JP2005120547A - Reinforcing material made from fiber-reinforced thermoplastic resin and method for producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reinforcing material made from a fiber-reinforced synthetic resin without becoming a cause of peeling off of concrete, etc., by corrosion. <P>SOLUTION: This reinforcing material is produced from a composite fiber bundle 1 obtained by bundling in a plurality of composite fibers. The composite fibers are equipped with a low melting point component consisting of a thermoplastic resin constituting a matrix resin, and a high melting point component consisting of a thermoplastic resin constituting the reinforcing fiber. In the case of producing the composite fiber bundle 1 from in the plurality of composite fibers, they are twisted for preventing them from becoming released and falling into pieces. The composite fiber bundle intermediate linear material 1 is wound on a linear material-delivery bobbin of a net-twisting machine, and a mesh-formed material 3 is formed. The mesh-formed material 3 is heated at or higher than the melting point of the low melting point component and at or lower than the melting point of the higher melting point component to melt the lower melting point component and then cooled to make a net-formed material made from a fiber-reinforced thermoplastic resin obtained by fixing the reinforcing fibers (the higher melting component) with the low melting component in one unit. The net-formed material can be used as the reinforcement of piled soil or slope surface. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a reinforcing material made of fiber reinforced thermoplastic resin (FRP) which is suitably used for reinforcing materials such as lattice reinforcing bars such as mortar and concrete, slope formation, embankment method, foundation reinforcing material for civil engineering structures and building walls, etc. And a manufacturing method thereof.

  Conventionally, reinforcing bars assembled in a lattice shape are used for reinforcing mortar, concrete, and the like. Resin concrete in which synthetic resin is mixed into concrete is used for secondary products such as channels, troughs, boxes, and lids for these, but these members are lighter, discarded, and recycled. In view of the above, conventionally, a wire mesh or a lattice-like FRP has been used as a reinforcing material.

  Furthermore, polyethylene nets, plastic grid materials, and the like are used as reinforcement materials for soft ground embankments and steep slopes due to their corrosion resistance, durability and light weight.

  In addition, lath wire mesh and lattice FRP are used as reinforcements when spraying mortar for slope reinforcement, and such reinforcements are also used as wall base materials for concrete structures in civil engineering and construction fields. . However, the reinforcing material used for such applications has the following technical problems.

  In other words, reinforcing bars embedded for reinforcing concrete structures are corroded by acid rain and have a problem of peeling of mortar and concrete. Moreover, in resin concrete, there exists a problem which requires an effort and expense for the separation process of lattice-like FRP and resin concrete at the time of a failure | damage.

  Further, the net or grit material used for embankment and slope reinforcement has a problem that it is difficult to fit a curved surface. Furthermore, the lath wire mesh used as the wall surface base material of the concrete structure has a problem that rust is generated.

  Therefore, the present inventors have intensively studied means that can solve problems such as mortar and concrete peeling due to corrosion of reinforcing bars and troublesome and expensive separation processing, and can also improve the fit to curved surfaces. The present invention has been completed, and the object thereof is to provide a fiber-reinforced thermoplastic resin reinforcing material that is low in cost, easy to handle, and excellent in durability, and a method for manufacturing the same. There is.

  In order to achieve the above object, the present invention is a composite in which a composite fiber having a low melting point component made of a thermoplastic resin constituting a matrix resin and a high melting point component made of a thermoplastic resin constituting a reinforcing fiber is converged. After the fiber bundle intermediate linear body is knitted into a mesh having a predetermined mesh size, the low melting point component is melted and solidified under tension, and the reinforcing fibers are integrally bound with the low melting point component. A fiber-reinforced thermoplastic resin reinforcement was constructed from the net.

  The composite fiber is a sheath-core type composite fiber having a sheath portion that constitutes the low-melting-point component and a core portion that constitutes the high-melting-point component, and the melting point of the sheath portion is the melting point of the core portion. Further, it can be lowered by 10 ° C. or more.

  The composite fiber bundle intermediate linear body may have a thermoplastic resin coating layer on the outer periphery of the composite fiber bundle.

The mesh-like body may be a knotless knitting.
The composite fiber may be stretched at a temperature equal to or higher than the melting point (softening point) of the sheath portion and equal to or lower than the melting point (softening point) of the core portion to have a tensile strength of 4.0 cN / dtex or higher.

  The composite fiber bundle has a fineness of one or a plurality of fiber bundles that are equal to or higher than the melting point (softening point) of the sheath portion and equal to or lower than the melting point (softening point) of the core portion. It can be.

  The net-like object may have a tensile strength of a linear member of each side component of 49 N or more.

  In the composite fiber, the core may be composed of a single resin or a plurality of mixed resins among polypropylene, polyethylene terephthalate, nylon, and aromatic polyester (LCP) resin.

  In this case, the use of aromatic polyester as the core component provides very high strength. The sheath component may be a resin having a lower melting point and softening point than the core component resin, and is preferably a copolymer polypropylene such as polyethylene or polyolefin, a crystalline polypropylene, or a low melting point PET. A core made of polypropylene and a sheath made of polyethylene is very advantageous in price. Moreover, colorants, such as a well-known light resistance agent and a pigment, can be added to core-sheath component resin as needed.

  Further, as the core component aromatic polyester, for example, if polyarylate having a melting point of 310 ° C. is used and the sheath is made of polyethylene naphthalate having a melting point of 270 ° C., a composite fiber bundle having a higher strength and higher heat resistance, or a net-like material Is obtained.

  The net-like object can be processed so that the composite fiber bundle becomes flat by hot pressing after the knitting net.

  The net-like material can form a thermoplastic resin film with a low melting point component that covers the reinforcing fiber bundle at the core by the hot press after the knitting net.

  The thermoplastic resin coating may have protrusions that protrude from the side surfaces with smooth upper and lower surfaces of the net-like material.

The thermoplastic resin coating can be subjected to uneven processing on the upper and lower surfaces thereof.
The reinforcing material can be used as a lattice of mortar or concrete.

The reinforcing material can be used as a slope or a reinforcing material for embankments.
The reinforcing material can be used as a foundation reinforcing material for civil engineering or construction wall surfaces.

  Further, the present invention provides a net-like reinforcement by a linear body composed of a composite fiber having a low melting point component made of a thermoplastic resin constituting a matrix resin and a high melting point component made of a thermoplastic resin constituting a reinforcing fiber. A composite fiber bundle intermediate linear body in which a plurality of the composite fibers are twisted and converged, and the composite fiber bundle intermediate linear body is knitted into a mesh-like body having a mesh size of 10 mm or more. Then, in a certain tension state, the mesh-like body is heated to a melting point of the low melting point component or higher and below the melting point of the high melting point component to melt the low melting point component, and then cooled to cool the reinforcing fiber. To form a net-like material integrally bound with the low melting point component.

  The present invention also relates to a method for producing a net-like reinforcing material comprising a composite fiber comprising a low melting point component comprising a thermoplastic resin constituting a matrix resin and a high melting point component comprising a thermoplastic resin constituting a reinforcing fiber. Then, after converging a plurality of the composite fibers, the composite fiber bundle intermediate linear body is obtained by coating with a thermoplastic resin having a melting point higher than that of the low melting point component, and a plurality of the coated composite fiber bundles. The intermediate linear body is knitted into a mesh body having a mesh size of 10 mm or more, and then the mesh body is in a constant tension state, the melting point of the low melting point component of the composite fiber, the high melting point component, or A net-like material in which the reinforcing fiber is integrally bonded with the low-melting component by heating to below the melting point of the coating resin of the coated composite fiber bundle intermediate linear body, melting the low-melting-point component and then cooling. To form.

  The composite fiber is stretched at a temperature equal to or higher than the melting point (softening point) of the sheath portion and equal to or lower than the melting point (softening point) of the core portion, and fuses the sheath portion to have a tensile strength of 4.0 cN / dtex or higher. The composite fiber bundle is obtained, and one or a plurality of the composite fiber bundles are converged to obtain a composite fiber intermediate linear body having a fineness of 5,550 dtex or less. The mesh-like body having the above-mentioned mesh is knitted, and then the mesh-like body is heated to a melting point of the low-melting component of the composite fiber to a melting point of the high-melting component in a constant tension state. The melting point component is melted and then cooled to form a net-like material in which the reinforcing fibers are integrally bound with the low melting point component.

  Further, in the production method of the present invention, after forming the mesh-like body by a knitted mesh, or in a state of constant tension of the mesh-like body, the melting point of the low melting point component of the composite fiber, the high melting point component, or A net-like material in which the reinforcing fiber is integrally bonded with the low-melting component by heating to below the melting point of the coating resin of the coated composite fiber bundle intermediate linear body, melting the low-melting-point component and then cooling. After forming, the hot pressing or heating roller is used to heat and press from above and below to melt the low melting point thermoplastic resin and flatten the composite fiber bundle linear body, or to reinforce the core A thermoplastic resin film composed of a low melting point component covering the fiber bundle can be formed.

  Further, in the production method of the present invention, after the formation of the mesh body by a knitted mesh, or in a state of constant tension of the mesh-like body, the melting point of the low melting point component of the composite fiber, the high melting point component, or the above Heating below the melting point of the coating resin of the coated composite fiber bundle intermediate linear body, melting the low melting point component and then cooling, to form a net-like material integrally binding the reinforcing fibers with the low melting point component After forming, heat pressurize from the upper and lower surfaces of the net with a hot press or heated roller to melt the thermoplastic resin of the low melting point component and form a thermoplastic resin film with a low melting point component covering the reinforcing fiber bundle in the core part. Thereafter, the top surface, the bottom surface, or both surfaces of the net-like material can be subjected to a concavo-convex process by a heating press or roller having a concavo-convex surface.

  The composite fiber bundle in which the composite fibers are converged is preferably about 5,550 dtex to 55,550 dtex when each one is independent. If the fineness is smaller than this, the strength of the net-like material is insufficient. However, if the fineness is larger than this, it is difficult to process the net.

  Further, in the case of a composite fiber bundle in which each one is independent, it is necessary to twist each composite fiber to prevent the composite fibers from falling apart. The number of twists at this time is preferably about (0.5 to 3) times / cm, for example. If the number of twists is less than this, it tends to fall apart, and if it is more, the strength of the fiber decreases. When the composite fiber bundle is not twisted, it is collectively covered with a thermoplastic resin.

  Examples of the coating resin material include flexible polyolefin, polyester, polyamide resin, and the like. When the core is made of polypropylene and the sheath is made of polyethylene, for example, when it is highly stretched at a temperature higher than the melting point of polyethylene and less than the melting point of polypropylene with high-temperature, high-pressure steam, the sheath polyethylene is fused and integrated in the stretched state. To do.

  When all of the convergent bodies of the composite fiber bundle are fused, if the rigidity becomes too high, the knitting network becomes difficult. Therefore, in the drawing tank, the fineness of the composite fiber bundle is divided so as to be 5,550 dtex or less. I need to do it.

  When forming a net-like material with an intermediate linear body using such a continuous composite fiber bundle, after forming a mesh-like body by knitting the composite fiber bundle intermediate linear body into a predetermined mesh Then, this is fixed to a mold with a pin or the like, or the length and width of the mesh body are stretched and heated to the melting point of the thermoplastic resin of the sheath portion to fuse the sheath portions to each other.

  In order not to generate a void in the linear body after the fusion, it is preferable to use a heating device capable of internal pressurization. According to the method of pressurizing simultaneously with heating, a linear body having a high density can be obtained.

  After the intermediate linear body of the mesh body is heated and fused, it is cooled, and the obtained net-like object is cut into a rectangular shape having a predetermined size. If the cut net-like object is doubled by heating and turning the end part with a heating dryer or the like as necessary, reinforcement can be easily performed.

  According to the reinforcing material made of fiber reinforced thermoplastic resin according to the present invention, it is possible to solve problems such as mortar caused by corrosion of reinforcing bars, separation of concrete, and troublesome and expensive separation processing, and fit to a curved surface. The property can be improved. Moreover, according to the manufacturing method of the fiber-reinforced thermoplastic resin reinforcing material according to the present invention, a reinforcing material having such characteristics can be manufactured at low cost.

  Embodiments of the present invention will be described below with reference to the drawings. 1 to 4 show a first embodiment of a fiber-reinforced thermoplastic resin reinforcing material and a method for manufacturing the same according to the present invention.

  FIG. 1 (A) is an external view schematically showing a cross-sectional state of a composite fiber bundle intermediate linear body 1 used in a fiber-reinforced thermoplastic resin reinforcing material and a manufacturing method thereof according to the present invention. ) Is an external view showing a cross-sectional state of the composite fiber 1, and FIG. 2 is an external view of a straight portion of the mesh-like body knitted by the composite fiber bundle intermediate linear body 1 shown in FIG. It is sectional drawing.

  FIG. 3 is an external view of a mesh-like body 3 using a plurality of the composite fiber bundle intermediate linear bodies 1 shown in FIG. 1 (A) and knitted to a predetermined mesh, and FIG. 2 is an external view and a cross-sectional view of a net-like object 4 formed from the mesh-like body 3 shown in FIG.

  The composite fiber 2 includes a low-melting-point component 2a made of a thermoplastic resin constituting a matrix resin and a high-melting-point component 2b made of a thermoplastic resin constituting a reinforcing fiber. It has a concentric sheath-core structure in which the outer periphery is covered with the low melting point component 2a.

  That is, in the case of the present Example, the composite fiber 2 has a sheath-core structure in which the low melting point component 2a is a sheath portion and the high melting point component 2b is a core portion. The composite fibers 2 are a number of converged composite fiber bundle intermediate linear bodies 1. When the composite fiber bundle 2 is made into the composite fiber bundle intermediate linear body 1, it is prevented that the composite fiber 2 is separated and separated by applying a twist.

  Although this twist varies depending on the diameter and number of the composite fibers 2, for example, about (0.5-3) times / cm is preferable. The composite fiber bundle intermediate linear body 1 is an intermediate body that is manufactured in a continuous state and has a flexibility capable of knitting, and is wound around a wire-feeding bobbin of a net twisting machine and knitted. 3 is formed into a mesh-like body 3 shown in FIG.

  The mesh of the mesh-like body 3 is, for example, 10 mm or more. FIG. 3 shows a part of the state in which the network is a knotless network. The mesh-like body 3 formed in this way is heated to a melting point of the low melting point component 2a, not lower than the melting point of the high melting point component 2b, in a constant tension state, and then cooled after melting the low melting point component 2a. The fiber-reinforced thermoplastic resin net 4 is obtained by integrally binding the reinforcing fibers (the high melting point component 2b) with the low melting point component 2a.

  Further, in the net-like product 4 in which the low melting point component 2a is melted and the reinforcing fibers (high melting point component 2b) are integrally bound, the low melting point components 2a are melted and integrated with each other. Thus, the twisted structure of the composite fiber bundle intermediate linear body 1 may be in a form that cannot be visually confirmed.

  The mesh-like body 3 in the form of a knotless net having a sufficient flexibility becomes a knotless net having a sufficient rigidity by subsequent heat treatment.

  In this case, a nodule network has been described as an example of the mesh-like body 3. However, if the object of the present invention can be achieved, for example, a mesh-like body can be created by any method such as a nodule net or a Russell net. Can do.

  FIG. 5 shows another embodiment of the net-like object and the method for manufacturing the same according to the present invention. The same or corresponding parts as those in the above embodiment are designated by the same reference numerals and the description thereof is omitted. Only the feature points will be described below.

  FIG. 5A shows a composite fiber intermediate linear body 1 ′ corresponding to the intermediate linear body 1 shown in FIG. 1 of the above embodiment. In the case of this example, the composite fiber 2 is used for the composite fiber bundle intermediate linear body 1 ′ as in the above example.

  The composite fiber 2 includes a low-melting-point component 2a made of a thermoplastic resin constituting a matrix resin and a high-melting-point component 2b made of a thermoplastic resin constituting a reinforcing fiber, as in the above-described embodiment. It has a concentric sheath-core structure in which the outer periphery of the arranged high melting point component 2b is covered with the low melting point component 2a.

  In the case of the present embodiment, when forming the composite fiber bundle intermediate linear body 1 ′, the composite fibers 2 are not twisted but are vertically attached, and the outer periphery thereof is coated with a thermoplastic resin coating layer 1a. By covering with, a plurality of composite fibers 2 are prevented from being separated and broken.

  In the composite fiber bundle intermediate linear body 1 ′ having such a configuration, as in the above-described embodiment, a plurality of knitted meshes are knitted to form a mesh-like body (FIG. 5B shows the straight portion thereof, and FIG. )), And after heating to a melting point of the low melting point component 2a and below the melting point of the high melting point component 2b in a constant tension state, the low melting point component 2a is melted and then cooled. Thus, the net-like product 4 is obtained by integrally binding the reinforcing fibers (the high melting point component 2b) with the low melting point component 2a.

  In addition, in the Example, although the case where a net-like thing was formed using a concentric sheath-core type composite fiber was illustrated, implementation of the present invention is not limited to this, for example, in FIG. As shown, the low melting point component 2a and the high melting point component 2b may constitute an eccentric type or parallel type composite fiber.

  FIG. 7 shows another embodiment of the fiber-reinforced synthetic resin reinforcing material according to the present invention. The same or corresponding parts as those in the above embodiment are designated by the same reference numerals and the description thereof is omitted. Only the feature points will be described.

  FIG. 7 is an external view and a cross-sectional view of a net-like object 40 that is a fiber-reinforced synthetic resin reinforcing material. The net-like object 40 of this embodiment is also a sheath-centered or parallel type composite as in the above-described embodiment. This composite fiber 20 includes a low melting point component 20a and a high melting point component 20b.

  In the case of the present embodiment, the net-like object 40 is formed into a flat shape by applying a heat press after the knitting net, and a coating 42 made of a thermoplastic resin by the low melting point component 20a covering the reinforcing fiber bundle at the core. Is formed. The coating 42 is a smooth surface with substantially flat upper and lower surfaces, and projections 44 projecting outward are provided on the side surfaces.

  Note that the upper and lower surfaces of the coating 42 do not necessarily need to be smooth, and for example, uneven processing may be performed by a heating roller or press having unevenness. In this case, the concavo-convex processing can be performed on either one of the upper and lower surfaces, or both surfaces, and by providing such concavo-convex and protrusions 44, a net shape is formed on the embankment, slope, concrete wall, etc. When the object 40 is buried, the contact area between the earth and sand and cement particles can be expanded.

  The net-like object 40 of this example is heated to a melting point of the low melting point component 20a and a melting point of the high melting point component 20b in a constant tension state after forming a mesh-like body as in the above example. The low melting point component 20a is melted and then cooled, and the reinforcing fibers (high melting point component 20b) are integrally bonded with the low melting point component 20a. Thermoplastic resin coating with the low melting point component 20a covering the reinforcing fiber bundle at the core while heating and pressurizing from the lower surface to melt the thermoplastic resin of the low melting point component 20a and flattening the composite fiber bundle linear body 42 is formed. The formation of the thermoplastic resin coating 42 is not necessarily required, and it may be merely flattened.

  FIG. 8 to FIG. 10 show an example of use of a fiber reinforced synthetic resin reinforcing material composed of the nets 4 and 40 shown in the above embodiment, and FIG. 8 shows a case where the reinforcing material 50 is used for reinforcing the embankment 50. Show.

  When reinforcing the embankment 50 with the net-like objects 4 and 40, the net-like objects 4 and 40 are embedded in layers in the embankment 50 with a predetermined interval in the vertical direction. The net-like objects 4 and 40 are formed according to the properties of the earth and sand of the embankment 50, and are formed in a predetermined scale. One or a plurality of the net-like objects are laid almost horizontally, and the embankment earth and sand are laminated on the upper part side. The

  Further, the use example shown in FIG. 9 is a case where a reinforcing material made of fiber reinforced synthetic resin made of nets 4 and 40 is used to reinforce the slope 52, and in the case of this use example, the slope 52 is used. A plurality of layers of net-like objects 4 and 40 are embedded along the slope of the slope to reinforce the slope 52.

  In this case, the net-like objects 4 and 40 can be embedded so as to fit along the slope of the slope 52 by appropriately selecting the number of composite fiber bundles and the size of the meshes.

  In the reinforcement of the slope 52, the net-like objects 4 and 40 are embedded along the slope 52 in addition to embedding the net-like objects 4 and 40 in the slope 52, and concrete or By spraying mortar, it can be reinforced by fixing it to the slope 52.

  Furthermore, the use example shown in FIG. 10 is an example in which a reinforcing material made of fiber reinforced synthetic resin made of net-like materials 4 and 40 is used to reinforce a slab 54 made of concrete or mortar.

  In the slab 54, the net-like objects 4 and 40 are embedded in three layers. In particular, in the case of the present embodiment, they are used in place of the lattice lines embedded in the slab 54.

  Next, more specific examples of the present invention will be described.

(Specific Example 1)
PP (polypropylene) is used for the core, PE (polyethylene) is used for the sheath, PP / PE volume ratio is 6: 4, single filament fineness is 23.6 dtex, 1600 filament aggregate (total fineness) 37,800 dtex), 1 twist per 1 cm was added thereto, and it was wound around a bobbin to obtain a composite fiber bundle intermediate linear body 1.

Using this composite fiber bundle intermediate linear body 1, a mesh-like body 3 is obtained by making a net with a knitting netting machine so as to form a knotless network having a mesh of 50 mm, and this mesh-like body 3 is subjected to tension. A net-like material 4 was formed by heat treatment.
In addition, in order to confirm the strength of the linear body of the net-like material 4, the tensile strength of the composite fiber bundle intermediate linear body 1 linearly heated and fused at 140 ° C. is 0.89 KN, and the apparent diameter is It was about 2.9 mm.

(Specific Example 2)
The 1,600 filaments of the composite stretched long fiber shown in the specific example 1 were introduced into the coating die as they were without twisting, and the polyethylene resin coating layer 1a having a thickness of 0.15 mm was provided to provide the coated composite fiber. A bundle intermediate linear body 1 ′ was produced and wound around a bobbin. The outer diameter was about 3.2 mm. Using this coated composite fiber bundle intermediate linear body 1, a fiber-reinforced synthetic resin net-like material was produced under the same conditions as in Example 1.

  In order to confirm the strength of the linear body of the net 4, the coated composite fiber bundle intermediate 1 ′ was linear, heated and fused at 140 ° C., the tensile strength was 0.94 kN, and the apparent diameter was about 3 2 mm.

(Specific Example 3)
An undrawn yarn having a PP (core portion) / PE (sheath portion) volume ratio of 6: 4 and a single yarn fineness of 444 dtex × 50 filaments was obtained, and the undrawn yarn was obtained at 155 ° C. (absolute pressure of 5. A flat PP fiber bundle of 50 filaments was obtained (tensile strength 5.1 cN / dtex) with a total fineness of 1,110 dtex, which was stretched 20 times with 7 kg / cm ² ) high-pressure steam and fused with PE in the sheath.

  Twenty-one of these were converged (total denier 23, 310 dtex), twisted once per cm, and wound on a bobbin. The intermediate was heated and fused in an oven at 140 ° C. under a constant length. The tensile strength was 1.13 kN, and the apparent diameter was about 2 mm.

(Comparative Example 1)
Using 12 high-strength polyester fiber bundles of 1,110 dtex, impregnated with uncured thermosetting resin mixed with Mitsui Chemicals' H2000HV and Nakamura Chemical's NK ester 3G and added with a catalyst, it is made of polyethylene thermoplastic Covered with resin. The outer shape was 2.05 mm, and the tensile strength of what was cured at 110 ° C. for 6 minutes was 90 kg. In addition, the material cost of this intermediate was about twice that of Example 1.

(Specific Example 4)
Polyethylene terephthalate (PET) having an intrinsic viscosity (IV) of 1.22 whose molecular weight is adjusted by a conventional solid phase polymerization method is used as a core component resin, and spinning is performed at a spinning temperature of 295 ° C. and a spinning fineness (composite nozzle 125H) of 111 dtex. An intermediate was obtained under the same conditions as in Example 1 except that the magnification was 5.5 (tensile strength 5.3 N / dtex). Twelve of these intermediate bodies were focused (35,000 dtex), heat-sealed at 140 ° C. under a constant length, the tensile strength was 1.18 kN, and the apparent diameter was about 2.4 mm.

(Specific Example 5)
The core component resin is polyethylene terephthalate (PET) having an intrinsic viscosity (IV) of 1.22 adjusted in molecular weight by a conventional solid-phase polymerization method, except that the spinning temperature is 295 ° C. and the spinning fineness (composite nozzle 50H) is 167 dtex. Spinning under the same conditions as in Example 3, and after stretching, the filament was fused with PE at the same time as stretching under the same conditions as in Example 3 except that it was stretched 7.5 times under 3% relaxation with hot air at 200 ° C. A PET fiber bundle intermediate fused with a flat PE having a denier of 1,110 dtex and a PET filament number of 50 filaments (theoretical PET monofilament denier: 15.2 dtex) was obtained (tensile strength: 5.0 CN / dtex).

  Twenty-one of these were converged (total denier 23, 310 dtex), twisted once per cm, and wound on a bobbin. This intermediate was heated and fused in an oven at 140 ° C. under a constant length. The tensile strength was 1.14 kN and the apparent diameter was about 1.8 mm.

(Specific Example 6)
Nylon 66 (PA66) having a relative viscosity of sulfuric acid (RV) of 2.7 is used as the core component resin, and spinning is performed at a spinning temperature of 290 ° C. and a spinning fineness (composite nozzle 125H) of 89 dtex, and the draw ratio is 4.3 times. An intermediate was obtained under the same conditions as in Example 1 (tensile strength 4.4 cN / dtex).

  Eleven of these intermediate bodies were focused (35,200 dtex), heat-fused at 140 ° C. under a constant length, the tensile strength was 0.88 kN, and the apparent diameter was about 2.3 mm.

(Specific Example 7)
Spinning under the same conditions as in Example 3 except that nylon 66 (PA66) having a relative viscosity of sulfuric acid (RV) of 2.7 is used as the core component resin and spinning is performed at a spinning temperature of 290 ° C. and a spinning fineness (composite nozzle 50H) of 128 dtex. 200 after stretching? Except for stretching 6 times under 6% relaxation with hot air, total denier 1,110 dtex in which filaments were fused with PE at the same time as stretching under the same conditions as in Example 3, nylon filament number: 50 filaments (theoretical PA66 single fiber denier : 14.2 dtex) obtained was a nylon 66 fiber bundle intermediate fused with a flat PE (tensile strength 5.4 cN / dtex).

  Twenty-one of these were converged (total denier 23, 310 dtex), twisted once per cm, and wound on a bobbin. The intermediate was heated and fused in an oven at 140 ° C. under a constant length, the tensile strength was 1.22 kN, and the apparent diameter was about 1.9 mm.

  The fiber-reinforced synthetic resin reinforcing material according to the present invention has no problems such as mortar due to corrosion, peeling of concrete, and problems such as requiring labor and cost for separation processing, and it can also improve the fit to curved surfaces, It can be effectively used for reinforcement of concrete structures in the civil engineering and construction fields, as well as for embankment and slope reinforcement.

It is an external view of the composite fiber bundle intermediate | middle linear body used for manufacture of the fiber reinforced thermoplastic resin reinforcement material concerning this invention, and a composite fiber. It is the external view and principal part sectional drawing of the linear part of the mesh-like thing used for manufacture of the fiber reinforced thermoplastic resin reinforcement material concerning this invention. It is an external view of the mesh-shaped body used for manufacture of the reinforcing material made from fiber reinforced thermoplastic resin concerning this invention. It is the external view and principal part sectional drawing of the reinforcing material made from a fiber reinforced thermoplastic resin concerning this invention. It is the external view and principal part sectional drawing which show the other example of the composite fiber bundle intermediate | middle linear body used for manufacture of the reinforcing material made from a fiber reinforced thermoplastic resin concerning this invention. It is sectional drawing which shows the other example of the composite fiber used for manufacture of the fiber-reinforced thermoplastic resin reinforcement material concerning this invention. It is the external view and principal part sectional drawing which show the other example of the reinforcement material made from a fiber reinforced thermoplastic resin concerning this invention. It is sectional drawing which shows the usage example of the reinforcing material made from a fiber reinforced thermoplastic resin concerning this invention. It is sectional drawing which shows the other usage example of the fiber-reinforced thermoplastic resin reinforcement material concerning this invention. It is sectional drawing which shows another example of use of the fiber reinforced thermoplastic resin reinforcement material concerning this invention.

Explanation of symbols

1, 1 'composite fiber bundle intermediate linear body 1a thermoplastic resin coating
2 Composite fiber 2a Low melting point component (sheath part)
2b High melting point component (core)
3 Mesh 4,40 Net

Claims (20)

  A composite fiber bundle intermediate linear body in which a composite fiber having a low melting point component made of a thermoplastic resin constituting a matrix resin and a high melting point component made of a thermoplastic resin constituting a reinforcing fiber is converged has a predetermined scale. A fiber reinforcement comprising a net-like material in which the low-melting-point component is melted and solidified under tension and then the reinforcing fibers are integrally bound with the low-melting-point component after being knitted into a mesh-like body Reinforcement material made of thermoplastic resin. The conjugate fiber is a sheath-core type conjugate fiber comprising a sheath portion constituting the low-melting-point component and a core portion constituting the high-melting-point component,
The fiber-reinforced thermoplastic resin reinforcing material according to claim 1, wherein a melting point of the sheath part is lower by 10 ° C or more than a melting point of the core part.   3. The fiber reinforced thermoplastic resin reinforcing material according to claim 1, wherein the composite fiber bundle intermediate linear body has a thermoplastic resin coating layer on an outer periphery of the composite fiber bundle.   The reinforcing material made of fiber-reinforced thermoplastic resin according to any one of claims 1 to 3, wherein the mesh-like body is a knotless knit.   The composite fiber is drawn at a temperature not lower than the melting point (softening point) of the sheath portion and not higher than the melting point (softening point) of the core portion, and has a tensile strength of 4.0 cN / dtex or higher. Item 5. The fiber-reinforced thermoplastic resin reinforcing material according to any one of Items 1 to 4.   The composite fiber bundle has a fineness of one or a plurality of fiber bundles that are equal to or higher than the melting point (softening point) of the sheath portion and equal to or lower than the melting point (softening point) of the core portion. The reinforcing material made of fiber-reinforced thermoplastic resin according to any one of claims 3 to 5, wherein   The fiber-reinforced thermoplastic resin reinforcing material according to any one of claims 1 to 4, wherein the net-like material has a tensile strength of a linear member of each side component of 49 N or more.   8. The composite fiber according to claim 1, wherein the core portion is made of a single resin or a plurality of mixed resins among polypropylene, polyethylene terephthalate, nylon, and aromatic polyester (LCP) resin. 9. The fiber-reinforced thermoplastic resin reinforcement described.   The fiber-reinforced thermoplastic resin reinforcing material according to any one of claims 1 to 8, wherein the net-like material is processed so that the composite fiber bundle is flattened by hot pressing after knitting.   The thermoplastic resin film according to any one of claims 1 to 8, wherein the net-like material is formed with a thermoplastic resin film of a low melting point component that covers the reinforcing fiber bundle of the core portion by the hot press after the knitting net. The fiber-reinforced thermoplastic resin reinforcement described.   The reinforcing material according to claim 10, wherein the thermoplastic resin film has protrusions protruding from a side surface with smooth upper and lower surfaces of the net-like material.   The reinforcing material made of fiber-reinforced thermoplastic resin according to claim 10, wherein the thermoplastic resin coating is subjected to uneven processing on upper and lower surfaces thereof.   The reinforcing material made of fiber reinforced thermoplastic resin according to any one of claims 1 to 12, wherein the reinforcing material is used as a lattice of mortar or concrete.   The reinforcing material made of fiber reinforced thermoplastic resin according to any one of claims 1 to 12, wherein the reinforcing material is used as a slope or a reinforcing material for embankment.   The reinforcing material made of fiber-reinforced thermoplastic resin according to any one of claims 1 to 12, wherein the reinforcing material is used as a foundation reinforcing material for civil engineering or construction wall surfaces.   A method for producing a net-like reinforcing material by a linear body composed of a composite fiber comprising a low melting point component made of a thermoplastic resin constituting a matrix resin and a high melting point component made of a thermoplastic resin constituting a reinforcing fiber. A composite fiber bundle intermediate linear body in which a plurality of the composite fibers are twisted and converged, and the composite fiber bundle intermediate linear body is knitted into a mesh-like body having a mesh size of 10 mm or more, and then, The mesh-like body is heated to a melting point of the low melting point component or higher and lower than the melting point of the high melting point component in a constant tension state, and the low melting point component is melted and then cooled to cool the reinforcing fiber with the low melting point component. A method for producing a reinforcing material made of a fiber-reinforced thermoplastic resin, characterized in that a net-like material integrally bonded is formed. A method for producing a net-like reinforcing material comprising a composite fiber comprising a low melting point component comprising a thermoplastic resin constituting a matrix resin and a high melting point component comprising a thermoplastic resin constituting a reinforcing fiber,
After converging a plurality of the composite fibers, the composite fiber bundle intermediate linear body is obtained by coating with a thermoplastic resin having a melting point higher than that of the low melting point component, thereby obtaining a plurality of the coated composite fiber bundle intermediate linear bodies Is then knitted into a mesh-like body having a mesh size of 10 mm or more, and then the mesh-like body is in a constant tension state, the melting point of the low-melting-point component or higher, the high-melting-point component or the coated composite fiber Heating below the melting point of the coating resin of the bundle intermediate linear body to melt the low melting point component and then cooling to form a net-like material in which the reinforcing fibers are integrally bound with the low melting point component A method for producing a reinforcing material made of fiber-reinforced thermoplastic resin.   The composite fiber is stretched at a temperature equal to or higher than the melting point (softening point) of the sheath portion and equal to or lower than the melting point (softening point) of the core portion, and fuses the sheath portion to have a tensile strength of 4.0 cN / dtex or higher. The composite fiber bundle is obtained, and one or a plurality of the composite fiber bundles are converged to obtain a composite fiber intermediate linear body having a fineness of 5,550 dtex or less. The mesh-like body having the above-mentioned mesh is knitted, and then the mesh-like body is heated to a melting point of the low-melting component of the composite fiber to a melting point of the high-melting component in a constant tension state. 19. The fiber-reinforced thermoplastic resin reinforcement according to claim 17 or 18, wherein a melting point component is melted and then cooled to form a net-like material in which the reinforcing fibers are integrally bound with the low melting point component. A method of manufacturing the material.   After forming the mesh-like body with a knitted net, or with the mesh-like body being in a certain tension state, the melting point of the low melting point component of the conjugate fiber, the high melting point component, or the coated conjugate fiber bundle intermediate linear body After heating to below the melting point of the coating resin, the low melting point component is melted and then cooled to form a net-like material in which the reinforcing fibers are integrally bound with the low melting point component, and then heated or heated. Heat from the upper and lower surfaces with a roller to melt the low-melting-point component thermoplastic resin to flatten the composite fiber bundle linear body, or heat by the low-melting-point component covering the reinforcing fiber bundle at the core The method for producing a fiber-reinforced thermoplastic resin reinforcing material according to any one of claims 17 to 18, wherein a plastic resin film is formed.   After forming the mesh body by a knitted net, or in a state of constant tension of the mesh body, the melting point of the low melting point component of the composite fiber is higher than the melting point, the high melting point component, or the coated composite fiber bundle intermediate linear body After heating to the melting point of the coating resin or lower, melting the low melting point component and then cooling to form a net-like material integrally binding the reinforcing fibers with the low melting point component, a heating press or a heating roller By heating and pressurizing from the upper and lower surfaces of the net, the thermoplastic resin of the low melting point component is melted to form a thermoplastic resin film by the low melting point component covering the reinforcing fiber bundle at the core, and then the surface has irregularities on the surface. The method for producing a reinforcing material made of fiber reinforced thermoplastic resin according to any one of claims 17 to 18, wherein the top surface, the bottom surface, or both surfaces of the net-like material are subjected to uneven processing by a press or a roller.

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