KR102183249B1 - Fiber Reinforcement Using Yarn Coating And Its Manufacturing Method - Google Patents

Abstract

The present invention relates to a fiber reinforcing material using a yarn coating, which comprises: a matrix reinforcing material made of a thermoplastic polymer; and a fiber assembly which is positioned in the matrix reinforcing material and in which a plurality of fibers are arranged in parallel with the matrix reinforcing material. A mono-yarn which is a composition of the fiber assembly is cooled and wound after coated by polypropylene or polyethylene resin having a melting index (MI) of 1 to 35 at a moment when the mono-yarn falls out of a nozzle hole. The matrix reinforcing material has a hollow at a central portion of a cross-section in a longitudinal direction.

Description

Fiber Reinforcement Using Yarn Coating And Its Manufacturing Method {Fiber Reinforcement Using Yarn Coating And Its Manufacturing Method}

The present invention relates to a fiber reinforcement material using yarn coating and a method for manufacturing the same, and more particularly, to a fiber reinforcement material using yarn coating that can improve the stability of the embankment layer by being buried in the soil during the process of forming a retaining wall, and a manufacturing method thereof. will be.

The reinforced soil retaining wall forms a reinforced soil structure with improved shear strength by the tensile resistance of the reinforcement installed inside the embankment and the binding force with the surrounding soil, thereby acting as a soil barrier structure that resists back soil pressure.

Reinforced soil retaining wall is generally composed of backfill and front wall reinforced with reinforcement. Concrete panels, mortar blocks, geotextiles, etc. may be used as the front wall, and strip-shaped, grid-shaped, front-laying or sheet-shaped reinforcements made of metal or geotextile may be used as the reinforcing material.

Fiber reinforcement is used for reinforcing retaining walls, reinforcing slopes, and reinforcing ground in civil works, and due to its characteristics, properties such as high tensile strength, low tensile strain and creep deformation properties, as well as construction resistance and friction properties, are required. In addition, since it is used as a reinforcing material for civil engineering structures, it is necessary to facilitate handling such as transport or installation at a civil engineering site. That is, there is a demand for a fiber reinforcement material that is lightweight and convenient to construct without significantly deteriorating mechanical properties.

Typically, a foaming method is used to lighten the plastic product. However, the plastic foam has a large pore size of 100 μm or more, and the distribution of the size is also non-uniform, resulting in poor mechanical properties and morphological stability. In addition, since the plastic foam is usually manufactured in a batch-type method in which a mixture of a polymer melt and a gas is put into a mold (see EP 432997, US 2005/0256215, US 2007/0202326), there is a problem of lowering productivity.

In addition, conventional reinforcing fibers mainly use a high-density fiber aggregate to maintain high strength, and thus a problem of reducing product weight and not being easy to handle may occur.

An object of the present invention is to solve the above problems, to provide a fiber reinforcement material that is not only light and economical, but also minimizes the decrease in mechanical properties due to introduction of the foam by controlling the amount and size of the micropore size of the foam.

In addition, the present invention is to provide a fiber reinforcement material having low density and weight and maintaining mechanical properties by yarn coating the constituent fibers of the fiber aggregate inside the matrix reinforcement material.

In addition, the present invention is to provide a fiber reinforcement material excellent in workability and physical properties by forming hollows and perforations in the matrix reinforcing material.

In addition, the present invention is to provide a method and apparatus for manufacturing a fiber reinforcement material having the above-described properties continuously.

In order to achieve the above object, the present invention is a fiber reinforcement material composed of a matrix reinforcement material made of a thermoplastic polymer and a fiber assembly in which a plurality of fibers are arranged in parallel with the matrix reinforcement material, and the configuration of the fiber assembly The moment the phosphorus mono-yarn exits the nozzle hole, it is coated with polypropylene or polyethylene resin having a melt index (MI) of 1 to 35 and then cooled, and the matrix reinforcement is characterized in that a hollow is formed in the center of the cross section in the longitudinal direction. It provides a fiber reinforcement using the yarn coating.

In addition, the matrix reinforcement of the present invention is a foam comprising a plurality of micropores having an average particle diameter of 0.1 to 60 μm, and the porosity is 10 to 70%, and the total cross-sectional area of the fiber aggregate is 10 to the total cross-sectional area of the fiber reinforcement. It provides a fiber reinforcement material using a yarn coating, characterized in that 80%.

In addition, the thermoplastic polymer of the present invention is a polyolefin resin having a melt index (MI) of 1 to 35, polyethylene terephthalate having an intrinsic viscosity (IV) of 0.64 to 1.0, polyamides, and polyacrylates ( polyacrylates), polyacrylonitrile, polycarbonates, polyvinylechloride, polystyrene and polybutadiene selected from the group consisting of, or a mixture of two or more of them It provides a fiber reinforcement material using a yarn coating as characterized.

In addition, the fiber aggregate of the present invention is any fiber selected from the group consisting of polyester fiber, glass fiber, aramid fiber, polyvinyl alcohol fiber, carbon fiber, basalt fiber, stainless steel fiber, copper fiber, and amorphous metal fiber, or 2 of them. It provides a fiber reinforcement material using a yarn coating, characterized in that consisting of a plied fiber of more than three kinds of fibers are plied.

In addition, the present invention (a) a step of winding the coated fiber by cooling after coating with polypropylene or polyethylene resin having a melt index (MI) of 1 to 35 as soon as the yarn exits the nozzle hole; (b) preparing a fiber aggregate by arranging a mixture of a gas and a polymer melt and a plurality of the coated fibers in parallel; (c) supplying the fiber assembly to the first inlet of the crosshead, and injecting the mixture of the gas and the polymer melt through the second inlet of the crosshead formed around the first inlet, and comprising a hollow forming part Adhering to each other while moving the fiber aggregate and the mixture of gas and polymer melt through a moving path and discharging them to an outlet of the cross head; And (d) it provides a fiber reinforcement manufacturing method using the yarn coating comprising the step of cooling the result of step (c).

In addition, the present invention provides a method for manufacturing a fiber reinforcement material using yarn coating further comprising the step of forming a perforation in the result of step (d).

In addition, the present invention provides a method for manufacturing a fiber reinforcement material using yarn coating, characterized in that the size of the outlet of the crosshead is smaller than the size of the moving path.

The fiber reinforcement according to the present invention has a hollow formed in the center of the cross section and has a matrix reinforcement made of a foam, so it is not only light and economical, but also reduces the phenomenon of mechanical properties due to introduction of the foam by controlling the amount and size of the micropore size of the foam. As it can be minimized, it can be usefully used as a reinforcing material.

In addition, the fiber reinforcement according to the present invention is composed of an aggregate of yarn-coated short fibers, and the weight of the reinforcing material is reduced and mechanical properties are maintained by a low-density coating material.

In addition, according to the method of manufacturing a fiber reinforcement material of the present invention, it is possible to continuously produce a fiber reinforcement material that is light and excellent in mechanical properties.

In addition, the fiber reinforcement material of the present invention can be easily folded by a hollow, so that the construction is convenient, and by a hollow and perforated, the tensile strength is high, and the construction resistance and friction characteristics are excellent.

1 is a partially enlarged perspective view schematically showing a fiber reinforcement of the present invention.
Figure 2 is a manufacturing process diagram of a fiber reinforcement according to an embodiment of the present invention.
3 is a schematic cross-sectional view of an assembly provided in the apparatus for manufacturing a fiber reinforcement material of the present invention.
4 is a view showing a nipple constituting the assembly provided in the fiber reinforcement manufacturing apparatus of the present invention.
5 is a view schematically showing the configuration of a yarn-coated mono yarn according to an embodiment of the present invention.

Hereinafter, a preferred embodiment of the present invention will be described in detail. In describing the present invention, detailed descriptions of related known functions or configurations are omitted so as not to obscure the subject matter of the present invention.

The terms "about", "substantially", etc. of the degree used in the present specification are used at or close to the numerical value when manufacturing and material tolerances specific to the stated meaning are presented, and To assist, accurate or absolute figures are used to prevent unfair use of the stated disclosure by unscrupulous infringers.

Referring to FIG. 1, the fiber reinforcement 1 according to the present invention may include a matrix reinforcement 2 made of a thermoplastic polymer and a fiber assembly 3 located inside the matrix reinforcement.

5 is a view of the configuration of the yarn coated mono yarn of the present invention. The fiber assembly 3 is composed of a plurality of mono yarns, and the mono yarn is coated with polypropylene or polyethylene resin having a melt index (MI) of 1 to 35 at the moment it exits the nozzle hole during spinning, and then cooled and wound.

The fiber assembly 3 is formed by arranging a plurality of fibers in parallel with the matrix reinforcing material, and the matrix reinforcing material 2 is formed of a foam, and may form a hollow in the longitudinal direction.

It is preferable that the foam is formed to include a plurality of fine pores having an average particle diameter of 0.1 to 60 µm, while controlling the porosity to 10 to 70%.

If the average particle diameter of the micropores included in the matrix reinforcing material foam is less than 0.1 µm, it is difficult to form micro-voids, and if the porosity is less than 10%, the specific gravity of the matrix reinforcing material increases, making it difficult to reduce the weight of the reinforcing material, making it difficult to have the characteristics as a foam. have. In addition, when the average particle diameter exceeds 60 µm and porosity of 70%, the mechanical properties of the reinforcing material are degraded due to excessive pores, so that it is difficult to prevent damage by the aggregate of the reinforcing fibers during installation, and thus it may be difficult to use for reinforcing purposes.

The total cross-sectional area of the fiber assembly 3 is 10 to 80% of the total cross-sectional area of the fiber reinforcement material, and it is light and economical, and it is possible to minimize the phenomenon of deterioration of mechanical properties due to the introduction of the foam.

If the total cross-sectional area of the fiber aggregate is less than 10% of the total cross-sectional area of the fiber reinforcement, the reinforcing effect by the fiber aggregate is insignificant, and when the cross-sectional area exceeds 80%, the thickness of the matrix reinforcement becomes too thin, and the aggregate during laying It can be easily damaged by.

In addition, as the thermoplastic polymer constituting the matrix reinforcing material, any polymer matrix resin used for manufacturing the fiber reinforcement material can be used.For example, a polyolefin-based resin having a melt index (MI) of 1 to 35, and an intrinsic viscosity (IV) of 0.64 To 1.0 of polyethylene terephthalate, polyamides, polyacrylates, polyacrylonitrile, polycarbonates, polyvinylechloride, polystyrene, Polybutadiene and the like may be used alone or in combination of two or more of them.

In addition, the fiber aggregate can also be used as long as it is an aggregate of fibers used for manufacturing fiber reinforcement, for example, polyester fiber, glass fiber, aramid fiber, polyvinyl alcohol fiber, carbon fiber, basalt fiber, stainless steel fiber, copper fiber, Amorphous metal fibers and the like may be used alone or in combination of two or more fibers.

Such fiber reinforcement may be manufactured in a shape having a thickness of a square cross section, preferably 50 to 120 mm in width (more preferably 70 to 100 mm), and 1 to 5 mm in thickness (more preferably 1.5 to 3.5 mm). mm) is preferably manufactured to have a rectangular cross section.

In addition, in the present invention, a hollow in the longitudinal direction may be formed in the center of the matrix reinforcement. The hollow may be arbitrarily selected and formed by a practitioner in a central portion of the cross section, a uniformly divided portion, or a non-uniformly divided portion. 1 shows that in an embodiment of the present invention, a hollow is formed in the longitudinal direction in the central portion of the cross section. By forming a hollow in the matrix reinforcing material, it is not only light and economical, but also overall flexibility is high, so construction can be convenient.

In addition, in the present invention, a perforation is formed in the fiber reinforcement, and the upper and lower portions of the fiber reinforcement are integrated with the soil through the perforation, so that the frictional force between the fiber reinforcement and the soil can be improved, thereby having excellent tensile strength. have.

A method of manufacturing the fiber reinforcement of the present invention will be described with reference to FIG. 2.

First, the moment the yarn exits the nozzle hole, it is coated with polypropylene or polyethylene resin having a melt index (MI) of 1 to 35, and then cooled to wind the coated fiber.

At this time, the yarn is any fiber selected from the group consisting of polyester fiber, glass fiber, aramid fiber, polyvinyl alcohol fiber, carbon fiber, basalt fiber, stainless steel fiber, copper fiber, and amorphous metal fiber.

Thereafter, a fiber aggregate in which a plurality of fibers are arranged in parallel, and a mixture of a gas and a polymer melt are prepared, respectively.

For a mixture of gas and polymer melt (hereinafter referred to as a gas/polymer mixture), gas is injected when the polymer resin is melted and kneaded in the extruder 6, or a foaming agent that generates gas by thermal decomposition with the polymer resin is added. Thus, a mixture of a homogeneous gas and a polymer melt is prepared in the extruder 6. In the case of direct gas injection, it is preferable to use a supercritical fluid such as carbon dioxide (CO ₂ ) or nitrogen (N ₂ ). When a foaming agent is added such as a polymer resin, a foaming agent is separately added or the foaming agent is a polymer resin. It can be added in the form of pellets mixed with.

Next, the gas/polymer mixture in the extruder 6 is transferred to the crosshead 13 on which the fiber assembly 3 is mounted using a gear pump, so that the gas/polymer compound and the fiber assembly 3 After allowing it to adhere, the fiber aggregate 3 to which the gas/polymer compound is attached is discharged out of the cross head 13. At this time, a fiber reinforcement material 1 having a micro-foaming structure formed by expanding the gas melted in the polymer resin due to a pressure difference between the pressure in the crosshead 13 and the atmospheric pressure and a hollow formed by the hollow forming portion is manufactured.

Next, the continuously extruded micro-foamed fiber reinforcement material 1 passes through the cooling water tank 16 to prevent the pores formed in the polymer resin from collapsing or from escaping out of the polymer resin. If the foamed matrix reinforcing material is not cooled as described above, a foam having a desired porosity cannot be obtained, and a foam having small and uniform pores cannot be obtained.

Next, the cooled fiber reinforcement material 1 having a microfoamed structure is drilled in the longitudinal direction at the perforated portion 17 and at regular intervals, and then wound on the bobbin at a speed of 2 to 20 m/min.

The perforated portion 17 is for perforating a perforation 4 in the central end portion 5 of the cross-section 5 of the fiber reinforcement material having a hollow of FIG. 1 as an embodiment, and is capable of holding the continuously moving fiber reinforcing material 1 It consists of a government and a drilling device. The cloth mill may use a conventional press device, and it may be more preferable to use an ultrasonic welding machine. By using the ultrasonic fusing machine, frictional heat that collides up and down the central portion of the hollow fiber reinforcement is generated to create a molten state, and then a perforation can be formed by pressing with a roller carved in an intaglio.

The present invention will be described in more detail with reference to the manufacturing apparatus and process diagram of the fiber reinforcement of the present invention. As shown in Fig. 2, a gas injection device 8 consisting of an extruder 6 for melt-extruding a polymer resin, a high-pressure metering pump 10 for quantitatively injecting the gas supplied from the gas tank 9, and a fiber assembly ( 3) A fiber feeding device 12 that supplies the krill 11 on which it is mounted, the fiber assembly 3 to the crosshead 13 of the extruder at a constant speed, and the molten polymer resin and the fiber assembly 3 meet A crosshead 13 for forming the reinforcing material 1, a knurling device 15 for imparting unevenness to the fiber reinforcement from the crosshead 13, a cooling device 16 for cooling the uneven fiber reinforcement, It consists of a perforation part 17 for imparting perforation to the cooled fiber reinforcement, a winding device 18 for pulling the perforated fiber reinforcement at a constant speed, and a winder 19 for winding to a certain length.

The configuration of the reinforcing material manufacturing process will be described in detail as follows.

Referring to the process diagram of FIG. 2, first, the fiber assembly 3 passes through the fiber supply device 12.

At this time, the yarn constituting the fiber assembly 3 is coated with polypropylene or polyethylene resin having a melt index (MI) of 1 to 35 as soon as it exits the nozzle hole, and then cooled to wind the coated fiber. A plurality of wound yarns are arranged in parallel to prepare a fiber aggregate.

The fiber supply device 12 adjusts the speed at which the fiber assembly 3 flows into the crosshead 13, and the winding device 18 adjusts the speed of pulling the fiber reinforcement 1 Make sure the tension is maintained. The fiber assembly 3 that has passed through the fiber supply device 12 passes through the crosshead 13.

In the process diagram of FIG. 2, a polymer resin in the form of pellets is introduced into the extruder 6 through the hopper 7. The polymer resin in the form of pellets forming the matrix reinforcing material 2 releases gas upon decomposition to form a gas/polymer mixture in the extruder. In addition, the gas injection device 8 may be used to directly feed the foamed gas into the barrel of the extruder 6 using the high-pressure metering pump 10.

The gas/polymer mixture is conveyed to the crosshead 13 where the fiber assembly is located. The fiber assembly and the gas/polymer mixture are attached to each other in an assembly 20 as shown in FIG. 3 in the crosshead 13. The assembly 20 is composed of a nipple 21, a bushing 22, and a die 23. The nipple 21 is formed with a first inlet 24 through which the fiber aggregate 3 is introduced and a second inlet 25 through which the gas/polymer mixture is introduced. The second inlet 25 is preferably formed around the first inlet 24, since this is advantageous in completely covering the fiber assembly 3 with a gas/polymer mixture.

The first inlet 24 of the nipple 21 is positioned so that the fiber assembly 3 in the fiber reinforcement 1 is located in the center of the fiber reinforcement 1, and in the moving path 22a of the bushing 22 The fiber aggregate (3) and the gas/polymer compound are attached. The die 23 is designed so that the combined fiber aggregate 3 and the gas/polymer resin mixture are subjected to high pressure, and the shape of the reinforcing material 1 may be determined according to the shape of the moving path 23a of the die. According to an embodiment of the present invention, the hollow forming part 26 may be positioned from the nipple through the bushing moving path 22a to the die moving path 23a to form a hollow in the center of the cross section of the reinforcing material. By changing the shape of the hollow forming part, the shape, size, or position of the hollow can be adjusted.

The fiber reinforcement material 1 exiting the crosshead 13 passes through a cooling water bath 16 capable of temperature control so that the gas in the matrix reinforcement material is not released to the outside. The thus-cooled fiber reinforcement material 1 is constantly perforated in the longitudinal direction in the perforated portion 17 and then wound to a predetermined length by a winder 19 through a winding device 18.

As described above, the fiber reinforcement material (1) having a micro-foamed structure and a hollow fabric manufactured by the method of the present invention does not significantly decrease the mechanical strength compared to the non-foamed fiber reinforcement material, and has uniform micropores, so its light weight and impact-reducing properties This is excellent and it is possible to reduce the cost of raw materials per unit volume.

In the present invention, the porosity is calculated by the following formula.

Porosity (%) = (ρN-ρF)/ ρN Ｘ 100

In the above formula, ρN is the density of the non-foaming material, and ρF is the density of the foamed material.

Hereinafter, the present invention will be described in more detail through Examples and Comparative Examples.

The method of measuring physical properties of the examples is as follows.

◈ Density: ASTM D 792

After cutting the fiber reinforcement material (1) into a certain length and removing the fibers, the density (d) is calculated by measuring the mass (m) and volume (V).

d = m/V

◈ Size of void

After breaking the fiber reinforcement (1), the cross section is measured using an electron microscope (SEM).

◈ Tensile strength and elongation: ASTM D 6637

Tensile stress according to tensile deformation is measured by stretching the distance between the clamps attached to the top and bottom of the strain control type tensile tester at a rate of 10±3%/min.

Example One

Dividing polyester high-strength yarn with a fineness of 600,000 denier into 8 bundles, passing through an 8-hole circular cross-section nipple (21), bushing (22), and square die (23), and a high-density polyethylene resin and a foaming agent of 1.2 wt%. Put into the extruder (6) preheated to 230℃, melt and knead, move the gas/polymer mixture to the crosshead (13), extrude the fiber aggregate and the gas/polymer mixture, and pass through the cooling water bath (16) at 20℃ , After cooling, it was punched at regular intervals in the perforated part and wound at 5 m/min to prepare a fiber reinforcement material 1 having a micro-foamed structure having a width of 70 mm and a thickness of 2.5 mm and a hollow.

At this time, the polyester high-strength yarn having a fineness of 600,000 denier was prepared by yarn coating treatment with polypropene (PP) as a mono yarn of a fiber aggregate. The fineness of the mono yarn before yarn coating is 540,000 denier.

Example 2

In the same manner as in Example 1, except that the yarn-coated resin was replaced with polyethylene (PE) instead of polypropylene, a fiber reinforcement material 1 having a micro-foamed structure and hollow was prepared.

Comparative example One

Fiber reinforcement was prepared in the same manner as in Example 1 using only polyester high tenacity yarn having a fineness of 600,000 denier without yarn coating of polyester high tenacity yarn.

The physical properties of the fiber reinforcement material (1) prepared in Examples and Comparative Examples are shown in Table 1 below.

unit
weight
(g/m) Size(mm) Average
air gap
size
(um) Porosity
(%) strong
(kN) Shinto
(%) LASE5%
(kN) curve
burglar
(kgf) width thickness Example 1 193 70 2.5 38 50.0 53 11.9 33 0.84 Example 2 192 70 2.5 42 51.4 52 11.4 32 0.86 Comparative Example 1 201 70 2.5 43 32.9 52 11.8 27 0.96

As shown in Table 1, the fiber reinforcement material (1) having a micro-foamed structure manufactured according to an embodiment of the present invention has an average pore size of 40 μm to 42 μm, which is not significantly different from the comparative example, but low density Yarn-coated with PP and PE resins, and the unit weight is low compared to Comparative Example 1, which has the same denier of the mono yarn of the fiber aggregate, and has lighter weight, and less high-strength yarn was used compared to the comparative example, but mechanical properties It can be seen that the phosphorus strength, flexural strength, and LASE 5% are not significantly different from those using yarns having the same fineness without yarn coating.

Therefore, it can be seen that the fiber reinforcement using the yarn coated with the low-density resin is lighter and more flexible. This can provide convenience to users when constructing a fiber reinforcement.

1: fiber reinforcement 2: matrix reinforcement
3: fiber assembly 4: perforation
5: central part 6: extruder
7: hopper 8: gas injection device
9: gas tank 10: high pressure metering pump
11: krill 12: fiber supply device
13: crosshead 14: mac
15: Knurling device 16: cooling water tank
17: perforation 18: winding device
19: winder 20: assembly
21: nipple 22: bushing
23: die 24: first inlet
25: second inlet 26: hollow forming part
100: yarn coated mono yarn 101: mono yarn
102: coating material

Claims (7)

delete delete delete delete (a) coating the mono-yarn with polypropylene or polyethylene resin having a melt index (MI) of 1 to 35 at the moment it exits the nozzle hole, and then cooling the yarn-coated fiber to wind up;
(b) preparing a fiber aggregate by arranging a mixture of a gas and a polymer melt and a plurality of the yarn-coated fibers in parallel so as to be in contact with each other;
(c) supplying the fiber assembly to the first inlet of the crosshead, and injecting the mixture of the gas and the polymer melt through the second inlet of the crosshead formed around the first inlet, and comprising a hollow forming part Adhering to each other while moving the fiber aggregate and the mixture of gas and polymer melt through a moving path and discharging them to an outlet of the cross head; And
(d) cooling the resultant of step (c),
Further comprising the step of forming a perforation in the result of step (d),
The size of the outlet of the crosshead is smaller than the size of the moving path, characterized by a unit weight of 192 to 193 g/m, strength of 52 to 53 kN, and an elongation of 11.4 to 11.9%. delete delete

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