh body 10 is visible through a transparent resin layer. In the mesh body shown in the figure, the reinforcing fiber 1 is used as a constituent yarn, and the oblique layer 13, the reverse oblique layer 14, and the upper warp layer 12 are laminated on the lower warp layer 11, and the intersection of each layer is thermally fused by heating. It is what I wore.
After the mesh body 10 is formed, the whole mesh body 10 may be thinned by further heating and pressing. Thereby, the softness | flexibility and flexibility of the mesh body 10 can be improved further. The heating temperature at that time is preferably close to the melting point of the thermoplastic resin constituting the sea. The pressurization can be performed by a method such as roller pressing.
メッシュ体に用いられる補強繊維は、繊維強度、伸度等の物性が、メッシュ体の構成糸として補強効果を有するものであれば、ビニロン繊維、ポリエステル繊維、ポリアミド繊維、ポリオレフィン繊維、芳香族ポリアミド繊維等その種類を問わない。
なかでも、メッシュ体は、（ａ）ポリオレフィン系樹脂からなる芯成分と（ｂ）該芯成分の融点よりも２０℃以上低い融点を有するポリオレフィン系樹脂からなる鞘成分と、からなる芯鞘型複合繊維の鞘成分を融合させた海島型複合糸を用い、該複合糸の交点を熱融着してなるメッシュ体、特に３軸積層布とすることが好適である。
本発明の海島型複合糸に使用できるポリオレフィン系樹脂としては、ポリエチレン、ポリプロピレン、エチレン、プロピレン、ブテン−１等のα−オレフィンの２元共重合体、又は３元共重合体等が挙げられる。
芯成分と鞘成分の好適な組み合わせとしては、例えば、芯成分としてアイソタクチックポリプロピレン（ｍｐ＝１６３℃）、鞘成分として直鎖状低密度ポリエチレン（ｍｐ＝１１０℃）を用いる組み合わせが挙げられる。
かかる、海島型複合糸は、例えばスピンドロー方式により、定法の複合紡糸設備、芯鞘型複合紡糸ノズルを用い、所定の鞘／芯断面比となるように紡糸し、直結する延伸装置に導いて、飽和水蒸気圧下で延伸し、延伸と共に鞘成分で複数数の繊維間を融合して得ることができる。また、特開２００３−３２６６０９号公報に記載の方法により製造することができる。
The reinforcing fiber used in the mesh body is vinylon fiber, polyester fiber, polyamide fiber, polyolefin fiber, aromatic polyamide fiber, as long as the physical properties such as fiber strength and elongation have a reinforcing effect as a constituent thread of the mesh body. It doesn't matter what kind.
In particular, the mesh body has a core-sheath type composite comprising: (a) a core component made of a polyolefin resin; and (b) a sheath component made of a polyolefin resin having a melting point 20 ° C. lower than the melting point of the core component. It is preferable to use a sea-island type composite yarn in which fiber sheath components are fused and to form a mesh body, particularly a triaxial laminated fabric, obtained by heat-sealing the intersection of the composite yarn.
Examples of the polyolefin-based resin that can be used for the sea-island composite yarn of the present invention include binary copolymers of olefins such as polyethylene, polypropylene, ethylene, propylene, and butene-1, and ternary copolymers.
Suitable combinations of the core component and the sheath component include, for example, a combination using isotactic polypropylene (mp = 163 ° C.) as the core component and linear low density polyethylene (mp = 110 ° C.) as the sheath component.
Such a sea-island type composite yarn is spun to have a predetermined sheath / core cross-section ratio by using, for example, a spin draw method, using a conventional composite spinning equipment and a core-sheath type composite spinning nozzle, and led to a drawing apparatus that is directly connected. It can be obtained by stretching under saturated water vapor pressure and fusing a plurality of fibers with a sheath component together with stretching. Moreover, it can manufacture by the method as described in Unexamined-Japanese-Patent No. 2003-326609.
海島型複合糸において、島部と海部との質量比は２０:８０〜８０:２０であることが好ましい。島部及び海部の合計質量に対する島部の質量比が２０質量％未満であると、メッシュ体による補強効果が小さくなる傾向があり、８０質量％を超えると熱接着強度が低下する傾向がある。同様の観点から、島部と海部との質量比は４０:６０〜７０:３０であることがより好ましい。
海島型複合糸の繊度は１００〜５０００ｄｔｅｘが好ましい。１００ｄｔｅｘ未満であると、目的とする物性が得られ難くなる傾向があり、５０００ｄｔｅｘを超えると柔軟性や追随性が損なわれ易くなる傾向がある。５００〜３０００ｄｔｅｘの繊度がより好ましい。
In the sea-island type composite yarn, the mass ratio of the island part to the sea part is preferably 20:80 to 80:20. If the mass ratio of the island part to the total mass of the island part and the sea part is less than 20% by mass, the reinforcing effect by the mesh body tends to be small, and if it exceeds 80% by mass, the thermal bond strength tends to be low. From the same viewpoint, the mass ratio between the island and the sea is more preferably 40:60 to 70:30.
The fineness of the sea-island type composite yarn is preferably 100 to 5000 dtex. If it is less than 100 dtex, the intended physical properties tend to be difficult to obtain, and if it exceeds 5000 dtex, flexibility and followability tend to be impaired. A fineness of 500 to 3000 dtex is more preferable.
図４は、海島型複合糸の一実施形態を示す説明図である。
図４の実施形態は、単一の芯部（島部）３及びこれの外周面を覆う鞘部５ａから構成される芯鞘構造を有する芯鞘型複合単繊維９を複数本集束して芯鞘型複合単繊維束１５（図４Ａ）を延伸しつつ鞘部５ａを溶融し、鞘部５ａ同士を融合して複数の島部３を内包する海部５を形成した形態（図４Ｂ）を備える海島型複合糸である。
FIG. 4 is an explanatory view showing an embodiment of a sea-island type composite yarn.
In the embodiment of FIG. 4, a plurality of core-sheath type composite single fibers 9 having a core-sheath structure composed of a single core part (island part) 3 and a sheath part 5 a covering the outer peripheral surface of the single core part (island part) 3 are concentrated. It comprises a form (FIG. 4B) in which the sheath 5a is melted while the sheath-type composite single fiber bundle 15 (FIG. 4A) is stretched, and the sheath 5a is fused to form the sea part 5 containing the plurality of islands 3. It is a sea-island type composite yarn.
本体用透明硬化性樹脂組成物（Ａ）及びバリア層用透明硬化性樹脂組成物（Ｃ）としては、本体用透明硬化性樹脂組成物（Ａ）とバリア層用透明硬化性樹脂組成物（Ｃ）が相溶性（接着性を含む）を有し、機械的物性において繊維強化樹脂シートの構成材料としての機能を有する透明性樹脂から選択される。この種の主体樹脂として、（メタ）アクリル系樹脂又はビニルエステル系樹脂が好ましい。特に（メタ）アクリル系樹脂は、アクリル基又はメタクリル基を有する重合性モノマーの重合により形成される重合体を主成分とする樹脂である。
キャリアフィルム上への本体用透明硬化性樹脂組成物（Ａ）又はバリア層用透明硬化性樹脂組成物（Ｃ）の塗布には、一般的な塗工装置が使用でき、例えばグラビアリバース、グラビアダイレクト、三本リバース、ダイコートなどの中から選んで使用できる。
As the transparent curable resin composition for main body (A) and the transparent curable resin composition for barrier layer (C), the transparent curable resin composition for main body (A) and the transparent curable resin composition for barrier layer (C ) Is compatible (including adhesiveness), and is selected from transparent resins having a function as a constituent material of the fiber-reinforced resin sheet in mechanical properties. As this type of main resin, a (meth) acrylic resin or a vinyl ester resin is preferable. In particular, the (meth) acrylic resin is a resin whose main component is a polymer formed by polymerization of a polymerizable monomer having an acrylic group or a methacrylic group.
For application of the transparent curable resin composition for main body (A) or the transparent curable resin composition for barrier layer (C) on the carrier film, a general coating apparatus can be used, for example, gravure reverse, gravure direct, etc. You can choose from 3 reverses or die coats.
図５は、本発明の製造方法の一例の工程説明図である。図５に係る製造方法においては、キャリアフィルム２１上にバリア層用透明硬化性樹脂組成物（Ｃ）２０ｃを塗布し、第２のカバーフィルム２３で挟み込んで硬化してバリア層１０１を形成した後、第２のカバーフィルム２３を剥離するバリア層形成工程（５）を経て、当該バリア層上にポンプ４３からノズル４８を経て本体用透明硬化性樹脂組成物（Ａ）２０ａを供給している。 FIG. 5 is a process explanatory diagram of an example of the manufacturing method of the present invention. In the manufacturing method according to FIG. 5, after the barrier layer transparent curable resin composition (C) 20 c is applied on the carrier film 21, sandwiched and cured by the second cover film 23 to form the barrier layer 101. After passing through the barrier layer forming step (5) for peeling the second cover film 23, the transparent curable resin composition for main body (A) 20a is supplied from the pump 43 through the nozzle 48 onto the barrier layer.
バリア層形成工程（５）は、先ず、キャリアフィルム２１上に、所定厚みのバリア層を形成するための重合性モノマーを含むバリア層用透明硬化性樹脂組成物（Ｃ）〔本態様ではバリア層用透明硬化性樹脂組成物（Ｃ）と本体用透明硬化性樹脂組成物（Ａ）を同一としている。〕２０ｃを調合槽４０ａで調合してリザーブタンク４０に投入しポンプ４１により、ノズル４２からキャリアフィルム２１上に塗布し第１スクイズローラー５２で所定の塗布厚みに調整し、加熱炉７０に挿通して、硬化したバリア層用透明硬化性樹脂組成物（Ｃ）からなるバリア層１０１を形成する。次いでバリア層１０１の上に所定厚みの繊維強化樹脂本体層（１０２）を形成するための本体用透明硬化性樹脂組成物（Ａ）２０ａを供給（塗布）して液層（樹脂プール）２０ａ'を形成し、予備含浸用透明硬化性樹脂組成物（Ｂ）２０ｂが含浸されたメッシュ体１０ａを前記液層上面から液層中に進入させて、メッシュ体１０aに、さらに本体用透明硬化性樹脂組成物（Ａ）２０ａを含浸し、含浸ローラー５５で含浸・脱泡、及び厚み調整をし、次いで、その上面に第１のカバーフィルム２２を第２スクイズローラー５６にて載置して、キャリアフィルム２１との間にメッシュ体１０ａを挟み込んで、硬化炉７１での硬化及び熱処理炉７２での熱処理を経て巻き取られる。
なお、この実施態様では、第１のカバーフィルム２２は、バリア層の形成に用いた第２のカバーフィルム２３を、バリア層の硬化後にローラー５３ａの部分で剥離し、ガイドローラー５３ｂ〜５３ｃを経て第２スクイズローラー５６の部分で第１のカバーフィルム２２として再利用している。なお、ガイドローラー５３ｂ〜５３ｃ間には、テンションローラー（図示省略）を設けて、第１のカバーフィルム２２の張力を調整し、キャリアフィルム２１側との速度バランスを調整している。
In the barrier layer forming step (5), first, a transparent curable resin composition for a barrier layer (C) containing a polymerizable monomer for forming a barrier layer having a predetermined thickness on the carrier film 21 [in this embodiment, a barrier layer] The transparent curable resin composition for use (C) and the transparent curable resin composition for main body (A) are the same. 20c is prepared in the preparation tank 40a, put into the reserve tank 40, applied onto the carrier film 21 from the nozzle 42 by the pump 41, adjusted to a predetermined application thickness by the first squeeze roller 52, and inserted into the heating furnace 70. Thus, the barrier layer 101 made of the cured transparent curable resin composition for barrier layer (C) is formed. Next, a transparent curable resin composition (A) 20a for main body for forming a fiber reinforced resin main body layer (102) having a predetermined thickness on the barrier layer 101 is supplied (applied) to form a liquid layer (resin pool) 20a ′. And the mesh body 10a impregnated with the pre-impregnating transparent curable resin composition (B) 20b is made to enter the liquid layer from the upper surface of the liquid layer, and further into the mesh body 10a, the transparent curable resin for the main body The composition (A) 20a is impregnated, impregnated and defoamed with an impregnation roller 55, and the thickness is adjusted, and then the first cover film 22 is placed on the upper surface thereof with a second squeeze roller 56, and the carrier The mesh body 10a is sandwiched between the film 21 and the film body 10a is wound through curing in the curing furnace 71 and heat treatment in the heat treatment furnace 72.
In this embodiment, the first cover film 22 peels off the second cover film 23 used for forming the barrier layer at the portion of the roller 53a after curing the barrier layer, and passes through the guide rollers 53b to 53c. The second squeeze roller 56 is reused as the first cover film 22. A tension roller (not shown) is provided between the guide rollers 53b to 53c to adjust the tension of the first cover film 22 and adjust the speed balance with the carrier film 21 side.
次に、メッシュ体へ予備含浸用透明硬化性樹脂組成物（Ｂ）２０ｂを含浸・脱泡する予備含浸工程（２）について説明する。
予備含浸用透明硬化性樹脂組成物（Ｂ）としては、本体用透明硬化性樹脂組成物（Ａ）と相溶性を有し、粘度５０〜１５０００ｃＰの組成ものから選択される。
予備含浸用透明硬化性樹脂組成物（Ｂ）２０ｂは、例えば、スチレンモノマーなどの溶剤（粘度５０ｃＰ以下、２５℃）とビニルエステルや不飽和ポリエステルなどの熱硬化性樹脂（粘度１００〜６０００ｃＰ、２５℃）を混合した組成であって、本体用透明硬化性樹脂組成物（Ａ）（ウレタンアクリレート）に相溶するものを用いることができる。予備含浸用透明硬化性樹脂組成物（Ｂ）２０ｂの粘度が低ければ低いほど脱気効果が高いので、本体用透明硬化性樹脂組成物（Ａ）を加温し粘度を下げて利用しても良い。ただし、熱硬化性樹脂は、硬化反応が起きないような温度にする必要がある。本体用透明硬化性樹脂組成物（Ａ）による液層中にメッシュ体を進入させる本含浸工程（３）に送るまでに、メッシュ体は予備含浸用透明硬化性樹脂組成物（Ｂ）２０ｂで濡れていることが重要なので、溶剤を使用した際は揮発する前に速やかに本含浸工程（３）に送る必要がある。
Next, the pre-impregnation step (2) for impregnating and defoaming the transparent curable resin composition (B) 20b for pre-impregnation into the mesh body will be described.
The pre-impregnating transparent curable resin composition (B) is selected from compositions having compatibility with the main body transparent curable resin composition (A) and a viscosity of 50 to 15000 cP.
The pre-impregnating transparent curable resin composition (B) 20b includes, for example, a solvent such as a styrene monomer (viscosity 50 cP or less, 25 ° C.) and a thermosetting resin such as vinyl ester or unsaturated polyester (viscosity 100 to 6000 cP, 25 C.), which is compatible with the transparent curable resin composition for main body (A) (urethane acrylate). The lower the viscosity of the pre-impregnating transparent curable resin composition (B) 20b, the higher the deaeration effect. Therefore, even if the transparent curable resin composition for main body (A) is heated to lower the viscosity, it can be used. good. However, the thermosetting resin needs to be at a temperature at which no curing reaction occurs. The mesh body is wetted with the pre-impregnating transparent curable resin composition (B) 20b before being sent to the main impregnation step (3) in which the mesh body enters the liquid layer of the transparent curable resin composition (A) for the main body. Since it is important that the solvent be used, it must be promptly sent to the impregnation step (3) before volatilization.
メッシュ体への含浸性とメッシュ体に内包する気泡を脱離させる観点から、予備含浸用透明硬化性樹脂組成物（Ｂ）２０ｂの粘度は５０〜１５０００ｃＰ、予備含浸ローラー４７の線圧は５〜３０Ｎ／ｃｍとすることが必須である。ここにおいて、ローラー線圧とは、ローラーを押さえる加重（Ｎ）をローラーの長さ（ｃｍ）で除したものである。
粘度が５０ｃＰ未満では、液垂れが発生し易くなる傾向がありメッシュ体による樹脂の保持量が不十分となり、１５０００ｃＰを超えると含浸不良となって、形成される透明樹脂層内に気泡が発生し易くなる傾向がある。
また、線圧が５Ｎ／ｃｍ未満では、メッシュ体が保持する樹脂組成物に気泡が多量に含んだ状態で本含浸工程に移行することになり、硬化した繊維強化樹脂シートに気泡が出現する。一方、線圧が３０Ｎ／ｃｍを超えると、予備含浸ローラー４７により、メッシュ本体１０ａが変形し、皺が発生するなど外観不良を来す。
From the viewpoint of impregnating the mesh body and removing bubbles contained in the mesh body, the pre-impregnation transparent curable resin composition (B) 20b has a viscosity of 50 to 15000 cP, and the pre-impregnation roller 47 has a linear pressure of 5 to 5. It is essential to set it to 30 N / cm. Here, the roller linear pressure is obtained by dividing the weight (N) for pressing the roller by the length (cm) of the roller.
If the viscosity is less than 50 cP, dripping tends to occur, and the amount of resin retained by the mesh body becomes insufficient. If the viscosity exceeds 15000 cP, impregnation is poor, and bubbles are generated in the formed transparent resin layer. It tends to be easier.
On the other hand, when the linear pressure is less than 5 N / cm, the resin composition held by the mesh body moves to the impregnation step in a state where a large amount of bubbles are contained, and bubbles appear in the cured fiber-reinforced resin sheet. On the other hand, when the linear pressure exceeds 30 N / cm, the pre-impregnation roller 47 deforms the mesh body 10a and causes defects such as wrinkles.
予備含浸されたメッシュ本体１０ａは、キャリアフィルム上又はキャリアフィルム上に形成されたバリア層１０１上に、本体用透明硬化性樹脂組成物（Ａ）２０ａを塗布して形成した液層２０ａ'に導かれ含浸ローラー５５にて含浸され、次いで第１のカバーフィルム２２に挟持されて第２スクイズローラー５６で厚みが調整される。
次いで、硬化炉７１、熱処理炉７２を経て、引取機６０を経て巻取機６１で巻き取られる。硬化炉７１では透明硬化性樹脂組成物が、放射線や、熱により硬化され、熱処理炉７２では、さらに未硬化状モノマー等のアフターキュアと繊維強化樹脂シートの熱的安定性を向上させるための処理が行われる。
The pre-impregnated mesh body 10a is guided to a liquid layer 20a ′ formed by applying the transparent curable resin composition (A) 20a for the body onto the carrier film or the barrier layer 101 formed on the carrier film. It is impregnated by the impregnation roller 55, and then sandwiched by the first cover film 22 and the thickness is adjusted by the second squeeze roller 56.
Subsequently, it is wound up by the winder 61 through the take-up machine 60 through the curing furnace 71 and the heat treatment furnace 72. In the curing furnace 71, the transparent curable resin composition is cured by radiation or heat, and in the heat treatment furnace 72, the after-curing of uncured monomer and the process for improving the thermal stability of the fiber-reinforced resin sheet are performed. Is done.
キャリアフィルム２１、第１のカバーフィルム２２及び第２のカバーフィルム２３としては、例えばポリエチレンテレフタレート、ポリエチレンナフタレート等のポリエステル系フィルムを用いることができる。なお、図５では、第１のカバーフィルムは、バリア層の形成に用いた第２のカバーフィルム２３を硬化後に剥離し、これを第２スクイズローラー５６の部位から再度導入して、本含浸、硬化工程以降で使用している。これらのキャリアフィルム２１及びカバーフィルム２２（２３）は、保護フィルム２１及び２２（２３）としてそのまま用いてもよい。保護フィルムは繊維強化樹脂シートが製造された後、検査、保管、輸送、切断などの作業等において繊維強化樹脂シートの表面を保護するもので、施工時には除去されるものである。 As the carrier film 21, the first cover film 22, and the second cover film 23, for example, a polyester film such as polyethylene terephthalate or polyethylene naphthalate can be used. In FIG. 5, the first cover film is peeled off after the second cover film 23 used for forming the barrier layer is cured, and this is again introduced from the site of the second squeeze roller 56 to perform the main impregnation, Used after the curing process. These carrier film 21 and cover film 22 (23) may be used as they are as protective films 21 and 22 (23). The protective film protects the surface of the fiber-reinforced resin sheet in operations such as inspection, storage, transportation, and cutting after the fiber-reinforced resin sheet is manufactured, and is removed during construction.
さらに、本体用透明硬化性樹脂組成物（Ａ）及び／又は予備含浸用透明硬化性樹脂組成物（Ｂ）には粘着剤成分を含有してもよい。粘着剤成分（例えば粘着性付与剤）を含むことによって、施工時にコンクリート構造物側の接着剤層と接着し易くなって、施工がはかどるなどの効果が期待できる。また、保護フィルムとの粘着により、繊維強化樹脂シートを有効に保護できる。 Furthermore, the transparent curable resin composition for main body (A) and / or the transparent curable resin composition for pre-impregnation (B) may contain an adhesive component. By including a pressure-sensitive adhesive component (for example, a tackifier), it becomes easy to adhere to the adhesive layer on the concrete structure side during construction, and effects such as rapid construction can be expected. Moreover, a fiber reinforced resin sheet can be effectively protected by adhesion with a protective film.
本体用透明硬化性樹脂組成物（Ａ）２０ａ、予備含浸用透明硬化性樹脂組成物（Ｂ）２０ｂ、及びバリア層用透明硬化性樹脂組成物（Ｃ）２０ｃは、例えば（メタ）アクリル系樹脂と、アクリル基又はメタクリル基を有する重合性モノマーを含有する組成のものを用いることができる。前記重合性モノマーとしては、例えば、ウレタン（メタ）アクリレート及び（メタ）アクリル酸エステルがある。
前記透明硬化性樹脂組成物（Ａ）〜（Ｃ）は、所望の透明性が得られる範囲内で、紫外線吸収剤、酸化防止剤などを更に含有していてもよい。前述した予備含浸用透明硬化性樹脂組成物（Ｂ）以外の本体用透明硬化性樹脂組成物（Ａ）及びバリア層用透明硬化性樹脂組成物（Ｃ）の粘度は５０〜１５０００ｃＰであることが好ましく、８００〜１０００ｃＰであることがより好ましい。
本体用透明硬化性樹脂組成物（Ａ）及びバリア層用透明硬化性樹脂組成物（Ｃ）の粘度が低いと液垂れが発生し易くなる傾向があり、硬化性樹脂組成物の粘度が高いと含浸不良となって、形成される透明樹脂層内に気泡が発生し易くなる傾向がある。
The transparent curable resin composition for main body (A) 20a, the transparent curable resin composition for pre-impregnation (B) 20b, and the transparent curable resin composition for barrier layer (C) 20c are, for example, (meth) acrylic resins And the thing of the composition containing the polymerizable monomer which has an acryl group or a methacryl group can be used. Examples of the polymerizable monomer include urethane (meth) acrylate and (meth) acrylic acid ester.
The said transparent curable resin composition (A)-(C) may further contain a ultraviolet absorber, antioxidant, etc. within the range from which desired transparency is acquired. The viscosity of the transparent curable resin composition for main body (A) and the transparent curable resin composition for barrier layer (C) other than the above-described transparent curable resin composition for pre-impregnation (B) is 50 to 15000 cP. Preferably, it is 800-1000 cP.
When the viscosity of the transparent curable resin composition for main body (A) and the transparent curable resin composition for barrier layer (C) is low, dripping tends to occur, and the viscosity of the curable resin composition is high. There is a tendency that bubbles are easily generated in the formed transparent resin layer due to poor impregnation.
前記透明硬化性樹脂組成物（Ａ）〜（Ｃ）は、放射線硬化タイプであってもよく、この場合は、塗布後に放射線を照射して硬化させることができる。
放射線硬化性樹脂としては、放射線によって架橋ないし重合反応を起こして硬化するプレポリマー（又はオリゴマー）、単量体、或いは両者を混合したものを用いる。かかるプレポリマーとしては、ウレタン（メタ）アクリレート、エポキシ（メタ）アクリレート、ポリエステル（メタ）アクリレート等の（メタ）アクリレート化合物、不飽和ポリエステル、エポキシ化合物等が用いられる。また、単量体としては、ジエチレングリコールジ（メタ）アクリレート、トリメチロールプロパントリ（メタ）アクリレート、ジペンタエリスリトールヘキサ（メタ）アクリレート等の（メタ）アクリレート化合物、３，４−エポキシシクロヘキセニルメチル−３’，４’−エポキシシクロヘキセンカルボキシレートなどの脂環式エポキシド類、ビスフェノールＡジグリシジルエーテルなどグリシジルエーテル類、４−ヒドロキシブチルビニルエーテルなどビニルエーテル類、３−エチル−３−ヒドロキシメチルオキセタンなどオキセタン類等が用いられる。なお、ここで（メタ）アクリレートとは、アクリレート又はメタアクリレートを意味する表記である。また、放射線としては、電子線等の粒子線、或いは紫外線、可視光線、Ｘ線等の電磁波が用いられる。特に、紫外線或いは可視光線で硬化させる場合には、通常、ベンゾフェノン、アセトフェノン、芳香族ヨウドニウム、メタロセン化合物等を光反応開始剤として添加する。
The transparent curable resin compositions (A) to (C) may be of a radiation curable type, and in this case, they can be cured by irradiation with radiation after coating.
As the radiation curable resin, a prepolymer (or oligomer) that cures by causing a crosslinking or polymerization reaction by radiation, a monomer, or a mixture of both is used. As such a prepolymer, urethane (meth) acrylate, epoxy (meth) acrylate, (meth) acrylate compounds such as polyester (meth) acrylate, unsaturated polyester, epoxy compounds and the like are used. Examples of the monomer include (meth) acrylate compounds such as diethylene glycol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, dipentaerythritol hexa (meth) acrylate, and 3,4-epoxycyclohexenylmethyl-3. Alicyclic epoxides such as', 4'-epoxycyclohexenecarboxylate, glycidyl ethers such as bisphenol A diglycidyl ether, vinyl ethers such as 4-hydroxybutyl vinyl ether, oxetanes such as 3-ethyl-3-hydroxymethyloxetane, etc. Used. Here, (meth) acrylate is a notation that means acrylate or methacrylate. As the radiation, particle beams such as electron beams, or electromagnetic waves such as ultraviolet rays, visible rays, and X-rays are used. In particular, when curing with ultraviolet rays or visible rays, benzophenone, acetophenone, aromatic iodonium, metallocene compounds and the like are usually added as photoinitiators.
メッシュ体１０は、繊維強化樹脂シートを形成する際に接触する各樹脂との接着性をよくするために、必要に応じて表面の濡れ性を調整することが好ましい。表面の濡れ性は、前記各樹脂に応じて適宜調整すればよいが、概ね、濡れ指数として５５〜７５ｍＮ／ｍの範囲に調整することが好ましい。特に、メッシュ体１０を構成するモノフィラメントの海部５がポリオレフィンからなる場合、表面活性が低いためにモノフィラメントと透明硬化樹脂２０との接着性が低下して、繊維強化樹脂シート１００による補強効果が小さくなる傾向や、保護フィルム２１若しくは２２（２３）を剥がした際に透明硬化樹脂２０の一部が保護フィルム側に剥離してしまい易くなる傾向があることから、親水化処理により表面濡れ性が調整されたメッシュ体１０を用いることが効果的である。親水化処理としては、コロナ放電処理、プラズマ処理などが挙げられる。 The mesh body 10 preferably adjusts the wettability of the surface as necessary in order to improve the adhesiveness with each resin that comes into contact with the fiber-reinforced resin sheet. The wettability of the surface may be appropriately adjusted according to each of the resins, but it is generally preferable to adjust the wettability index to a range of 55 to 75 mN / m. In particular, when the sea part 5 of the monofilament constituting the mesh body 10 is made of polyolefin, the surface activity is low, so that the adhesion between the monofilament and the transparent cured resin 20 is lowered, and the reinforcing effect by the fiber reinforced resin sheet 100 is reduced. The surface wettability is adjusted by the hydrophilization treatment because when the protective film 21 or 22 (23) is peeled off, there is a tendency that a part of the transparent cured resin 20 is easily peeled to the protective film side. It is effective to use the mesh body 10. Examples of the hydrophilic treatment include corona discharge treatment and plasma treatment.
本発明の製造方法により得られた繊維強化樹脂シートの断面拡大図を図２（Ａ）に示す。同図においてメッシュ体の構成繊維がバリア層１０１側にも埋設した状態になっているが、これは一旦硬化したバリア層１０１の表面が、未硬化状の本体用透明硬化性樹脂組成物（Ａ）との接触によって相互の相溶性により膨潤するので、メッシュ体１０ａがローラー５５、５６等による作用を受けて、バリア層側にもその一部が埋設される。バリア層とのかかる界面状態は、繊維強化樹脂シートとして、界面剥離が発生し難いので好ましい。なお、同図において、保護フィルム２１及び２２（２３）は、製造時にはキャリアフィルム２１及びカバーフィルム２２（２３）も兼ねたものであり、繊維強化樹脂シートとしての施工時には剥離される。 FIG. 2A shows an enlarged cross-sectional view of the fiber-reinforced resin sheet obtained by the production method of the present invention. In the drawing, the constituent fibers of the mesh body are also embedded in the barrier layer 101 side. This is because the surface of the barrier layer 101 once cured is uncured transparent curable resin composition for main body (A ) Swells due to mutual compatibility, and the mesh body 10a is subjected to the action of the rollers 55, 56, etc., and a part of the mesh body 10a is also embedded on the barrier layer side. Such an interface state with the barrier layer is preferable as the fiber reinforced resin sheet hardly causes interface peeling. In the figure, the protective films 21 and 22 (23) also serve as the carrier film 21 and the cover film 22 (23) at the time of manufacture, and are peeled off during construction as a fiber reinforced resin sheet.
本発明の製造方法では、キャリアフィルム及び／又は第１のカバーフィルムを透明な（メタ）アクリル系樹脂フィルムとすることができる。
（メタ）アクリル系樹脂フィルムを用いると、当該（メタ）アクリル系樹脂フィルムは、キャリアフィルムとバリア層、さらには保護層を兼ねる機能をもたせることができる。
In the production method of the present invention, the carrier film and / or the first cover film can be a transparent (meth) acrylic resin film.
When a (meth) acrylic resin film is used, the (meth) acrylic resin film can have a function of serving as a carrier film, a barrier layer, and further a protective layer.
図５において、キャリアフィルム２１として（メタ）アクリル系樹脂フィルムを用い、当該フィルム２１上にタンク４０からノズル４８を経て本体用透明硬化性樹脂組成物（Ａ）２０ａ'を塗布し、続いて予備含浸用透明硬化性樹脂組成物（Ｂ）２０ｂ'が予備含浸されたメッシュ体１０ａが導入され、含浸ローラー５５にてメッシュ体１０ａを案内しつつ、本体用透明硬化性樹脂組成物（Ａ）２０ａ'を含浸し、次いでこれらを第１のカバーフィルム２２で挟み込み、その後、スクイズローラー５６の間で加圧することにより、メッシュ体１０ａに本体用透明硬化性樹脂組成物（Ａ）２０ａ'をさらに含浸し、厚みを調整する。 In FIG. 5, a (meth) acrylic resin film is used as the carrier film 21, and the transparent curable resin composition (A) 20 a ′ for the main body is applied on the film 21 from the tank 40 through the nozzle 48, followed by a preliminary operation. The transparent curable resin composition (A) 20a for main body is introduced while the mesh body 10a preliminarily impregnated with the transparent curable resin composition (B) 20b ′ for impregnation is introduced and the mesh body 10a is guided by the impregnation roller 55. Then, the mesh body 10a is further impregnated with the transparent curable resin composition (A) 20a 'for the main body by sandwiching them with the first cover film 22 and then pressing between the squeeze rollers 56. And adjust the thickness.
続いて、硬化炉７１内で、紫外線を照射することにより硬化する。この紫外線を照射により透明硬化性樹脂組成物２０ａ及び２０ｂにおいて重合性モノマーの重合が進行する。繊維強化樹脂本体層として透明樹脂層が形成された繊維強化樹脂シート１００は、硬化炉７１から出てきた後、さらに熱処理炉７２にてアフターキュアと寸法安定化の熱処理を受け、ローラー６０により引取られて、巻取機６１により巻き取られる。なお、硬化炉および熱処理炉を通過させる際は、繊維強化樹脂シート１００の両端はクリップで挟持して、繊維強化樹脂シートを緊張状で処理することが、皺が無く、一定幅の繊維強化樹脂シートを得る点で好ましい。 Then, it hardens | cures by irradiating an ultraviolet-ray in the curing furnace 71. FIG. Polymerization of the polymerizable monomer proceeds in the transparent curable resin compositions 20a and 20b by irradiation with the ultraviolet rays. The fiber reinforced resin sheet 100 in which the transparent resin layer is formed as the fiber reinforced resin main body layer, after coming out of the curing furnace 71, is further subjected to after-curing and dimensional stabilization heat treatment in the heat treatment furnace 72, and taken up by the roller 60. And is wound up by a winder 61. When passing through a curing furnace and a heat treatment furnace, both ends of the fiber reinforced resin sheet 100 are sandwiched between clips, and the fiber reinforced resin sheet is processed in a tension state, so that there is no wrinkle and the fiber reinforced resin has a certain width. It is preferable at the point which obtains a sheet | seat.
本発明のコンクリート構造物の補修又は補強用繊維強化樹脂シートは、透明硬化樹脂からなる非通気性のバリア層と、補強繊維によって所定の開口部が形成されたメッシュ体に該バリア層と相溶性を有する透明硬化性樹脂組成物を含浸・硬化させた繊維強化樹脂本体層とを積層一体化させてなる透明性繊維強化樹脂シートであって、該繊維強化樹脂本体層中における直径２ｍｍ以上の気泡含有数が、１個／ｍ2以下であることを特徴としている。
前記バリア層と、前記繊維強化樹脂本体層とを積層一体化させてなるとは、両層が相互に接着一体化し、コンクリート構造物の補修又は補強用繊維強化樹脂シートとしての機能を備えている状態を言う。
本発明の繊維強化樹脂シートにおいて、バリア層の厚みは、５０〜１００μｍとするのが好ましく、５０〜１００μｍの範囲であれば、コンクリート構造物への補修又は補強工事時に塗布された接着剤がしごかれて漏出するなどの現象が発生することがなく、漏出防止のバリア層としての機能を発現できる。
また、メッシュ体に該バリア層と相溶性を有する透明硬化性樹脂組成物を含浸・硬化した繊維強化樹脂本体層をバリア層と積層一体化した繊維強化樹脂シートの厚みは、４００〜５００μｍとするのが、コンクリート構造物表面への追随可能な柔軟性や取り扱い性、作業性、軽量性、補強効果、経済性等の点から好ましい。
本発明の繊維強化樹脂シートは、直径２ｍｍ以上の気泡含有数が、１個／ｍ2以下と、直径２ｍｍ以上の気泡がほとんど含まれていないので、気泡による補強物性への負の影響が殆どなく、メッシュ体によるコンクリート構造物の補修又は補強の効果を最大限に発揮させることができる。
The fiber reinforced resin sheet for repairing or reinforcing a concrete structure of the present invention is compatible with a non-breathable barrier layer made of a transparent cured resin and a mesh body in which a predetermined opening is formed by the reinforcing fiber. A transparent fiber reinforced resin sheet obtained by laminating and integrating a fiber reinforced resin main body layer impregnated and cured with a transparent curable resin composition having an air bubble having a diameter of 2 mm or more in the fiber reinforced resin main body layer The content is 1 piece / m 2 or less.
When the barrier layer and the fiber reinforced resin main body layer are laminated and integrated, both layers are bonded and integrated with each other, and have a function as a fiber reinforced resin sheet for repairing or reinforcing a concrete structure. Say.
In the fiber reinforced resin sheet of the present invention, the thickness of the barrier layer is preferably 50 to 100 μm, and if it is in the range of 50 to 100 μm, the adhesive applied during repair or reinforcement work on the concrete structure is used. There is no occurrence of a phenomenon such as spilling and leakage, and the function as a barrier layer for preventing leakage can be exhibited.
The thickness of the fiber reinforced resin sheet obtained by laminating and integrating the fiber reinforced resin main body layer impregnated and cured with the transparent curable resin composition having compatibility with the barrier layer in the mesh body with the barrier layer is 400 to 500 μm. This is preferable from the viewpoints of flexibility, handling, workability, lightness, reinforcement effect, economy, and the like that can follow the surface of a concrete structure.
Since the fiber reinforced resin sheet of the present invention has a bubble content of 2 mm or more in diameter and 1 bubble / m 2 or less and contains almost no bubbles of 2 mm or more in diameter, there is almost no negative influence on the reinforcing physical properties by the bubbles. In addition, the effect of repairing or reinforcing the concrete structure with the mesh body can be maximized.
以下、本発明を実施例及び比較例により説明するが、本発明はこれら実施例に限定されるものではない。 Hereinafter, although an example and a comparative example explain the present invention, the present invention is not limited to these examples.
＜海島型複合糸の製造＞
芯成分にアイソタクチックポリプロピレン（ｍｐ＝１６３℃）、鞘成分にメタロセン触媒による直鎖状低密度ポリエチレン（ｍｐ＝１１０℃）を使用し、定法の複合紡糸設備、芯鞘型複合紡糸ノズル（２４０ホール）を用い、鞘／芯断面比が３５/６５となるように２６０℃で紡糸し、直結する延伸装置に導いて、０．４２ＭＰａ、１４５℃の飽和水蒸気圧下で、延伸倍率１３倍で延伸を行い、延伸と共に鞘成分で繊維間を融合したトータル繊度１,８５０dｔｅｘ、フィラメント数２４０本の、芯のポリプロピレンを島成分、鞘の直鎖状低密度ポリエチレンを海成分とする海島型複合糸を得た（スピンドロー方式）。
この海島型複合糸の引張強度は、６．５ｃＮ／dｔｅｘ、伸度は、１５％、ヤング率は、９２．０ｃＮ／dｔｅｘ、１４０℃で測定した熱収縮率は、６．８％であった。
<Manufacture of sea-island type composite yarn>
Isotactic polypropylene (mp = 163 ° C.) is used for the core component, and linear low density polyethylene (mp = 110 ° C.) using a metallocene catalyst is used for the sheath component, and a conventional composite spinning equipment, core-sheath type composite spinning nozzle (240 Hole), spinning at 260 ° C. so that the sheath / core cross-section ratio is 35/65, and guiding to a stretching apparatus that is directly connected, and stretching at a stretching ratio of 13 times under a saturated water vapor pressure of 0.42 MPa and 145 ° C. A sea-island type composite yarn having a total fineness of 1,850 dtex and a filament number of 240, which is drawn and fused with fibers by a sheath component, and having a core polypropylene as an island component and a sheath linear low-density polyethylene as a sea component. Obtained (spin draw method).
The sea-island type composite yarn had a tensile strength of 6.5 cN / dtex, an elongation of 15%, a Young's modulus of 92.0 cN / dtex, and a heat shrinkage measured at 140 ° C. of 6.8%. .
＜メッシュ体の作製及び親水化処理＞
得られた海島型複合糸を、積層布製造装置に配置し、経方向、斜方向及び逆方向の３方向に、経糸、斜交糸及び逆斜交糸を１０ｍｍピッチで積層し、次いで表面温度１５０℃の加熱ローラーで接触加熱して複合糸の海部樹脂を溶融し各層の複合糸が接着した３軸のメッシュ体を得た。目合いは１０ｍｍ、単位面積当たりの質量は６５ｇ／ｍ2であった。
得られた３軸積層布の連続メッシュ体を連続したメッシュ状物１０をコロナ放電処理装置（春日電機社製、機種名：発振器ＡＧＩ−０２３、電極アルミ製６山）に通して、電圧、処理速度等を変更して、メッシュ体の改質度合いを、表１、表２に記載の濡れ指数にそれぞれ調製した。なお、濡れ指数の評価方法は、ＪＩＳ Ｋ６７６８による濡れ性試験方法を用いた。
以下、実施例について図５を参照して説明する。
<Preparation of mesh body and hydrophilization>
The obtained sea-island type composite yarn is placed in a laminated fabric manufacturing apparatus, and warp yarns, oblique yarns and reverse oblique yarns are laminated at a pitch of 10 mm in three directions of warp direction, oblique direction and reverse direction, and then the surface temperature By contact heating with a 150 ° C. heating roller, the sea part resin of the composite yarn was melted to obtain a triaxial mesh body in which the composite yarn of each layer was bonded. The mesh was 10 mm, and the mass per unit area was 65 g / m 2 .
The obtained mesh-like product 10 including the continuous mesh body of the triaxial laminated fabric is passed through a corona discharge treatment apparatus (manufactured by Kasuga Denki Co., Ltd., model name: oscillator AGI-023, electrode aluminum 6 piles), voltage, treatment The degree of modification of the mesh body was adjusted to the wetting index shown in Tables 1 and 2 by changing the speed and the like. The wettability index was evaluated by a wettability test method according to JIS K6768.
Hereinafter, an embodiment will be described with reference to FIG.
実施例１
（バリア層の形成工程）
キャリアフィルム２１としてポリエチレンテレフタレートフィルム（厚み５０μｍ）を繰り出し、該キャリアフィルム２１上にバリア層１０１を形成するためにバリア層用透明硬化性樹脂組成物（Ｃ）の液状物２０ｃ'を塗布した。
バリア層用透明硬化性樹脂組成物（Ｃ）は、ウレタンアクリレートとビニルエステルの混合液（日本ユピカ製：ネオポール８１３６）１００質量部（希釈剤スチレンモノマーで粘度１００００ｃＰに調整、２５℃）に有機過酸化物を４質量部添加して、調合槽４０ａで撹拌し、リザーブタンク４０からポンプ４１によりノズル４２から供給した。これを第１スクイズローラー５２により、硬化後の厚みが５０μｍとなるように調整した後、第２のカバーフィルム２３としてポリエチレンテレフタレートフィルム（厚み２５μｍ）により挟んで、硬化炉７０に導き、紫外線を照射して液状物２０ｃ'を硬化してバリア層１０１を形成した。しかる後、第２のカバーフィルム２３は、ローラー５３ａの部位で、バリア層１０１の表面（上面）から剥離し、ローラー５３ｂ、５３ｃを介して第２スクイズローラー５６の部分から供給して、第１のカバーフィルム２２として再利用することとした。
なお、本実施例１では、本体用透明硬化性樹脂組成物（Ａ）とバリア層を形成するためのバリア層用透明硬化性樹脂組成物（Ｃ）とを同一とし、配管及び供給ポンプのみを区別した。このように、同一の樹脂を使用すれば、相溶性の有無の判断の必要がなく、調合槽やリザーブタンクも同一にできるので、設備の簡略化を図ることができる。
Example 1
(Barrier layer formation process)
A polyethylene terephthalate film (thickness 50 μm) was drawn out as the carrier film 21, and a liquid 20 c ′ of the transparent curable resin composition for barrier layer (C) was applied to form the barrier layer 101 on the carrier film 21.
The transparent curable resin composition for the barrier layer (C) is an organic solution containing 100 parts by mass of a mixed liquid of urethane acrylate and vinyl ester (manufactured by Nippon Iupika: Neopol 8136) (adjusted to a viscosity of 10000 cP with a diluent styrene monomer, 25 ° C.). 4 parts by mass of oxide was added, stirred in the mixing tank 40a, and supplied from the reserve tank 40 through the nozzle 42 through the pump 41. After this is adjusted by the first squeeze roller 52 so that the thickness after curing is 50 μm, it is sandwiched by a polyethylene terephthalate film (thickness 25 μm) as the second cover film 23, guided to the curing furnace 70, and irradiated with ultraviolet rays Then, the liquid material 20c ′ was cured to form the barrier layer 101. Thereafter, the second cover film 23 is peeled off from the surface (upper surface) of the barrier layer 101 at the site of the roller 53a, and supplied from the second squeeze roller 56 portion via the rollers 53b and 53c, The cover film 22 was reused.
In Example 1, the transparent curable resin composition for main body (A) and the transparent curable resin composition for barrier layer (C) for forming the barrier layer are the same, and only the piping and the supply pump are used. Differentiated. In this manner, if the same resin is used, it is not necessary to determine the compatibility, and the preparation tank and the reserve tank can be made the same, so that the equipment can be simplified.
（予備含浸工程）
ウレタンアクリレートとビニルエステルの混合液（日本ユピカ製：ネオポール８１３６）１００質量部（希釈剤スチレンモノマーで粘度１００００ｃＰに調整、２５℃）に有機過酸化物を４質量部添加して、予備含浸用透明硬化性樹脂組成物（Ｂ）としての液状組成物２０ｂをリザーブタンク４４で調製した。
含浸槽４６にポンプ４５により液状組成物２０ｂを供給し、メッシュ体１０を含浸槽４６の液層中に走行させて液状組成物２０ｂ'を含浸し、予備含浸ローラー４７で２０Ｎ／ｃｍの線圧で把持して気泡を追い出し、脱気処理を施して予備含浸を行い、予備含浸済のメッシュ体１０ａを得た。
なお、液状組成物２０ｂ'は、５０℃に加温し、１０００ｃＰに粘度を下げて、予備含浸による脱気を行った。
(Pre-impregnation process)
4 parts by mass of organic peroxide is added to 100 parts by mass of a mixed liquid of urethane acrylate and vinyl ester (manufactured by Nippon Pica: Neopol 8136) (adjusted to a viscosity of 10000 cP with diluent styrene monomer, 25 ° C.), and transparent for pre-impregnation A liquid composition 20 b as a curable resin composition (B) was prepared in a reserve tank 44.
The liquid composition 20 b is supplied to the impregnation tank 46 by the pump 45, the mesh body 10 is run in the liquid layer of the impregnation tank 46 to impregnate the liquid composition 20 b ′, and the linear pressure of 20 N / cm is applied by the pre-impregnation roller 47. To remove the bubbles, to perform deaeration treatment and to perform pre-impregnation, to obtain a pre-impregnated mesh body 10a.
The liquid composition 20b ′ was deaerated by pre-impregnation by heating to 50 ° C. and decreasing the viscosity to 1000 cP.
（本含浸工程及び硬化工程）
５０μｍ厚のバリア層（アクリルバリア層）１０１が形成されたキャリアフィルム２１上に、本体用透明硬化性樹脂組成物（Ａ）〔バリア層用透明硬化性樹脂組成物（Ｃ）及び予備含浸用透明硬化性樹脂組成物（Ｂ）と同一〕の液状組成物２０ａをリザーブタンク４０からポンプ４３によりノズル４８から供給して、塗付し、均一な厚み（２ｍｍ）の液層（プール）２０ａ'を形成した。
この液層上に予備含浸済のメッシュ体１０ａを導き、含浸ローラー５５で含浸し、さらにその上に第１のカバーフィルム２２として、第２のカバーフィルム２３としてバリア層の形成工程に用い、その後剥離されたポリエチレンテレフタレートフィルム（厚さ２５μｍ）で挟みこみ、第２スクイズローラー５６で厚みを調整した。
その後、硬化炉７１で紫外線（ＵＶ）照射を５分間行い、次いで熱処理炉７２に導いて１００℃で１０分間加熱することによりモノマーを重合させ繊維強化樹脂シート１００を得た。
得られた繊維強化樹脂シートは、厚みが５２０μｍ、単位質量５００ｇ／ｍ2であり、直径が２ｍｍ以上の気泡は０個／ｍ2と、気泡が大幅に減少しピンホールは確認できなかった。
(Main impregnation process and curing process)
On a carrier film 21 on which a 50 μm thick barrier layer (acrylic barrier layer) 101 is formed, a transparent curable resin composition for main body (A) [transparent curable resin composition for barrier layer (C) and transparent for pre-impregnation The liquid composition 20a of the same as the curable resin composition (B)] is supplied from the reserve tank 40 by the pump 43 through the nozzle 48 and applied to form a liquid layer (pool) 20a ′ having a uniform thickness (2 mm). Formed.
The pre-impregnated mesh body 10a is guided onto the liquid layer, impregnated with the impregnation roller 55, and further used as the first cover film 22 and the second cover film 23 in the barrier layer forming step, and thereafter The film was sandwiched between peeled polyethylene terephthalate films (thickness: 25 μm), and the thickness was adjusted with the second squeeze roller 56.
Thereafter, ultraviolet ray (UV) irradiation was performed in the curing furnace 71 for 5 minutes, and then the monomer was polymerized by being guided to a heat treatment furnace 72 and heated at 100 ° C. for 10 minutes, whereby a fiber reinforced resin sheet 100 was obtained.
The obtained fiber reinforced resin sheet had a thickness of 520 μm, a unit mass of 500 g / m 2 , 0 / m 2 bubbles having a diameter of 2 mm or more, and the bubbles were greatly reduced, and pinholes could not be confirmed.
実施例２及び３
実施例１において予備含浸工程における予備含浸ローラー４７の押圧を１０Ｎ／ｃｍ（実施例２）、３０Ｎ／ｃｍ（実施例３）としたところ、いずれの実施例においてもメッシュ体から気泡が抜けることが確認され、実施例１と同様に気泡が大幅に減少しピンホールのない繊維強化樹脂シートを得た。
Examples 2 and 3
In Example 1, when the pressure of the pre-impregnation roller 47 in the pre-impregnation step was set to 10 N / cm (Example 2) and 30 N / cm (Example 3), in any of the examples, bubbles may escape from the mesh body. As confirmed in the same manner as in Example 1, bubbles were significantly reduced, and a fiber-reinforced resin sheet without pinholes was obtained.
実施例４
実施例１において予備含浸用透明硬化性樹脂組成物（Ｂ）の液状組成物２０ｂ'の温度を１０℃に下げて、粘度を１５０００ｃＰにしたが、メッシュ体から気泡を抜くことができることを確認し、実施例１と同様の性状の繊維強化樹脂シートを得た。
Example 4
In Example 1, the temperature of the liquid composition 20b ′ of the transparent curable resin composition for pre-impregnation (B) was lowered to 10 ° C. and the viscosity was set to 15000 cP, but it was confirmed that bubbles could be removed from the mesh body. A fiber-reinforced resin sheet having the same properties as in Example 1 was obtained.
実施例５
実施例１において予備含浸用透明硬化性樹脂組成物（Ｂ）の液状組成物２０ｂ'として、粘度５０ｃＰのスチレンモノマーを使用したところ、メッシュ体から気泡を抜くことができることを確認し、実施例１と同様の性状の繊維強化樹脂シートを得た。
Example 5
When a styrene monomer having a viscosity of 50 cP was used as the liquid composition 20b ′ of the transparent curable resin composition for pre-impregnation (B) in Example 1, it was confirmed that air bubbles could be removed from the mesh body. A fiber-reinforced resin sheet having the same properties as the above was obtained.
実施例６
実施例１において、予備含浸用透明硬化性樹脂組成物（Ｂ）の液状組成物２０ｂ'及び本体用透明硬化性樹脂組成物（Ａ）２０ａへの有機酸化物の添加量を２質量部とし、本含浸以降の硬化に紫外線を使用せず熱処理炉で１００℃、１０分の熱硬化としたが、実施例１と同様の性状の繊維強化樹脂シートを得た。
Example 6
In Example 1, the addition amount of the organic oxide to the liquid composition 20b ′ of the transparent curable resin composition for pre-impregnation (B) and the transparent curable resin composition for main body (A) 20a is 2 parts by mass, Although the ultraviolet rays were not used for curing after the impregnation, heat curing was performed at 100 ° C. for 10 minutes in a heat treatment furnace, but a fiber reinforced resin sheet having the same properties as in Example 1 was obtained.
実施例７
実施例１において、バリア層を形成することなく、第１のキャリアフィルム２１上に液層２０ａ'を形成した後、予備含浸済みのメッシュ体１０ａと含浸ローラー５５で合体させて含浸した他は実施例１と同様にして繊維強化樹脂シートを得た。得られたシートは、気泡が大幅に減少しピンホールのない、実施例１と同様の性状の繊維強化樹脂シートであった。
Example 7
In Example 1, a liquid layer 20a ′ was formed on the first carrier film 21 without forming a barrier layer, and then impregnated by combining with a pre-impregnated mesh body 10a and an impregnation roller 55. A fiber reinforced resin sheet was obtained in the same manner as in Example 1. The obtained sheet was a fiber reinforced resin sheet having the same properties as in Example 1 and having no air bubbles and no pinholes.
実施例８
実施例７において、キャリアフィルムにアクリルフィルム（三菱レーヨン社製、「アクリプレン」ＨＢＸＮ４７、厚み５０μｍ）を用いた他は実施例７と同様にして繊維強化樹脂シートを得た。得られたシートは、気泡が大幅に減少しピンホールのない、実施例１と同様の性状の繊維強化樹脂シートであった。
以上、各実施例の組成、条件及び結果についてまとめて表１に示す。
Example 8
In Example 7, a fiber-reinforced resin sheet was obtained in the same manner as in Example 7 except that an acrylic film (manufactured by Mitsubishi Rayon Co., Ltd., “Acryprene” HBXN47, thickness 50 μm) was used as the carrier film. The obtained sheet was a fiber reinforced resin sheet having the same properties as in Example 1 and having no air bubbles and no pinholes.
The composition, conditions and results of each example are summarized in Table 1 above.
比較例１
実施例１の予備含浸用透明硬化性樹脂組成物２０ｂにウレタンアクリレートとメタクリル酸エステルとの混合液〔希釈剤（アクリルモノマー）で２５℃の粘度を３００００ｃＰに調整したもの。〕１００質量部に有機過酸化物を４質量部添加した液状組成物２０ｂ'を使用したところ、予備含浸ローラー４７を通過してもメッシュ体に樹脂が十分含浸しなかったため、気泡が多く、図３に部分拡大写真を示すような繊維強化樹脂シートとなった。
Comparative Example 1
The pre-impregnated transparent curable resin composition 20b of Example 1 was mixed with urethane acrylate and methacrylic acid ester [with a diluent (acrylic monomer) and a viscosity at 25 ° C. adjusted to 30000 cP. When the liquid composition 20b ′ in which 4 parts by mass of organic peroxide was added to 100 parts by mass was used, the mesh body was not sufficiently impregnated with the resin even after passing through the pre-impregnation roller 47. A fiber reinforced resin sheet as shown in FIG.
比較例２
実施例１において、予備含浸ローラー４７の押圧を３Ｎ／ｃｍにしたところ、気泡を含んだ樹脂の回収が不十分となり、気泡を持ち込んだシートを得た。
Comparative Example 2
In Example 1, when the pressure of the pre-impregnation roller 47 was set to 3 N / cm, recovery of the resin containing bubbles became insufficient, and a sheet carrying bubbles was obtained.
比較例３
実施例１において、予備含浸工程における、予備含浸ローラー４７の押圧を４０Ｎ／ｃｍにしたところ、メッシュ体が変形し皺が発生した。
Comparative Example 3
In Example 1, when the pressure of the pre-impregnation roller 47 in the pre-impregnation step was 40 N / cm, the mesh body was deformed and wrinkles were generated.
比較例４
実施例１において、液層（樹脂プール）２０ａ'をなくしたところ、バリア層の形成工程に用い、その後剥離された第２のカバーフィルム２３であって、これを再使用した第１のカバーフィルム２２と予備含浸済みメッシュ体１０ａの間で気泡を持ち込むため、気泡のある繊維強化樹脂シートが得られた。
以上、各比較例の組成、条件及び結果についてまとめて表２に示す。
Comparative Example 4
In Example 1, when the liquid layer (resin pool) 20a ′ was eliminated, it was the second cover film 23 that was used in the barrier layer forming process and then peeled, and the first cover film was reused. Since air bubbles were brought in between 22 and the pre-impregnated mesh body 10a, a fiber-reinforced resin sheet having air bubbles was obtained.
The composition, conditions and results of each comparative example are summarized in Table 2 above.
本発明の繊維強化樹脂シートの製造方法は、予備含浸工程において、メッシュ本体に内包する気泡を脱泡するので、硬化後において、繊維強化樹脂本体層における気泡の出現を極力抑えて、施工時の未硬化状接着剤の漏出がなく、気泡による外観不良や、コンクリート面の経時変化の観察障害のない繊維強化樹脂シートを、安定して効率よく製造できる方法として利用できる。
また、本発明のコンクリート構造物の補修又は補強用繊維強化樹脂シートは、コンクリート表面に塗布された未硬化状の接着剤が、繊維強化樹脂シートの透明樹脂層に気泡等に起因する貫通孔が無いので、漏出した接着剤を拭取る作業が無く、作業が非常に簡易化され、短工期で施工でき、かつ、透明なので、施工後においても、コンクリート構造物表面の経時観察が可能であり、かつメッシュ本体による補強効果を十分に発現できるコンクリート構造物の補強又は補修用繊維強化樹脂シートとして利用できる。
The method for producing a fiber-reinforced resin sheet of the present invention defoams bubbles contained in the mesh body in the pre-impregnation step. Therefore, after curing, the appearance of bubbles in the fiber-reinforced resin body layer is suppressed as much as possible. It can be used as a method for stably and efficiently producing a fiber reinforced resin sheet free from leakage of an uncured adhesive and free from appearance defects due to air bubbles and obstruction of observation of changes in the concrete surface over time.
Further, the fiber reinforced resin sheet for repairing or reinforcing a concrete structure according to the present invention has an uncured adhesive applied to the concrete surface, and a through-hole caused by bubbles or the like in the transparent resin layer of the fiber reinforced resin sheet. Since there is no work to wipe off the leaked adhesive, the work is very simplified, it can be constructed in a short construction period, and it is transparent, so it is possible to observe the surface of the concrete structure over time even after construction, Moreover, it can be used as a fiber reinforced resin sheet for reinforcing or repairing a concrete structure that can sufficiently exhibit the reinforcing effect of the mesh body.
１ 補強繊維（海島型複合糸）
３ 芯部（島部）
５ａ 鞘部
５ 海部
１０ メッシュ体
１０ａ 予備含浸メッシュ体
１１ 下経糸（層）
１２ 上経糸（層）
１３ 斜交糸（層）
１４ 逆斜交糸（層）
２０ａ 本体用透明硬化性樹脂組成物（Ａ）
２０ｂ 予備含浸用透明硬化性樹脂組成物（Ｂ）
２０ｃ バリア層用透明硬化性樹脂組成物（Ｃ）
２０ａ' 本体用透明硬化性樹脂組成物（Ａ）の液層
２０ｂ' 予備含浸用透明硬化性樹脂組成物（Ｂ）の液層
２０ｃ' バリア層用透明硬化性樹脂組成物（Ｃ）の液層
２１ キャリアフィルム
２２ 第１カバーフィルム
２３ 第２カバーフィルム
２５ 気泡
４０、４４ リザーブタンク
４０ａ 調合槽
４１、４３、４５ ポンプ（樹脂供給ポンプ）
４２、４８ ノズル
４６ 含浸槽
４７ 予備含浸ローラー
５５ 含浸ローラー
５２ 第１スクイズローラー
５３ａ、５３ｂ、５３ｃ ガイドローラー
５６ 第２スクイズローラー
６０ 引取りローラー
６１ 巻取機
７０、７１ 硬化炉
７２ 熱処理炉（熱硬化炉）
１００ 繊維強化樹脂シート
１０１ バリア層
１０２ 繊維強化樹脂本体層
1 Reinforcing fiber (Umijima type composite yarn)
3 core (island)
5a sheath part 5 sea part 10 mesh body 10a pre-impregnated mesh body 11 lower warp (layer)
12 Upper warp (layer)
13 Oblique yarn (layer)
14 Reverse diagonal thread (layer)
20a Transparent curable resin composition for main body (A)
20b Transparent curable resin composition for pre-impregnation (B)
20c Transparent curable resin composition for barrier layer (C)
20a ′ Liquid layer of transparent curable resin composition for main body (A) 20b ′ Liquid layer of transparent curable resin composition for pre-impregnation (B) 20c ′ Liquid layer of transparent curable resin composition for barrier layer (C) 21 Carrier film 22 1st cover film 23 2nd cover film 25 Air bubbles 40, 44 Reserve tank 40a Preparation tank 41, 43, 45 Pump (resin supply pump)
42, 48 Nozzle 46 Impregnation tank 47 Pre-impregnation roller 55 Impregnation roller 52 First squeeze roller 53a, 53b, 53c Guide roller 56 Second squeeze roller 60 Take-up roller 61 Winder 70, 71 Curing furnace 72 Heat treatment furnace (thermal curing) Furnace)
100 Fiber Reinforced Resin Sheet 101 Barrier Layer 102 Fiber Reinforced Resin Body Layer
Claims (8)
（１）キャリアフィルム上、又は該キャリアフィルム上に形成されたバリア層上に、本体用透明硬化性樹脂組成物（Ａ）を塗布する液層形成工程、
（２）メッシュ体を、前記本体用透明硬化性樹脂組成物（Ａ）と相溶性を有し、かつ粘度５０〜１５０００ｃＰの予備含浸用透明硬化性樹脂組成物（Ｂ）が注入された含浸槽に浸漬させつつ走行させ、次いで樹脂液を保持したメッシュ体を含浸ローラー間に通して、ローラー線圧５〜３０Ｎ／ｃｍで含浸・脱泡する予備含浸工程、
（３）前記本体用透明硬化性樹脂組成物（Ａ）の液層上面から前記予備含浸用透明硬化性樹脂組成物（Ｂ）が含浸されたメッシュ体を前記液層中に進入させ、さらにその上面に第１のカバーフィルムを載置して、キャリアフィルム上又は該キャリアフィルム上に形成されたバリア層との間に挟み込んだメッシュ体に本体用透明硬化性樹脂組成物（Ａ）を含浸する本含浸工程、及び
（４）前記予備含浸用透明硬化性樹脂組成物（Ｂ）及び本体用透明硬化性樹脂組成物（Ａ）を硬化する硬化工程。 A method for producing a fiber reinforced resin sheet for repairing or reinforcing a concrete structure obtained by impregnating and curing a transparent curable resin composition in a mesh body, the production method comprising the following steps (1) to (4): The manufacturing method of the fiber reinforced resin sheet characterized by including.
(1) A liquid layer forming step of applying the transparent curable resin composition for main body (A) on the carrier film or on the barrier layer formed on the carrier film,
(2) The impregnation tank in which the mesh body is compatible with the transparent curable resin composition for main body (A) and the transparent curable resin composition for pre-impregnation (B) having a viscosity of 50 to 15000 cP is injected. Pre-impregnation step in which the mesh body holding the resin liquid is passed between the impregnation rollers, and impregnated and defoamed at a roller linear pressure of 5 to 30 N / cm,
(3) The mesh body impregnated with the transparent curable resin composition for pre-impregnation (B) is introduced into the liquid layer from the upper surface of the liquid layer of the transparent curable resin composition for main body (A), and further The first cover film is placed on the upper surface, and the mesh body sandwiched between the carrier film or the barrier layer formed on the carrier film is impregnated with the transparent curable resin composition for main body (A). A main impregnation step, and (4) a curing step of curing the pre-impregnation transparent curable resin composition (B) and the main body transparent curable resin composition (A).
（５）キャリアフィルム上にバリア層用透明硬化性樹脂組成物（Ｃ）を塗布し第２のカバーフィルムで挟み込んで硬化してバリア層を形成した後、該第２のカバーフィルムを剥離して該バリア層を前記液層形成工程（１）に供するバリア層形成工程。 Furthermore, the said fiber layer formation process (1) WHEREIN: The formation process (5) of the following barrier layer for forming a barrier layer on the upper part of a carrier film is included. Production method.
(5) After applying the transparent curable resin composition (C) for the barrier layer on the carrier film and sandwiching and curing with the second cover film to form the barrier layer, the second cover film is peeled off. A barrier layer forming step of subjecting the barrier layer to the liquid layer forming step (1);
補強繊維によって所定の開口部が形成されたメッシュ体に該バリア層と相溶性を有する透明硬化性樹脂組成物を含浸・硬化させた繊維強化樹脂本体層とを積層一体化させてなる透明性繊維強化樹脂シートであって、
該繊維強化樹脂本体層中における直径２ｍｍ以上の気泡含有数が、１個／ｍ2以下である、ことを特徴とするコンクリート構造物の補修又は補強用繊維強化樹脂シート。 A non-breathable barrier layer made of a transparent cured resin;
A transparent fiber formed by laminating and integrating a fiber reinforced resin main body layer impregnated and cured with a transparent curable resin composition compatible with the barrier layer in a mesh body in which predetermined openings are formed by reinforcing fibers. A reinforced resin sheet,
A fiber-reinforced resin sheet for repairing or reinforcing a concrete structure, wherein the number of bubbles having a diameter of 2 mm or more in the fiber-reinforced resin main body layer is 1 / m 2 or less.
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