JP5919080B2 - Method for producing flat fiber reinforced plastic lattice streaks - Google Patents

Description

The present invention is mainly related to the production method of flat-shaped fiber-reinforced plastic grid-like muscles that can be used to reinforce and embedded in a concrete structure is a civil engineering and construction structures.

  Conventionally, flat-shaped fiber-reinforced plastic lattice bars are mainly used by being embedded in a concrete structure as a civil engineering building structure as a reinforcing bar.

  FIG. 3B attached to the present application shows an example of the flat fiber reinforced plastic lattice-like streak 1. The flat-shaped fiber-reinforced plastic lattice-like streak 1 usually includes a plurality of flat-shaped fiber-reinforced plastic wires (stripes) that are arranged in a lattice shape so as to intersect at right angles, that is, a vertical lattice-like line 101 and a horizontal lattice-like line 102. ing. Conventionally, each of the streaks 101 and 102 is mainly formed by arranging a plurality of reinforcing fibers impregnated with a matrix resin such as a vinyl ester resin by arranging reinforcing fibers such as glass fibers, carbon fibers, and aramid fibers in one direction. It is formed. The flat fiber reinforced plastic lattice streaks, that is, the FRP lattice material 1 is usually such that each of the streaks 101 and 102 has a streak width (w1, w2) of 3 to 10 mm and a thickness (t) of 1 to 5 mm. The distance (W1, W2) is 3 to 15 cm. As described above, the respective stripes 101 and 102 are arranged orthogonal to each other, but can be configured to cross each other at a predetermined angle other than 90 degrees and to form a lattice shape as desired. is there.

Usually, when using glass fibers as reinforcing fibers, FRP grating material 1 has 500 N / mm ² or more in tensile strength, the 30000 N / mm ² or more tensile modulus.

  Moreover, the FRP lattice material 1 having such a configuration is lightweight, corrosion-resistant, easy to bend, and excellent in workability. Further, as shown in the figure, the intersecting portion of the streaks 101 and 102 is substantially on the same plane as the other streaks, and is formed into a thin sheet shape, which is not bulky.

  Patent Document 1 discloses a method for manufacturing such a fiber-reinforced plastic lattice. According to the manufacturing method described in Patent Document 1, a plurality of linear longitudinal members made of continuous fibers impregnated with an uncured resin material are arranged in parallel in the traveling direction of the carrier, such as a belt conveyor. . On the other hand, a linear horizontal member made of continuous fibers impregnated with an uncured resin material so as to be orthogonal to the linear vertical member is folded into a U-shape at both ends of the carrier while Laminated on top to form a lattice. Thereafter, the grid-like body is pressed from above by pressing means, and the uncured resin material is heat-cured in a thermosetting furnace in a state where the intersection of the vertical member and the horizontal member is pressure-bonded.

  According to the invention described in Patent Document 1, a fiber-reinforced resin grid-like streak can be continuously produced.

  However, according to the results of the research experiments of the present inventors, according to the method for producing a fiber-reinforced resin lattice-like streak described in Patent Document 1, a plurality of linear vertical members and linear horizontal members are provided. A fiber bundle in which continuous fibers are arranged in parallel and impregnated with an uncured resin. A linear vertical member and a linear horizontal member made of such a resin-impregnated fiber bundle are simply pressed by pressing means to form a lattice. Therefore, a sharp edge surface is generated in the product “grid-like streaks” after molding, and there is a problem in handling in terms of safety when used as a reinforcing bar. Further, in the method described in Patent Document 1, it is difficult to form a lattice-shaped streak with a fine mesh, that is, with a small space W1 and W2 between the streaks.

  As a result of conducting many research experiments to solve the above problems, the present inventors have paid attention to the method for producing a round fiber-reinforced plastic wire proposed by the present inventors described in Patent Document 2.

The first method for producing a round fiber-reinforced plastic wire disclosed in Patent Document 2 is:
(A) a step of continuously feeding a reinforcing fiber bundle composed of a plurality of reinforcing fibers arranged in one direction while twisting;
(B) a step of impregnating a matrix resin into a reinforcing fiber bundle that is continuously fed;
(C) a step of heating the resin-impregnated reinforcing fiber bundle while tensioning it at a predetermined strength to cure the resin in a circular cross section of the reinforcing fiber bundle;
It is a manufacturing method provided with.

The second manufacturing method is
(A) a step of continuously feeding a reinforcing fiber bundle composed of a plurality of reinforcing fibers arranged in one direction;
(B) a step of impregnating a matrix resin into a reinforcing fiber bundle that is continuously fed;
(C) a step of twisting the reinforcing fiber bundle impregnated with resin,
(D) a step of heating the reinforcing fiber bundle impregnated with the resin and twisted with tension at a predetermined strength to cure the resin so that the cross section of the reinforcing fiber bundle has a circular shape;
It is a manufacturing method provided with.

The manufacturing method described in Patent Document 2 is
(1) Twist the reinforcing fiber, control the resin impregnation amount of the matrix resin, and heat cure the resin-impregnated reinforcing fiber, by applying tension force to the reinforcing fiber, without using a mold Shaped fiber reinforced plastic wire can be produced.
(2) Since no mold is used, it is possible to produce 30 or more wires at a time, and it is not necessary to add a mold release agent to the matrix resin. Roughing work is also unnecessary, and significant cost reduction and quality improvement can be achieved.
It has the following advantages.

  The present inventors have found that lattice-like streaks can be manufactured very efficiently using the round fiber-reinforced plastic wire obtained by the manufacturing method described in Patent Document 2.

  In other words, by twisting the uncured resin-impregnated fiber bundle that forms the lattice-like streaks, and by applying tension at the time of molding, once the cross-sectional shape of the fiber bundle is rounded, a certain thickness is obtained. By crushing with, the uniformity of the width of the reinforcing material constituting the lattice is ensured, and the cross section of the reinforcing material is rounded, no sharp edge surface is generated, and safety when used as a reinforcing bar It was found that there was a marked improvement. It was also found that small mesh lattice streaks can be stably produced.

JP 2003-103642 A JP 2008-222846 A

  The present invention has been made based on such novel findings of the present inventors.

Therefore, the object of the present invention is to solve the problem of handling in terms of safety when used as a reinforcing bar, without the occurrence of a sharp edge surface in the molded product “grid-like streaks”, and for the fine mesh It is an object of the present invention to provide a method for producing a flat fiber reinforced plastic lattice-like streak capable of forming a lattice-like streak.

The above object is achieved by the method for producing a flat fiber reinforced plastic lattice streak according to the present invention. In summary, according to the first aspect of the present invention,
In a manufacturing method for continuously manufacturing lattice-shaped streaks formed by arranging a plurality of flat-shaped fiber-reinforced plastic wires in a lattice shape,
(A) a step of continuously feeding a reinforcing fiber bundle composed of a plurality of reinforcing fibers arranged in one direction while twisting;
(B) impregnating a matrix resin into the reinforcing fiber bundle continuously fed;
(C) A plurality of reinforced fiber bundles impregnated with the resin and twisted are tensed with a predetermined strength, and the cross section of the reinforced fiber bundle is formed into a circular shape and continuously sent in the manufacturing direction of the lattice-like streaks. The vertical wire rod is a horizontal wire rod in which the reinforcing fiber bundle impregnated with the resin and twisted is tensed with a predetermined strength and the cross section of the reinforcing fiber bundle is circular. A step of feeding in a direction intersecting with, and arranging in a lattice form with the vertical wire,
(D) Next, a state in which a high-density woven fabric having releasability with a resin is arranged on both side surfaces of a laminate formed by the vertical wire and the horizontal wire arranged so as to form the lattice shape. Then, the laminated body is drawn between two heated flat plates, and the vertical wire and the horizontal wire are bonded to each other at an intersection while forming a cross section of the vertical wire and the horizontal wire into a flat shape, and A step of first curing the resin;
(E) a step of secondarily curing the vertical wire and the horizontal wire, which are bonded to each other in a lattice shape and have a flat cross-sectional shape, through a heated curing furnace;
A method for producing a continuous flat fiber-reinforced plastic lattice-like streak is provided.

According to a second aspect of the invention,
In a manufacturing method for continuously manufacturing lattice-shaped streaks formed by arranging a plurality of flat-shaped fiber-reinforced plastic wires in a lattice shape,
(A) a step of continuously feeding a reinforcing fiber bundle composed of a plurality of reinforcing fibers arranged in one direction;
(B) impregnating a matrix resin into the reinforcing fiber bundle continuously fed;
(C) a step of twisting the resin-impregnated reinforcing fiber bundle,
(D) A plurality of reinforced fiber bundles impregnated with resin and twisted are tensioned at a predetermined strength, and the cross section of the reinforced fiber bundle is circularly sent continuously in the manufacturing direction of the lattice-like streaks. The vertical wire rod is a horizontal wire rod in which the reinforcing fiber bundle impregnated with the resin and twisted is tensed with a predetermined strength and the cross section of the reinforcing fiber bundle is circular. A step of feeding in a direction intersecting with, and arranging in a lattice form with the vertical wire,
(E) Next, a state in which a high-density woven fabric having releasability with a resin is arranged on both side surfaces of a laminate formed by the vertical wire and the horizontal wire arranged so as to form the lattice shape. Then, the laminated body is drawn between two heated flat plates, and the vertical wire and the horizontal wire are bonded to each other at an intersection while forming a cross section of the vertical wire and the horizontal wire into a flat shape, and A step of first curing the resin;
(F) A step of secondarily curing the vertical wire and the horizontal wire, which are bonded to each other in a lattice shape and have a flat cross section, and the horizontal wire through a heated curing furnace,
A method for producing a continuous flat fiber-reinforced plastic lattice-like streak is provided.

  According to one embodiment of the present invention, the fiber reinforced plastic wire has a thickness (t) of 0.2 mm to 5.0 mm and a width (w) of 1.0 mm to 10.0 mm.

  According to another embodiment of the present invention, the number of twists of the reinforcing fiber bundle is 5 times / m to 20 times / m.

  According to another embodiment of the present invention, the resin-impregnated reinforcing fiber bundle is tensioned at a strength of 500 g / line to 3000 g / line.

  According to another embodiment of the present invention, the amount of the matrix resin impregnated into the reinforcing fiber in the reinforcing fiber bundle is 36% to 60% in volume ratio (Vf).

  According to another embodiment of the present invention, the reinforcing fiber is any one of glass fiber, carbon fiber, aramid fiber, PBO (polyphenylenebenzbisoxazole) fiber, and polyester fiber.

  According to another embodiment of the present invention, the matrix resin is one of an epoxy resin, a vinyl ester resin, an MMA resin, an unsaturated polyester resin, or a phenol resin.

  According to another embodiment of the present invention, the high-density woven fabric is a plain woven fabric in which a total number of warp yarns and weft yarns between inch lengths is 210 or more.

  According to another embodiment of the present invention, the high-density fabric is either a single fabric of continuous filament yarn such as polyester fiber, nylon fiber, vinylon fiber, or a mixed fabric.

  According to the present invention, there is no generation of a sharp edge surface in the molded product “grid-like streaks”, which solves the problem of handling in safety when used as a reinforcing bar, and the mesh-like lattice shape A streak can be formed.

BRIEF DESCRIPTION OF THE DRAWINGS It is a schematic block diagram of the manufacturing apparatus for demonstrating one Example of the manufacturing method of the flat shape fiber reinforced plastic lattice-like streak concerning this invention. BRIEF DESCRIPTION OF THE DRAWINGS It is a schematic block diagram of the manufacturing apparatus for demonstrating one Example of the manufacturing method of the flat shape fiber reinforced plastic lattice-like line | wire based on this invention, Fig.2 (a) is a top view, FIG.2 (b) It is a front view. FIG. 3 (a) is a plan view for explaining an embodiment of a method for producing a flat fiber reinforced plastic lattice-like line according to the present invention, and FIG. It is a perspective view explaining one Example. Moreover, FIG.3 (c) is a perspective view which shows the other Example of the flat shape fiber reinforced plastic lattice-like stripe | line | muscle which concerns on this invention. It is a schematic block diagram which shows one Example of the heating plate apparatus in the manufacturing apparatus of the flat-shaped fiber reinforced plastic lattice-like streaks concerning this invention. It is a schematic block diagram explaining the action | operation of the unwinding bobbin in the manufacturing apparatus for demonstrating one Example of the manufacturing method of the flat shape fiber reinforced plastic lattice-like streaks concerning this invention. It is sectional drawing of the flat shape fiber reinforced plastic wire which comprises the grid | lattice form line | wire of this invention. FIG. 7A is a schematic configuration diagram of a manufacturing apparatus for explaining another embodiment of the manufacturing method of the flat fiber-reinforced plastic lattice-like streak according to the present invention, FIG. 7A is a plan view, and FIG. It is a front view. It is a schematic block diagram of the wire manufacturing part for demonstrating the other Example of the manufacturing method of the flat shape fiber reinforced plastic wire which concerns on this invention. It is a schematic block diagram explaining the action | operation of the winding bobbin in the manufacturing apparatus for demonstrating the other Example of the manufacturing method of the flat shape fiber reinforced plastic lattice-like line | wire based on this invention.

  Hereinafter, a method for producing a flat fiber-reinforced plastic lattice-like line according to the present invention and a flat-shaped fiber-reinforced plastic lattice-like line produced by the production method will be described in detail with reference to the drawings.

  The overall configuration of the flat fiber-reinforced plastic lattice-shaped streaks formed by arranging the flat-shaped fiber-reinforced plastic wires in the form of a lattice according to the present invention is the conventional configuration described above with reference to FIG. It is set as the structure similar to a flat shape fiber reinforced plastic lattice-like line | wire. Therefore, the re-explanation about the whole structure of a flat fiber reinforced plastic lattice-like line | wire is abbreviate | omitted.

Example 1
[Overall Configuration of Manufacturing Apparatus 100]
1 to 4 show an embodiment of a manufacturing apparatus 100 (100A, 100B) for continuously manufacturing a long flat fiber-reinforced plastic lattice streak according to the present invention. FIG. 6 shows a cross-sectional structure of the wire rods 101 and 102 of the flat fiber-reinforced plastic lattice-like streak 1 (FIG. 3B) manufactured according to the present invention.

  In the present embodiment, the flat fiber-reinforced plastic lattice-shaped manufacturing apparatus 100 (100A, 100B) includes a wire manufacturing unit 100A and a lattice-shaped manufacturing unit 100B. The wire manufacturing unit 100A includes fiber feeding, resin impregnation, and winding sections 100A1 to A3 (FIG. 1), and the lattice-shaped streak manufacturing unit 100B includes fiber feeding tension, flat lattice streaking, heat curing, winding The take sections 100B1 to B4 are provided.

  FIG. 1 shows fiber feeding, resin impregnation, and winding sections 100A1 to A3 of the wire manufacturing unit 100A. In the drawing, reinforcing fiber strands (reinforcing fiber bundles) composed of a plurality of reinforcing fibers f from the left side to the right side. f1 moves, during which twisting and resin impregnation are performed.

  FIGS. 2A and 2B show the fiber feeding tension, flat lattice forming, heat curing, and winding sections 100B1 to B4 of the lattice-like string manufacturing unit 100B, and are twisted from the left side to the right side in the drawing. The uncured resin reinforcing fiber bundle f2 (f21, f22) subjected to the processing and the resin impregnation step moves, and flat lattice forming, resin hardening, and lattice-shaped wire winding are performed under a predetermined tension. The wire rod manufacturing unit 100A and the grid-like line manufacturing unit 100B will be further described.

[Wire Material Manufacturing Department 100A]
In the wire manufacturing section 100A composed of the fiber feeding, resin impregnation and winding sections 100A1 to A3 shown in FIG. 1, a plurality (usually 3 to 18) of three fibers are used in this embodiment to simplify the drawing. A supply bobbin (cylindrical bobbin) 11 (11a, 11b, 11c) for supply is prepared, and each bobbin 11 has a reinforced fiber strand (reinforced fiber bundle) in which a predetermined number of reinforcing fibers f not impregnated with resin are converged. f1 is wound.

  The reinforcing fiber bundle f1 wound around each bobbin 11 is continuously fed to the resin impregnation step in which the resin impregnation tank 17 is disposed. At the same time, the reinforcing fiber bundle f1 is twisted (supply of reinforcing fiber bundle, twisting process).

  That is, the reinforcing fiber bundle f1 fed to the resin impregnation step is impregnated with the resin in the resin impregnation tank 17, and the reinforcing fiber bundle f2 impregnated with the resin is wound with the winding bobbin 22 (22a, 22b). 22c) (resin impregnation and twisting process).

  Next, the above steps will be described in more detail.

(Reinforcement fiber bundle supply, twisting process)
In this embodiment, as can be better understood with reference also to FIG. 5, in the fiber feeding, resin impregnation and winding sections 100 </ b> A <b> 1 to A <b> 3, the bobbins 11 (11 a, 11 b, 11 c) The rotary shaft 12 (12a, 12b, 12c) provided is attached, and the rotary shaft 12 is rotatably attached to the rotary main shaft 13 (13a, 13b, 13c) of the unwinding device.

  Each bobbin 11 (11a, 11b, 11c) is rotated around the rotation shaft 12 (12a, 12b, 12c) of each bobbin 11 (11a, 11b, 11c) by the drive motor M and the gear transmission mechanism G. The reinforcing fiber bundle f1 wound around the bobbin 11 (11a, 11b, 11c) is unwound. At the same time, each bobbin 11 (11a, 11b, 11c) rotates together with the rotating shaft 12 (12a, 12b, 12c) while rotating around the rotating shaft 12 (12a, 12b, 12c) as described above. It is rotated around the main shaft 13 (13a, 13b, 13c).

  That is, the bobbin 11 rotates around the rotating shaft 12 and simultaneously rotates around the rotating main shaft 13 to unwind the reinforcing fiber bundle f1.

  A reinforcing fiber bundle f1 composed of a plurality of reinforcing fibers arranged in one direction and unwound from the bobbin 11 is guided by guide holes 15 (15a, 15b, 15c) formed in the guide 14, and is guided by an inlet guide roll 16. It is introduced into the resin impregnation tank 17.

  With the above configuration, the reinforcing fiber bundle f1 supplied to the impregnation step provided with the resin impregnation tank 17 is supplied with a twist.

  By adjusting the number of rotations of the bobbin 11 around the rotation main shaft 13 and the unwinding speed of the reinforcing fiber bundle f1, the number of twists per 1 m can be controlled.

  The number of twists of the reinforcing fiber bundle f1 is preferably 5 times / m to 20 times / m. Although details will be described later, FIG. 3B and FIG. 6 show the wire rods (streaks) 101 and 102 of the lattice-like streaks 1 of the present invention, which have such a rectangular cross section, that is, are flat. The shape of the wire must be twisted into a plurality of uncured fibers (fiber bundles) impregnated with resin, pulled with a constant tension, rounded, and then molded into a constant thickness with a flat plate mold (mold) , Can not be produced in a nearly uniform width. That is, when the shape before flattening is random, molding with a constant plate thickness (t) and a nearly uniform width (w) cannot be performed.

  If it is less than 5 times / m, it is difficult to ensure a stable circular shape (round shape) even if tension is applied before resin curing, and if the twist exceeds 20 times / m, it becomes difficult to form a flat shape, It is not preferable to exceed 20 times / m. In particular, the twist is optimally in the range of 10 times / m to 15 times / m.

  According to the present embodiment, each of the stripes 101 and 102 of the lattice-like stripe 1 has a thickness (t) of 0.2 mm to 5.0 mm and a width (w1, w2) of 1.0 mm to 10.0 mm. When the thickness (t) is less than 0.2 mm, the wire rod is damaged at the time of flat pressing, and the reinforcing fiber f is broken or becomes too thin and the end face of the product becomes sharp. On the other hand, when the thickness (t) exceeds 5.0 mm, when the wire f2 is wound around the winding bobbin 31, the fiber f is broken and the physical properties such as the strength of the cured streaks 101 and 102 are deteriorated. It becomes remarkable. Each of the streaks 101 and 102 of the lattice-like streaks 1 is particularly preferably a thickness (t) of 0.4 mm to 1.5 mm and a width (w1, w2) of 1.2 mm to 4.5 mm. Therefore, the wire diameter of the uncured resin-impregnated wire f2 (f21, f22) before being flattened is preferably 0.5 mm to 8.0 mm.

  Accordingly, the reinforcing fiber bundle f1 supplied to the impregnation step is, for example, carbon in which 3000 to 320,000 carbon fibers (filaments) f having a wire diameter of 6 to 10 μm are converged when carbon fibers are used as reinforcing fibers. The fiber strand (carbon fiber bundle) f1 is used.

  As the reinforcing fiber f of the wire, glass fiber, aramid fiber, PBO (polyphenylene benzbisoxazole) fiber, and polyester fiber can be used in addition to carbon fiber. Among these, carbon fiber is preferably used. Other fibers are used for special applications such as markets requiring electrical insulation, markets with electrical corrosion with metals.

(Resin impregnation process)
A matrix resin R is accommodated in the resin impregnation tank 17. As the matrix resin, epoxy resin, vinyl ester resin, MMA resin, unsaturated polyester resin, and phenol resin can be used, and among them, epoxy resin is preferably used. Other resins are used for special applications such as a market used at high temperatures and a market requiring special corrosion resistance.

  As described above, the inlet guide roller 16 for guiding the reinforcing fiber bundle f1 is disposed at the inlet portion of the impregnation tank 17. An impregnation roller 18 is disposed in the impregnation tank 17, and an exit guide roller pair 19 (19 a, 19 b) is disposed at the outlet of the impregnation tank 17.

  The inlet guide roller 16 serves to align the plurality of fibers f constituting the reinforcing fiber bundle f1 supplied to the impregnation tank 17 before impregnation in the step of impregnating the reinforcing fiber bundle f1 with resin.

  The impregnation roller 18 serves to forcibly immerse the reinforcing fiber bundle f1 in the resin R, and is used in a state where at least the lower half is immersed in the resin R stored in the impregnation tank 17.

  The pair of outlet guide rollers 19 (19a, 19b) serves to squeeze the reinforcing fiber bundle f2 impregnated with the resin, and the resin adhesion amount is controlled here.

  That is, the amount of resin impregnated in the reinforcing fiber bundle f2 is controlled by controlling the pressing pressure of the upper and lower rollers 19a, 19b.

  In this embodiment, the ratio of the reinforcing fiber f and the matrix resin R constituting the resin-impregnated wire f2 is a volume ratio (Vf) of the matrix resin, and a range of 36% to 60% can be used. If it is less than 36%, the resin is insufficient, and the physical properties such as strength of the fiber-reinforced plastic wires 101 and 102 after manufacture are lowered. On the other hand, if it exceeds 60%, the resin becomes excessive, and resin sag occurs when the resin is cured, making it difficult to ensure a round shape. In particular, the volume ratio of the matrix resin is optimally in the range of 40% to 50%.

  The resin-impregnated reinforcing fiber bundle f <b> 2 is guided by guide holes 21 (21 a, 21 b, 21 c) formed in the guide 20, and taken up by the take-up bobbins 22 (22 a, 22 b, 22 c) in the take-up device 52.

  Each take-up bobbin 22 is driven to rotate around a rotation shaft 23 (23a, 23b, 23c).

  The bobbin 22 around which the reinforcing fiber bundle f2 impregnated with the resin is wound is removed, and the fiber feeding tension, flat lattice forming, heat curing, and winding section 100B1 to B4 shown in FIG. Supplied with.

[Lattice-like stripe manufacturing department 100B]
First, with reference to FIGS. 2A and 2B, the overall configuration of the lattice-shaped streak manufacturing unit 100B will be described.

  The grid-like line manufacturing unit 100B installs a plurality of bobbins 22 (22a, 22b, 22c) in which the uncured resin-impregnated reinforcing fiber bundle f2 is wound by the winding device 52 of the wire manufacturing unit 100A. The apparatus 53A and other bobbins similar to the winding bobbins 22a to 22c of the wire f2 manufactured by the wire manufacturing section 100A, a horizontal wire unwinding apparatus 53B for installing the bobbin 22d in this embodiment are included. .

  The lattice-shaped streak manufacturing unit 100B is adjacent to the vertical wire unwinding device 53A and the horizontal wire unwinding device 53B, and the wire (uncured resin-impregnated reinforcing fiber bundle f2) supplied from these devices 53A and 53B, that is, the vertical wire unwinding device 53B. Conveying means 40 is provided for feeding the wire rod f21 and the horizontal wire rod f22 to the primary curing furnace 27a while arranging them in a lattice pattern.

  The conveyance means 40 is arrange | positioned along the longitudinal direction (manufacturing direction) of the grid-like streak 1 made long. That is, in the present embodiment, the conveying means 40 includes a pair of chain conveyors 41 (41A and 41B) arranged in parallel to each other along the longitudinal axis direction of the vertical wire f21, that is, the manufacturing direction of the lattice-like streaks 1. Is done. Both chain conveyors 41 (41A, 41B) have the same configuration, and include a drive roller 42 and a driven roller 43, and a chain belt 44 stretched between these rollers 42, 43, and are driven in the direction of the arrow. ing. In addition, guide pins 45 are provided on the outer periphery of the chain belt 44 at predetermined intervals.

  The lattice-shaped streak manufacturing unit 100B is completely heat-cured in the secondary curing furnace 27b and the secondary curing furnace 27b for further curing the lattice-shaped wires f21 and f22 fed to the primary curing furnace 27a. And a winding device 54 including a winding bobbin 31 for winding the lattice-like streaks 1.

  Next, the sections 100B1 to 100B4 of the lattice-shaped streak manufacturing unit 100B will be further described.

  A plurality of bobbins 22 (22a to 22d) in which the uncured resin-impregnated reinforcing fiber bundle f2 is wound by the winding device 52 of the wire manufacturing unit 100A are used to unwind the vertical wire (f21) and the horizontal wire (f22). It installs in the rotating shaft 24 (24a-24d) of 53A, 53B. That is, the winding bobbin 22 (22a to 22d) in the previous process shown in FIG. 1 functions as the unwinding bobbin 22 (22a to 22d) of the vertical wire (f21) and the horizontal wire (f22) in the lattice line manufacturing unit 100B. .

  The twisted vertical wire rod (uncured reinforcing fiber bundle) f21 and the horizontal wire rod (uncured reinforcing fiber bundle) f22, which are impregnated with resin and wound around the unwinding bobbin 22 (22a to 22d), rotate the bobbin 22 around the rotary shaft 24. It is unwound by rotating around (24a-24d).

  The vertical wire f21 is passed through the conveying means 40, the primary and secondary curing furnaces 27a and 27b through the guide holes 26 (26a to 26c) formed in the guide 25 along the manufacturing direction of the lattice-like streaks 1, and the winding device 54 is wound around the winding bobbin 31. Each wire is driven by the winding tension of the winding device 54.

  The horizontal wire (uncured reinforcing fiber bundle) f22 unwound from the horizontal wire unwinding device 53B is, as shown in FIG. 3A, a chain conveyor 41 (41A) constituting the conveying means 40 by the horizontal wire supplying device 70. , 41B) perpendicular to (or inclined at a predetermined angle), that is, so as to intersect with the vertical wire f21 fed along the moving direction of the chain conveyor 41 (41A, 41B). When the horizontal wire f22 fed by the horizontal wire supply device 70 reaches the guide pin 45 of the chain conveyor (one-side chain conveyor 41A), the horizontal wire supply device 70 stops once. When the guide pin 45 on the upstream side in the movement direction of the chain conveyor 41A reaches the horizontal wire position due to the movement of the chain conveyor 41A, the horizontal wire supply device 70 moves in the direction opposite to that when the horizontal wire is first fed. And move toward the other side chain conveyor 41B. Thereby, the horizontal wire f22 is latched in a U-shape by the guide pin 45 provided on the outer periphery of the chain conveyor 41A on one side.

  Next, the horizontal wire feeding device 70 feeds the horizontal wire f22 toward the other side chain conveyor 41B, and the horizontal wire f22 is guided by the guide pin of the chain conveyor (other side chain conveyor 41B) as in the previous time. When reaching 45, the horizontal wire supply device 70 stops once. When the guide pin 45 on the upstream side in the movement direction of the chain conveyor 41B reaches the horizontal wire position due to the movement of the chain conveyor 41B, the horizontal wire supply device 70 is in the direction opposite to that when the horizontal wire f22 is fed first. It moves toward the chain conveyor 41A on one side. Thereby, the horizontal wire f22 is latched by the guide pin 45 provided in the outer periphery of the chain conveyor 41B of the other side in a U shape. In the above embodiment, the chain conveyor 41 (41A, 41B) has been described as being continuously driven, but intermittent driving (tact driving) is also possible. In this case, the horizontal wire supply device 70 can move the horizontal wire f22 from the chain conveyor on one side to the chain conveyor on the other side when the chain conveyor 41 is stopped. Further, the winding device 54 performs the same movement as the movement of the chain conveyor 41 (41A, 41B), and advances the vertical wire f21 by the same distance as the distance the chain conveyor 41 (41A, 41B) has moved.

  By repeating the operation of the horizontal wire supply device 70 as described above, the horizontal wire f22 is arranged so as to intersect the vertical wire f21 while being folded back. Therefore, the horizontal wire f22 is arranged on the vertical wire 21 at a predetermined interval in a manner that the horizontal wire f22 is orthogonal (or intersects at a predetermined angle) with respect to the moving direction of the chain conveyor 41 (41A, 41B). A stacked body of the vertical wire f21 and the horizontal wire f22 is formed so that the lattice shape is formed by crossing the f21 and the horizontal wire f22.

  When the vertical wire f21 and the horizontal wire f22 are fed to the conveying means 40 and the primary curing furnace 27a, the vertical wire f21 and the horizontal wire f22 are fed in a state where a predetermined tension is applied. Thereby, the vertical wire f21 and the horizontal wire f22 are arranged in a lattice shape in a state in which the cross-sectional shape is round, and are fed into the primary curing furnace 27a.

  That is, the fiber feeding tension section 100B1 and the flat lattice streak forming section 100B2 in the lattice streak manufacturing unit 100B have a round cross section of the uncured reinforcing fiber bundles f21 and f22 that have been impregnated with resin and twisted, and at the same time a vertical wire The operation of arranging the f21 and the horizontal wire f22 in a lattice shape is performed.

  Therefore, in this embodiment, the unwinding device 53 (53A, 53B) is provided with a function such as an electromagnetic brake, and the uncured resin-impregnated reinforcing fiber bundle f21 unwound from the bobbin 22 (22a-22d), Appropriate tension can be applied to f22.

  That is, a reinforced fiber impregnated with uncured resin and twisted between the vertical wire unwinding device 53A and the heating plate device 27a and between the horizontal wire unwinding device 53B and the chain conveyor 40. Appropriate tension is applied to the bundles f21 and f22, whereby the reinforcing fibers f in the bundle are uniformly tensioned, and the cross-sectional shape of the reinforcing fiber bundles f21 and f22 is a circular cross-section, that is, a round shape. can do.

  In the specification and claims of the present application, the term “circular” includes “substantially circular” in which the diameter ratio in the vertical and horizontal directions in the cross section is within the range of 1.0 to 1.5. Means.

  As described above, according to the present embodiment, the uncured reinforcing fiber bundles f21 and f22 are unwound while applying an electromagnetic brake to the unwinding bobbin 22 (22a to 22d), and an appropriate tension force is applied. Then, it is arranged in a lattice shape, formed into a flat shape by the heating plate device 27a, and first-cured (semi-cured), and then the resin is completely cured in the heat-curing furnace 27b.

  In the present embodiment, as the tension, it is preferable to impart a strength of 500 g / line to 3000 g / line to the resin-impregnated reinforcing fiber bundles f21 and f22.

  That is, regarding the tension force that is applied when the matrix resin is cured, an appropriate amount is 500 g / piece to 3000 g / piece for the fiber bundle (strand) f1. If it is less than 500 g / piece, it will be difficult to secure a round shape, and if it exceeds 3000 g / piece, there will be a problem that the reinforcing fiber f breaks during production, resulting in a problem that stable production cannot be achieved. . In particular, the tension force is optimally in the range of 1000 g / line to 2000 g / line.

  After the horizontal wire f22 is sandwiched between the heating plate devices 27a, the U-shaped ears at both ends are cut off by the rotary blade 80 as the ear catching means disposed in the inlet end cutout portion 27a10 of the heating plate device 27a.

  The heating plate device 27a will be described with reference to FIG.

  In the present embodiment, the heating plate device 27a includes two first and second heating plates 27a1 and 27a2 that are symmetrically arranged in the vertical direction and are arranged in parallel with each other and horizontally in the present embodiment. Yes. Each of the heating plates 27a1 and 27a2 is formed of a forming flat plate 27a3 and 27a4, each made of a metal such as steel or stainless steel, and the forming flat plates 27a3 and 27a4. Panel heaters (heat sources) 27a5 and 27a6 provided integrally on the outside.

  Each of the heating plates 27a1 and 27a2 is formed to form round wire rods f21 and f22 inserted between inner surfaces facing each other into a flat wire rod having a thickness (t) and a width (w1, w2) (FIG. 3). (A), see FIG. 6), thickness adjusting shim plates 27a6 are arranged on both sides at least in the width direction (direction perpendicular to the moving direction of the vertical wire f21 inserted into the heating plate device 27a) They are separated by a distance (t1, where t1> t).

  As shown in the figure, the heating plates 27a1 and 27a2 are united by a vertical heating plate fastening bracket 270 with a thickness adjusting shim plate 27a7 interposed therebetween. That is, the upper and lower heating plate clamps 270 are positioned on the outer side (upper side in FIG. 4) of the first heating plate 27a1 and on the outer side (lower side in FIG. 4) of the second heating plate 27a2. The horizontal metal fitting 272 is provided. The horizontal fittings 271 and 272 are larger than the width (W27a) of the first and second heating plates 27a1 and 27a2 in the width direction, and protrude to both sides. The horizontal metal fittings 271 and 272 are provided with bolts 273 penetrating using the protruding portions, and are clamped with nuts 274 to sandwich the heating plates 27a1 and 27a2 and the thickness adjusting shim plate 27a7. Hold it together. In FIG. 4, only one upper and lower heating plate clamp 270 is shown along the length L27a of the heating plate device 27a. However, an appropriate number, for example, 2 is selected according to the length L27a of the heating plate device 27a. About 4 pieces are arranged.

  According to the present embodiment, the notch 27a10 (see FIG. 3) is formed on the inlet end side of the heating plate device 27a, that is, on the feeding inlet side of the wire rods f21 and f22, and the U-shape of the wire rod f22 is formed. A rotary blade 80 for excising the ear is disposed.

  As described above, according to the present invention, since the mold is a flat plate, it is possible to create various thickness shapes with one mold by adjusting the gap between the upper and lower sides.

  In addition, it is only necessary to draw a round fiber bundle impregnated with resin into a flat plate mold, and as will be described later, the upper and lower sides are protected by a thin cloth for mold release, and the metal mold and resin impregnated Since the fiber bundle is not in direct contact with the fiber bundle, the damage to the fiber bundle impregnated with the resin is small, and the frequency of yarn breakage during the production is scarce, and the molding yield can be greatly increased.

  On the other hand, the heating and curing furnace 27b basically has a closed structure except for an inlet and an outlet, and has a heater function or a hot air circulation function inside, and is semi-cured and fed from the heating plate device 27a. The wire f3, that is, the vertical wire f31 and the horizontal wire f32 can be heated.

  Here, according to the present invention, as is understood with reference to FIGS. 2 (a), 2 (b), and 4 as well, the heating plate device 27a includes the first and second heating units arranged symmetrically in the vertical direction. The upper surface peel ply 63 and the lower surface peel ply 64 are arranged inside the plates 27a1 and 27a2 along the moving direction of the wire rod inserted into the heating plate device 27a (that is, the direction of the length L27a of the heating plate device 27a). . Similarly, in the secondary curing furnace 27b, the upper surface peel ply 63 and the lower surface peel ply 64 are arranged along the moving direction of the wire inserted into the curing furnace 27b (that is, the direction of the length L27b of the curing furnace 27b). The

  In this embodiment, the upper surface peel ply 63 and the lower surface peel ply 64 are disposed so as to penetrate from the inlet side of the heating plate device 27a to the outlet side of the secondary curing furnace 27b, as shown in FIGS. 2 (a) and 2 (b). Has been. That is, the upper surface peel ply 63 and the lower surface peel ply 64 are respectively unwound from the unwinding reels 61a and 62a disposed on the inlet side of the heating plate device 27a and are disposed on the outlet side of the secondary curing furnace 27b. It is wound around 61b and 62b. However, it is also possible to make a product with the peel ply attached, according to the desire of a user who dislikes oil adhesion due to handling after molding.

  The upper surface peel ply 63 and the lower surface peel ply 64 are formed in a lattice shape by the conveying means 40 in the molded primary curing section 100B2 (that is, in the heating plate device 27a) and the secondary curing section 100B3 (that is, in the secondary curing furnace 27b). It arrange | positions in the aspect which clamps the both sides | surfaces of the laminated body formed with the arrange | positioned vertical wire f21 (f31) and horizontal wire f22 (f32), and an up-and-down surface in a present Example.

  Accordingly, the uncured resin-impregnated reinforcing fiber bundles f21 and f22 that have been unwound from the vertical and horizontal unwinding devices 53A and 53B and arranged in a lattice shape by the conveying means 40 and the horizontal wire supply device 70 are The molded primary curing section 100B2 (that is, inside the heating plate device 27a) is moved in such a manner that it is sandwiched from above and below by the peel ply 63 and the bottom peel ply 64. In this step, the reinforcing fiber bundles f21 and f22 are formed from a round shape to a flat shape, and the vertical wire f21 and the horizontal wire f22 are bonded to each other at the intersection and latticed by the semi-cured wires f31 and f32. A streak is formed. Subsequently, it is introduced into the secondary curing section 100B3 (that is, in the secondary curing furnace 27b) and further heat-cured, and the lattice-like streaks 1 are produced.

  Usually, the moving speed of the reinforcing fiber bundles f21 and f22 (f31 and f32) stacked in a lattice shape that moves through the molding and curing sections 100B2 and 100B3 is 0.3 to 2.0 m / min, and the heating plate device 27a1. The internal temperature is 120 to 140 ° C., and the temperature in the secondary curing furnace 27 b is 130 to 150 ° C.

  The moving speed of the reinforcing fiber bundles moving through the molding and curing sections 100B2 and 100B3, the temperature in the heating plate device 27a, and the temperature in the secondary curing furnace 27b are determined by the type of resin impregnated.

  By increasing the lengths (L27a, L27b) of the heating plate device 27a and the curing furnace 27b, the production speed of the fiber reinforced plastic lattice 1 can be increased.

  The upper surface peel ply 63 and the lower surface peel ply 64 are high density fabrics having releasability from the resin impregnated in the reinforcing fiber bundle.

  In the present invention, the “high-density fabric” refers to a reinforcing fiber bundle that acts as a buffer material between the mold and the reinforcing fiber bundle so as not to damage the reinforcing fiber bundle when the reinforcing fiber bundle is drawn into and passed through the heating plate device. To protect the flat product twisted in one direction in the secondary curing furnace so as not to twist, and to supply a flat strand without twisting to the take-up winding device, And after peeling the high-density fabric, when the surface of the flat strand generates minute irregularities and is reinforced by sticking to the structure, or when used in the resin as a reinforcing material, Has the role of greatly improving adhesion.

  For that purpose, it is necessary to have a dense woven structure so as not to enter between the folds of the woven fabric, as a matter of course to have a parting property with the resin. For that purpose, a high-density woven fabric in which the total number of warp yarns and weft yarns between inch lengths is 210 or more is indispensable. For example, it is a high-density woven fabric in which warps × wefts (50D × 75D, 75D × 75D, 84D × 84D, etc.) are arranged so that the total number of input yarns is 210 or more between inch lengths.

  A mold release film is also considered as one that fulfills such a role, but a mold release agent is necessary to make the mold release film easy to peel off, or after peeling the film, the surface is smooth and adheres to the resin. There is a problem that the sex is not enough, so I can not recommend much.

  In this embodiment, the high-density fabric is either a single fabric of continuous filament yarn such as polyester fiber, nylon fiber, vinylon fiber, or a mixed fabric.

  As described above, the high-density fabric is a fabric in which warps and wefts between inch lengths are arranged in a total of 210 or more, usually 400 or less, and is preferably a plain fabric. Further, when the total of warp yarns and weft yarns between inch lengths is less than 210, there is a problem that peeling is difficult. Moreover, there is a problem that if it exceeds 400, the cost becomes high. In this embodiment, the thickness t2 of the woven fabric is 0.1 to 0.3 mm, and a thickness of 0.15 to 0.2 mm is usually preferable.

  The manufacturing method according to the present invention described above has the following advantages.

  According to the results of our research experiments, a flat wire rod is formed by twisting a plurality of resin-impregnated fibers (fiber bundles), pulling them with a constant tension, rounding them, It has been found that it is impossible to produce a uniform width unless the mold is molded to a certain thickness. That is, when the shape before flattening is random, molding with a constant plate thickness (t) and a nearly uniform width (w) cannot be performed.

  Furthermore, the present inventors use a flat plate-shaped mold (mold) in order to make the round shape into a flat shape, and a mold release agent is used for releasing the flat plate-shaped mold from the flat product. In addition, it was found that a thin cloth (a peel ply made of a polyester woven fabric) that does not adhere to the adhesive can be continuously inserted into the upper and lower surfaces to be molded, and then cured and peeled off.

  On the other hand, since the mold is a flat plate, it is possible to create a variety of shapes with a single mold by adjusting the gap between the upper and lower sides.

  In this embodiment, the round wire can be formed by applying an appropriate tension to the resin-impregnated reinforcing fiber in which the reinforcing fiber is twisted at a certain level or more. In this embodiment, the resin-impregnated round fiber bundle may be simply drawn into the flat plate mold, and the metal mold is protected by a thin cloth (high-density woven fabric) for release at the top and bottom thereof. It was found that the resin-impregnated fiber bundle was not in direct contact with the resin-impregnated fiber bundle, so that there was little damage to the resin-impregnated fiber bundle, there was almost no frequency of yarn breakage during production, and the molding yield could be greatly increased.

  As described above, a flat fiber reinforced plastic wire rod having a constant thickness and a substantially constant width can be produced continuously and very efficiently. Can be manufactured. In addition, the flat fiber reinforced plastic grid streaks produced in this way require no release agent, does not require roughening of the product after manufacture, and does not require a separate sheet to be processed. Reduction and quality improvement can be achieved.

  In other words, according to the present invention, there is no generation of sharp edge surfaces in the molded product “grid-like streaks”, which solves the problem of safety handling when used as reinforcing bars, and the fine mesh Lattice streaks can be formed.

(Modified Example 1)
With reference to FIG. 7, another modified embodiment of the lattice-shaped streak manufacturing unit 100B will be described.

  In the embodiment described above, with reference to FIGS. 2A and 2B, the lattice-like streaks in which the vertical lattice stripes 101 and the horizontal lattice stripes 102 are produced one by one using the vertical wire rod f21 and the horizontal wire rod f22. The manufacturing method 1 was described.

  By applying the manufacturing method described in the above embodiment, the lattice-like streak 1 can be manufactured by stacking a plurality of vertical wires f21 and horizontal wires f22. In the present modified embodiment, a method for manufacturing the lattice-like streak 1 by stacking a plurality of vertical wires f21 and horizontal wires f22 will be described with reference to FIG.

  In the present modified example shown in FIG. 7, a method of manufacturing the lattice-like streak 1 by stacking three layers of the vertical wire f21 and the horizontal wire f22 is shown.

  The lattice-shaped manufacturing unit 100B of this modified example shown in FIG. 7 has the same overall configuration as the lattice-shaped manufacturing unit 100B shown in FIG. 2, and members having the same configuration and function are denoted by the same reference numerals. The description uses the description of the above embodiment, and a description thereof is omitted here.

  The difference between this modified embodiment and the above embodiment is the following configuration.

  That is, in the above embodiment, one vertical wire unwinding device 53A arranged on the inlet side of the lattice-shaped manufacturing unit 100B is used to supply the vertical wire f21 forming the vertical lattice streak 101. In the modified embodiment, the vertical wire unwinding devices 53A1, 53A2, and 53A3 are arranged and provided in three steps in the height direction, and three layers of the vertical wire f21 can be stacked at the same location.

  Moreover, in the said Example, in order to supply the horizontal wire f22 which forms the horizontal lattice line 102, one horizontal wire unwinding apparatus 53B was arrange | positioned along the moving direction of the chain conveyor 41 (41A, 41B). However, in this modified embodiment, the length of the chain conveyor 41 (41A, 41B) is increased, and three horizontal wire unwinding devices 53B1, 53B2, 53B3 are arranged in parallel, and the same work is arranged in parallel. It is possible to cause the supply device 70 (70-1, 70-2, 70-3) to stack three layers of the horizontal wire f22 at the same location.

  The vertical wire unwinding devices 53A1, 53A2, 53A3, the chain conveyor 41 (41A, 41B), the horizontal wire unwinding devices 53B1, 53B2, 53B3 and the horizontal wire supplying device 70 (70-1, 70) used in this modified embodiment. -2 and 70-3) have the same configuration and function as the vertical wire unwinding device 53A, the chain conveyor 41 (41A, 41B), the horizontal wire unwinding device 53B, and the horizontal wire supplying device 70 described in the above embodiment. However, the same operation is performed.

  As described above, in the present modified embodiment, the horizontal wire f22 is folded with respect to the vertical wire f21 by repeatedly operating the horizontal wire supply device 70 (70-1, 70-2, 70-3). Arranged so as to intersect. Therefore, the horizontal wire f22 is arranged on the vertical wire 21 at a predetermined interval in a manner orthogonal to the moving direction of the chain conveyor (or intersecting at a predetermined angle), and the vertical wire f21 and the horizontal wire f22 Are stacked to form a lattice shape, thereby forming a stacked body of the vertical wire f21 and the horizontal wire f22 that are stacked and stacked on the three layers.

  When the vertical wire f21 and the horizontal wire f22 are fed to the conveying means 40 and the primary curing furnace 27a, the vertical wire f21 and the horizontal wire f22 are fed in a state where a predetermined tension is applied. Thereby, the vertical wire f21 and the horizontal wire f22 are arranged in a lattice shape in a state in which the cross-sectional shape is round, and are fed into the primary curing furnace 27a.

  That is, the laminated body of the vertical wire f21 and the horizontal wire f22 laminated in three layers is sent to the flat lattice forming section 100B2, so that the vertical lattice 101 and the horizontal lattice 102 are laminated in three layers. After forming a grid-like streak of shape, it passes through the secondary hardened portion B3 and is wound up at the winding portion B4 (see FIG. 2), but not shown in FIG. A streak can be obtained.

  Of course, if the manufacturing method described in this modified embodiment is used, it is possible to obtain not only a two-layer structure but also four or more layers.

(Experimental example 1: Production of flat fiber-reinforced plastic lattice streaks)
Next, an experimental example will be described more specifically with respect to the production of the flat fiber-reinforced plastic lattice 1 of the present embodiment.

  In this Experimental Example 1, the lattice-like streak 1 was manufactured in the following manner using the apparatus shown in FIGS.

  Reinforcing fiber f uses PAN-based carbon fiber strand (carbon fiber bundle f1) (“TR50” (trade name) manufactured by Mitsubishi Rayon Co., Ltd.) having an average diameter of 7 μm and a converged number of 15000, and cured at 120 ° C. as matrix resin R. Epoxy resin (“Epomic R140P” (trade name) manufactured by Mitsui Chemicals, Inc.) was used.

  In this experimental example, the number of twists was 10 times / m, and the resin impregnated strand (carbon fiber bundle f2 (f21, f22)) was produced with a resin volume ratio (Vf) of 45%. . The distance between the two heating plates (t1) of the heating plate device 27a was 0.8 mm, the length in the strand running direction (L27a) was 1.5 m, and the width (W27a) was 300 mm. The temperature of the heating plates 27a1 and 27a2 was 120 ° C.

  The secondary heating furnace 27b had a width (W27b) of 400 mm, a length (L27b) of 10 m, and a curing furnace temperature of 140 ° C.

  The vertical wire f21 and the horizontal wire f22 were applied with a tension force of 2000 g / bar, fed to the conveying means 40, and arranged in a lattice pattern. The vertical wire f21 and the horizontal wire f22 arranged and laminated in a lattice shape are sandwiched between the upper surface and lower surface peel plies 63 and 64, and moved in the heating plate device 27a and the curing furnace 27b at a moving speed of 5 mm / sec. It was.

  In this experimental example, “Release Ply F” (trade name), which is a high-density fabric manufactured by Airtech, was used as the upper and lower surface peel plies 63 and 64. The specifications of this high density fabric were as follows.

High density fabric Fiber Polyester fiber Weight 95g / m ²
Total of warp and weft: 230 / inch Thickness (t2) 0.15mm

  In the above-described configuration, the resin-impregnated strands f2 (f21, f22), which are vertical and horizontal wires, are primary-cured (semi-cured) strands f3 (having a rectangular cross section formed by the heating plate device 27a ( f31, f32), and then a fiber reinforced plastic lattice 1 completely cured in the secondary curing furnace 27b was obtained. The fiber reinforced plastic lattice-like streaks 1 were peeled off from the upper surface and lower surface peel plies 63 and 64 very smoothly and without any problems at the outlet of the secondary curing furnace 27b.

  Each of the stripes 101 and 102 of the belt-like continuous fiber-reinforced plastic lattice stripe 1 thus obtained has a flat cross section with a thickness (t) of 0.6 mm and a width (w1, w2) of 1.7 mm. Had.

  In addition, there was no generation of sharp edge surfaces in the molded product “grid-like streaks”, and there was no problem in handling in terms of safety when used as reinforcing bars. The width accuracy of the reinforcing bars is also within 1.7 mm ± 0.4 mm, and an aim to reduce the lattice spacing is obtained.

(Experimental example 2: Reinforcement of concrete structure with flat fiber reinforced plastic lattice streaks)
The concrete beam was reinforced using the flat fiber reinforced plastic lattice-like streaks 1 which are the sheet-like reinforcing material of the present invention.

  In this experimental example, the lattice-like streak 1 having the configuration shown in FIG.

That is, each of the streaks 101 and 102 in the lattice-like streaks 1 has a flat cross section with a thickness (t) of 0.6 mm and a width (w1 = w2) of 1.7 mm. Moreover, the space | interval (W1 = W2) (FIG.3 (b)) of each reinforcement 101,102 was 50 mm. In the experiment, the length of the lattice-like streak 1 in the longitudinal direction was cut to 500 cm and the width orthogonal to the length was cut to 50 cm. Grid-like muscles 1 had 1000 N / mm ² or more in tensile strength, the 100000N / mm ² or more tensile modulus.

  Next, the lattice streaks 1 were embedded in the surface of the concrete structure and reinforced. The desired reinforcement strength as designed was obtained.

Example 2
100 A of wire manufacturing parts at the time of manufacturing the fiber reinforced plastic lattice-like line | wire based on this invention are not limited to the structure demonstrated in Example 1. FIG.

  Next, with reference to FIG. 8, another embodiment of the wire rod manufacturing unit 100A for manufacturing the fiber-reinforced plastic lattice-like streak 1 of the present invention will be described.

  100 A of wire manufacturing parts of a present Example are set as the structure similar to 100 A of wire manufacturing parts of Example 1 demonstrated with reference to FIG. 1, and have fiber feeding, resin impregnation, and winding sections 100A1-A3. Yes.

  However, in this embodiment, the wire manufacturing unit 100A is different from the wire manufacturing unit 100A of Example 1 only in that the twisting process on the fiber is performed after the resin impregnation as shown in FIG. . Accordingly, members having the same configuration and the same function as those of the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

  FIG. 8 shows a wire rod manufacturing unit 100A in the present embodiment. A reinforcing fiber strand (reinforced fiber bundle) f1 composed of a plurality of reinforcing fibers f moves from the left side to the right side in the drawing, and resin impregnation is performed between them. Twist processing.

  That is, referring to FIG. 8, a plurality of unwinding bobbins (cylindrical bobbin) 11 (11a, 11b, 11c) for supplying reinforcing fibers are prepared in the unwinding device 51, and each bobbin 11 has no resin. A reinforcing fiber strand (reinforced fiber bundle) f1 in which a predetermined number of impregnated reinforcing fibers f are converged is wound.

  The reinforcing fiber bundle f1 wound around each bobbin 11 (11a to 11b) is guided by the guide holes 15a, 15b, 15c of the guide 14 and continuously fed to the resin impregnation step (reinforcing fiber bundle). Supply process).

The reinforcing fiber bundle f1 fed to the resin impregnation step is impregnated with resin in the resin impregnation tank 17.
The configuration of the resin impregnation step and the work contents are the same as those in the first embodiment.

  The resin-impregnated reinforcing fiber bundle f2 is wound around the winding bobbin 22 (22a, 22b, 22c) in the winding device 52.

  At this time, the winding bobbins 22 (22a, 22b, 22c) are attached to the rotary shafts 23 (23a, 23b, 23c) provided in the winding device 52, as can be better understood with reference to FIG. Further, the rotary shaft 23 is rotatably attached to the rotary main shaft 32 (32a, 32b, 32c) of the winding device 52.

  Each bobbin 22 is rotated around the rotation shaft 23 of each bobbin 22 by the drive motor M and the gear transmission mechanism G to wind up the reinforcing fiber bundle f2 impregnated with the resin. At the same time, each bobbin 22 (22a, 22b, 22c) rotates with the rotation shaft 23 (23a, 23b, 23c) while rotating around the rotation shaft 23 (23a, 23b, 23c) as described above. It is rotated around the main shaft 32 (32a, 32b, 32c).

  That is, the bobbin 22 rotates around the rotation shaft 23 and simultaneously rotates around the rotation main shaft 32 to wind up the reinforcing fiber bundle f2.

  Accordingly, the reinforcing fiber bundle f 2 guided from the resin impregnation tank 17 by the guide hole 21 (21 a, 21 b, 21 c) formed in the outlet guide roller pair 19 (19 a, 19 b) and the guide 20 and wound by the bobbin 22. Is twisted.

  By adjusting the number of rotations of the bobbin 22 around the rotation main shaft 32 and the winding speed of the reinforcing fiber bundle f2, the number of twists per 1 m can be controlled.

  According to this example, as in Example 1, the wire diameter of the round uncured resin-impregnated reinforcing fiber bundle f2 (f21, f22) is preferably 0.5 mm to 8.0 mm. Accordingly, the reinforcing fiber bundle f1 supplied to the impregnation step is, for example, carbon in which 3000 to 320,000 carbon fibers (filaments) f having a wire diameter of 6 to 10 μm are converged when carbon fibers are used as reinforcing fibers. The fiber strand (carbon fiber bundle) f1 is used.

  The number of twists of the reinforcing fiber bundle f1 is preferably 5 times / m to 20 times / m.

  The bobbin 22 around which the reinforcing fiber bundle f2 impregnated with the resin is wound is removed and supplied to the next lattice-shaped streak manufacturing unit 100B.

  Also in the present embodiment, the lattice-shaped streak manufacturing unit 100B has the same configuration as that of the first embodiment described with reference to FIGS. 2 (a) and 2 (b).

  That is, the plurality of bobbins 22 wound up with the uncured resin-impregnated reinforcing fiber bundle f2 by the winding device 52 of the wire manufacturing unit 100A are, for example, the lattice streak manufacturing unit 100B shown in FIGS. 2 (a) and 2 (b). The vertical wire (f21) and the horizontal wire (f22) are installed on the rotating shafts 24 (24a to 24d) of the unwinding devices 53A and 53B. That is, the winding bobbin 22 in the previous process shown in FIG. 8 functions as the unwinding bobbin 22 (22a to 22d) of the vertical wire (f21) and the horizontal wire (f22) in the lattice line manufacturing unit 100B.

  The twisted vertical wire rod (uncured reinforcing fiber bundle) f21 and the horizontal wire rod (uncured reinforcing fiber bundle) f22 impregnated with resin and wound around the unwinding bobbin 22 are arranged on the rotating shaft 24 (24a to 24d) of the bobbin 22. It is unwound by rotating around.

  The subsequent manufacturing process of the lattice-like streaks 1 is the same as that described in the first embodiment, and a description thereof will be omitted.

  Comparing the manufacturing method of Example 1 and the manufacturing method of this example, the difference between the manufacturing methods of both examples is that according to the manufacturing method of Example 1, the fiber feeding of the wire manufacturing unit 100A, the resin impregnation, It is possible to connect the winding sections 100A1 to A3 and the fiber feeding tension, flat lattice forming, heat curing, and winding sections 100B1 to B4 of the lattice-shaped streak manufacturing unit 100B to make the manufacturing process continuous. . On the other hand, according to the manufacturing method of the present embodiment, it is difficult to continue the manufacturing process.

  On the other hand, in the production method of Example 1, a twist was added when producing a large flat (rectangular cross-section) fiber reinforced plastic wire having a thickness (t) of 1.0 mm and a width (w) of 3.3 mm. When the post-resin impregnation is performed, there is a problem that it is difficult to sufficiently impregnate the resin into the reinforcing fiber bundle f1.

  Therefore, it is appropriate to use the manufacturing methods of Examples 1 and 2 depending on the kind to be manufactured.

(Experimental example 3: Production of flat fiber-reinforced plastic lattice streaks)
Next, an experimental example will be described more specifically with respect to the production of the flat fiber-reinforced plastic lattice 1 of the present embodiment.

  In this Experimental Example 1, the lattice-like streak 1 was manufactured in the following manner using the apparatus shown in FIGS.

  In Experimental Example 3, a fiber reinforced plastic wire 2 was manufactured using the apparatus shown in FIGS.

  Similar to Experimental Example 1 described in Example 1, the reinforcing fiber f has an average diameter of 7 μm and a converged number of 15,000 PAN-based carbon fiber strands (carbon fiber bundle f1) (“TR50” manufactured by Mitsubishi Rayon Co., Ltd. (trade name). )) And a 120 ° C. epoxy resin (“Epomic R140P” (trade name) manufactured by Mitsui Chemicals, Inc.) was used as the matrix resin R.

  Further, a fiber reinforced plastic wire 2 was manufactured in the same manner as in Example 1 with the number of twists being 10 times / m and the resin impregnation amount being a resin volume ratio of 45%.

  Thereafter, in the same manner as in Example 1, the lattice-shaped streaks 1 were produced by the lattice-shaped streak manufacturing unit 100B shown in FIGS. 2 (a) and 2 (b).

  In addition, the structure of manufacturing apparatuses 100, such as the conveyance means 40, the heating plate apparatus 27a, and the curing furnace 27b, was the same as that of Experimental Example 1.

  As a result, the cross-sectional shape of the product was almost the same as that of Experimental Example 1 in terms of appearance and performance with lattice-like streaks manufactured by the manufacturing method of Experimental Example 1 of Example 1.

  In addition, using the fiber reinforced plastic lattice 1 manufactured in Experimental Example 3, the experiment was performed in the same manner as described in Experimental Example 2. As a result, the same result as that of the lattice-like streaks 1 described in Experimental Example 1 could be obtained.

  From this, it was found that there is no difference in the products manufactured in Examples 1 and 2 as a method of manufacturing the lattice-like streak 1.

  According to the manufacturing method of the present invention described in each of the above embodiments, as shown in FIG. 3 (b), for example, a plurality of flat fiber reinforced plastic wires (stripes) arranged in a grid pattern intersecting at right angles. In other words, the flat fiber-reinforced plastic lattice-like streaks 1 constituted by including the vertical lattice stripes 101 and the horizontal lattice stripes 102 were suitably manufactured.

  According to the present invention, as shown in FIG. 3 (c), a cloth-like mesh having a structure in which a cloth-like mesh 90 is bonded to one side or both sides of a flat-shaped fiber-reinforced plastic lattice-like streak 1 with a resin. The attached flat fiber-reinforced plastic lattice-like streaks 1A can be manufactured. FIG. 3C shows a lattice line 1A in which a cloth mesh 90 is bonded to one side.

  As shown in the figure, the cloth-like mesh 90 is composed of a warp yarn 91 and a weft yarn 92 made of glass fiber or organic fiber having a predetermined diameter in a biaxial orientation (or triaxial orientation, etc.). The yarn intervals W91 and W92 can be made smaller than the lattice intervals W1 and W2 of the lattice-like streak 1 (W91 <W1, W92 <W2), respectively. That is, the cloth-like mesh 90 has a smaller mesh (opening area) than the lattice-like streaks 1.

  Therefore, when reinforcing work such as a concrete structure (reinforcement object) such as a tunnel ceiling wall is performed using the flat fiber reinforced plastic lattice-like streaks 1A with a cloth mesh as shown in FIG. In addition, it is possible to prevent the strips from peeling off from the surface of the object to be reinforced during the operation and falling through the openings of the lattice-like streaks 1A.

  Such a flat fiber reinforced plastic lattice-like streak 1A with a cloth-like mesh is formed by, for example, a vertical wire f21 and a horizontal wire f22 arranged in a lattice shape as shown in FIG. The fabric mesh 90 is supplied from the supply reel 90a to one side or both sides of the laminated body, and then a high-density fabric having releasability from the resin, that is, the upper surface peel ply 63 and the lower surface peel ply 64 are disposed thereon. To do. Thereafter, in a state where the upper surface peel ply 63 and the lower surface peel ply 64 are arranged, the laminated body is drawn between two heated flat plates, and the vertical wire rods are formed while the cross sections of the vertical wire rods f21 and the horizontal wire rods f22 are formed in a flat shape. The f21 and the horizontal wire f22 are bonded at the intersection, and at the same time, the cloth mesh 90 is also bonded, and further primary cured and then secondarily cured. As a result, a flat fiber-reinforced plastic lattice-like streak 1A with a cloth-like mesh shown in FIG. 3C is produced. Of course, even in the manufacturing method of the present invention described with reference to FIG. 7, the flat fiber-reinforced plastic lattice-like streaks 1A with cloth-like mesh can be produced in the same manner as described above.

DESCRIPTION OF SYMBOLS 1 Flat shape fiber reinforced plastic lattice line 11 Unwinding bobbin 17 Resin impregnation tank 22 Winding bobbin (unwinding bobbin)
27a Heating plate device 27a1, 27a2 First and second heating plates 27a3, 27a4 Flat plates for molding 27a5, 27a6 Panel heater (heat source)
27b Heat curing furnace 32 Winding bobbin 40 Conveying means 63 Upper surface peel ply (high density fabric)
64 Bottom peel ply (high density fabric)
101 Vertical lattice line 102 Horizontal lattice line

Claims (10)

In a manufacturing method for continuously manufacturing lattice-shaped streaks formed by arranging a plurality of flat-shaped fiber-reinforced plastic wires in a lattice shape,
(A) a step of continuously feeding a reinforcing fiber bundle composed of a plurality of reinforcing fibers arranged in one direction while twisting;
(B) impregnating a matrix resin into the reinforcing fiber bundle continuously fed;
(C) A plurality of reinforced fiber bundles impregnated with the resin and twisted are tensed with a predetermined strength, and the cross section of the reinforced fiber bundle is formed into a circular shape and continuously sent in the manufacturing direction of the lattice-like streaks. The vertical wire rod is a horizontal wire rod in which the reinforcing fiber bundle impregnated with the resin and twisted is tensed with a predetermined strength and the cross section of the reinforcing fiber bundle is circular. A step of feeding in a direction intersecting with, and arranging in a lattice form with the vertical wire,
(D) Next, a state in which a high-density woven fabric having releasability with a resin is arranged on both side surfaces of a laminate formed by the vertical wire and the horizontal wire arranged so as to form the lattice shape. Then, the laminated body is drawn between two heated flat plates, and the vertical wire and the horizontal wire are bonded to each other at an intersection while forming a cross section of the vertical wire and the horizontal wire into a flat shape, and A step of first curing the resin;
(E) a step of secondarily curing the vertical wire and the horizontal wire, which are bonded to each other in a lattice shape and have a flat cross-sectional shape, through a heated curing furnace;
A method for producing a continuous flat fiber-reinforced plastic lattice streak characterized by comprising: In a manufacturing method for continuously manufacturing lattice-shaped streaks formed by arranging a plurality of flat-shaped fiber-reinforced plastic wires in a lattice shape,
(A) a step of continuously feeding a reinforcing fiber bundle composed of a plurality of reinforcing fibers arranged in one direction;
(B) impregnating a matrix resin into the reinforcing fiber bundle continuously fed;
(C) a step of twisting the resin-impregnated reinforcing fiber bundle,
(D) A plurality of reinforced fiber bundles impregnated with resin and twisted are tensioned at a predetermined strength, and the cross section of the reinforced fiber bundle is circularly sent continuously in the manufacturing direction of the lattice-like streaks. The vertical wire rod is a horizontal wire rod in which the reinforcing fiber bundle impregnated with the resin and twisted is tensed with a predetermined strength and the cross section of the reinforcing fiber bundle is circular. A step of feeding in a direction intersecting with, and arranging in a lattice form with the vertical wire,
(E) Next, a state in which a high-density woven fabric having releasability with a resin is arranged on both side surfaces of a laminate formed by the vertical wire and the horizontal wire arranged so as to form the lattice shape. Then, the laminated body is drawn between two heated flat plates, and the vertical wire and the horizontal wire are bonded to each other at an intersection while forming a cross section of the vertical wire and the horizontal wire into a flat shape, and A step of first curing the resin;
(F) A step of secondarily curing the vertical wire and the horizontal wire, which are bonded to each other in a lattice shape and have a flat cross section, and the horizontal wire through a heated curing furnace,
A method for producing a continuous flat fiber-reinforced plastic lattice streak characterized by comprising:   The continuous flat fiber according to claim 1 or 2, wherein the fiber reinforced plastic wire has a thickness (t) of 0.2 mm to 5.0 mm and a width (w) of 1.0 mm to 10.0 mm. A method of manufacturing reinforced plastic lattice streaks.   The production of continuous flat fiber-reinforced plastic lattices according to any one of claims 1 to 3, wherein the number of twists of the reinforcing fiber bundle is 5 times / m to 20 times / m. Method.   The continuous flat fiber reinforced plastic according to any one of claims 1 to 4, wherein the resin-impregnated reinforcing fiber bundle is tensioned at a strength of 500 g / strand to 3000 g / strand. A method for manufacturing lattice-like streaks.   The continuous amount according to any one of claims 1 to 5, wherein the amount of the matrix resin impregnated with respect to the reinforcing fibers in the reinforcing fiber bundle is 36% to 60% in volume ratio (Vf). A method for producing a flat fiber-reinforced plastic lattice.   The continuous fiber according to any one of claims 1 to 6, wherein the reinforcing fiber is any one of glass fiber, carbon fiber, aramid fiber, PBO (polyphenylenebenzbisoxazole) fiber, and polyester fiber. A method for producing a flat fiber-reinforced plastic lattice.   The continuous flat shape according to any one of claims 1 to 7, wherein the matrix resin is one of an epoxy resin, a vinyl ester resin, an MMA resin, an unsaturated polyester resin, or a phenol resin. A method for producing fiber-reinforced plastic lattice.   The continuous flat fiber according to any one of claims 1 to 8, wherein the high-density woven fabric is a woven fabric in which a total number of warp yarns and weft yarns between inch lengths is 210 or more. A method of manufacturing reinforced plastic lattice streaks.   The said high-density fabric is either a single fabric of continuous filament yarns such as polyester fiber, nylon fiber, vinylon fiber, or a mixed fabric, according to any one of claims 1 to 9. Manufacturing method of continuous flat fiber reinforced plastic lattice streaks.

Images