TW202419270A - Sheet for structure - Google Patents

Abstract

The sheet material 2 for structure has a functional layer 4, an intermediate layer 6, an adhesive layer 8 and a reinforcement body 10. The material of the functional layer 4 is a polymer composition. The polymer composition contains a first substrate polymer and a second substrate polymer. The first substrate polymer has a first glass transition point T1. The second substrate polymer has a second glass transition point T2. The second glass transition point T2 is lower than the first glass transition point T1. The preferred first glass transition point T1 is above 25°C. The preferred second glass transition point T2 is below -10°C.

Description

Sheet for structure

This specification discloses a sheet material for use by being attached to a structure.

When artificial slate roofs are exposed to wind and rain for a long time, they will deteriorate. There is a concern that the deteriorated roof will leak. In order to prevent leaks, paint is applied on the artificial slate. However, in the case of severe deterioration of the artificial slate on the roof, sometimes even applying paint cannot prevent leaks.

International Patent Publication No. 2021/010456 discloses a structural protection sheet having a polymer cement layer and a resin layer. By attaching the sheet to the roof, it is possible to suppress roof leakage. [Prior Technical Literature] [Patent Literature]

[Patent Document 1] International Patent Publication No. 2021/010456

[The problem that the invention wants to solve]

Structural protection sheets require excellent weather resistance (heat resistance). Structural protection sheets also require the ability to follow the roof. It is expected that the sheet can have both weather resistance and followability.

In the repair of roofs other than artificial slate roofs, the sheet material is also required to have both weather resistance and followability. In the repair or reinforcement of structures other than roofs, the sheet material is also required to have both weather resistance and followability.

The applicant intends to provide a sheet material for structures with excellent weather resistance and tracking properties. [Technical means to solve the problem]

The sheet material for structures disclosed in this specification has an adhesive layer and a functional layer, and the material of the functional layer is a polymer composition. The polymer composition contains a first substrate polymer and a second substrate polymer. The first substrate polymer has a first glass transition point T1. The second substrate polymer has a second glass transition point T2. The second glass transition point T2 is lower than the first glass transition point T1. [Effect of the invention]

In the structural sheet, a resin with a higher glass transition point contributes to weather resistance. In the sheet, a resin with a lower glass transition point contributes to followability. The structural sheet has excellent weather resistance and followability.

The preferred implementation is described in detail below with reference to the drawings as appropriate.

[First embodiment] [Layer structure] Figures 1 to 3 show a sheet 2 for a structure. In Figure 1, arrow X indicates the width direction of the sheet 2, arrow Y indicates the length direction of the sheet 2, and arrow Z indicates the thickness direction of the sheet 2. The planar shape of the sheet 2 is roughly rectangular. According to Figure 3, the sheet 2 has a functional layer 4, an intermediate layer 6, an adhesive layer 8, and a reinforcing body 10. The reinforcing body 10 is buried in the intermediate layer 6. The materials of each layer will be described in detail below. The sheet 2 is attached to the structure. The sheet 2 may also have a release paper or a release film. The release paper and the release film are laminated with the adhesive layer 8.

[Roof repair] The typical use of the sheet material 2 for the structure is the repair of the roof. Figures 4 to 6 show the roof 12 after repair. In these figures, two sheets 2 (a first sheet material 2a and a second sheet material 2b) are shown together with the roof 12. The specification of the second sheet material 2b is the same as that of the first sheet material 2a. As the roof 12, there can be listed: artificial slate roof, tile roof, steel plate roof (including folded plate roof), copper plate roof, galvanized iron plate roof, and concrete roof, etc.

In Fig. 4, the position of the lower edge 14a of the first sheet 2a is substantially consistent with the position of the lower end 16 of the roof 12. The first sheet 2a is attached to the roof 12 in an integral form. As shown in Fig. 5, the roof 12 has a step 18. The first sheet 2a is bent near the step 18. The first sheet 2a follows the step 18 by the bend.

As shown in FIG6 , the second sheet 2b overlaps the upper edge 20a of the first sheet 2a near its lower edge 14b. The overlap forms a seam 22. The portion of the second sheet 2b other than the seam 22 is attached to the roof 12. The upper edge 20a of the first sheet 2a forms a step 24 between the first sheet 2a and the roof 12. The second sheet 2b is bent near the step 24. The second sheet 2b follows the step 24 by the bend.

[Base coating] The sheet material 2 for structures is usually attached to the roof 12 via a base coating. In this specification, including the case where the sheet material 2 is attached to the roof 12 via a base coating, etc., it is referred to as "the sheet material is attached to the roof". The base coating is omitted in Figures 5 and 6.

The material of the base coating is preferably a curable resin composition. Examples of the curable resin include thermosetting resins and light curing resins. Preferred curable resins are epoxy compounds. Examples of the epoxy compounds include bisphenol A type epoxy resins, bisphenol F type epoxy resins, bisphenol S type epoxy resins, o-cresol novolac type epoxy resins, aliphatic epoxy resins, phenolic diglycidyl etherates, and alcoholic diglycidyl etherates. Examples of the curing agent for epoxy compounds include polyfunctional phenols, amines, polyamines, thiols, imidazoles, acid anhydrides, and phosphorus-containing compounds.

[Young's modulus of sheet material] The Young's modulus of the sheet material 2 for the structure is preferably 20 MPa or more and 300 MPa or less. When tension is applied to the sheet material 2 having a Young's modulus of 20 MPa or more, permanent deformation and fracture are less likely to occur. The sheet material 2 has excellent operability. From this point of view, the Young's modulus is more preferably 30 MPa or more, and more preferably 40 MPa or more. The sheet material 2 having a Young's modulus of 300 MPa or less has excellent tracking performance. From this point of view, the Young's modulus is preferably 280 MPa or less, and more preferably 260 MPa or less. The Young's modulus is measured in accordance with the provisions of "JIS K 7161". An example of a device suitable for measurement is the "Precision Universal Testing Machine AGXTM-V" manufactured by Shimadzu Corporation.

[Water vapor permeability] The water vapor permeability of the sheet 2 for structure is preferably 10 g/m ² ·day or more. After the sheet 2 is attached to the structure, the moisture contained in the structure or the moisture existing between the structure and the sheet 2 can be discharged through the sheet 2. The sheet 2 can inhibit the corrosion of the metal in the structure. The sheet 2 is also suitable for structures containing moisture (for example, structures with insufficiently dried concrete). The sheet 2 is also suitable for construction on rainy days. From these viewpoints, the water vapor permeability is more preferably 20 g/m ² ·day or more, and particularly preferably 25 g/m ² ·day or more. The water vapor permeability is preferably 50 g/m ² ·day or less. The water vapor permeability is measured in accordance with the provisions of "JIS Z0208".

[Functional layer] According to FIG. 3 , in this embodiment, the functional layer 4 is located at the top. In other words, when the sheet 2 is attached to the structure, the functional layer 4 is located at the position farthest from the structure in the thickness direction Z (see FIG. 1 ). The functional layer 4 contributes to the functions required by the sheet 2. Examples of such functions include weather resistance, abrasion resistance, chemical resistance, water impermeability, moisture impermeability, and moisture permeability. Typical weather resistance is heat resistance and light resistance. The functional layer 4 may contribute to one or more functions.

The preferred material of the functional layer 4 is a polymer composition. The functional layer 4 is generally soft. The sheet 2 having the functional layer 4 can follow the unevenness of the substrate. The polymer composition includes a base polymer. Synthetic resin, synthetic rubber and natural rubber can be included in the composition as the base polymer. The functional layer 4 whose base polymer is a synthetic resin is also called a "resin layer".

When light resistance is required for the functional layer 4, a base polymer that is not easily degraded by ultraviolet rays is preferred. Specifically, a polymer having a stronger binding energy than ultraviolet rays (410 KJ/mol) is preferred. Examples of polymers that can contribute to the light resistance of the functional layer 4 and the flexibility of the sheet 2 include acrylic resins, acrylic urethane resins, acrylic polysilicone resins, fluororesins, soft epoxy resins, and polybutadiene.

From the viewpoint of light resistance, a resin particularly suitable for the base polymer of the functional layer 4 is an acrylic polysilicone resin. Acrylic polysilicone resin contains a siloxane bond. Acrylic polysilicone resin is also excellent in heat resistance and cold resistance. Specific examples of compositions containing acrylic polysilicone resin include: Dainichi Seika Co., Ltd.'s product name "Cool Life SP Black (CB1) P5-0", Fujikura Chemicals Co., Ltd.'s product name "Bell earth Elastic Black", Toagosei Co., Ltd.'s product name "ARONBULLCOAT T-1000", and Nippon Shokubai Co., Ltd.'s product names "Acryset EMN325E" and "UWR EF-008".

[Glass transition point of substrate polymer] In this embodiment, the polymer composition includes a first substrate polymer and a second substrate polymer. The glass transition point (Tg) of the second substrate polymer is different from the glass transition point (Tg) of the first substrate polymer. In this specification, the glass transition point of the first substrate polymer is referred to as the first glass transition point T1, and the glass transition point of the second substrate polymer is referred to as the second glass transition point T2. The second glass transition point T2 is lower than the first glass transition point T1.

According to the knowledge obtained by the present inventors, a polymer having a high glass transition point (Tg) contributes to the weather resistance of the structural sheet 2. The polymer particularly contributes to the heat resistance of the sheet 2. From this viewpoint, the first glass transition point T1 is preferably 25°C or higher, more preferably 27°C or higher, and even more preferably 29°C or higher.

According to the findings of the inventors, a polymer with a low glass transition point (Tg) helps the sheet 2 for structures to follow. The polymer is particularly helpful for the sheet 2 to follow when attached to a roof 12 in a cold environment. Even if the sheet 2 follows the step 18 shown in FIG. 5 , the sheet 2 is not likely to crack. Even if the sheet 2 follows the step 24 shown in FIG. 6 , the sheet 2 is not likely to crack. From the perspective of followability, the second glass transition point T2 is preferably below -10°C, more preferably below -13°C, and even more preferably below -15°C.

The structural sheet 2 has both the heat resistance of the first substrate polymer and the tracking property of the second substrate polymer. From the viewpoint of heat resistance and tracking property, the difference (T1-T2) between the first glass transition point T1 and the second glass transition point T2 is preferably 30°C or more, more preferably 35°C or more, and even more preferably 40°C or more.

The polymer composition may also contain other base polymers. The glass transition point (Tg) of the other base polymers is different from the first glass transition point T1 and the second glass transition point T2.

The glass transition point (Tg) is calculated based on the storage elastic modulus measured by a dynamic viscoelasticity measuring device. As an example of a device suitable for the measurement, the "DMAQ850 RHEOMETER DHR-2" of TA INSTRUMENTS can be cited. A specimen cut out from the functional layer 4 is used for the measurement. The measurement conditions are as follows. Specimen size: 40 mm × 5 mm Heating rate: 5℃/min Measurement range: from -20℃ to 100℃ Frequency: 1 Hz Deformation: -0.1%

[Polymer Combination] The second substrate polymer is preferably of the same type as the first substrate polymer. Examples of preferred combinations of the first substrate polymer and the second substrate polymer include: (1) a combination of an acrylic resin having a higher glass transition point and an acrylic resin having a lower glass transition point, (2) a combination of an acrylic amine resin having a higher glass transition point and an acrylic amine resin having a lower glass transition point, and (3) a combination of an acrylic polysilicone resin having a higher glass transition point and an acrylic polysilicone resin having a lower glass transition point.

The mass ratio of the first substrate polymer to the second substrate polymer of the polymer composition is preferably 30/70 or more and 80/20 or less. The sheet material 2 for structures having a mass ratio of 30/70 or more has excellent heat resistance. From this point of view, the mass ratio is more preferably 40/60 or more, and more preferably 45/55 or more. The sheet material 2 for structures having a mass ratio of 80/20 or less has excellent tracking performance. From this point of view, the mass ratio is more preferably 70/30 or less, and more preferably 65/35 or less.

[Glass transition point of polymer composition] The polymer composition includes a plurality of base polymers, so the polymer composition can have a plurality of glass transition points (Tg). In this specification, the highest glass transition point in the polymer composition is referred to as the upper glass transition point TU, and the lowest glass transition point in the polymer composition is referred to as the lower glass transition point TL. From the perspective of heat resistance, the upper glass transition point TU is preferably above 15°C, more preferably above 20°C, and particularly preferably above 25°C. The upper glass transition point TU is preferably below 30°C. From the perspective of tracking, the lower glass transition point TL is preferably below 0°C, more preferably below -5°C, and particularly preferably below -8°C. The lower glass transition point TL is preferably above -15°C.

From the viewpoint of heat resistance and tracking property of the functional layer 4, the difference (TU-TL) between the upper glass transition point TU and the lower glass transition point TL is preferably 20°C or more, more preferably 25°C or more, and particularly preferably 30°C or more. From the viewpoint of homogeneity of the functional layer 4, the difference (T1-T2) is preferably 50°C or less.

[Characteristics of functional layer] The elongation at break of the functional layer 4 at a temperature of 5°C is preferably 10% or more and 175% or less. The sheet material 2 for structures having an elongation at break of the functional layer 4 of 10% or more has excellent tracking properties. From this point of view, the elongation at break is more preferably 30% or more, and more preferably 50% or more. The sheet material 2 for structures having an elongation at break of the functional layer 4 of 175% or less has excellent durability. From this point of view, the elongation at break is more preferably 155% or less, and more preferably 140% or less.

The elongation at break of the functional layer 4 in an environment of a temperature of 80° C. is preferably 250% or more. The elongation at break at this temperature is related to the heat resistance of the structural sheet 2. From the viewpoint of heat resistance, the elongation at break is more preferably 300% or more, and particularly preferably 350% or more.

The elongation at break is measured in accordance with the provisions of "JIS K 7161". As an example of a suitable device for the measurement, the "Precision Universal Testing Machine AGXTM-V" manufactured by Shimadzu Corporation can be exemplified. A constant temperature device is used in the test. As an example of a constant temperature device suitable for the test, the "Constant Temperature and Humidity Tester THC1" manufactured by Shimadzu Corporation can be exemplified. The measurement conditions are as follows. Specimen shape: flat plate Specimen size: 15 mm × 100 mm Distance between chucks: 20 mm Tensile speed: 200 mm/min

When the functional layer 4 is required to be water-impermeable and moisture-permeable, the water vapor permeability of the functional layer 4 is preferably not less than 10 g/m ² ·day and not more than 50 g/m ² ·day. The water vapor permeability is measured in accordance with the provisions of "JIS Z0208".

The polymer composition of the functional layer 4 may contain additives such as pigments, fillers, reinforcing materials, and antifouling agents as needed. The functional layer 4 containing pigments is excellent in design. The polymer composition may contain organic pigments and inorganic pigments. As fillers, metal oxide particles such as silicon dioxide, aluminum oxide, and titanium dioxide may be exemplified. As reinforcing materials, cellulose nanofibers may be exemplified. The content of each additive may be adjusted depending on the function.

In FIG. 3 , arrow t1 indicates the thickness of the functional layer 4. From the viewpoint of function, the thickness t1 is preferably 10 μm or more, more preferably 30 μm or more, and particularly preferably 50 μm or more. From the viewpoint of the followability, productivity, and lightness of the sheet 2, the thickness t1 is preferably 500 μm or less, more preferably 300 μm or less, and particularly preferably 150 μm or less. The distribution of the thickness t1 is preferably within the range of ±50 μm. The sheet 2 for structure may also have two or more functional layers 4.

[Intermediate layer] The intermediate layer 6 contributes to the rigidity of the sheet 2, etc. The preferred material of the intermediate layer 6 is a composite material of a polymer and a filler. Examples of the polymer of the composite material include: acrylic resin, acrylic polysilicone resin, fluororesin, polysilicone resin, epoxy resin, ethylene-vinyl acetate copolymer and styrene-butadiene copolymer. Examples of the filler of the composite material include: cement, silica, alumina, titanium oxide, calcium carbonate and carbon black. The preferred composite material is polymer cement. The polymer cement contains a polymer and cement. A typical polymer is acrylic resin. As cement, Portland cement and alumina cement and mixtures thereof can be exemplified. Portland cement is preferred. The intermediate layer 6 made of polymer cement is also called a "polymer cement hardening layer".

When the intermediate layer 6 contains a polymer and cement, the mass ratio of the polymer in the solid content of the intermediate layer 6 is preferably 10% or more and 40% or less. When the ratio is 10% or more, the intermediate layer 6 has excellent adhesion to other layers (functional layer 4 or adhesive layer 8). From this point of view, the ratio is more preferably 15% or more, and more preferably 20% or more. When the ratio is 40% or less, the intermediate layer 6 can contain a sufficient amount of cement. From this point of view, the ratio is more preferably 35% or less, and more preferably 30% or less.

When the middle layer 6 contains polymer and cement, the mass ratio of cement in the solid content of the middle layer 6 is preferably 20% or more and 70% or less. The sheet 2 having the middle layer 6 with the ratio of 20% or more can achieve a larger tensile strength and a smaller elongation. The sheet 2 has excellent operability. From this point of view, the ratio is more preferably 30% or more, and more preferably 35% or more. The middle layer 6 with the ratio of 70% or less can contain a sufficient amount of polymer. From this point of view, the ratio is more preferably 60% or less, and more preferably 55% or less.

The water vapor permeability of the intermediate layer 6 including polymer and cement is excellent. Even if the structure is covered with the sheet 2 having the intermediate layer 6, the metal in the structure is not easily corroded. The water vapor permeability of the intermediate layer 6 is preferably 20 g/m ² ·day or more and 60 g/m ² ·day or less. The water vapor permeability is measured in accordance with the provisions of "JIS Z0208".

The middle layer 6 can be formed by a mixed liquid obtained from a composition containing a polymer and a composition containing cement. A preferred composition containing a polymer is an acrylic emulsion. The acrylic emulsion can be obtained by emulsion polymerization of monomers. Emulsion polymerization can be performed by an emulsifier. Polymerization can be performed in water containing a surfactant. Typical monomers are acrylates or methacrylates. The content of the monomer component in the acrylic emulsion is 20 mass % to 100 mass %.

Specific examples of compositions containing a polymer suitable for the intermediate layer 6 include "Spring Coat brush-coating mixture" produced by Kikusui Chemical Industry Co., Ltd. and "ARONBULLCOAT A450 base" produced by Toagosei Co., Ltd. Specific examples of compositions containing cement suitable for the intermediate layer 6 include "Spring Coat brush-coating powder" produced by Kikusui Chemical Industry Co., Ltd. and "ARONBULLCOAT A450 Setter" produced by Toagosei Co., Ltd.

In FIG3 , arrow t2 indicates the thickness of the intermediate layer 6. In the present embodiment, as described above, the reinforcing body 10 is buried in the intermediate layer 6. Therefore, the thickness t2 including the reinforcing body 10 is measured. From the viewpoint of the operability of the sheet 2, the thickness t2 is preferably greater than 100 μm, more preferably greater than 300 μm, and particularly preferably greater than 500 μm. From the viewpoint of the followability, productivity, and lightness of the sheet 2, the thickness t2 is preferably less than 1500 μm, more preferably less than 1000 μm, and particularly preferably less than 700 μm. The distribution of the thickness t2 is preferably within the range of ±100 μm.

The material of the intermediate layer 6 may be a resin composition or a rubber composition. The sheet material 2 for structure may have two or more intermediate layers 6. The sheet material 2 for structure may have two intermediate layers 6 of different materials. The sheet material 2 for structure may have a layer structure without an intermediate layer 6.

From the viewpoint of close contact between the intermediate layer 6 and the functional layer 4 , the base polymer of the intermediate layer 6 is preferably of the same type as the base polymer of the functional layer 4 .

[Adhesive layer] The adhesive layer 8 (or bonding layer) is connected to the substrate. The sheet 2 can be attached to the structure by the adhesive force of the adhesive layer 8. The adhesive layer 8 can achieve an adhesive force of 0.5 N/ ^mm2 or more between the sheet 2 and the structure.

The preferred material of the adhesive layer 8 is an adhesive composition with a polymer as a base material. Examples of polymers suitable for the adhesive composition include acrylic resin, polysilicone, polyurethane, polyester, natural rubber, and synthetic rubber. As a base material, an acrylic resin is a particularly preferred polymer. Specific examples of the adhesive composition include the product names "Oribain BPS6574", "Oribain BPS6554", and "Oribain BPS5565K" of TOYOCHEM.

The adhesive composition may also include a hardener. When the substrate is an acrylic resin, a preferred hardener is an isocyanate hardener. The ratio of the isocyanate hardener to 100 parts by mass of the acrylic resin is preferably 1.0 parts by mass or more, more preferably 2.0 parts by mass or more, and particularly preferably 2.5 parts by mass or more. The ratio is preferably 10 parts by mass or less, more preferably 8 parts by mass or less, and particularly preferably 7 parts by mass or less.

The adhesive composition may include an adhesive imparting agent. Examples of adhesive imparting agents include rosin-based adhesives, terpene-based adhesives, petroleum resin-based adhesives, and phenolic resin-based adhesives. The ratio of the adhesive imparting agent to 100 parts by mass of the base polymer is preferably 0.5 parts by mass or more, more preferably 1.0 parts by mass or more, and particularly preferably 1.5 parts by mass or more. The ratio is preferably 15 parts by mass or less, more preferably 10 parts by mass or less, and particularly preferably 7 parts by mass or less. Specific examples of adhesive imparting agents include Arakawa Chemical's trade names "Ester Gum H", "Ester Gum AA-V", and "Ester Gum 105".

In FIG. 3 , arrow t3 indicates the thickness of the adhesive layer 8. From the viewpoint of adhesiveness, the thickness t3 is preferably 20 μm or more, more preferably 40 μm or more, and particularly preferably 50 μm or more. From the viewpoint of productivity, lightness, and operability of the sheet 2, the thickness t3 is preferably 500 μm or less, more preferably 200 μm or less, and particularly preferably 150 μm or less. The amount of the adhesive layer 8 is preferably 20 g/m ² or more and 250 g/m ² or less. The sheet 2 for structures may also have two or more adhesive layers 8.

[Reinforcement] The reinforcement 10 can give a suitable Young's modulus to the sheet 2 for structure. The reinforcement 10 can contribute to the greater tensile strength of the sheet 2. The reinforcement 10 can further contribute to the smaller elongation of the sheet 2. The sheet 2 including the reinforcement 10 has excellent operability. As described above, the reinforcement 10 is embedded in the intermediate layer 6. The reinforcement 10 can also be embedded in the functional layer 4. The reinforcement 10 can also be embedded in the adhesive layer 8. The reinforcement 10 can also be located between the functional layer 4 and the intermediate layer 6. The reinforcement 10 can also be located between the intermediate layer 6 and the adhesive layer 8. In this specification, the reinforcement 10 means an object that can give the sheet 2 a greater tensile strength than the imaginary sheet. The imaginary sheet has the same layer structure as the sheet 2 except that it does not have the reinforcement 10.

[Tensile strength and elongation of the reinforcement] The tensile strength of the reinforcement 10 is preferably 5.0 MPa or more. The sheet 2 having a tensile strength of 5.0 MPa or more is not easily damaged even when tension is applied. The sheet 2 has excellent operability. From this point of view, the tensile strength is more preferably 5.5 MPa or more, and more preferably 6.0 MPa or more. From the perspective of the followability of the sheet 2, the tensile strength of the reinforcement 10 is preferably 15.0 MPa or less, more preferably 10.0 MPa or less, and most preferably 7.0 MPa or less.

The elongation at break of the reinforcement 10 is preferably 15.0% or less. The sheet 2 having an elongation of 15.0% or less is not easily deformed even when tension is applied. The sheet 2 has excellent operability. From this point of view, the elongation of the reinforcement 10 is more preferably 13.0% or less, and particularly preferably 11.0% or less. From the point of view of the followability of the sheet 2, the elongation of the reinforcement 10 is preferably 5.0% or more, more preferably 7.0% or more, and particularly preferably 8.5% or more.

The tensile strength and elongation are measured according to the general nonwoven fabric test method specified in "JIS L1913:2010". The test pieces used for the measurement are cut from the reinforcement 10 or its original sheet. Five test pieces whose length direction is consistent with the length direction of the reinforcement 10 or its original sheet, and five test pieces whose length direction is consistent with the width direction of the reinforcement 10 or its original sheet are used for the measurement. The 10 measured values are averaged to calculate the tensile strength and elongation.

The ratio of the outline area of the reinforcement body 10 to the area of the sheet material 2 for structure in a top view is preferably 60% or more. The reinforcement body 10 having a ratio of 60% or more can help the handling of the sheet material 2. From this point of view, the ratio is more preferably 70% or more, and particularly preferably 75% or more. The ratio may also be 100%. From the viewpoint of the tracking property of the seam 22, the ratio is preferably 95% or less.

[Fabric] FIG. 7 shows a reinforcement 10. A plurality of warp yarns 26a and a plurality of weft yarns 26b are woven in the reinforcement 10. In other words, the reinforcement 10 is a woven fabric. In the present embodiment, the woven fabric has a plain woven structure. A woven fabric is a type of fabric. The reinforcement 10 as a fabric may be impregnated with a composition of the middle layer 6. The impregnation may contribute to a greater tensile strength of the sheet 2. The impregnation may further contribute to a smaller elongation of the sheet 2. The reinforcement 10 may also be a fabric other than a woven fabric. As fabrics other than woven fabrics, knitted fabrics and intersection welded meshes can be exemplified.

As the material of the reinforcement 10, synthetic resin compositions and metals can be exemplified. As preferred base resins of the synthetic resin composition, polyethylene terephthalate, polyethylene naphthalate, aromatic polyamide, vinylene, polypropylene, polystyrene and polyvinylidene fluoride can be exemplified. As preferred metals, aluminum alloys, carbon steel and alloy steel can be exemplified. By using warp yarns 26a and weft yarns 26b with greater tensile strength, a sufficiently large tensile strength of the sheet 2 can be achieved. By using warp yarns 26a and weft yarns 26b with less elongation, a sufficiently small elongation of the sheet 2 can be achieved.

As shown in FIG. 7 , the reinforcing body 10 has a plurality of meshes 28. In the present embodiment, the planar shape of each mesh 28 is substantially square. The middle layer 6 penetrates through the meshes 28. The penetration can contribute to a greater tensile strength of the sheet 2. The penetration can further contribute to a smaller elongation of the sheet 2.

In FIG. 7 , arrow P1 indicates the spacing of the yarn 26. The spacing P1 is preferably greater than 1.0 mm and less than 50 mm. In the reinforcement 10 having a spacing P1 greater than 1.0 mm, a large amount of polymer cement or the like passes through the mesh 28. The reinforcement 10 can contribute to a larger tensile strength and smaller elongation of the sheet 2. From this viewpoint, the spacing P1 is more preferably greater than 1.2 mm, and particularly preferably greater than 1.5 mm. Regarding the reinforcement 10 having a spacing P1 less than 50 mm, the reinforcement 10 can contribute to a larger tensile strength and smaller elongation of the sheet 2. From this viewpoint, the spacing P1 is more preferably less than 40 mm, and particularly preferably less than 35 mm.

In FIG. 7 , arrow D1 indicates the thickness of the yarn 26. By using the yarn 26 with a larger thickness D1, a larger tensile strength and a smaller elongation of the sheet 2 can be achieved. From this point of view, the thickness D1 is preferably 0.05 mm or more, more preferably 0.10 mm or more, and even more preferably 0.15 mm or more. The thickness is preferably 1.0 mm or less.

The sheet material 2 for structures may also include a reinforcing body 10 other than a fabric. Examples of the reinforcing body 10 other than a fabric include nonwoven fabrics, long fibers, resin films, and metal foils. A plurality of short fibers dispersed in a composition may also be the reinforcing body 10.

[Other layers] The sheet material 2 for structures may also have other layers located on the functional layer 4. A typical other layer is a transparent coating layer. Other layers may also be layers that enhance or add functions such as design and heat insulation. The sheet material 2 for structures may also have a layer located between the functional layer 4 and the intermediate layer 6. The sheet material 2 for structures may also have a layer located between the intermediate layer 6 and the adhesive layer 8.

[Total thickness] In FIG. 3 , arrow Tt indicates the total thickness of the sheet 2. The total thickness Tt is preferably 200 μm or more, more preferably 400 μm or more, and particularly preferably 500 μm or more. The total thickness Tt is preferably 5.0 mm or less, more preferably 3.0 mm or less, and particularly preferably 1.0 mm or less. The distribution of the total thickness Tt is preferably within the range of ±100 μm.

[Manufacturing method] Hereinafter, an example of a method for manufacturing the sheet 2 for the structure will be described. In the manufacturing method, a polymer composition of the functional layer 4 is mixed with a solvent to obtain a first coating. The first coating is applied on a base film to obtain a first coating film. The first coating film is heated to evaporate the solvent from the first coating. The base polymer is cured by the heating, thereby obtaining the functional layer 4.

Next, the composite material of the intermediate layer 6 is mixed with a solvent to obtain a second coating. The second coating is applied on the functional layer 4 to obtain a second coating film. The reinforcement 10 is pressed against the second coating film. The second coating film is heated to evaporate the solvent from the second coating. The polymer is hardened by the heating, thereby obtaining the intermediate layer 6 including the reinforcement 10.

Next, the adhesive composition of the adhesive layer 8 is mixed with a solvent to obtain a third coating. The third coating is applied on a release film to obtain a third coating film. The third coating film is heated to volatilize the solvent from the third coating, thereby obtaining the adhesive layer 8.

The adhesive layer 8 is stacked on the intermediate layer 6. Then, the base film is peeled off from the functional layer 4, and the release film is peeled off from the adhesive layer 8, thereby obtaining the structure sheet 2. The release film may remain on the structure sheet 2.

[Effect] The sheet material 2 for structures has excellent tracking properties, so it can also be applied to the roof 12 with the step 18 as described above. By connecting and attaching a plurality of sheets 2, the surface of the roof 12 can be covered with a large area by the sheet material 2. Since the sheet material 2 has the adhesive layer 8, it is not necessary to apply an adhesive to the roof 12. Since the adhesive layer 8 has excellent adhesion, even when the material on the surface of the roof 12 is a composite type, the surface of the roof 12 can be covered with a large area by the sheet material 2. For example, even if the surface of the roof 12 includes both metal and artificial slate tiles, the surface of the roof 12 can be covered with a large area by the sheet material 2.

The entire surface of the roof 12 may also be covered by the sheet material 2. In this specification, the surface of the roof 12 refers to the surface that can be seen when the roof 12 is observed from the vertical direction above. In the prior art, no repair method for covering the entire surface of the roof 12 with a single type of sheet material 2 has been found.

The sheet material 2 is relatively light compared to steel plates, copper plates, galvanized iron plates, etc. Therefore, even if a large area of the surface of the roof 12 is covered by the sheet material 2, the adverse effect on the earthquake resistance of the building is relatively small. From the perspective of earthquake resistance, the density of the sheet material 2 is preferably 4.0 g/cm ³ or less, more preferably 3.0 g/cm ³ or less, and even more preferably 2.5 g/cm ³ or less. This density is much smaller than the density of the aluminum-zinc alloy coated steel plate (trade name "Galvalume steel plate") commonly used to repair the roof 12.

[Other uses] The sheet material 2 can be used to repair or reinforce structures other than the roof 12. Examples of structures other than the roof 12 include residential walls, columns, eaves, fences, doors, door panels, parapets, copings, etc. The sheet material 2 can also be used in commercial buildings, factories, warehouses, bridges, sewage facilities, railway facilities, tunnels, etc.

[Repair and Reinforcement] After the sheet 2 or other sheets are used to repair or reinforce a structure (roof 12, etc.), the sheet 2 or the structure may be damaged or deteriorated due to changes over time. Repair or reinforcement can be performed by attaching a newly prepared sheet 2 to the damaged or deteriorated sheet. By attaching a new sheet 2 to an old sheet, the value of the structure can be preserved and maintained for a very long time. The overlapping attachment can be achieved by the adhesive force of the adhesive layer 8 of the new sheet 2. The repair and reinforcement do not require the old sheet to be discarded. The repair and reinforcement can suppress the generation of waste. The sheet 2 conforms to the purpose of the circular economy. Even if the sheet 2 with lower density is layered on the old sheet, the adverse effect on the earthquake resistance of the structure is relatively small.

[Second embodiment] [Layer structure] FIG. 8 shows a sheet 30 for a structure according to another embodiment. The sheet 30 has a functional layer 32, an intermediate layer 34, and an adhesive layer 36. The material, thickness, and other specifications of the functional layer 32, the intermediate layer 34, and the adhesive layer 36 are respectively the same as the specifications of the functional layer 4, the intermediate layer 6, and the adhesive layer 8 of the sheet 2 for a structure shown in FIGS. 1 to 3. The sheet 30 does not have a reinforcing body 10 (see FIG. 3).

[Functional layer] The material of the functional layer 32 is the same polymer composition as the polymer composition of the functional layer 4 shown in Figures 1 to 3. The polymer composition of the functional layer 32 includes a first substrate polymer and a second substrate polymer. The glass transition point of the second substrate polymer, i.e., the second glass transition point T2, is lower than the glass transition point of the first substrate polymer, i.e., the first glass transition point T1. The first substrate polymer contributes to the heat resistance of the sheet 30 for the structure. The second substrate polymer contributes to the tracking property of the sheet 30. [Example]

The following is an explanation of the effects of the sheet for structures of the embodiments. The scope disclosed in this specification should not be interpreted in a limiting sense based on the description of the embodiments.

[Example 1] As the first base polymer, an acrylic polysilicone resin having a glass transition point of 29.66°C was prepared. As the second base polymer, an acrylic polysilicone resin having a glass transition point of -15.93°C was prepared. 70 parts by mass of the first base polymer and 30 parts by mass of the second base polymer were mixed using a defoaming mixer (product name "Defoaming Mixer Taro AR-250" of THINKY Corporation) to obtain a first coating. The mixing conditions are as follows. Stirring temperature: 25°C Stirring time: 2min Revolution speed: 2000 rpm Rotation speed: 800 rpm Defoaming time: 3min Defoaming conditions: 2200 rpm､60 rpm The first coating material is applied to the demoulding sheet with a convex shape by a coating machine (YOSHIMITSU SEIKI's "YBA-5 model") to obtain a first coating film. The first coating film is placed in an oven (ESPEC's "LC-114") and maintained at 80°C for 1 hour to prepare a functional layer. The thickness of the functional layer is 110 μm. The "breaking elongation of the functional layer at -10℃, -5℃, 0℃, 5℃ and 80℃" measured by the above method (JIS K 7161) is shown in Table 1 below.

An acrylic emulsion (the above-mentioned trade name "Spring Coat brush-coating mixture") and a cement component (the above-mentioned trade name "Spring Coat brush-coating powder") are mixed to obtain a second coating. The second coating is applied to the functional layer to obtain a second coating film. A woven fabric (Kuraray's trade name "Cold Yarn #600") serving as a reinforcement is pressed against the second coating film. The second coating film is heated to obtain an intermediate layer containing a reinforcement. The thickness of the intermediate layer is 300 μm.

100 parts by weight of an adhesive containing an acrylic resin (the above-mentioned trade name "Oribain BPS6574") and 6 parts by weight of an isocyanate-based hardener (TOYOCHEM's trade name "BHS8515") were mixed to obtain a third coating having a gel fraction of 57%. The third coating was applied on a release film to obtain a third coating film. The third coating film was heated to obtain an adhesive layer. The thickness of the adhesive layer was 100 μm.

The adhesive layer and the intermediate layer are stacked. Then, the release sheet is peeled off from the functional layer, and the release film is peeled off from the adhesive layer, thereby obtaining the sheet for structure of Example 1 having the layer structure shown in FIGS. 1 to 3 .

[Example 2 and Comparative Examples 1 to 3] Except that the mass ratio of the first substrate polymer and the second substrate polymer was set as shown in Table 1 below, the structural sheets of Example 2 and Comparative Examples 1 to 3 were obtained in the same manner as Example 1.

[Heat resistance] The "elongation at break of the functional layer in an environment of 80°C" measured by the above method (JIS K 7161) was rated according to the following criteria. A: 400% or more B: 250% or more but less than 400% C: less than 250% The results are shown in Table 1 below.

[Follow-up performance] In the cold season, workers were asked to attach structural sheets to the roof. The workers were asked about the follow-up performance. The performance was rated based on the following criteria. A: Very good B: Good C: Poor The results are shown in Table 1 below.

[Table 1] Evaluation results Comparison Example 1 Embodiment 2 Embodiment 1 Embodiment 3 Comparison Example 2 First glass transition point T1 (℃) - 29.66 29.66 29.66 29.66 First glass transition point T2 (℃) -15.93 -15.93 -15.93 -15.93 - T1-T2 (℃) - 45.59 45.59 45.59 - Quality Ratio 0/100 50/50 70/30 80/20 100/0 Upper glass transition point TU (℃) - 27.03 27.97 29.27 29.66 Lower glass transition point TL (℃) -15.93 -12.50 -8.00 -2.70 - TU-TG (℃) - 39.53 35.97 31.97 - Elongation at break -10℃ 59.7 38.1 2.1 1.3 1.1 -15℃ 84.0 72.2 7.9 2.2 1.3 0℃ 123.9 92.5 39.4 2.7 1.4 5℃ 176.1 132.2 61.4 9.0 1.4 80℃ 199.8 343.8 440.0 ＞500 ＞500 Heat resistance C B A A A Followability A A A B C

As can be seen from Table 1, the heat resistance and tracking properties of the structural sheet of each embodiment are excellent. According to the evaluation results, the advantages of the structural sheet are obvious.

[Revelation Items] Each of the following items discloses a preferred implementation method.

[Item 1] A sheet material for a structure, comprising an adhesive layer and a functional layer, wherein the functional layer is made of a polymer composition, wherein the polymer composition comprises a first substrate polymer and a second substrate polymer, wherein the first substrate polymer has a first glass transition point T1, wherein the second substrate polymer has a second glass transition point T2, and wherein the second glass transition point T2 is lower than the first glass transition point T1.

[Item 2] The sheet material for a structure as in Item 1, wherein the difference (T1-T2) between the first glass transition point T1 and the second glass transition point T2 is 30°C or more.

[Item 3] The sheet for structure as in item 1 or 2, wherein the mass ratio of the first substrate polymer to the second substrate polymer in the polymer composition is 30/70 or more and 80/20 or less.

[Item 4] A sheet for a structure according to any one of items 1 to 3, wherein the first glass transition point T1 is 25°C or higher.

[Item 5] A sheet for a structure as in any one of items 1 to 4 or 2, wherein the second glass transition point T2 is below -10°C.

[Item 6] The sheet material for a structure as in Item 4 or 5, wherein the first glass transition point T1 is above 25°C, and the second glass transition point T2 is below -10°C.

[Item 7] A sheet for a structure as in any one of items 1 to 6, wherein the polymer composition has an upper glass transition point TU and a lower glass transition point TL, and the upper glass transition point TU is below 30°C, and the lower glass transition point TL is above -15°C.

[Item 8] A sheet for a structure as in any one of items 1 to 7, wherein the polymer composition contains a pigment, a filler or a reinforcing material.

[Item 9] For a sheet material for a structure as in any one of items 1 to 8, the elongation at break of the functional layer at a temperature of 5°C is not less than 10% and not more than 175%.

[Item 10] The sheet material for a structure as described in any one of items 1 to 9 further comprises an intermediate layer located between the functional layer and the adhesive layer, and the material of the intermediate layer is a composite material containing a polymer and a filler (e.g. cement).

[Item 11] The sheet material for a structure as recited in any one of Items 1 to 10 further comprises a reinforcing body located between the functional layer and the adhesive layer, and the reinforcing body is a fabric.

[Item 12] A method for repairing or reinforcing a structure, which is performed by using a sheet and comprises: (1) a step of preparing the following sheet, the sheet having an adhesive layer and a functional layer, the functional layer being made of a polymer composition, the polymer composition comprising a first substrate polymer and a second substrate polymer, the first substrate polymer having a first glass transition point T1, the second substrate polymer having a second glass transition point T2, and the second glass transition point T2 being lower than the first glass transition point T1; and (2) a step of attaching the sheet to the surface of the structure by means of the adhesive force of the adhesive layer.

[Item 13] A method for repairing or reinforcing a structure, which is a method for repairing or reinforcing a structure that has been repaired or reinforced with an old sheet, and comprises: (1) a step of preparing the following new sheet, the new sheet having an adhesive layer and a functional layer, the functional layer being made of a polymer composition, the polymer composition comprising a first substrate polymer and a second substrate polymer, the first substrate polymer having a first glass transition point T1, the second substrate polymer having a second glass transition point T2, and the second glass transition point T2 being lower than the first glass transition point T1; and (2) a step of attaching the new sheet to the surface of the damaged or deteriorated old sheet by means of the adhesive force of the adhesive layer. [Industrial Applicability]

The sheet for structures described above can be attached to various objects for use.

2: Sheet for structure 2a: First sheet 2b: Second sheet 4: Functional layer 6: Intermediate layer 8: Adhesive layer 10: Reinforcement 12: Roof 18: Step 22: Seam 24: Step 26: Yarn 26a: Warp 26b: Weft 28: Mesh 30: Sheet for structure 32: Functional layer 34: Intermediate layer t1: Thickness of functional layer t2: Thickness of intermediate layer t3: Thickness of adhesive layer Tt: Total thickness of sheet

[FIG. 1] is a perspective view showing a portion of a structural sheet material of one embodiment. [FIG. 2] is a cross-sectional view along line II-II of FIG. 1. [FIG. 3] is an enlarged view showing a portion marked with symbol III in FIG. 2. [FIG. 4] is a cross-sectional view showing the structural sheet material of FIG. 1 together with a roof. [FIG. 5] is an enlarged view showing a portion marked with symbol V in FIG. 4. [FIG. 6] is an enlarged view showing a portion marked with symbol VI in FIG. 4. [FIG. 7] is an enlarged top view showing a portion of a reinforcing body included in the structural sheet material of FIG. 1. [FIG. 8] is a cross-sectional view showing a portion of a structural sheet material of another embodiment.

2: Sheets for structures

4: Functional layer

6: Middle layer

8: Adhesive layer

10: Strengthen the body

t1: Thickness of functional layer

t2: Thickness of the middle layer

t3: Thickness of adhesive layer

Tt: Total thickness of the sheet

Claims (13)

A sheet material for a structure, which has an adhesive layer and a functional layer, wherein the material of the functional layer is a polymer composition, The polymer composition includes a first substrate polymer and a second substrate polymer, The first substrate polymer has a first glass transition point T1, The second substrate polymer has a second glass transition point T2, and The second glass transition point T2 is lower than the first glass transition point T1. The structural sheet of claim 1, wherein a difference (T1-T2) between the first glass transition point T1 and the second glass transition point T2 is 30°C or more. The sheet for structure as claimed in claim 1 or 2, wherein the mass ratio of the first substrate polymer to the second substrate polymer in the above-mentioned polymer composition is 30/70 or more and 80/20 or less. The sheet for a structure according to claim 1 or 2, wherein the first glass transition point T1 is above 25°C. The sheet for a structure as claimed in claim 1 or 2, wherein the second glass transition point T2 is below -10°C. The sheet for structure of claim 1 or 2, wherein the first glass transition point T1 is above 25°C, and the second glass transition point T2 is below -10°C. The sheet material for a structure as claimed in claim 1 or 2, wherein the polymer composition has an upper glass transition point TU and a lower glass transition point TL, and the upper glass transition point TU is below 30°C, and the lower glass transition point TL is above -15°C. The sheet for structure as claimed in claim 1 or 2, wherein the polymer composition contains a pigment, a filler or a reinforcing material. For the sheet for structure of claim 1 or 2, the elongation at break of the functional layer at a temperature of 5°C is not less than 10% and not more than 175%. The sheet material for a structure as claimed in claim 1 or 2 further comprises an intermediate layer located between the functional layer and the adhesive layer, and the material of the intermediate layer is a composite material containing a polymer and a filler. The sheet material for a structure as claimed in claim 1 or 2 further comprises a reinforcing body located between the functional layer and the adhesive layer, and the reinforcing body is a fabric. A method for repairing or reinforcing a structure, which is performed by a sheet and comprises: (1) a step of preparing the following sheet, the sheet having an adhesive layer and a functional layer, the functional layer being made of a polymer composition, the polymer composition comprising a first substrate polymer and a second substrate polymer, the first substrate polymer having a first glass transition point T1, the second substrate polymer having a second glass transition point T2, and the second glass transition point T2 being lower than the first glass transition point T1; and (2) a step of attaching the sheet to the surface of the structure by means of the adhesive force of the adhesive layer. A method for repairing or reinforcing a structure, which is a method for repairing or reinforcing a structure that has been repaired or reinforced with an old sheet, and comprises: (1) a step of preparing the following new sheet, the new sheet has an adhesive layer and a functional layer, the functional layer is made of a polymer composition, the polymer composition comprises a first substrate polymer and a second substrate polymer, the first substrate polymer has a first glass transition point T1, the second substrate polymer has a second glass transition point T2, and the second glass transition point T2 is lower than the first glass transition point T1; and (2) a step of attaching the new sheet to the surface of the damaged or deteriorated old sheet by the adhesive force of the adhesive layer.

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