JPH0435934A - Laminated sheet structure - Google Patents

Abstract

PURPOSE:To obtain laminated sheet structure having strength in three-dimensional directions by a method wherein a short fiber of a fiber material such as a carbon fiber or an aramid fiber is entwined in three-dimensional directions, formed into a feltlike fiber body having a fixed thickness, into which curing resin is infiltrated, a sheet material such as a cement sheet is laminated on the surface and cured. CONSTITUTION:A short fiber 1 of a fiber material, which has high strength and is superior in high elasticity and corrosion resistance, such as a carbon fiber or an aramid fiber is entwinded in three-dimensional directions, formed into a feltlike fiber body 2 having a fixed thickness. Curing resin such as epoxy is infiltrated into the feltlike fiber body 2 and a laminated sheet 4 constituted by sticking sheet materials 3, 3 such as a cement sheet on the surface. In this instance, the sheet materials 3, 3 are pressed against the surface of the fiber body 2 while curing resin is in an uncured state, the fiber body 2 and sheet materials 3, 3 are stuck to each other by curing of the resin and the title laminated sheet is formed. Therefore, since the short fiber 1... are oriented in three-dimensional directions, entwined, compressed and unified with the resin under a compact state, strength of a thicknesswise direction also meeting at right angles with the surface can be secured and the laminated sheet becomes free from ply separation and high-strength in the three-dimensional directions.

Description

Detailed Description of the Invention (Field of Industrial Application) The present invention relates to a laminate structure, and more particularly to a laminate structure in which a fiber-reinforced resin having a predetermined thickness and reinforced in three dimensions is used as a reinforcing material. Regarding.

(Prior art) In general, fiber-reinforced resin sheets (hereinafter abbreviated as FRP sheets) are made by aligning long fibers of fibrous materials with high strength and high elasticity, such as carbon fibers and aramid fibers, in one direction. A sheet material impregnated with a curable resin agent such as an epoxy resin is laminated thereon, and the long fibers and the sheet material are integrated by curing of the resin agent. Therefore, the FRP sheet produced in this manner has mechanical directionality depending on the orientation direction of the fibers. In other words, it becomes strong against force in the longitudinal direction due to the orientation of the FA fibers, or becomes extremely weak against force in the transverse direction.

Therefore, when manufacturing an FRP joint that is strong against both longitudinal and lateral forces, it is necessary to
The RP sheets are formed in multiple layers with different directions.

That is, as shown in Japanese Patent Publication No. 56-54207, for example, when making a plate-shaped FRP sheet having a desired thickness by impregnating unidirectional reinforcing fibers with a curable resin agent and using prepreg, The fibers are laminated with their orientation crossed, correcting the difference in heat shrinkage due to fiber orientation and warping caused by this, and being cured as one piece according to the required thickness while providing strength in each direction.
An FRP sheet with a predetermined thickness is obtained.

Although the FRP sheet laminated in this way can ensure sufficient strength against forces in two-dimensional directions (vertical and horizontal), the layers are bonded to each other by resin and are not able to withstand forces in the thickness direction. It is difficult to obtain sufficient strength and elasticity because it is only a flat surface, and there is a risk of delamination in the layers like plywood due to forces acting in a direction perpendicular to the surface. There were some points that made it unsuitable for use as a material. Therefore, in order to eliminate this drawback, as shown in Japanese Patent Publication No. 62-25094, for example, carbon fiber needles are arranged to penetrate between each layer to ensure strength against three-dimensional forces. An FRP sheet structure has also been proposed.

(Problem to be solved by the invention) In recent years, there has been a technological trend toward making heavy use of FRP composite materials in building structures in order to reduce the weight of the building blocks and save labor as much as possible. It's increasing. Then, one of the composite materials is laminated by integrally fixing FRP sheets as reinforcing materials to board materials such as cement boards, and the laminates obtained in this way are used for flooring materials, wall materials, etc. I have an idea to try.

However, in the conventional FRP sheet as described above, in order to form it into a panel with a certain thickness, it is necessary to make the center of the thickness of the panel symmetrical so that the orientation of the long fibers is the same. It is necessary to laminate the long fibers in multiple layers and orient the fibers in various directions.In order to provide strength in three dimensions, it is necessary to insert carbon fiber needles through each layer. Because it is necessary to allocate
The disadvantage is that the structure becomes complicated, making manufacturing difficult and increasing costs. Moreover, since the surface of the FRP sheet to be formed is smooth, it has the disadvantage of poor adhesion to board materials such as cement boards that are laminated to it, making it difficult to ensure the integrity of the two. It was difficult to do so, and there were concerns about the strength of the joint.

This invention was made in view of the above-mentioned circumstances, and its purpose is to firmly bond a board material such as a cement board and a fiber-reinforced resin laminated thereon as a reinforcing material, as well as to create a three-dimensional structure. The object of the present invention is to provide a laminate structure having strength in various directions at a low cost.

(Means for Solving the Problems) In order to achieve the above object, the present invention involves forming a felt-like fibrous body of a predetermined thickness by intertwining short fibers of fibrous materials such as carbon fibers and aramid fibers in a three-dimensional direction. , impregnating the felt-like fibrous body with a curable resin, laminating a board material such as a cement board on the surface of the felt-like fibrous body, and fixing the felt-like fibrous body and the board material together by curing the resin. to form a laminate.

(Function) Since the surface of the felt-like fibrous body formed by intertwining short fibers in three-dimensional directions has fluffy ends, the felt-like fibrous body is impregnated with a curable resin. When plates are laminated on the surface and the felt fibers and the plate are fixed together by curing the resin, the ends of each short fiber in a fluffy state are firmly attached to the plate as an anchor. However, a strong laminate in which the plate material and the fiber-reinforced resin are strongly adhered to each other can be obtained. In addition, the fiber-reinforced resin itself is formed by impregnating a curable resin into a felt-like fiber body formed by entwining short fibers in a three-dimensional direction and hardening it integrally, so it has strength in three-dimensional directions. Moreover, it is easy to manufacture and can be provided at low cost.

(Embodiments) Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

FIG. 1 is a partially cutaway perspective view showing a preferred embodiment of the laminate structure according to the present invention.

This laminate structure uses short fibers 1 of a fiber material with high strength, high elasticity, and excellent corrosion resistance, such as carbon fiber or aramid fiber, as a reinforcing material, and the short fibers 1 are intertwined in three dimensions. The felt fibrous body 2 is impregnated with a hardening resin such as epoxy, and the surface of the felt fibrous body 2 is coated with plate materials 3, 3 such as cement boards. are fixed to form the laminate 4.

In other words, this laminate 4 is produced by pressing the plate material 3.3 onto the surface of the felt fibrous body 2 while the curable resin impregnated in the felt fibrous body 2 is in an uncured state. By curing the resin, the felt-like fiber body 2 and the plate materials 3, 3 are integrally fixed and formed.

The felt-like fibrous body 2 includes a large number of short fibers 1. ... are intertwined in three-dimensional directions, so there is a large gap between each short fiber of 1°, creating a so-called sponge-like shape, which can be compressed to any desired thickness by applying pressure.

And this short fiber 1. The epoxy resin impregnated into the gaps between the short fibers 1,...
・It solidifies in a state where the spaces are integrated with each other, and it hardens when a certain amount of heat is applied.

That is, short fibers 1. ... are oriented and intertwined in three dimensions, compressed in the thickness direction, and integrated with resin in a dense state, ensuring sufficient strength in the thickness direction perpendicular to the plane, and also preventing delamination. The strength is high in the three-dimensional direction where there is no

Further, the surface of the felt-like fiber body 2 has short fibers 1. oriented in the thickness direction. The ends of the ... are upright and fluffy, and this fluff functions as an anchor for the plate material 3.3 fixed to the surface, producing a mechanical bonding effect. Therefore, after the resin has hardened, the felt-like fibrous body 2 and the plate material 3.3 are firmly fixed and joined, and the two are integrated to form a strong laminate plate 4.

In addition, the laminate 4 made in this manner uses FRP, which is made by hardening the felt-like fiber body 2 with a curable resin, as a reinforcing material.
Not only does it have high strength in the dimensional direction, it is also as light as possible compared to concrete plates with similar strength, and it is easy to handle and has excellent workability. Moreover, fiber-reinforced resins do not require the conventional work of stacking multiple layers of long fibers oriented in one direction with different orientations, making it extremely easy to manufacture and cost-effective compared to conventional methods. It will also be cheaper.

In particular, short fibers 1. If the laminate 4 is formed using carbon fiber and used as the outer wall of a building, the carbon fiber has the property of absorbing radio waves, so it is possible to generate reflected waves. It is possible to reduce the number of radio waves as much as possible, and to prevent radio wave interference.

FIG. 2 is a partially cutaway perspective view showing another embodiment of the invention.

The laminated board 4 shown in FIG. 2 is produced by forming a large number of hollow parts S in the felt-like fiber body 2 in advance, and by fixing the plate materials 3, 3 to the felt-like fiber body 2. It is designed to function as a sealed heat and sound insulation space, and can be expected to have excellent sound insulation and heat insulation properties, making it particularly useful for use as wall and floor materials in buildings.

(Effects of the Invention) As described above in detail in the Examples, according to the laminate structure according to the present invention, the surface of the felt-like fibrous body formed by intertwining short fibers in a three-dimensional direction is Since the ends are fluffy, the felt fibrous body is impregnated with a curable resin and a board is laminated on the surface of the felt fibrous body, and as the resin hardens, the felt fibrous body and the board are integrated. When fixed, the end of each short fiber in a fluffy state is firmly attached to the plate material as an anchor, and a strong laminate in which the plate material and the fiber-reinforced resin are strongly adhered to each other can be obtained. In addition, the fiber-reinforced resin itself is formed by impregnating a curable resin into a felt-like fiber body made of short fibers intertwined in a three-dimensional direction and hardening it integrally, so it has strength in three-dimensional directions, and It is easy to manufacture and can be provided at low cost.

[Brief explanation of the drawing]

FIG. 1 is a perspective view showing one embodiment of the present invention, and FIG. 2 is a perspective view showing another embodiment. 1... Short fiber 2... Felt-like fibrous body 3... Board material 4... Laminated board S... Hollow part

Claims (2)

[Claims] (1) Short fibers of fibrous materials such as carbon fibers and aramid fibers are intertwined in three dimensions to form a felt-like fibrous body with a predetermined thickness, and the felt-like fibrous body is impregnated with a curable resin, and the felt-like fibrous body is impregnated with a curable resin. A laminate structure characterized in that a board material such as a cement board is laminated on the surface of a fibrous body, and the felt-like fibrous body and the board material are integrally fixed by curing the resin. (2) The laminate structure according to claim 1, wherein the felt-like fibrous body has a hollow portion.