JPS5910856B2 - Metal-reinforced composite materials and their manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present application relates to a metal-reinforced composite and its manufacturing method, and the metal used in the composite of the present application is used as a mesh net. Wire meshes made of wires woven or welded at intersections, and wire meshes that have a large apparent thickness, are strong, and are rigid enough to move independently when mixed with other materials, such as lath mesh used for wall cores. Instead, similar to a lath net 20, if the width of a thin metal sheet is widened in the direction perpendicular to the cut line in the horizontal or vertical direction, the rectangular cross-section strands will stand up diagonally and the apparent thickness will increase, creating a stiff net-like body that can be rolled. The mesh wire is passed between rolls to make it flat, or the mesh wire is spread thinner and wider, and sometimes the wire is drawn to increase its flexibility, and the adhesive surface with other materials is expanded to create a composite matrix. The present invention is characterized in that it is used as a flat thin layered flexible metal rolled net that is easily defoamed and acts together with the matrix.

30, which uses such a new special rolled metal mesh as a reinforcement material.
Alternatively, a composite material in which a fiber material is further added as a reinforcing material is the invention of Claim 1 of the present application, and depending on the type of matrix, 1. Composite material with thermosetting resin (abbreviated as MRP), 2. Thermoplastic resin/film. There are composite materials such as MRTP (approximately MRTP), composite materials 35 (approximately MRG) with 3 gypsum-based coagulants, and composite materials 35 (approximately MRC) with 4 cement-based coagulants.

Before explaining Claim 1, a method for manufacturing a rolled metal net used as a reinforcing material for the composite material of the present invention and a continuous method for manufacturing the composite material will be explained in advance.

Conventionally, pressed lath nets cut to length have existed on the market.

Even if it is called rolling, rolling is simply pressing to smooth the surface of the lath mesh, and it is used for purposes that require it to be strong even after rolling, so the material is There is no particular consideration for rolling it thinly, and the plate material used as the raw material is thick, so it is sold commercially after being cut to a fixed length, and it is difficult to roll it into long lengths, and there are few uses for it, so there are no long-rolled commercially available products at all. Conventionally, metal lath mesh is used as a core material for the walls of buildings, etc., and because it is desirable for it to have a small basis weight and be strong, the wide side of the rectangular cross section of the cut wire stands up from the flat surface and has a large apparent thickness. Therefore, it is a product suitable for applications in which it is desirable to have a low wire density and yet be strong in the thickness direction, and there is no commercially available long-rolled product that is cut to a fixed length and is commercially available.

In this lath net, the wide side of the rectangular cross-section strands is on the slope, and the thin edges of the strands protrude in a wavy shape on the front and back (top and bottom) surfaces, so when textile materials, especially woven fabrics and non-woven fabrics are laminated, the bonding area Not only is it extremely small, making it unsuitable for use as a laminated composite material, but it also requires a large basis weight of matrix resin to fill in the metal net, and the stiffness of the lath net makes it difficult to match the flexibility of the resin or fiber material. Due to the large difference in physical properties, a combined effect cannot be expected.

Currently, it is desirable for lath mesh to be strong in the thickness direction, so thin metal plates are not used, and in many cases, thin iron plates are made of materials with a thickness of 0.41 Lm or more. is used, and the products are cut into regular lengths and sold commercially. On the other hand, since the rolled net of the present invention is mainly used as a composite material, it is thinner, has a larger planar adhesion surface area per mesh, and is highly flexible.

In other words, even when iron plates are used as raw materials, the thickness after rolling is 0.4 m1 to 0.15 m1 L, and in order to make continuous processing advantageous when combining this with a matrix in a separate process,
The rolled net must be rolled as long as possible and must be easily rewound. In the first place, at the edge of a rolled net, such as a lath net or the like, which is vertically cut to the intended width,
The mesh intersection points and strands are protruding, making them easy to bend when the roll is moved and transported, and easily caught when unwinding from the winding roll.
If it gets caught and tension is applied, the rolled net is thin and flexible and has no dimensional stability in the longitudinal direction, so the net deforms into a thin piece, making it difficult to use.

If the wire length of the mesh is 8 mm or less and the mesh is fine, there is considerable dimensional stability, but as the wire length increases (10 m 1 L or more), the flexibility of the rolled mesh increases, but the dimensional stability of the mesh increases. decreases. To deal with this, in many cases, a narrow selvage material made of the same kind of soft metal as the mesh (e.g. annealed wire or hot melt glued thereon) or a composite resin is used at the selvage part or the part to be longitudinally cut during rolling. The net intersection point and the cut line protruding from the ear part are fixed by plastic deformation crimping of the ear material, and the area to be cut vertically is cut and the length direction of the rolled net is stabilized with the ear material. For example, a long rolled product with selvedge material that is easy to handle in post-processing can be obtained.

Conventional commercially available lath nets and rolled laths have thick, flat wires but are less flexible and are cut to length, and there are no wound roll products, but the product of this application is thin, flexible, and has long lengths. It can be rolled up, and it is easy to rewind with the selvedge material attached, and it is suitable as a continuous composite processing material with a matrix in a separate process.It is a new product with completely different physical properties and uses in terms of thickness, and the manufacturing method is also different. It is also new. Next, the steel cord parallel body and the rope-shaped mesh metal wire will be described.

By making vertical cuts in the length direction of a thin metal sheet and widening it in the horizontal direction, a vertically long rhombic lath net with diagonally rising cut lines can be obtained. If it is rolled in one or more stages, it becomes a longitudinally elongated diamond-shaped rolled net with increased strength in the longitudinal direction.

If this is plated with brass, it can be used as a steel cord parallel body instead of the blind weave of the tire cord. In addition, if a vertically long rhombic lath net or its rolled net is gathered into a certain width unit and drawn through a die in one or more steps, the wire becomes thinner, stronger, and more flexible, and can be wound as is or by heating. A rope-like braided metal wire material in which the base wires do not come apart can be obtained. If rubber or resin is extruded and coated around it, it will be rust-proofed and insulated, and used for each purpose. In recent years, the automobile industry has become a major consumer of steel, with a particularly large consumption of cold-rolled sheets.

On the other hand, from an energy-saving perspective, it is desired to make automobiles lighter, and thin steel plates are made of lighter FRP (fiber-reinforced thermosetting plastic) or FRTP (fiber-reinforced thermoplastic).
Alternative development is underway. The disadvantage of FRP is that it takes time to shape it.

Even with FRTP, which can be shaped in a shorter time than FRP, it cannot be removed from the mold unless it is cooled and solidified after shaping. The time-consuming process causes high imprinting costs. However, when the metal rolled mesh of the present invention is used as a substitute for FRP-FRTP fibers or as an additional material, the shaping is stabilized at the moment of pressing with the mold, and the shaping is maintained even if the hardening of the resin is delayed. Since the material is hardened at a high speed, high-speed 5-speed shaping is possible, and processing costs can be significantly reduced. The presence of a rolled metal mesh on the surface helps harden the surface and improve wear resistance. If a mixture of thick and coarse wire mesh is shaped, the wire mesh and other composite materials will each follow their own deformation process, with the drawback that the adhesive at one interface will peel off.
The rolled net is a thin layer, and its surface area and flexibility are increased by an order of magnitude, and the fibers and matrix arranged on the front and back through the mesh space wrap the metal wire and adhere directly to it, so even though the adhesive strength at the wire interface is the same, it is difficult to shape. At times, each material no longer behaves in its own way, and the phenomenon of interfacial delamination does not occur.

The composite material in this state is subjected to MRP. It's called MRTP. Next, the difference between a thin metal sheet and the rolled mesh of the present invention during shaping is as follows: thin sheets often require wrinkling on curved surfaces, but in the case of mesh, the shaping force is due to the deformation of the mesh. Another feature of the net-like body of the present invention is that even if the thickness of the metal plate is the same, the basis weight of the strands can be changed arbitrarily by adjusting the width of the net. Also MRP
．． MRTP is different from conventional FRP in that it can be stably fixed to other objects by nailing the mesh h intersections. This is a notable difference from FRTP. The thinner the metal plate, the lower the basis weight, but the higher the cost. However, the net cover type has the effect that the metal wire basis weight can be adjusted as desired by increasing the width magnification. In short, MRP according to the present application. To recapitulate the characteristics of MRTP, the firmness, formability, and tear resistance of the product depend on the rolling net, while the specific gravity, strength, and dimensional stability depend on the mass-produced glass fibers, organic fibers, or other nonwoven fabrics. , thermoplastics that rely on woven fabrics and are used as adhesive matrices;
Thermosetting polymers help prevent rust and corrosion of metals and reduce the weight of composite materials.

In particular, glass fiber is often used as a material for the composite material of the present invention because it has high heat resistance and strength and low elongation.

In such fiber materials, short and small fibers may be mixed in the matrix, but the present applicant's earlier invention, ``Wide web laminated cloth material using glass fibers or various threads'', was disclosed in Japanese Patent Publication No. 53-38783. The warp-warp orthogonal non-woven fabric produced by the above manufacturing method is a more desirable composite reinforcing fiber material because it is less expensive than woven fabric and is free of plastic deformation between warp and weft.

The strength of the composite material in the warp and weft directions can be achieved by laminating it with a rolled mesh by changing the basis weight of fibers, which have a lower specific gravity than metals.

The rolled net may be placed on one side of the fibrous material, or it may be sandwiched between two layers of fibrous material, front and back.

Made of a composite of rolled net, glass fiber non-woven fabric, and adhesive resin, this lightweight board is similar in weight to aluminum board, but is stronger, particularly tear-resistant, and rust-free and can be used in a wide range of applications such as automobiles, home appliances, furniture, various containers, and packaging boxes. It will be.

If lightweight aluminum metal is used as raw material, lightweight and rust-resistant products can be produced.

When the rolled net of the present invention is to be adhered to other objects, it is conventionally known to plate the rolled net to improve rust prevention and adhesion, to bake the rolled net through a fluidized bed of resin powder under heat, or to coat it with adhesive. method is used.

In short, the rolled net of the present invention has a large surface area per grain size and is a flat plate, which makes it possible to achieve stronger lamination adhesion. Next, the method of making cuts to form rectangular cross-section strands in the thin metal plate may be such that the length direction of the cuts is perpendicular or parallel to the machine direction (the length direction of the metal plate). If you make a cut and stretch it at right angles to the length of the cut, it will become a lath-like net.

If the cut interval (the length of the uncut part) on the same score line is small, widening the width will result in a diamond-shaped mesh (usually the metal lath mesh on the market has this shape), and the cut interval will become larger. In this case, after widening, a hexagonal hexagonal hexagonal mesh is formed in which the strands with twice the cut width are on two symmetrical sides. In this application, any net fabric with regular or irregular cuts other than those mentioned above can be used as a material, and the expanded state of the product will depend on the use. change.

The material for the rolled net in this application is a flat thin layer of iron, aluminum, stainless steel, titanium, copper, and other alloys. used.

When a rolled mesh is made from a resin-coated resin iron plate as a raw material, the surface resin spreads over the cut surface of the mesh wire to coat the cut surface and prevent rust. Next, the metal reinforced composite and its continuous manufacturing method will be explained.

As mentioned above, the metal reinforcing material is a flat thin layer of flexible rolled metal mesh with ears, and if a long roll of the mesh is supplied, it becomes possible to easily repeat and produce a low-cost composite material in a continuous process.

Since the rolled net with selvedge material is a new product, the continuous manufacturing method of the composite material of the present invention is also new. That is, a rolling net is continuously unwound from a long winding roll and coated with an organic/inorganic matrix, or paper, film, fiber material, etc., which are also unwound from a long winding roll, are added and laminated, and then rolled onto a hot drum. If it is heated to an appropriate temperature while being moved and pressed between pressing rollers, MRTP, M
RG and MRC are serially produced.

In particular, since the rolled mesh used in the present application is a flat thin layer, it is characterized in that interlayer defoaming is much easier than when conventional wire mesh with a large apparent thickness is used. Then, it is possible to directly connect the waveform forming device and stamping process to the composite crimping process, and if it is cut to a fixed length and taken off after forming, it is possible to form MRTP.
is produced at extremely low cost. Then, by mixing a foaming agent into the matrix and heating and foaming it during the process, or by laminating separately prepared foam sheets, a composite material of the present invention with a large apparent thickness and good heat retention and cushioning properties can be obtained.

Example 1 5009 is a thin plate with a thickness of 0.4 to 0.57n1L, which has been expanded to about 7 times the area by making horizontal cuts in a conventional commercially available lath net.
/ Place a band iron with a thickness of 0.3 mm and a width of 3 m 1 L on the edge of the flat lath of A, and roll it between rolling rollers to approximately double the width of the strand to form a thin flat plate with a basis weight of approximately 5009/d. After forming into a rolled mesh with large flexible ears, surface-treated and heated at 250 to 300°C, a fine powdered polyvinyl chloride powder fluidized bed was formed. :Approximately 150 resin through the inside
F1/I was baked and painted and rolled up into a long length (1000 to 2000 m).

MMA with a thickness of 0.05mm is used on the surface of the above product for great weather resistance.
A film (methacrylic acid methyl ester resin) (Sandyuren manufactured by Kanebuchi Chemical Co., Ltd.) is arranged, and the back side is a glass fiber orthogonal nonwoven fabric with a polyethylene vinyl acetate hot melt adhesive (fiber amount 60g).
/ A) Thickness of polyvinyl chloride 211110
After stacking double-foamed sheets and heat-pressing them, they were passed through an internal water-cooled corrugation machine to obtain a corrugated building material covered with foamed PVC with excellent weather resistance and heat retention.

4 Example 2 A 0.5U1 galvanized iron plate was cut with a wire length longer than that in Example 1, and a lath net that was expanded 10 times was rolled to obtain a wire thickness of approximately 0.25111 tsubo weight. A rolled net of approximately 3509/I was placed on a 0.3U1 thick MMA plate and at the same time M
Fill the rolled net with the initial polymerization of MA, and make it 0.3 mm thick.
MRT for greenhouses with great translucency by sandwiching between A plates and hardening.
I got P.

Example 3 In the safety glass manufacturing process where a conventional PVA Petit Lar film is sandwiched between two glass plates, an aluminum rolled net with a wire thickness of 0.1 m1 and a basis weight of 1009/I and Petit Lar were used instead of the Petit Lar film. Using MRTP with a resin film, a safer aluminum wired safety glass was obtained.

MMA using steel rolled net or aluminum rolled net as reinforcement material
(7) If you make MRTP with a thickness of 0.2 to 0.3 and paste it on the inside of the glass window of a high-rise building, it will become an earthquake-resistant glass window, regardless of whether it is an existing or new building.

Furthermore, if only the rolled wire mesh is inserted between two glass plates, the wire cost is cheaper and defoaming is easier than when conventional wire mesh is inserted.

In addition, in the continuous forming process of gypsum board, galvanized with the basis weight of Example 1 or rolled net coated with antirust/adhesive resin was charged and solidified as a reinforcing material on either one or both sides of the surface paper layer surface. A gypsum board that is hard to crack can be obtained.

At this time, if the metal mesh is pre-coated with L-hemihydrate gypsum and another gypsum material is injected thereon, a stronger product can be obtained. If the rolled iron net of the present invention is used as a cement-based setting material and an orthogonal nonwoven fabric of alkali-resistant organic fibers is added as a reinforcing material, it can be used as an asbestos substitute.

The uses and processing methods of the proposed composite material will be described. Among the products of the present application, the MRTP has a metal mesh arranged in layers with substantially uniform density.

This makes it possible to quickly soften, press, and fuse the resin layer by dielectric heating of the metal when making a container, two pipes, etc. by laminating one layer or multiple layers of the MRTP plate of the present invention, which is extremely important in terms of processing. This is an advantageous feature. That is, when connecting the MRTP boards of the present invention, the resins are softened and fused by wrapping them by a certain width and pressing them under high frequency heating.

Even if it is not possible to weld between metals, the adhesive strength is sufficient as long as the resin is fused over a wide area. From rust-proof and corrosion-free large and medium-sized aquariums, liquid tanks, waste liquid tanks, toilet tanks, sake barrels, soy sauce barrels, pickle tanks, and fermentation tanks, to containers, fish boats, boats, and automobile parts with light specific gravity. Stamping is a widely used product.
It is made by molding the mouth and ring, and then welding the lap joint with high frequency heat. The tube can also be made by softening and crimping a tube with a diameter of 20 mm or more using high-frequency heating using a moving body pasting type or end tube type winding method on a core tube.

Sometimes 100 to 200 mm of the MRTP of this application is used for the purpose of anti-corrosion packaging of large diameter metal pipes or reinforcing PVC pipes.
Width products may also be wrapped in gaiters.

In such gaiter winding, a horizontally long diamond-shaped rolling net is used as the rolling net, and glass fiber parallel bodies or Japanese Patent No. 835956, which is an earlier invention of the present applicant, are used. Using a glue cloth made of glued filaments as reinforcing fibers, a lengthwise cut MRTP tape with a width of 100 to 200 mm is gaited at an angle of 45 degrees using the tension of glass fibers.

Even if the temperature rises too high during bonding, the rolled mesh and glass fibers have high heat resistance, so the resin parts can be easily softened and bonded or fused without thermal deterioration.

When extrusion laminating polyolefin onto MRTP or paper, you can laminate rolled nets and roll them into a paper tube to expose the paper surface to the outside. Printing will be done on the paper surface, and the other surface will be heat-sealable, thin, lightweight, and sturdy. MRTP paper tubes can be made.

This application is extremely wide. Furthermore, if the thick, medium, and thin ends of MRTP pipes are fitted together and the joint ends are bonded using high-frequency heating, it is possible to create a light pole that is resistant to salt damage, even for something like a light pole on a highway.

20-50m71L with the long diagonal direction of the diamond-shaped mesh of MRTP rolling mesh as the length direction and the circumferential direction wrapped and bonded.
The caliber pipes are lightweight and inexpensive, and can be cut into 2-3m lengths to support agricultural crops.

At this time, one end is squeezed under heat to make it easier to sink into the soil, bamboo comb-shaped resin protrusions are attached here and there in the middle, and the top is crushed or capped as appropriate. As a packaging band that is still on the market, there is a PP band made only of polypropylene (PP) stretched in the longitudinal direction.

However, PP is made from an extruder in one unit. If the band is made of MRTP, a large number of MRTP bands can be lined up in parallel to form a stiff, heat-adhesive MRTP band at low cost. For example, when extrusion laminating low softening point PE (LDPE) to a thickness of 0.2 mm on one side of 80-1009/Trl kraft paper, the thickness is 0.15-0.2 mm and the basis weight is 500-7009/Trl. Vertically long diamond-shaped rolling nets of iron are stacked, and on the opposite side to the paper side, either glass thread, polyester thread, PE membrane stretched material, etc. are laminated in parallel, and the non-stretched length of PE is 0 between them. .1~0.2mm membranes are laminated,
After heat-pressing and embossing, cut vertically to the appropriate band width and wind each piece alternately into upper and lower parts.One side is paper and the other side is reinforced with fiber material with exposed PE resin film and rolled mesh. A large number of MRTP packaging bands can be simultaneously produced at low cost depending on the paper width.

PP instead of paper. A PE stretched material may also be used.

Further, stretched materials may be placed on the front and back surfaces.

If you use a rotating cutter when cutting into multiple pieces, the resin will soften and melt due to the heat generated at the cutting part, and the resin will spread over the metal cut edge, coating and protecting the metal edge to prevent rust and prevent bending. Stabilizing properties are provided by rolled netting, adhesive properties are provided by resin, and anti-slip properties are provided by embossing or paper surface.Packaging bands suitable for a wide range of uses in appropriate thickness and width are simultaneously produced in multiple strips and in parallel. sell.

In addition, a horizontally long diamond-shaped rolled net is pasted with thermoplastic resin on the length of the veneer veneer (in the direction in which the wood fibers are arranged), or the M of the rolled net is pasted with thermoplastic resin.
By pasting RTP, you can create a strong building material box material that is reinforced vertically with wood fibers and horizontally with rolled mesh.

This product can be stably attached to a phase n or other object by nailing the rolled mesh portion into a square shape. By attaching a vertically long diamond-shaped rolled mesh to the length of a plywood veneer using adhesive resin, the stiffness in the vertical direction is exceptionally strong.
A heavy packaging material that is flexible and unbreakable in the lateral direction is created.

In short, the rolled mesh used in this application is useful as a formable reinforcing material for all planar materials, and is inexpensive and has an extremely wide range of uses.

Claims (1)

[Claims] 1. Flattened 0.5 as the main reinforcement of the composite.
Consisting of a wire mesh wire with a rectangular cross section having a thickness of mm or less,
Furthermore, a metal-reinforced composite consisting of a wire mesh flat mesh having selvedges at both ends, a fiber material added thereto, and a thermosetting or thermosetting plastic covering these. 2. In the method of making a flat metal net by making cuts in a thin metal plate and rolling it, (a) After making cuts in a running thin metal plate that will become a net shape when widened, A net-like body whose width is widened in the right angle direction so that the mesh wires with a rectangular cross section stand up diagonally and have an apparent thickness greater than the thickness of the thin metal plate. (b) Vertical cutting at both ends of the net-like body or at both ends and the middle Place the selvedge material on the planned part and pass the whole thing between rolling rollers. (a) Roll the entire net-like body to a thickness of 0.5 mm or less. (b) Flatten the wires that make up the net-like body to increase its surface area. (c) The net-like body The flexibility of the mesh is increased.In the case where the selvage material is placed in the middle of the mesh, the middle of the selvage material is cut to form multiple meshes, which makes it easy to roll back and is dimensionally stable in the length direction. The rolling net, which is continuously unwound from a long roll of continuously wound metal rolling net, is coated with an organic matrix or laminated with paper, film, fiber material, etc. A continuous manufacturing method for metal-reinforced composites in which the metal-reinforced composites are shaped, cut to a fixed length, and then collected.