JP7238391B2 - Manufacturing method of fiber sheet laminate, fiber sheet laminate, and concrete spalling prevention material - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for producing a fiber sheet laminate, a fiber sheet laminate, and a concrete spalling prevention material using the fiber sheet laminate.

Conventionally, there is known a method of attaching a reinforcing material to the surface of a concrete structure for the purpose of preventing spalling of concrete structures, repairing them, or reducing cracks. As a reinforcing material, for example, a spalling prevention material is known in which a mesh composed of glass fiber bundles or synthetic fiber bundles is embedded in a matrix such as cement mortar or resin.

Patent Literature 1 below discloses a concrete spalling preventive material in which a mesh laminate is embedded in a matrix resin. The mesh laminate includes a mesh composed of a fiber bundle formed by bundling a plurality of filaments, a coating resin covering the mesh, and a non-woven fabric adhered to the mesh by the coating resin. The coating resin is formed by coating the mesh by spraying or dipping after weaving the mesh. Alternatively, it is formed through a drying process after application.

JP 2018-89822 A

By the way, a reinforcing material such as a concrete spalling prevention material is sometimes cut to a size corresponding to the place of use at a construction site. In addition, it is sometimes used by sticking it on places where construction is difficult, such as vertical surfaces and ceiling surfaces. In such a case, if the mesh that constitutes the reinforcing material has a weak filling between the fiber bundles, misalignment may occur. Therefore, the filament may come off when the mesh is cut to the size of the part to be used or when it is attached to the construction surface, and the workability may not be sufficient. In addition, openings of a predetermined size may collapse, and the mesh may not exhibit sufficient performance.

In addition, when the fiber bundles are sealed by applying a coating resin as in Patent Document 1, the coating resin may clog the filaments constituting the fiber bundles, and the matrix material is the filament. It may become difficult to impregnate between them. If it is difficult for the matrix material to impregnate between the filaments, the adhesion between the mesh and the matrix cannot be enhanced, and the mesh may not sufficiently reinforce the matrix.

An object of the present invention is to laminate a fiber sheet that can be easily manufactured, is excellent in workability on site, and allows easy impregnation of a matrix material between filaments constituting a fiber bundle. An object of the present invention is to provide a method for manufacturing a body, a fiber sheet laminate, and a concrete spalling prevention material using the fiber sheet laminate.

In the method for producing a fiber sheet laminate according to the present invention, a first fiber sheet having a plurality of openings is formed by weaving a fiber bundle composed of a plurality of monofilaments in a state in which a heat-fusible yarn is arranged along the fiber bundle. A step of producing a sheet, and laminating the first sheet on a second sheet made of nonwoven fabric, paper, or film, and heat-pressing at a temperature at which the fiber bundle is not softened to form the first sheet. and a step of bonding the second sheet.

In the present invention, the melting point of the heat-fusible yarn is preferably 70°C or higher and 160°C or lower.

In the present invention, the heat-fusible yarn is preferably composed of one selected from the group consisting of polyester, polyamide, polyacrylonitrile, polyvinyl alcohol, and polyolefin.

In the present invention, it is preferable that the heat-fusible yarn has a count of 10 dtex or more and 500 dtex or less.

In the present invention, the fiber bundle in the first sheet is composed of at least one fiber selected from the group consisting of carbon fiber, aramid fiber, glass fiber, vinylon fiber, polyester fiber, and polyolefin fiber. preferably. More preferably, the fiber bundle in the first sheet is composed of the glass fiber.

In the present invention, it is preferable that the area of the opening of the first sheet is 1 mm ² or more and 400 mm ² or less.

In the present invention, the volume of the nonwoven fabric or the paper is preferably 20 cm ³ /m ² or more and 1000 cm ³ /m ² or less.

The fiber sheet laminate according to the present invention is composed of a fiber bundle composed of a plurality of monofilaments, and includes a fiber sheet having a plurality of openings and a first sheet having heat-fusible yarns, nonwoven fabric, and paper. , or a second sheet made of a film, wherein the heat-fusible yarn is provided so as to be interposed between the fiber sheet and the second sheet, and the heat-fusible yarn The first sheet and the second sheet are laminated together.

A concrete spalling preventive material according to the present invention is characterized by comprising a matrix and a fiber sheet laminate constructed according to the present invention.

INDUSTRIAL APPLICABILITY According to the present invention, a laminate of fiber sheets that can be easily manufactured, is excellent in workability on site, and allows easy impregnation of a matrix material between filaments constituting a fiber bundle. It is possible to provide a method for manufacturing a body, a fiber sheet laminate, and a concrete spalling prevention material using the fiber sheet laminate.

FIG. 1 is a schematic plan view showing a first sheet used in a method for manufacturing a fiber sheet laminate according to one embodiment of the present invention. FIG. 2 is a schematic plan view showing a modification of the first sheet used in the method for producing a fiber sheet laminate according to one embodiment of the present invention. FIG. 3 is a schematic cross-sectional view for explaining the bonding step in the method for manufacturing a fiber sheet laminate according to one embodiment of the present invention. FIG. 4 is a schematic cross-sectional view for explaining the details of the heating press in the method for manufacturing a fiber sheet laminate according to one embodiment of the present invention. FIG. 5 is a schematic cross-sectional view for explaining the effect as an example of the method for manufacturing a fiber sheet laminate according to one embodiment of the present invention. FIG. 6 is a schematic cross-sectional view for explaining a bonding step in a method for manufacturing a fiber sheet laminate according to another embodiment of the invention. FIG. 7 is a schematic plan view showing a fiber sheet laminate according to one embodiment of the invention. 8 is a schematic cross-sectional view of a portion along line AA in FIG. 7. FIG. FIG. 9 is a schematic cross-sectional view showing a concrete spalling prevention material according to one embodiment of the present invention.

Preferred embodiments are described below. However, the following embodiments are merely examples, and the present invention is not limited to the following embodiments. Moreover, in the drawings, members having substantially the same functions may be referred to by the same reference numerals.

[Manufacturing method of fiber sheet laminate]
In the method for producing a fiber sheet laminate of the present invention, first, a fiber bundle composed of a plurality of monofilaments is woven in a state in which a heat-fusible yarn is arranged along the first fiber bundle having a plurality of openings. sheet is produced (first sheet producing step). Next, the prepared first sheet is laminated on a second sheet made of nonwoven fabric, paper, or film, and hot-pressed at a temperature at which the fiber bundle is not softened to obtain the first sheet and the second sheet. are pasted together (a pasting step). Thereby, a fiber sheet laminate can be obtained.

Hereinafter, each step will be described in detail by dividing into a first sheet manufacturing step and a bonding step.

(Manufacturing step of the first sheet)
FIG. 1 is a schematic plan view showing a first sheet used in a method for manufacturing a fiber sheet laminate according to one embodiment of the present invention. FIG. 2 is a schematic plan view showing a modification of the first sheet used in the method for producing a fiber sheet laminate according to one embodiment of the present invention.

In the manufacturing process of the first sheet 1, first, fiber bundles forming the warp yarn 2 and the weft yarn 3 are prepared. In this embodiment, the fiber bundles forming the warp yarn 2 and the weft yarn 3 are both glass fiber bundles. A glass fiber bundle can be obtained by bundling several tens to several hundreds of glass fiber monofilaments.

A glass fiber bundle is obtained by the following method. First, frit fed into a glass melting furnace is melted to form molten glass, and after the molten glass is homogenized, the molten glass is pulled out from a heat-resistant nozzle attached to a bushing. After that, the drawn molten glass is cooled to form a glass fiber monofilament (glass fiber).

Next, a sizing agent is applied to the surface of this glass fiber. With the sizing agent evenly applied, hundreds to thousands of the glass fibers are aligned, bundled, and dried to obtain a glass fiber bundle.

The glass fiber monofilaments constituting the glass fiber bundle each contain 12% by mass of ZrO ₂ and 10% by mass or more of R ₂ O (R is at least one selected from Li, Na and K) as a glass composition. is preferred. In this case, the alkali resistance can be further improved, and the rigidity can be further improved. The R ₂ O content of 10% by mass or more means that the total content of Li ₂ O, Na ₂ O and K ₂ O in the glass fiber monofilament is 10% by mass or more.

As such a glass fiber monofilament, for example, as a glass composition, SiO ₂ 54 to 65%, ZrO ₂ 12 to 25%, Li ₂ O 0 to 5%, Na ₂ O 10 to 17%, K ₂ O 0-8%, R'O (R' represents Mg, Ca, Sr, Ba, Zn) 0-10%, TiO ₂ 0-10%, Al ₂ O ₃ 0-2%. SiO ₂ 57-64%, ZrO ₂ 14-24%, Li ₂ O 0-3%, Na ₂ O 10-17%, K ₂ O 0-5%, R'O (However, R' represents Mg, Ca, Sr, Ba, Zn) 0.2 to 8%, TiO ₂ 0.5 to 9%, Al ₂ O ₃ 0 to 1% can be used. can.

The average diameter of the glass fiber monofilament is preferably 13 μm or more, more preferably 15 μm or more, and preferably 30 μm or less, more preferably 25 μm or less. When the average diameter of the glass fiber monofilament is at least the above lower limit, the rigidity can be further enhanced. When the average diameter of the glass fiber monofilament is equal to or less than the above upper limit, the surface area can be further increased, and the adhesiveness to the matrix resin or cement can be further increased.

Examples of the bundling agent for bundling glass fiber monofilaments include polyester resins. The polyester resin may be a saturated polyester resin or an unsaturated polyester resin. It may also be a vinyl acetate resin, a urethane resin, an epoxy resin, or an acrylic resin. These may be used alone or in combination.

Moreover, the sizing agent preferably further contains a silane coupling agent in addition to the above components. Examples of the silane coupling agent that can be used include aminosilane, epoxysilane, vinylsilane, acrylsilane, chlorosilane, mercaptosilane, and ureidosilane. By adding a silane coupling agent, the adhesion to the matrix resin or cement can be further enhanced.

In addition to the silane coupling agent described above, the sizing agent may also contain other components such as lubricants, nonionic surfactants, water-soluble polymers, and antistatic agents. The ratio may be determined as required. Examples of water-soluble polymers that can be used include polyvinyl alcohol, polyoxyethylene polyoxypropylene glycol, and polyvinylpyrrolidone.

The coating amount of the sizing agent is preferably adjusted so that the ignition loss of the glass fiber bundle is 0.5 to 2.0% by mass. The ignition loss can be measured according to JIS R3420 (2013).

However, the fiber bundles forming the warp 2 and the weft 3 are not limited to glass fiber bundles, and synthetic fiber bundles may be used. Moreover, the warp yarn 2 and the weft yarn 3 may be composed of the same fiber bundle as in the present embodiment, or may be composed of different fiber bundles. Moreover, it may be configured by combining a plurality of fibers. For example, the warp threads 2 may be glass fiber bundles and the weft threads 3 may be synthetic fiber bundles. The warp threads 2 may be synthetic fiber bundles and the weft threads 3 may be glass fiber bundles. However, from the viewpoint of further enhancing rigidity, it is preferable that glass fiber bundles are included.

Examples of fibers constituting the synthetic fiber bundle include carbon fibers, aramid fibers, vinylon fibers, polyester fibers, polyolefin fibers, and the like. One type of these fibers may be used alone, or a plurality of types may be used in combination. Among them, carbon fiber, aramid fiber, vinylon fiber, and polyolefin fiber are preferred. From the viewpoint of further improving heat resistance, the polyolefin fibers are preferably polypropylene fibers.

Although the yarn count of the fiber bundles constituting the warp yarn 2 and the weft yarn 3 is not particularly limited, it is preferably 100 tex or more and 3000 tex or less. When the count of the fiber bundle is within the above range, the rigidity of the fiber sheet 1 can be further enhanced.

The softening temperature of the fiber bundle is preferably 120°C or higher. In this case, it is possible to make it more difficult to break during hot pressing.

Next, using the obtained fiber bundle as the warp 2 and the weft 3, plain weaving is performed. At this time, as shown in FIG. 1, the heat-fusible yarn 4 is arranged along the warp yarn 2 and woven by being woven in the same manner as the warp yarn 2 . Thereby, the first sheet 1 having a plurality of openings 5 can be obtained. The weaving method is not particularly limited, and may be leno weaving or gauze weaving. However, the plain weave is preferable from the viewpoint of facilitating the impregnation of the later-described matrix material between the filaments constituting the fiber bundle.

The heat-fusible thread 4 is a thread that is fused by heating. In this embodiment, the heat-fusible yarns 4 are arranged along all the warp yarns 2 out of the plurality of warp yarns 2 . However, the heat-fusible yarn 4 may be arranged along some of the warp yarns 2 among the plurality of warp yarns 2 .

The melting point of the heat-fusible thread 4 is preferably 70° C. or higher and 160° C. or lower. When the melting point of the heat-fusible thread 4 is equal to or higher than the above lower limit, a wider variety of materials can be used. Moreover, when the melting point of the heat-fusible yarn 4 is equal to or lower than the above upper limit, the fiber sheet 7 and the second sheet 10 can be made more difficult to tear.

The heat-fusible thread 4 can be made of, for example, polyester, polyamide, polyacrylonitrile, polyvinyl alcohol, polyolefin, or the like. Among them, polyester, polyamide or polyolefin is preferable because it is easier to obtain a low melting point. These resins may be used individually by 1 type, and may use multiple types together.

Although the count of the heat-fusible yarn 4 is not particularly limited, it is preferably 10 dtex or more, more preferably 50 dtex or more, preferably 500 dtex or less, and more preferably 350 dtex or less. When the thickness of the heat-fusible thread 4 is equal to or greater than the above lower limit, the adhesiveness to the fiber sheet 7 and the second sheet 10 can be further enhanced. Further, when the thickness of the heat-fusible yarn 4 is equal to or less than the above upper limit, the heat-fusible yarn 4 is more difficult to penetrate between the plurality of filaments constituting the fiber bundle, and the matrix material is further spread between the filaments. Impregnation can be facilitated.

Moreover, the volume of the heat-fusible yarn 4 is preferably 0.1 cm ³ /cm ² or more and 35.0 cm ³ /cm ² or less with respect to the area of the main surface 10a of the second sheet 10 described later. . In this case, the matrix material can be more easily impregnated between the filaments, and the bonding strength can be further increased. The volume of the heat-fusible yarn 4 is more preferably 1.0 cm ³ /cm ² or more, more preferably 3.0 cm ³ /cm ² or more, and more preferably 30.0 cm ³ /cm ² or less, still more preferably It is 15.0 cm ³ /cm ² or less.

As in the first sheet 1A of the modified example shown in FIG. 2, heat-fusible yarns 4A may be arranged along the weft yarns 3 as well. In the first sheet 1A, heat-fusible yarns 4A are arranged every other one of the plurality of weft yarns 3. As shown in FIG. As for the weft yarns 3, the heat-fusible yarns 4A may be arranged along all the weft yarns 3, or the heat-fusible yarns 4A may be arranged along some of the weft yarns 3. good. Alternatively, the heat-fusible yarn 4A may be arranged along only the weft yarn 3 . The heat-fusible yarns 4 and 4A may be arranged along at least one fiber bundle out of the plurality of warp yarns 2 and the plurality of weft yarns 3 . However, as in the embodiment shown in FIG. 1, it is preferable to arrange the heat-fusible yarns 4 along all the fiber bundles (all the warp yarns 2) in one direction. In this case, the first sheet 1 and the second sheet 10 can be adhered to each other more reliably in the lamination step, and moreover, it is easier to impregnate the filaments constituting the fiber bundle with the matrix material described later. can do.

Further, in this embodiment, heat-fusible yarns 4 and 4A are arranged so as to extend parallel to the warp yarns 2 and the weft yarns 3 (fiber bundles), respectively. However, the heat-fusible threads 4 and 4A may be entangled with the fiber bundle. From the viewpoint of facilitating the impregnation of the matrix material, which will be described later, between the filaments constituting the fiber bundle, the heat-fusible yarns 4 and 4A may be arranged so as to extend parallel to the fiber bundle as in the present embodiment. is preferred. Also, at that time, it is desirable to arrange the heat-fusible yarns 4 and 4A so as to be in contact with the fiber bundle. However, the heat-fusible yarns 4, 4A may partially or completely contact the fiber bundle.

In this embodiment, the area of the opening 5 in the first sheet 1 is preferably 1 mm ² or more and 400 mm ^{2 or} less. When the area of the openings 5 is equal to or greater than the above lower limit, the later-described matrix material can be more easily passed through, and the adhesiveness between the matrix material and the fiber sheet laminate can be further enhanced. . Further, when the area of the openings 5 is equal to or less than the above upper limit, the area ratio of the fiber bundles constituting the first sheet 1 can be further increased. The second sheet 10 can be adhered more reliably.

Moreover, the thickness of the first sheet 1 is not particularly limited, but can be, for example, 0.2 mm or more and 1 mm or less.

(Lamination process)
FIG. 3 is a schematic cross-sectional view for explaining the bonding step in the method for manufacturing a fiber sheet laminate according to one embodiment of the present invention. FIG. 4 is a schematic cross-sectional view for explaining the hot press method in the method for manufacturing a fiber sheet laminate according to one embodiment of the present invention. Moreover, FIG. 5 is a schematic cross-sectional view for explaining the effects of the method for manufacturing a fiber sheet laminate according to one embodiment of the present invention.

In the bonding process, first, the second sheet 10 is prepared. In this embodiment, the second sheet 10 is a nonwoven fabric. The second sheet 10 may be paper or film. The second sheet 10 is preferably a continuous sheet.

Fibers constituting the nonwoven fabric or paper are not particularly limited, but examples thereof include glass fiber, polyester fiber, polyethylene fiber, polypropylene fiber, rayon fiber, nylon fiber, acrylic fiber, vinylon fiber, polylactic acid fiber and the like. One type of these fibers may be used alone, or a plurality of types may be used in combination.

The non-woven fabric is a sheet-like one in which these fibers are intertwined without being woven. Moreover, paper is fiber paper which consists of these fibers.

The volume of the nonwoven fabric or paper is not particularly limited, but is preferably 20 cm ³ /m ² or more and 1000 cm ³ /m ² or less. When the volume of the nonwoven fabric or paper is at least the above lower limit, the strength of the continuous sheet can be further increased, and the continuous sheet can be made more difficult to tear during hot pressing. In addition, when the volume of the nonwoven fabric or paper is equal to or less than the above upper limit, it is possible to further facilitate the permeation of the matrix material, thereby further enhancing the adhesiveness to the matrix.

Although the thickness of the nonwoven fabric or paper is not particularly limited, it is preferably 0.02 mm or more and 1 mm or less. When the thickness of the nonwoven fabric or paper is within the above range, the strength of the continuous sheet can be further increased, and the continuous sheet is more resistant to tearing during hot pressing.

The film is not particularly limited, but includes polyolefin films such as polypropylene films and polyethylene films, polyethylene terephthalate films, fluorine-based films, and the like. These may be used individually by 1 type, and may use multiple types together.

Although the basis weight of the film is not particularly limited, it is preferably 5 g/m ² or more and 200 g/m ² or less. When the basis weight of the film is within the above range, the strength as a continuous sheet can be further increased, and the film is more resistant to tearing during hot pressing. The basis weight of the film is more preferably 20 g/m ² or more and 100 g/m ² or less.

Although the thickness of the film is not particularly limited, it is preferably 10 μm or more and 100 μm or less. When the thickness of the film is within the above range, the strength as a continuous sheet can be further increased, and it becomes much more difficult to break during hot pressing.

Preferably, the film is a transparent film. In this specification, the term “transparent” means that the light transmittance in the visible wavelength range is 70% or more at a wavelength of 450 nm to 700 nm.

Also, the softening temperature of the nonwoven fabric, paper, and film is preferably 120° C. or higher. In this case, it is possible to make it more difficult to break during hot pressing.

Next, as shown in FIG. 3, the first sheet 1 described above is laminated on the main surface 10a of the second sheet 10. Next, as shown in FIG. Then, in a state where the first sheet 1 is laminated on the second sheet 10, hot pressing is performed. Thereby, the first sheet 1 and the second sheet 10 can be laminated to obtain a fiber sheet laminate. In FIG. 3, details of the first sheet 1 such as the heat-fusible yarn 4 are omitted.

Hot pressing can be performed, for example, by hot roll pressing or hot mold pressing. Moreover, the heat press is performed at a temperature at which the fiber bundles (the warp yarn 2 and the weft yarn 3) constituting the first sheet 1 are not softened. Moreover, it is desirable that the second sheet 10 is also heated at a temperature at which it does not soften. In addition, the "temperature at which softening does not occur" refers to a temperature lower than the softening point in the case of a material having a softening point, and refers to a temperature below the softening point in the case of a material having no softening point. shall be

The temperature of the heat press is preferably 80° C. or higher, more preferably 100° C. or higher, and preferably 250° C. or lower, more preferably 160° C. or lower, depending on the type of material constituting the fiber bundle. can. The pressure of the hot press is preferably 5 N/cm ² or more, more preferably 7 N/cm ² or more, and preferably 40 N/cm ² or less, more preferably 15 N/cm ² or less.

When the fiber bundle constituting the first sheet 1 is polypropylene fiber, which is a type of polyolefin fiber, the fiber bundle may shrink due to the heat press, causing the warp 2 or weft 3 to meander. As such, the polypropylene fibers may shrink due to this hot pressing, causing meandering of the mesh, particularly the weft, so that preheating may be carried out before weaving. If preheating is performed, meandering is less likely to occur even if hot press processing is performed. The preheating conditions are not particularly limited, but specifically, preheating in which the rate of decrease in breaking elongation in a tensile test is 1 to 15% is preferable.

In this embodiment, the first sheet 1 is laminated on the second sheet 10, and the heat-sealing yarns 4 are melted by hot pressing. In this state, by pressing in the X direction (thickness direction of the laminate) shown in FIG. sheet 10 can be pasted together.

As described above, in the manufacturing method of the present embodiment, by interposing the heat-fusible yarn 4, the warp yarn 2 and the weft yarn 3 constituting the first sheet 1 are closed, and the first sheet 1 and the second sheet 1 are attached. sheet 10 can be pasted together. Therefore, the fiber sheet laminate can be easily produced, is excellent in workability on site, and can be easily impregnated with the matrix material between the filaments constituting the fiber bundle. This will be described in detail below in comparison with the conventional manufacturing method. Conventionally, when fabricating a fiber sheet laminate by laminating a mesh fabric to a sheet such as a nonwoven fabric, the mesh fabric is first woven and then coated with a coating resin as a secondary binder. Furthermore, after passing through a drying process as necessary, a fiber sheet laminate is obtained by laminating with a sheet such as a nonwoven fabric.

On the other hand, in the manufacturing method of the present embodiment, the fiber sheet laminate is obtained by weaving the heat-fusible yarn 4 together with the fiber bundle such as the warp yarn 2 during weaving, and then heat-pressing the laminated sheet such as nonwoven fabric. is getting Therefore, complicated processes such as a coating resin coating process and a drying process, which are required in conventional manufacturing methods, are not required. A fiber sheet laminate can be easily obtained by heat-pressing the first sheet 1 in which the heat-fusible yarns 4 are woven together with the fiber bundle on the second sheet 10 in a state of being laminated.

Further, as shown in FIG. 4, the warp yarns 2 and the weft yarns 3 constituting the first sheet 1 are stitched by a hot press with the heat-fusible yarns 4 interposed therebetween, and the first sheet 1 and the second sheet , the sheets 10 are pasted together. Therefore, the warp yarn 2 and the weft yarn 3 can be securely tied with the second sheet 10 interposed. Therefore, since misalignment is unlikely to occur in the obtained fiber sheet laminate, it is possible to prevent the filaments from falling off during handling at the site when cutting the fiber sheet laminate or when attaching it to a construction surface. can. Therefore, the obtained fiber sheet laminate is excellent in workability on site. In addition, since the openings 5 of a predetermined size are less likely to collapse, sufficient performance as a fiber sheet laminate can be exhibited.

In addition, in the manufacturing method of the present embodiment, by fusing the heat-fusible thread 4 to a part of the fiber bundles constituting the first sheet 1 , the fiber bundles are sealed together and the second sheet 10 is bonded. I am pasting. Therefore, unlike the conventional manufacturing method in which a coating resin is applied, the spaces between the plurality of filaments forming the fiber bundle are less likely to be blocked. Therefore, for example, as shown in FIG. 5, when the fiber sheet laminate is embedded in the matrix resin 6, the filaments constituting the fiber bundle can be impregnated with the matrix resin 6 reliably. Therefore, it is possible to enhance the adhesiveness between the matrix resin 6 and the fiber sheet laminate, thereby enhancing the effect of reinforcing the matrix by the fiber sheet laminate. It should be noted that the fiber sheet laminate embedded in the matrix resin 6 can be used by being attached to, for example, the concrete frame 32 shown in FIG.

Further, since a secondary binder is not used, spaces between the filaments constituting the fiber bundle are not blocked, and the spaces between the filaments can be easily impregnated with the matrix resin 6. Therefore, as in the present embodiment, the fiber bundle can be If it is made of glass fiber, it can be made more transparent. Therefore, the obtained fiber sheet laminate can facilitate visual observation of the surface state of the concrete structure, for example, when it is attached to the surface of the concrete structure.

FIG. 6 is a schematic cross-sectional view for explaining a bonding step in a method for manufacturing a fiber sheet laminate according to another embodiment of the invention.

In the manufacturing method of another embodiment shown in FIG. 6, the second sheets 10 are laminated on both main surfaces 1a and 1b of the first sheet 1 and then hot-pressed. As a result, the first sheet 1 and the second sheet 10 are bonded together to produce a fiber sheet laminate in which the first sheet 1 is sandwiched between the two second sheets 10 . Other points are the same as the embodiment shown in FIG. In FIG. 6 as well, details of the first sheet 1 such as the heat-fusible yarn 4 are omitted.

In this manner, the second sheets 10 may be attached to the main surfaces 1a and 1b on both sides of the first sheet 1, respectively. In this case, too, the first sheet 1 and the second sheet 10 can be bonded together by interposing the heat-fusible yarn 4 to seal the warp yarn 2 and the weft yarn 3 constituting the first sheet 1. can be done. Therefore, the fiber sheet laminate can be easily produced, is excellent in workability on site, and can be easily impregnated with the matrix material between the filaments constituting the fiber bundle.

Further, when the second sheets 10 are attached to the main surfaces 1a and 1b on both sides of the first sheet 1, respectively, the second sheets 10 can further absorb the matrix resin, thereby preventing resin dripping. can be further suppressed.

Hereinafter, a fiber sheet laminate as an example manufactured by the manufacturing method according to one embodiment of the present invention will be described in detail.

[Fiber sheet laminate]
FIG. 7 is a schematic plan view showing a fiber sheet laminate according to one embodiment of the invention. 8 is a schematic cross-sectional view of a portion along line AA in FIG. 7, illustration of the heat-fusible thread 4 is omitted.

As shown in FIGS. 7 and 8, the fiber sheet laminate 20 includes a first sheet 1 and a second sheet 10. As shown in FIGS. The first sheet 1 has a fiber sheet 7 and heat-fusible yarns 4 . The fiber sheet 7 is a mesh fabric woven from the warp threads 2 and the weft threads 3 described above. The fiber sheet 7 is a portion of the first sheet 1 excluding the heat-fusible yarns 4 .

A heat-sealing yarn 4 is woven together with warp yarn 2 and weft yarn 3 . Also, the heat-fusible thread 4 is provided so as to be interposed between the fiber sheet 7 and the second sheet 10 . In particular, in this embodiment, the heat-fusible thread 4 is provided so as to be interposed between the principal surface 7a of the fiber sheet 7 and the principal surface 10a of the second sheet 10 . Thereby, the first sheet 1 and the second sheet 10 are bonded together by the heat-sealing thread 4 .

The fibrous sheet laminate 20 is easily manufactured by heat-pressing the first sheet 1 in which the heat-fusible yarns 4 are woven together with the fiber bundles such as the warp yarns 2 while being laminated on the second sheet 10. can do.

In addition, the second sheet 10 is adhered and the warp yarn 2 and the weft yarn 3 constituting the first sheet 1 are stitched by the heat press with the heat-fusible yarn 4 interposed, so that the stitching is performed reliably. It is Therefore, since misalignment hardly occurs, it is excellent in workability on site.

In addition, since the fibers are bonded together by the heat-fusible yarn 4, the matrix material can be easily impregnated between the filaments constituting the fiber bundle such as the warp yarn 2, so that the matrix material and the fiber sheet laminate can be easily impregnated. 20 can be enhanced, and the fiber sheet laminate 20 can also provide a matrix reinforcing effect.

[Concrete spalling prevention material]
FIG. 9 is a schematic cross-sectional view showing a concrete spalling prevention material according to one embodiment of the present invention. As shown in FIG. 9 , concrete spalling prevention material 31 includes fiber sheet laminate 20 and matrix resin 33 . The fiber sheet laminate 20 is the fiber sheet laminate 20 according to one embodiment described above. The mesh laminate 20 is embedded inside the matrix resin 33 . The concrete spalling prevention material 31 is provided on the concrete skeleton 32 .

Thus, in the concrete spalling prevention material 31 , the fiber sheet laminate 20 is embedded inside the matrix resin 33 . In the fiber sheet laminate 20, when the fiber sheet laminate 20 is embedded in the matrix resin 33 as described above, the filaments constituting the fiber bundle can be impregnated with the matrix resin 33 without fail. Therefore, the adhesiveness between the matrix resin 33 and the fiber sheet laminate 20 can be enhanced, and the effect of reinforcing the matrix resin by the fiber sheet laminate 20 can be enhanced. Further, since the matrix resin 33 can be easily impregnated between the filaments constituting the fiber bundle, the fiber bundle can be made more transparent when the fiber bundle is made of glass fibers as in the present embodiment. Therefore, according to the fiber sheet laminate 20, it is easy to visually observe the surface condition of the concrete skeleton 32. FIG.

In this embodiment, the first sheet 1 side is arranged on the concrete frame 32 side. Although it is desirable that the first sheet 1 side is arranged on the concrete frame 32 side as in this embodiment, the second sheet 10 side may be arranged on the concrete frame 32 side.

The matrix resin 33 is not particularly limited, and examples thereof include epoxy resin, acrylic resin, urethane resin, and silicon resin. These may be used singly or in combination.

The concrete spalling prevention material 31 can be formed, for example, by applying a primer and an undercoat resin on the concrete skeleton 32 and then bonding the fiber sheet laminate 20 together. Moreover, after laminating the fiber sheet laminated body 20, topcoat resin may be further applied.

Hereinafter, the present invention will be described in more detail based on specific examples. The present invention is by no means limited to the following examples, and can be modified as appropriate without changing the gist of the invention.

(Example 1)
First, SiO ₂ 57.9% by mass, ZrO ₂ 17.2% by mass, Li ₂ O 0.5% by mass, Na ₂ O 14.8% by mass, K ₂ O 1.3% by mass, CaO 0.9% by mass % and TiO ₂ 7.4% by mass, and the molten glass was pulled out from a bushing having hundreds to thousands of nozzles into glass fiber monofilaments.

Next, a sizing agent prepared by dispersing vinylsilane, a saturated polyester resin, and a lubricant in water was applied to the surface of the obtained glass fiber monofilament with an applicator so that the ignition loss was 0.7% by mass. After applying the sizing agent and bundling the glass fibers, the sizing agent was dried to produce a glass fiber bundle (count: 320 tex).

Next, a first sheet 1 shown in FIG. 1 was produced. Specifically, the glass fiber bundles obtained as described above are used as the warp yarn 2 and the weft yarn 3, and the polyester yarn (melting point: 110°C, count: 110 dtex) as the heat-sealing yarn 4 is laid along the warp yarn 2. The first sheet 1 was obtained by weaving at 9 wefts/25 mm in the warp and weft and by plain weaving at 230 g/m ² .

Next, the first sheet 1 is placed on a polyester non-woven fabric (volume: 10 cm ³ /m ² , thickness: 0.06 mm) as the second sheet 10, and pressed by a hot roll press at a temperature of 120° C. and a pressure of 10 N. A mesh sheet laminate of Example 1 was obtained by hot pressing at a pressure of 1/cm ² .

(Example 2)
The mesh sheet of Example 2 was laminated in the same manner as in Example 1, except that glass paper (volume: 4 cm ³ /m ² , thickness: 0.18 mm) was used as the second sheet 10 instead of the polyester nonwoven fabric. got a body

(Example 3)
The above glass fibers and polypropylene fiber bundles (count: 900 dtex) were woven at 6 strands/25 mm at the same time in the warp and weft, and were woven in a plain weave of 197 g/m ² in the same manner as in Example 1. A mesh sheet laminate was obtained.

However, the polypropylene fiber shrinks by this heat press, and the mesh, especially the weft, is meandered. Therefore, preheating was performed at 120° C. for 30 minutes before weaving.

(Example 4)
The above glass fibers and aramid fiber bundles (count: 1670 dtex) were woven at 5 / 25 mm at the same time in the warp and weft, and were woven by plain weaving of 195 g / m ² in the same manner as in Example 1. A mesh sheet laminate was obtained.

The mesh sheet laminate obtained in Examples 1 to 4 was cut into a size of 100 mm lengthwise and 100 mm wide to prepare 10 samples. Next, 10 sheets of samples were pulled in one direction, and workability was evaluated based on whether or not the first sheet and the second sheet were separated. As a result, in each example, the number of sheets in which the first sheet and the second sheet 10 were separated was zero.

In addition, when the mesh sheet laminates obtained in Examples 1 to 4 were pulled vertically by 30 mm, no misalignment occurred in the first sheet.

Reference Signs List 1, 1A First sheets 1a, 1b Principal surface 2 Warp 3 Weft 4, 4A Heat fusion yarn 5 Opening 6 Resin 7 Fiber sheet 10 Second sheet 20 Lamination of fiber sheets Body 31... Concrete spalling prevention material 32... Concrete frame 33... Matrix resin

Claims (9)

a step of fabricating a first sheet having a plurality of openings by weaving a fiber bundle composed of a plurality of monofilaments in a state in which heat-fusible yarns are arranged along the fiber bundle;
The first sheet is laminated on a second sheet made of non-woven fabric, paper, or film, and hot-pressed at a temperature at which the fiber bundles do not soften, thereby separating the first sheet and the second sheet. a bonding process;
with
A method for producing a fiber sheet laminate , wherein the heat-fusible yarn has a count of 10 dtex or more and 110 dtex or less . The method for producing a fiber sheet laminate according to claim 1, wherein the melting point of the heat-fusible yarn is 70°C or higher and 160°C or lower. The method for producing a fiber sheet laminate according to claim 1 or 2, wherein the heat-fusible yarn is composed of one selected from the group consisting of polyester, polyamide, polyacrylonitrile, polyvinyl alcohol, and polyolefin. 2. The fiber bundle of the first sheet is composed of at least one fiber selected from the group consisting of carbon fiber, aramid fiber, glass fiber, vinylon fiber, polyester fiber, and polyolefin fiber. 4. A method for producing a fiber sheet laminate according to any one of items 1 to 3 . 5. The method for producing a fiber sheet laminate according to claim 4 , wherein the fiber bundle in the first sheet is made of the glass fiber. The method for producing a fiber sheet laminate according to any one of claims 1 to 5 , wherein the opening of the first sheet has an area of 1 mm ² or more and 400 mm ² or less. The method for producing a fiber sheet laminate according to any one of claims 1 to 6 , wherein the nonwoven fabric or paper has a volume of 20 cm ³ /m ² or more and 1000 cm ³ /m ² or less. A first sheet comprising a fiber bundle composed of a plurality of monofilaments and having a plurality of openings and a heat-fusible yarn;
a second sheet made of nonwoven fabric, paper, or film;
with
The thermal fusion yarn is provided so as to be interposed between the fiber sheet and the second sheet, and the thermal fusion yarn bonds the first sheet and the second sheet together. cage,
A fibrous sheet laminate, wherein the count of the heat-fusible yarn is 10 dtex or more and 110 dtex or less . a matrix;
A fiber sheet laminate according to claim 8 ;
A concrete spalling prevention material.

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