JP7288134B1 - Spray base material - Google Patents

Abstract

An object of the present invention is to provide a spray base material that can be substituted for a metal wire mesh and that has increased adhesion to a lining layer due to a simple structure. SOLUTION: A spraying base material 10 made of a knitted fabric made of fibers and used by being embedded in a layered lining layer 32 constructed by spraying a spraying material on a slope, and a strand 20 constituting the knitted fabric is on the surface. The knitted fabric is heat-treated in a state in which the meshes are open, and is made of a plurality of types of resin fiber materials that are not coated with a resin and have different melting temperatures. [Selection drawing] Fig. 4

Description

TECHNICAL FIELD The present invention relates to a fiber spray base material used for slope protection work involving spraying of mortar or vegetation base material, protective work for inner walls of tunnels, and the like.

If cut slopes and fill slopes are left unattended, surface erosion and slope failure will occur due to rainfall.
As one of the slope protection works to solve these problems, mortar spraying is known in which mortar is sprayed on the entire surface of the slope and the surface of the slope is covered with a mortar layer having a thickness of about 3 to 30 cm (Patent Document 1). ).
In order to ensure the fixability and strength of the mortar layer, a metal net is laid on the slope in advance, and the mortar is sprayed until the metal net is hidden, and the metal net is embedded in the mortar layer. (Patent Document 2).
In general, a rhombic wire mesh called a lath mesh is used as a metal mesh material.

JP-A-8-35232 Japanese Utility Model Laid-Open No. 60-146544 JP 2017-214781 A JP 2017-222524 A

Conventional slope protection technology has the following problems.
<1> The surface of the metal mesh material is plated and finished smoothly. It cannot follow the land and is difficult to get used to.
<2> Furthermore, since the metal mesh material is heavy, it is difficult to lay it on site. In particular, the steeper the slope, the worse the laying workability.
<3> Since the mesh material is made of metal, there is also the problem of corrosion.
<4> Use of a fiber net can be considered instead of a metal material.
Since fiber nets are too soft to maintain a regular shape, they are difficult to lay on site.
<5> Since the material of the fiber net is too soft, the mesh of the fiber net is likely to close, and if the mortar is sprayed with the mesh closed, the mortar will not flow to the back side of the net.
<6> In place of metal materials, it is conceivable to use woven fabrics, knitted fabrics (nets) made of fibers coated with resin, or resin nets such as geogrids (for example, Patent Documents 3 and 4).
These resin nets have a resin coating on the surface of the net material, and the surface is finished smooth, so the adhesion with mortar is poor, and the followability to uneven slopes is poor. , There are issues such as.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a textile base material for spraying, which can solve the above problems.

The present invention is a spraying base consisting of a knitted fabric made of fibers, which is used by being embedded in a layered lining layer constructed by knitting a plurality of strands in a net shape, having meshes between the strands, and constructing by spraying a spraying material. The strand is made of a plurality of types of resin fibers having different melting temperatures and the surface of which is not coated with a resin, and the knitted fabric is heat-treated with the mesh open.
In another aspect of the present invention, the strands constituting the net fabric are composed of a strand main body made of a heat-fusible fiber material whose surface is not coated with a resin, and a plurality of fiber materials woven along the strand main body. The pile yarn is knitted along the strand body to project a plurality of laterally directed piles parallel to the surface direction of the knitted fabric, and the plurality of laterally directed piles are attached to the lining layer. Equipped with a dowel function to increase the attachment force.
In another embodiment of the invention, the knitted fabric is a Raschel knitted fabric having a single-layer structure or a laminated structure.
In another aspect of the present invention, the melting point of the pile yarn is at least equal to the melting point of the resin fibers forming the filaments of the strand body.
In another aspect of the present invention, the strand body includes at least a monofilament core yarn and a multifilament or monofilament knitting yarn arranged around the core yarn for chain stitching.
In another aspect of the present invention, the core yarn is made of a plurality of types of resin fibers having different melting temperatures, and the knitting yarn is a resin fiber having both heat-sealability and heat-shrinkability.
In another aspect of the invention, the mesh is diamond or square.

The present invention has at least one of the following effects.
<1> The sprayed base material according to the present invention is obtained by heat-treating a heat-fusible fiber material without forming a resin film on the surface, leaving unevenness on the surface of the strands constituting the mesh. Appropriate rigidity (form retention) can be imparted to the mesh fabric.
Therefore, compared to conventional metal nets, it has better followability to unevenness of the laying surface, and has better adhesion to the sprayed material than conventional metal or resin nets with smooth surfaces.
<2> When a plurality of pile yarns for forming horizontal piles are woven into the strand body, the outer peripheral surface of the plurality of horizontal piles adheres to the lining layer to increase the adhesion area, and the strand body and the Since the sprayed material enters into the through spaces formed between the lateral piles to impart continuity to the sprayed material on both the front and back sides of the knitted fabric, the adhesion between the strands and the lining layer is further increased.
<3> Since the horizontal piles are not protruded from the front and back surfaces of the sprayed base material, but protrude parallel to the surface direction of the sprayed base material, the horizontal piles are easily crushed during handling or laying work of the sprayed base material. No worries.
<4> When knitting a knitted fabric, by knitting pile yarns along the strand body, a plurality of lateral piles can be easily knitted.
<5> Constructing the sprayed base material from a knitted fabric made of fibers makes it possible to reduce the weight compared to a metal wire mesh, so that the workability of laying the sprayed base material can be improved and it can be used even in salt-damaged areas. can.

Explanatory drawing of the spray base material according to the present invention Explanatory drawing of the strands constituting the spray base material, (A) is an enlarged view of the strands, (B) is a cross-sectional view of BB in (A) It is an explanatory diagram of a slope lining method using a spray base material, in which (A) is an explanatory diagram of the process of laying the spray base material on the slope, and (B) is an explanation of the process of forming a lining layer on the slope. figure Cross section of lining layer

Embodiments of the present invention will be described below with reference to the drawings.

<1> Outline of Spray Base Material Made of Fiber A spray base material 10 according to the present invention will be described with reference to FIG.
The spray base material 10 is a knitted fabric made of fibers in which a plurality of strands 20 arranged at predetermined intervals are knitted in a net shape.
The knitting yarns of the adjacent strands 20 intersect at regular intervals to form intersections, thereby forming meshes 24 between the strands 20 .

The knitted fabric constituting the spray base material 10 may have a single structure, or may have a laminated structure in which two knitted fabrics having the same structure are stacked and integrated.
In this example, the knitted fabric constituting the spray base material 10 is a raschel net, but the knitted fabric is not limited to raschel knitting, and known knitted fabrics can be applied.
In the case of raschel knitting, a knitted fabric (warp-knitted net fabric) with a single weave structure or a double raschel structure can be obtained by a raschel machine or a double raschel machine.
The reason why the material of the spray base material 10 is a knitted fiber fabric is that it has better adhesion to mortar than a metal wire mesh, improves the workability of laying on the slope 30, and This is to reduce the weight of 10 and prevent it from rusting.

The knitted fabric constituting the spray base material 10 is hardened by heating to give stiffness so that the knitted fabric can maintain its self-supporting shape.
The knitted fabric constituting the spray base material 10 not only has stiffness, but also has plasticity enough to allow plastic deformation when folded.

<2> Strand To explain the strand 20 illustrated in FIG. and
The strand 20 may be composed of only the strand main body 21 by omitting the pile yarn 25 .
In selecting raw yarns for the strand main body 21 and the pile yarn 25, it is assumed that they are materials having alkali resistance.

<2.1> Strand Main Body The strand main body 21 includes at least a monofilament core yarn 22 and a multifilament or monofilament knitting yarn 23 arranged around the core yarn 22 and chain knitted.
If necessary, the strand 20 is knitted with an additional insertion yarn or yarns.

The core thread 22 is a core member for imparting rigidity to the strand body 21, and is made of a monofilament.
The plurality of knitting yarns 23 are multifilaments for covering the outer peripheral surface of the strand body 21, and cover the outer circumference of the core yarn 22 by forming a chain stitch.
The reason why the knitting yarn 23 is chain stitched is that the outer peripheral surface of the strand body 21 is formed in an uneven shape to increase the adhesion surface force with the mortar.

<2.1.1> Strand body material The core yarn 22 uses a plurality of types of resin fiber materials with different melting temperatures, and the knitting yarn 23 has heat-fusibility (by heat treatment at a melting temperature or higher). A fibrous material that has both heat-shrinkability and heat-shrinkability is used.
The reason why the constituent materials 22 and 23 of the strand body 21 are made of heat-sealable fiber material is to heat-harden the knitted fabric to give the sprayed base material 10 an appropriate hardness.

<2.1.2> Material Example of Core Thread As a material example of the core thread 22, a PE monofilament, a PP (polypropylene) monofilament, a nylon 6 monofilament, or the like can be used.

<2.1.3> Material example of knitting yarn As the knitting yarn 23, a fibrous material having both heat-sealability and heat-shrinkability is used.
As a material for the knitting yarn 23, PP multifilament, nylon 6 multifilament, vinylon multifilament, PE monofilament, PP (polypropylene) monofilament, nylon 6 monofilament, or the like can be used.

<2.2> Pile yarn The pile yarn 25 is a multifilament for forming a plurality of horizontal piles 26 along the outer peripheral surface of the strand body 21 .
The lateral pile 26 has a dowel function that enhances adhesion (adhesion strength) to the lining layer 32 such as mortar.
The pile thread 25 may also be used as an insertion thread, or may be a separate dedicated thread.

<2.2.1> Horizontal pile The horizontal pile 26 is alternately directed along the longitudinal direction of the strand body 21 (chain-stitched knitting yarn 23) in the left-right direction (plane direction of the spray base material 10). protrude to
In other words, the plurality of lateral piles 26 protrude toward the inside of the mesh 24 .
Using a known Russell machine, it is possible to knit a transverse pile 26 on the side surface of the strand body 21 with the pile yarn 25 .

Each lateral pile 26 extends from the strand body 21 in a substantially C-shape or substantially U-shape, and has a through space 27 inside the lateral pile 26 .

The exposed full length of the lateral pile 26 becomes the length of attachment to the mortar.
The total length of the transverse pile 26 can be appropriately selected by adjusting the payout length of the pile yarn 25 at the time of knitting.

<2.2.2> Formation Direction of Horizontal Pile A plurality of horizontal piles 26 were protruded parallel to the surface direction of the knitted fabric.
In other words, a plurality of horizontal piles 26 are projected toward both left and right sides of the strand body 21 .
The reason why the projecting directions of the plurality of horizontal piles 26 are aligned in such a specific direction is to prevent the horizontal piles 26 from collapsing when the knitted-blown base material 10 is stacked or laid on a slope.
For example, if the horizontal piles 26 are provided on both the front and rear sides of the strand body 21, the horizontal piles 26 are easily crushed when the sprayed base material 10 is stacked or when laying on a slope, and the horizontal piles 26 have a function of adhering to mortar or the like. This is because it becomes impossible to fully demonstrate

<2.2.3> Material of pile yarn The pile yarn 25 uses a fibrous material that is unlikely to melt and thermally shrink when the knitted fabric of the spray base material 10 is heat-treated.
As the material of the pile yarn 25, a resin fiber having a melting point higher than that of the resin fibers composing the core yarn 22 and the knitting yarn 23 is desirable.
As the material of the pile thread 25, for example, nylon 66, polyester, aramid fiber, vinylon, cellulose fiber, glass fiber, or the like can be used.

<2.2.4> Melting Point Difference of Resin Fiber The melting point of the resin fiber of the pile yarn 25 is higher than the melting point of the resin fiber of the strand body 21 (the core yarn 22 and the knitting yarn 23).
The reason why both filaments have different melting points is that only the strand main body 21 is thermally cured when the knitted fabric of the spray base material 10 is heat-treated.

<2.3> Heat treatment of knitted fabric In the present invention, the knitted fabric constituting the spray base material 10 is targeted, and heat treatment is performed at a predetermined temperature with the meshes open, so that the knitted fabric has morphological stability and moderate heat treatment. of hardness.
By heat-treating the knitted fabric at a predetermined temperature, the fiber materials of the core yarn 22 and the knitting yarn 23 constituting the strand body 21 are heat-sealed and integrated, and the knitted fabric hardens to open the mesh. The form of the knitted fabric is stabilized as it is.

The heating temperature of the heat treatment is the temperature at which the core yarn 22 and the knitting yarn 23 forming the strand body 21 are heat-sealed.

<2.3.1> Overhang Length of Horizontal Pile By heat-treating the mesh fabric, the strand main body 21 shrinks and deforms, so the overhang length of the horizontal pile 26 becomes longer than before heating.

The total length of the horizontal pile 26 can be appropriately selected by adjusting the payout length of the pile yarn 25 at the time of knitting, but by using heat treatment, the overhang length of the horizontal pile 26 can be set longer. .

<2.3.2> Heat shrinkability of pile yarn As described above, the melting point of the resin fiber of the pile yarn 25 is higher than the melting point of the resin fiber of the strand body 21 (the core yarn 22 and the knitting yarn 23). be.
Therefore, even if the knitted fabric is heat-treated, the pile yarn 25 hardly undergoes heat shrinkage, so there is no concern that the overhang length of the pile 26 will be shortened.

<3> Mesh The shape of the mesh 24 may be either a diamond shape or a square shape (square mesh).
Although the size of the mesh 24 can be selected as appropriate, it is practically desirable to have a size of around 50 mm.

[Slope lining method]
A method of lining the slope 30 using the spray base material 10 will be described with reference to FIGS.

<1> Laying of Spraying Base Material The spraying base material 10 wound in a roll is brought into the site, and the spraying base material 10 is unfolded and laid on the slope 30 .
In laying the sprayed base material 10, the sprayed base material 10 is fixed to the slope 30 by driving an anchor pin, an anchor bar, or the like.

Since the horizontal pile 26 does not protrude from the front and back surfaces of the spray base material 10, there is no concern that the horizontal pile 26 will be easily crushed during the laying work of the spray base material 10.例文帳に追加
Furthermore, since the spray base material 10 has hardness (shape retention) that allows plastic deformation, even if the slope 30 has some undulations, the spray base material 10 can be laid by following the unevenness of the slope. can do.

<2> Spraying A lining layer 32 is formed by spraying a cement-based spraying material 31 such as mortar toward the slope 30 until the spraying base material 10 is hidden.
In the present embodiment, a cement-based spraying material such as mortar is used as the spraying material 31. However, the spraying material 31 may be a vegetation base material for greening such as soil.

The sprayer for the spraying material 31 in this example can use a known spraying device equipped with a compressor.
A spray nozzle 33 is provided at the tip of a hose extending from a spray machine (not shown), and a spray material 31 is sprayed through the spray nozzle 33 .
The thickness of the lining layer 32 is preferably about 10 to 20 cm.

<2.1> Adhesion between Strand Main Body and Mortar function as a reinforcing member of

Since unevenness is formed on the surface of the strand body 21, the fiber-made spray base material 10 has much higher adhesion to the lining layer 32 than a metallic wire mesh with a smooth surface.

<2.2> Adhesion between the lateral pile and the lining layer In particular, as shown in an enlarged view in FIG. The sprayed material 31 enters the penetration space 27 formed between the outer peripheral surface of the main body 21 and the lateral pile 26, and continuity is imparted to the sprayed material 31 on both the front and back surfaces of the knitted fabric, so that the strands 20 and the lining layer 32 are formed. The adhesive force (bonding force) with is further increased.

[Other embodiments]
The fiber spray base material 10 can be applied not only to slope protection work but also to tunnel inner wall protection work.
After the sprayed base material 10 is installed along the existing tunnel inner wall, concrete is cast until the sprayed base material 10 is hidden to form a lining layer on the inner wall of the tunnel.
In this example, since the lining layer formed on the inner wall of the existing tunnel functions as a protective layer, it is possible to prevent the inner wall of the tunnel from peeling off and suppress the cracking of the surface layer of the lining layer.

10 Spraying base material 20 Strand 21 Strand body 22 Core yarn 23 Knitting yarn 25 Pile yarn 26 Lateral pile 27 . . . through space 30 .. slope 31 .. spraying material 32 .. lining layer 33 .

Claims (5)

A spray base material consisting of a knitted fabric made of fibers that is used by embedding in a layered lining layer constructed by knitting a plurality of strands into a net, having meshes between the strands, and constructing by spraying a spray material. ,
The strands are made of a plurality of types of resin fibers with different melting temperatures that are not coated with a resin on the surface,
The knitted fabric is heat-treated with the mesh open,
The strand constituting the knitted fabric is a strand main body made of a fiber material whose surface is not coated with resin,
a plurality of pile yarns made of a fiber material woven along the strand body,
Knitting the pile yarn along the strand body to project a plurality of lateral piles parallel to the surface direction of the knitted fabric,
The strand body comprises at least a core yarn and a knitting yarn arranged around the core yarn for chain knitting,
The core yarn is made of a plurality of types of resin fibers with different melting temperatures,
The knitting yarn is a resin fiber having both heat-fusibility and heat-shrinkability ,
Spray base material. 2. A sprayed base material according to claim 1 , characterized in that said knitted fabric is a Raschel knitted fabric of single layer or laminated construction. 2. The base material for spraying according to claim 1 , wherein the melting point of said pile yarn is at least equal to the melting point of resin fibers forming the filaments of said strand body. 2. The strand body according to claim 1 , characterized in that the strand body comprises at least a monofilament core yarn and a multifilament or monofilament knitting yarn arranged around the core yarn for chain knitting. spray base material. A spray base material according to claim 1, characterized in that said mesh is diamond-shaped or square-shaped.

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