JP5698517B2 - Method for producing flat fiber reinforced plastic wire - Google Patents

Description

The present invention relates to a method for producing a fiber reinforced plastic wire of a flat shape. In particular, a flat fiber reinforced plastic wire and a fiber reinforced sheet in which such flat fiber reinforced plastic wires are arranged in a sheet form are, for example, a concrete structure, a steel structure, a fiber reinforced plastic structure which is a civil engineering building structure. It can be used to reinforce by adhering or embedding it in a structure (in this specification, including a concrete structure, a steel structure, a fiber reinforced plastic structure, etc.). .

  As a method for reinforcing a structure, in recent years, a bonding method has been developed in which a continuous fiber reinforced sheet is attached to or wound around the surface of an existing or new structure.

  However, the above-mentioned bonding method is only simple bonding, and there is a limit to the ultimate strength reinforcement hardening due to the early destruction of the structure due to the peeling of the FRP (fiber reinforced plastic) reinforcing material. There is a limit to the suppression effect. In addition, the high performance of the FRP reinforcement is often not utilized effectively. In addition, it is impossible to recover from crack damage of existing structures or to reinforce dead loads.

  In order to improve such problems, a tension bonding method is being used in which a load is applied to a sheet-shaped reinforcing material and the sheet-shaped reinforcing material is tensioned, and the sheet-shaped reinforcing material is bonded to the structure surface in a tensioned state. The sheet-like reinforcing material used in this tension bonding method is currently a sheet in which fibers not impregnated with resin are aligned in one direction, a so-called reinforcing fiber sheet, or a flat plate of fiber reinforced plastic having a width of 50 mm or more. Is used.

  However, in the reinforcing fiber sheet using the fibers not impregnated with the resin, the reinforcing fibers are not always uniformly arranged in one direction due to a manufacturing problem or a handling problem. For this reason, in order to introduce tension, partial thread breakage may occur when a tension is applied to the reinforcing fiber sheet to cause tension, and sufficient tension may not be introduced. That is, the reinforcing fiber sheet may not exhibit sufficient force necessary for tension. Usually, the tension is reduced by about 50% to 30% of the final breaking load.

  Further, when a fiber reinforced plastic flat plate is used, since the plate width is wide, there is a problem that when adhering, voids are mixed into the bonding surface and it is difficult to obtain a sufficient bonding force. In order to avoid the generation of voids, it is conceivable to make a hole in the fiber-reinforced plastic flat plate, but in this case, the reinforcing fiber of the fiber-reinforced plastic flat plate is cut, which is not preferable.

  Therefore, as described in Patent Document 1, the present inventors have arranged a plurality of continuous fiber reinforced plastic wires that are impregnated with a matrix resin in a reinforced fiber and cured, and are arranged in a slender shape in the longitudinal direction. A fiber reinforced plastic wire sheet, that is, a fiber reinforced sheet, which are fixed to each other with a fixing fiber material, has been proposed.

  Such a fiber reinforced sheet can solve the problem of thread breakage during tension, and can also avoid generation of voids during construction to obtain a sufficient adhesion force to the reinforced surface. Reinforcement of concrete structures based on the bonding method can be performed with extremely good workability.

  On the other hand, conventionally, a round continuous fiber-reinforced plastic wire used for the fiber-reinforced sheet is usually manufactured by a pultrusion method called a pultrusion method.

  Next, with reference to FIG. 9, the manufacturing method of the fiber reinforced plastic wire material according to the conventional pultrusion method is demonstrated easily. FIG. 9 shows a process in which reinforcing fibers move from the left side to the right side, during which resin impregnation, round shape molding, primary heat curing, secondary heat curing, and winding are performed.

  According to the manufacturing apparatus 200 that performs the pultrusion method shown in FIG. 9, a reinforcing fiber bundle f1 made of a plurality of reinforcing fibers not impregnated with resin wound around the unwinding bobbin 11 (11a, 11b) of the unwinding apparatus 51. Is unwound by rotating the rotary shaft 12 (12a, 12b) and fed to the resin impregnation step.

  That is, the reinforcing fiber bundle f1 unwound from the bobbin 11 is guided by the guide holes 15 (15a, 15b) of the guide 14, and is fed to the resin impregnation step which is the next step.

  The reinforcing fiber bundle f1 fed to the resin impregnation step is introduced into the impregnation roller 18 by the inlet guide roller 16 and impregnated with the resin. The entrance guide roller 16 serves to align a plurality of fibers constituting the reinforcing fiber bundle f1 before the resin-impregnated reinforcing fiber bundle f1 made of a plurality of reinforcing fibers.

  The impregnation roller 18 serves to forcibly immerse the reinforcing fiber bundle f1 in the resin R, and is used in a state where at least the lower half is immersed in the resin R stored in the resin impregnation tank 17.

  The outlet guide roller 19 provided at the outlet of the resin impregnation tank 17 serves to align the resin-impregnated reinforcing fiber bundle f2 before sending it to the primary heat curing step of the next step.

  The resin-impregnated reinforcing fiber bundle f2 is fed to the heating mold 27A and then fed to the heating and curing furnace 27B.

  That is, the heating mold 27A has a role of round molding using the mold and primary curing of the resin. In the mold 27A, round grooves 27Aa and 27Ab having a predetermined diameter are carved in the moving direction of the reinforcing fiber bundle f2, and the reinforcing fiber bundle f2 impregnated with resin in the round grooves 27Aa and 27Ab is formed. When passing, it is heated by a heat ray incorporated in the mold, and the resin is primarily cured to obtain semi-cured round fiber reinforced plastic wires 2a and 2b.

  Since the resin content in the fiber reinforced plastic wire is controlled by squeezing excess resin at the entrance of the mold 27A, the resin must be changed unless the amount of the reinforcing fiber bundle f2 to be inserted into the hole grooves 27Aa and 27Ab of the mold is changed. It has the disadvantage that the content cannot be changed.

  Further, since the reinforcing fiber bundle f2 impregnated with resin moves in the mold 27A, it is absolutely not allowed to stick between the resin and the mold. For this reason, the resin contains a large amount of release agent so that the resin does not stick to the mold.

  The secondary heating furnace 27B is a step of performing secondary heat curing. Here, the shortage of primary curing in the round fiber-reinforced plastic wires 2a and 2b semi-cured by the mold 27A is compensated, and the impregnation resin is completely cured here.

  The wire 2 completely cured in the secondary heating furnace 27B is fed to the bobbin 30 (30a, 30b) of the winding device 52 through the guide holes 21 (21a, 21b) of the guide guide 20, It is wound up by a bobbin 30 that rotates around a rotary shaft 31 (31a, 31b).

  As described above, the conventional pultrusion molding method uses a heated die having a round opening to form a round wire, and thus resistance is generated when passing through the die. There is a problem that the speed cannot be increased. In addition, due to restrictions on the size of the mold, the number of holes provided in the mold is limited, and there is a problem that the number of wires that can be manufactured at one time is at most 20-30. When the shape such as the size and width of the wire changed, it was necessary to change the mold. Therefore, the cost is increased.

  Furthermore, a release agent is used to prevent the matrix resin and the mold from sticking together, and the release agent comes out on the surface of the wire. This wire is used as a sheet reinforcement (fiber reinforced sheet) to reinforce the structure. In the case of use in the above, there has been a problem that the adhesion between the adhesive and the surface of the wire does not work well when adhering to the structure. Therefore, when a fiber reinforced sheet is used, there is a problem that the surface must be roughened with sandpaper after the wire is cured.

  Because of this problem, the production cost has been increased, and the quality has been lowered due to brazing of the wire when the surface is rough.

  Then, the present inventors proposed the manufacturing method of a round shape fiber reinforced plastic wire, as disclosed by patent document 2. FIG.

In other words, the first manufacturing method is
(A) a step of continuously feeding a reinforcing fiber bundle composed of a plurality of reinforcing fibers arranged in one direction while twisting;
(B) a step of impregnating a matrix resin into a reinforcing fiber bundle that is continuously fed;
(C) a step of heating the resin-impregnated reinforcing fiber bundle while tensioning it at a predetermined strength to cure the resin in a circular cross section of the reinforcing fiber bundle;
It is a manufacturing method provided with.

The second manufacturing method is
(A) a step of continuously feeding a reinforcing fiber bundle composed of a plurality of reinforcing fibers arranged in one direction;
(B) a step of impregnating a matrix resin into a reinforcing fiber bundle that is continuously fed;
(C) a step of twisting the reinforcing fiber bundle impregnated with resin,
(D) a step of heating the reinforcing fiber bundle impregnated with the resin and twisted with tension at a predetermined strength to cure the resin so that the cross section of the reinforcing fiber bundle has a circular shape;
It is a manufacturing method provided with.

The manufacturing method described in Patent Document 2 is
(1) Twist the reinforcing fiber, control the resin impregnation amount of the matrix resin, and heat cure the resin-impregnated reinforcing fiber, by applying tension force to the reinforcing fiber, without using a mold Shaped fiber reinforced plastic wire can be produced.
(2) Since no mold is used, it is possible to produce 30 or more wires at a time, and it is not necessary to add a mold release agent to the matrix resin. Roughing work is also unnecessary, and significant cost reduction and quality improvement can be achieved.
It has the following advantages.

JP 2004-197325 A JP 2008-222846 A

  On the other hand, when a fiber reinforced sheet is bonded to a structure such as a concrete structure or a steel structure to be reinforced, if the fiber reinforced plastic wire constituting the fiber reinforced sheet has a round shape, the reinforcing thickness increases and the resin to be bonded The amount increases. The flat shape can reduce the reinforcement thickness and reduce the amount of resin to be bonded to provide the same reinforcement strength.

  Similarly, when the fiber reinforced plastic wire is used as a reinforcing bar embedded in a concrete structure or glass fiber reinforced plastic structure, the thickness of the part where the reinforcing bar is inserted can be reduced. Many reinforcing fibers can be introduced, and the fiber content (ie, Vf) within a certain volume, the target cross-sectional rigidity and strength of the structure can be compared with those of a round shape, and can be manufactured with a thinner plate thickness. .

  However, when a flat fiber-reinforced plastic wire is made by pultrusion in the same manner as a round shape, there are restrictions on the mold, and there is a restriction on the number of production due to the limit of the number of holes. Further, in order to prevent the matrix resin from sticking, it is essential to use a mold release agent, and there has been a problem that the product after molding and the resin or concrete to be bonded later do not adhere well.

  In addition, according to the results of the inventors' experiment, a plurality of fibers impregnated with resin (fiber bundles) are twisted, pulled with a constant tension, rounded, and then molded into a constant thickness on a flat plate. It was found that it was not possible to produce with a width that was nearly uniform. That is, when the shape before flattening is random, molding with a constant plate thickness and a nearly uniform width cannot be performed.

  On the other hand, since the mold is a flat plate, it is possible to create various thickness shapes with one mold by adjusting the gap between the upper and lower sides.

  Furthermore, the present inventors use a flat plate mold (die) in order to change the round shape into a flat plate shape, and a mold release agent is used for releasing the flat plate mold from the flat wire product. Instead, it was found that a thin cloth (polyester woven fabric called peel ply, etc.) that does not adhere to the adhesive can be continuously inserted into the upper and lower surfaces of the wire to be molded, cured, and peeled off. This method is difficult to adopt in the pultrusion molding because wrinkles are generated due to the mold having a shape.

  In addition, since the mold for forming a round wire into a flat (flat) wire is a flat plate, the die can be made thin, and can be installed vertically in two or three steps within a narrow range, and can be formed at once. The number of wires can be increased to, for example, 30 or more and about 300, which is efficient.

  Moreover, it is only necessary to draw a round fiber bundle impregnated with a resin into a flat plate mold, and the metal mold and the fiber bundle impregnated with the resin are directly protected by a thin release cloth on the upper and lower sides thereof. Since it was not touched, it was found that there was little damage to the resin-impregnated fiber bundle, there was almost no frequency of yarn breakage during production, and the molding yield could be greatly increased.

  The present invention has been made based on such novel findings of the present inventors.

Therefore, the object of the present invention is to remove the restrictions on the molding speed and the number of parts that can be manufactured at one time, eliminate the use of a mold release agent, eliminate the work such as roughening after molding, and greatly reduce the manufacturing cost. And to provide a method for producing a flat-shaped fiber-reinforced plastic wire that can greatly improve product quality.

The above object is manually achieved in the manufacture how the flat-shaped fiber-reinforced plastic wire according to the present invention. In summary, according to the first aspect of the present invention,
(A) a step of continuously feeding a reinforcing fiber bundle composed of a plurality of reinforcing fibers arranged in one direction while twisting;
(B) impregnating a matrix resin into the reinforcing fiber bundle continuously fed;
(C) The reinforcing fiber bundle impregnated with the resin and twisted is tensed with a predetermined strength to make the reinforcing fiber bundle have a circular cross section, and then the cross section is made circular. With a high-density fabric having releasability from the resin placed on the upper and lower surfaces of the bundle, the resin is drawn in between the two heated flat plates and the cross section of the reinforcing fiber is molded into a flat shape. A primary curing step,
(D) a step of secondarily curing the reinforcing fiber bundle which has been flatly cured in the transverse cross section through a heated curing furnace;
There is provided a method for producing a continuous flat fiber-reinforced plastic wire, characterized in that a fiber-reinforced plastic wire having a flat cross-section with a flat shape is produced.

According to a second aspect of the invention,
(A) a step of continuously feeding a reinforcing fiber bundle composed of a plurality of reinforcing fibers arranged in one direction;
(B) impregnating a matrix resin into the reinforcing fiber bundle continuously fed;
(C) a step of twisting the resin-impregnated reinforcing fiber bundle,
(D) The reinforcing fiber bundle impregnated with the resin and twisted is tensed with a predetermined strength so that the cross section of the reinforcing fiber bundle has a circular shape, and then the cross section of the reinforcing fiber bundle has a circular shape. With a high-density fabric having releasability from the resin placed on the upper and lower surfaces of the bundle, the resin is drawn in between the two heated flat plates and the cross section of the reinforcing fiber is molded into a flat shape. A primary curing step,
(E) a step of secondarily curing the reinforced fiber bundle, which has a flat cross-sectional cross section, through a heated curing furnace;
There is provided a method for producing a continuous flat fiber-reinforced plastic wire, characterized in that a fiber-reinforced plastic wire having a flat cross-section with a flat shape is produced.

  According to one embodiment of the present invention, the fiber reinforced plastic wire has a thickness (t) of 0.2 mm to 5.0 mm and a width (w) of 1.0 mm to 10.0 mm.

  According to another embodiment of the present invention, the number of twists of the reinforcing fiber bundle is 5 times / m to 20 times / m.

  According to another embodiment of the present invention, the resin-impregnated reinforcing fiber bundle is tensioned at a strength of 500 g / line to 3000 g / line.

  According to another embodiment of the present invention, the amount of the matrix resin impregnated into the reinforcing fiber in the reinforcing fiber bundle is 36% to 60% in volume ratio (Vf).

  According to another embodiment of the present invention, the reinforcing fiber is any one of glass fiber, carbon fiber, aramid fiber, PBO (polyphenylenebenzbisoxazole) fiber, and polyester fiber.

  According to another embodiment of the present invention, the matrix resin is one of an epoxy resin, a vinyl ester resin, an MMA resin, an unsaturated polyester resin, or a phenol resin.

  According to another embodiment of the present invention, the high-density woven fabric is a plain woven fabric in which a total number of warp yarns and weft yarns between inch lengths is 210 or more.

According to another embodiment in the present invention, the high-density woven fabric, polyester fiber, nylon fiber, or vinylon fiber continuous filament yarn of a single fabric Wei, or is either mixed fabrics.

  According to the present invention, a flat-shaped fiber-reinforced plastic wire having a constant thickness and a substantially constant width can be efficiently manufactured in a large amount at a time, and the yield is improved, no mold release agent is required. With no need for roughening, significant cost reduction and quality improvement can be achieved.

It is a schematic block diagram of the manufacturing apparatus for demonstrating one Example of the manufacturing method of the flat shape fiber reinforced plastic wire which concerns on this invention. BRIEF DESCRIPTION OF THE DRAWINGS It is a schematic block diagram of the manufacturing apparatus for demonstrating one Example of the manufacturing method of the flat shape fiber reinforced plastic wire which concerns on this invention, Fig.2 (a) is a top view, FIG.2 (b) is a front view. It is. It is a schematic block diagram which shows one Example of the heating plate apparatus in the flat shape fiber reinforced plastic wire manufacturing apparatus which concerns on this invention. It is a schematic block diagram explaining the action | operation of the unwinding bobbin in the manufacturing apparatus for demonstrating one Example of the manufacturing method of the flat shape fiber reinforced plastic wire which concerns on this invention. It is sectional drawing of the flat shape fiber reinforced plastic wire which comprises the fiber reinforced sheet | seat of this invention. It is a perspective view which shows one Example of the fiber reinforced sheet | seat of this invention. It is a schematic block diagram of the manufacturing apparatus for demonstrating the other Example of the manufacturing method of the flat shape fiber reinforced plastic wire which concerns on this invention. It is a schematic block diagram explaining the action | operation of the winding bobbin in the manufacturing apparatus for demonstrating the other Example of the manufacturing method of the flat shape fiber reinforced plastic wire which concerns on this invention. It is a schematic block diagram of the wire manufacturing apparatus for demonstrating the conventional pultrusion method.

  Hereinafter, a flat fiber-reinforced plastic wire manufacturing method according to the present invention, a fiber-reinforced plastic wire manufactured by the manufacturing method, and a fiber-reinforced sheet manufactured using the wire, will be described in detail with reference to the drawings. explain.

Example 1
1 to 4 show an embodiment of a manufacturing apparatus 100 (100A, 100B) for manufacturing a flat fiber-reinforced plastic wire according to the present invention. FIG. 5 shows a cross-sectional structure of a flat fiber-reinforced plastic wire 2 produced according to the present invention, and FIG. 6 shows an example of a staple-like fiber-reinforced sheet 1 using the flat fiber-reinforced plastic wire 2. An example is shown.

  In this embodiment, the manufacturing apparatus 100 (100A, 100B) includes fiber feeding, resin impregnation, winding section 100A (FIG. 1), fiber tension, oblate, heat curing section 100B (100B1, 100B2) (FIG. 2).

  FIG. 1 shows a fiber feeding, resin impregnation, and winding section 100A of the manufacturing apparatus 100, and a reinforcing fiber strand (reinforced fiber bundle) f1 composed of a plurality of reinforcing fibers f moves from the left side to the right side in the drawing. In the meantime, twisting and resin impregnation are performed.

  2A and 2B show the fiber tension, oblate shape, and heat-curing section 100B (molded primary curing section 100B1, secondary curing section 100B2) of the manufacturing apparatus 100, and from the left side to the right side in the drawing. The reinforcing fiber f2 that has been subjected to the twisting process and the resin impregnation step moves, and flat shape molding and resin curing are performed under a predetermined tension.

  More specifically, in the fiber feeding, resin impregnation and winding section 100A shown in FIG. 1, a plurality (usually 3 to 18) of windings for supplying two fibers are used in this embodiment to simplify the drawing. A take-out bobbin (cylindrical bobbin) 11 (11a, 11b) is prepared, and a reinforcing fiber strand (reinforced fiber bundle) f1 in which a predetermined number of reinforcing fibers f not impregnated with resin are converged is wound around each bobbin 11. Yes.

  The reinforcing fiber bundle f1 wound around each bobbin 11 is continuously fed to the resin impregnation step in which the resin impregnation tank 17 is disposed. At the same time, the reinforcing fiber bundle f1 is twisted (supply of reinforcing fiber bundle, twisting process).

  That is, the reinforcing fiber bundle f1 fed to the resin impregnation step is resin impregnated in the resin impregnation tank 17, and the reinforcing fiber bundle f2 impregnated with the resin is wound around the bobbin 22 for winding (22a, 22b). ) (Resin impregnation, twisting process).

  In the fiber tension / heat-curing section 100B shown in FIGS. 2 (a) and 2 (b), a plurality of (usually 50 to 300) reinforcing fiber bundles f2 impregnated with resin and twisted are used. In the example, the two bobbins 22 (22a, 22b) corresponding to FIG. 1 are unwound in order to make the drawing easy to understand, and introduced into the heating plate device 27a for primary heating and curing of the molded primary curing section 100B1. And heat-cured (primary curing). At this time, the resin-impregnated reinforcing fiber bundle f2 is subjected to flat shape molding and primary heat curing in a state in which a predetermined tension is applied (strengthening fiber bundle tension, oblate shape, primary heat curing step). The reinforcing fiber bundle f3 that has been flattened and primary-cured is subsequently guided to the secondary heat-curing furnace 27b of the secondary-curing section 100B2 and further heat-cured (secondary-cured) (secondary heat-cured). Process). The heat-cured (secondary-cured) reinforcing fiber bundle, that is, the reinforcing fiber plastic wire 2 is wound around a bobbin 30 (30a, 30b) for winding.

  Next, the above steps will be described in more detail.

(Reinforcement fiber bundle supply, twisting process)
In this embodiment, as will be better understood with reference also to FIG. 4, in the fiber feeding, resin impregnation and winding section 100A, the bobbin 11 (11a, 11b) is a rotation provided in the unwinding device 51. The rotary shaft 12 is attached to a shaft 12 (12a, 12b), and is further rotatably attached to a rotary main shaft 13 (13a, 13b) of the unwinding device.

  Each bobbin 11 (11a, 11b) is rotated around the rotation shaft 12 (12a, 12b) of each bobbin 11 (11a, 11b) by the drive motor M and the gear transmission mechanism G, and the bobbin 11 (11a, 11b) is rotated. The reinforcing fiber bundle f1 wound around (1) is unwound. At the same time, as described above, each bobbin 11 (11a, 11b) rotates around the rotary shaft 12 (12a, 12b) and rotates along with the rotary shaft 12 (12a, 12b). ).

  That is, the bobbin 11 rotates around the rotating shaft 12 and simultaneously rotates around the rotating main shaft 13 to unwind the reinforcing fiber bundle f1.

  The reinforcing fiber bundle f1 unwound from the bobbin 11 is guided by the guide holes 15 (15a, 15b) formed in the guide 14, and is introduced into the resin impregnation tank 17 by the inlet guide roll 16.

  With the above configuration, the reinforcing fiber bundle f1 supplied to the impregnation step provided with the resin impregnation tank 17 is supplied with a twist.

  By adjusting the number of rotations of the bobbin 11 around the rotation main shaft 13 and the unwinding speed of the reinforcing fiber bundle f1, the number of twists per 1 m can be controlled.

  According to the present embodiment, as will be described in detail later, the fiber reinforced plastic wire before being flattened to have a thickness (t) of 0.2 mm to 5.0 mm and a width (w) of 1.0 mm to 10.0 mm. The wire diameter is preferably 0.5 mm to 8.0 mm. Accordingly, the reinforcing fiber bundle f1 supplied to the impregnation step is, for example, carbon in which 3000 to 320,000 carbon fibers (filaments) f having a wire diameter of 6 to 10 μm are converged when carbon fibers are used as reinforcing fibers. The fiber strand (carbon fiber bundle) f1 is used.

  The number of twists of the reinforcing fiber bundle f1 is preferably 5 times / m to 20 times / m. Details will be described later.

(Resin impregnation process)
Matrix resin R is accommodated in the resin impregnation tank 17, and the inlet guide roller 16 for guiding the reinforcing fiber bundle f1 is disposed at the inlet of the impregnation tank 17 as described above. An impregnation roller 18 is disposed in the impregnation tank 17, and an outlet guide roller pair 19 is disposed at the outlet of the impregnation tank 17.

  The inlet guide roller 16 serves to align the plurality of fibers f constituting the reinforcing fiber bundle f1 supplied to the impregnation tank 17 before impregnation in the step of impregnating the reinforcing fiber bundle f1 with resin.

  The impregnation roller 18 serves to forcibly immerse the reinforcing fiber bundle f1 in the resin R, and is used in a state where at least the lower half is immersed in the resin R stored in the impregnation tank 17.

  The pair of outlet guide rollers 19 (19a, 19b) serves to squeeze the reinforcing fiber bundle f2 impregnated with the resin, and the resin adhesion amount is controlled here.

  That is, the amount of resin impregnated in the reinforcing fiber bundle f2 is controlled by controlling the pressing pressure of the upper and lower rollers 19a, 19b.

  In this embodiment, the amount of the matrix resin impregnated with respect to the reinforcing fiber f is preferably 36% to 60% in volume ratio (Vf). Details will be described later.

  The resin-impregnated reinforcing fiber bundle f <b> 2 is guided by guide holes 21 (21 a, 21 b) formed in the guide 20, and taken up by the take-up bobbins 22 (22 a, 22 b) in the take-up device 52.

  Each take-up bobbin 22 is rotationally driven around a rotation shaft 23 (23a, 23b).

  The bobbin 22 around which the reinforcing fiber bundle f2 impregnated with the resin is wound is removed and supplied to the tension, oblate shape, molding in the heat curing section 100B and the heat curing step shown in FIG.

(Tension, oblate shape, heat curing process)
Referring to FIGS. 2 (a) and 2 (b), in the tension, oblate shape, and heat-curing section (in the following description, it may be simply referred to as “molding / curing section”) 100B, The bobbin 22 (22a, 22b) around which the resin-impregnated reinforcing fiber bundle f2 is wound is installed on the rotating shaft 24 (24a, 24b) of the unwinding device 53. That is, the take-up bobbin 22 functions as an unwind bobbin in the tension, oblate shape, and curing process.

  The twisted uncured reinforcing fiber bundle f2 impregnated with resin and wound around the unwinding bobbin 22 is unwound by rotating the bobbin 22 around the rotation shaft 24 (24a, 24b). The reinforcing fiber bundle f2 is passed through the guide 25 through the molding and hardening section 100B, and is wound around the winding bobbins 30 (30a, 30b) of the winding device 54.

  The molded and cured section 100B includes a molded primary cured section 100B1 including a heating plate device 27a for molding the resin-impregnated and twisted uncured reinforcing fiber bundle f2 into a flat shape and simultaneously performing primary curing (semi-curing). The secondary heat-curing section 100B2 includes a curing furnace 27b for secondarily curing the reinforcing fiber bundle f3 formed into a flat shape and semi-cured.

  More specifically, the unwinding device 53 is provided with a function such as an electromagnetic brake, and can impart appropriate tension to the uncured resin-impregnated reinforcing fiber bundle f2 unwound from the bobbin 22.

  That is, the reinforcing fibers that are bundled by applying appropriate tension to the reinforcing fiber bundle f2 that is twisted and impregnated with the uncured resin between the unwinding device 53 and the heating plate device 27a. It is possible to uniformly strain f and to make the cross-sectional shape of the reinforcing fiber bundle f2 a circular cross-section, that is, a round shape.

  In the specification and claims of the present application, the term “circular” includes “substantially circular” in which the diameter ratio in the vertical and horizontal directions in the cross section is within the range of 1.0 to 1.5. Means.

  As described above, according to the present embodiment, the uncured reinforcing fiber bundle f2 is unwound while the electromagnetic brake is applied to the unwinding bobbin 22, and the unwinding bobbin 30 passes through the heating plate device 27a and the curing furnace 27b. While applying an appropriate tension, it is molded into a flat shape by the heating plate device 27a and is first-cured (semi-cured), and then the resin is completely cured in the heat-curing furnace 27b.

  In this example, as the tension, it is preferable to impart a strength of 500 g / piece to 3000 g / piece to the reinforcing fiber bundle f2 impregnated with the resin.

  The twisted and uncured resin-impregnated reinforcing fiber f2 unwound from the unwinding bobbin 22 is guided by guide holes 26 (26a, 26b) formed in the guide 25, and a heating plate device 27a, a heating curing furnace 27b is continuously supplied.

  Each unwinding bobbin 22 is rotationally driven around a rotating shaft 24 (24a, 24b).

  In this embodiment, the heating plate device 27a has a structure shown in FIG.

  That is, the heating plate device 27a includes two first and second heating plates 27a1 and 27a2 that are symmetrically arranged in the vertical direction in the present embodiment and that are arranged in parallel with each other and horizontally in the present embodiment. I have. Each of the heating plates 27a1 and 27a2 constitutes inner surfaces that face each other, and are usually made of metal such as steel or stainless steel, and are formed on the outer sides of the forming plates 27a3 and 27a4 and the forming plates 27a3 and 27a4. Are provided with panel heaters (heat sources) 27a5 and 27a6 provided integrally therewith.

Each of the heating plates 27a1 and 27a2 has at least a width direction (heating plate device) in order to form a round wire inserted between inner surfaces facing each other into a flat wire having a thickness (t) and a width (w). Thickness adjusting shim plates 27a7 are arranged on both sides (in a direction orthogonal to the moving direction of the wire rod inserted into 27a) and are separated by a predetermined distance (t1, where t1> t).

As shown in the figure, the heating plates 27a1 and 27a2 are united by a vertical heating plate fastening bracket 270 with a thickness adjusting shim plate 27a7 interposed therebetween. That is, the upper and lower heating plate clamps 270 are positioned on the outer side of the first heating plate 27a1 (upper side in FIG. 3) and the outer side of the second heating plate 27a2 (lower side in FIG. 3). The horizontal metal fitting 272 is provided. The horizontal fittings 271 and 272 are larger than the width (W27a) of the first and second heating plates 27a1 and 27a2 in the width direction, and protrude to both sides. The horizontal metal fittings 271 and 272 are provided with bolts 273 penetrating using the protruding portions, and are clamped with nuts 274 to sandwich the heating plates 27a1 and 27a2 and the thickness adjusting shim plate 27a7. Hold it together. In FIG. 3, only one upper and lower heating plate clamp 270 is shown along the length L27a of the heating plate device 27a. However, an appropriate number, for example, 2 is selected according to the length L27a of the heating plate device 27a. About 4 pieces are arranged.

  As described above, according to the present invention, since the die is a flat plate, it is possible to create various thickness shapes by adjusting the gap between the upper and lower sides.

  In addition, since the mold for forming a round wire into a flat wire is a flat plate, the die can be made thin and installed vertically in two or three steps within a narrow range, increasing the number of wires that can be formed at one time. Can be efficient. In practice, the number of wires that can be simultaneously molded can be 30 or more, and there is no problem about 100 to 300 wires.

  Moreover, it is only necessary to draw a round fiber bundle impregnated with a resin into a flat plate mold, and the metal mold and the fiber bundle impregnated with the resin are directly protected by a thin release cloth on the upper and lower sides thereof. Since it was not touched, it was found that there was little damage to the resin-impregnated fiber bundle, there was almost no frequency of yarn breakage during production, and the molding yield could be greatly increased.

  On the other hand, the heating and curing furnace 27b basically has a closed structure except for the inlet and outlet, has a heater function or a hot air circulation function inside, and is semi-hardened to be fed from the heating plate device 27a. The fiber f3 can be heated.

  Here, according to the present invention, as understood with reference to FIGS. 2B and 3, the heating plate device 27 a includes the first and second heating plates 27 a 1 and 27 a 2 arranged symmetrically in the vertical direction. The upper surface peel ply 63 and the lower surface peel ply 64 are arranged along the movement direction of the wire rod inserted into the heating plate device 27a (that is, the direction of the length L27a of the heating plate device 27a). Similarly, in the secondary curing furnace 27b, the upper surface peel ply 63 and the lower surface peel ply 64 are arranged along the moving direction of the wire inserted into the curing furnace 27b (that is, the direction of the length L27b of the curing furnace 27b). The

  In this embodiment, the upper surface peel ply 63 and the lower surface peel ply 64 are disposed so as to penetrate from the inlet side of the heating plate device 27a to the outlet side of the secondary curing furnace 27b, as shown in FIGS. 2 (a) and 2 (b). Has been. That is, the upper surface peel ply 63 and the lower surface peel ply 64 are unwound from the unwinding reels 61a and 62a disposed on the inlet side of the heating plate device 27a, respectively, and are taken up on the outlet side of the secondary curing furnace 27b. It is wound around 61b and 62b.

  The upper peel ply 63 and the lower peel ply 64 are molded in the molding and curing section 100B, that is, the molding primary curing section 100B1 (that is, in the heating plate device 27a) and the secondary curing section 100B2 (that is, in the secondary curing furnace 27b). It arrange | positions in the aspect which clamps the wire which moves the hardening section 100B up and down.

  Accordingly, the uncured resin-impregnated reinforcing fiber f2 that has been untwisted and unwound from the unwinding device 53 is formed into a primary cured section 100B1 (that is, in a form that is sandwiched between the upper surface peel ply 63 and the lower surface peel ply 64 from above and below. The inside of the heating plate device 27a) is moved, forming from a round shape to a flat shape and semi-cured heat curing. Subsequently, it is introduced into the secondary curing section 100B2 (that is, in the secondary curing furnace 27b) and further heat curing is performed.

Usually, the moving speed of the reinforcing fiber bundle moving in the molding and curing section 100B is 0.3 to 2.0 m / min, and the temperature in the heating plate device 27a is 120 to 140 ° C. in the secondary curing furnace 27b. The temperature is set to 130 to 150 ° C.

  The moving speed of the reinforcing fiber bundle moving through the molding and curing section 100B, the temperature in the heating plate device 27a, and the temperature in the secondary curing furnace 27b are determined by the type of resin impregnated.

  By increasing the lengths (L27a, L27b) of the heating plate device 27a and the curing furnace 27b, the production speed of the fiber reinforced plastic wire can be increased, and higher productivity can be achieved than the method using a mold described later. Can do.

  The upper surface peel ply 63 and the lower surface peel ply 64 are high density fabrics having releasability from the resin impregnated in the reinforcing fiber bundle.

  In the present invention, the “high-density fabric” refers to a reinforcing fiber bundle that acts as a buffer material between the mold and the reinforcing fiber bundle so as not to damage the reinforcing fiber bundle when the reinforcing fiber bundle is drawn into and passed through the heating plate device. To protect the flat product twisted in one direction in the secondary curing furnace so as not to twist, and to supply a flat strand without twist to the take-up winding device, And after peeling the high-density fabric, when the surface of the flat strand generates minute irregularities and is reinforced by sticking to the structure, or when used in the resin as a reinforcing material, Has the role of greatly improving adhesion.

  For that purpose, it is necessary to have a dense woven structure so as not to enter between the folds of the woven fabric, as a matter of course to have a parting property with the resin. For that purpose, a high-density woven fabric in which the total number of warp yarns and weft yarns between inch lengths is 210 or more is indispensable. For example, it is a high-density woven fabric in which warps × wefts (50D × 75D, 75D × 75D, 84D × 84D, etc.) are arranged so that the total number of input yarns is 210 or more between inch lengths.

  A mold release film is also considered as one that fulfills such a role, but a mold release agent is necessary to make the mold release film easy to peel off, or after peeling the film, the surface is smooth and adheres to the resin. There is a problem that the sex is not enough, so I can not recommend much.

  In this embodiment, the high-density fabric is either a single fabric of continuous filament yarn such as polyester fiber, nylon fiber, vinylon fiber, or a mixed fabric.

  As described above, the high-density fabric is a fabric in which warps and wefts between inch lengths are arranged in a total of 210 or more, usually 400 or less, and is preferably a plain fabric. Further, when the total of warp yarns and weft yarns between inch lengths is less than 210, there is a problem that peeling is difficult. Moreover, there is a problem that if it exceeds 400, the cost becomes high. In this embodiment, the thickness t2 of the woven fabric is 0.1 to 0.3 mm, and a thickness of 0.15 to 0.2 mm is usually preferable.

  The manufacturing method according to the present invention described above has the following advantages.

  First, when a flat fiber reinforced plastic wire is made by drawing like the round wire, there are restrictions on the mold, and there is a restriction on the number of production due to the limit of the number of holes. Further, in order to prevent the matrix resin from sticking, it is essential to use a mold release agent, and there has been a problem that the product after molding and the resin or concrete to be bonded later do not adhere well.

  In other words, in terms of quality, the method of the present invention does not use a mold release agent unlike the conventional mold method in pultrusion molding, so the adhesive strength between the finished fiber-reinforced plastic wire and the adhesive is good, and the fiber-reinforced plastic It eliminates the need for roughening the surface of the wire, eliminates the risk of wrinkling the surface of the wire, and is excellent in terms of quality and cost.

  Further, according to the results of the research experiments by the present inventors, the flat wire rod is formed by twisting a plurality of fibers (fiber bundles) impregnated with resin, pulling them with a constant tension, rounding them, It was found that if the mold (mold) was not molded to a certain thickness, it could not be produced with a nearly uniform width. That is, when the shape before flattening is random, molding with a constant plate thickness (t) and a nearly uniform width (w) cannot be performed.

  Furthermore, the present inventors use a flat plate-shaped mold (mold) in order to make the round shape into a flat shape, and a mold release agent is used for releasing the flat plate-shaped mold from the flat product. In addition, it was found that a thin cloth (a peel ply made of a polyester woven fabric) that does not adhere to the adhesive can be continuously inserted into the upper and lower surfaces to be molded, and then cured and peeled off. This method is difficult to adopt in the pultrusion molding because wrinkles are generated due to the mold having a shape.

  Also, since the mold that molds the round shape into a flat shape is a flat plate shape, the mold can be made thin, and can be installed vertically in two or three steps within a narrow range, increasing the number of molds that can be molded at one time. It is possible and efficient. As described above, up to about 300 is possible.

  On the other hand, since the mold is a flat plate, it is possible to create a variety of shapes with a single mold by adjusting the gap between the upper and lower sides.

  That is, in the system of the present embodiment, the resin impregnated reinforcing fibers can be arranged and passed using the entire inner cross-sectional area of the heating plate device 27a and the curing furnace 27b, and manufactured at a time within a limited volume. The number of products that can be produced is much higher than that of a conventional mold method such as pultrusion molding, which is a very efficient manufacturing method.

  Further, in the method of this embodiment, the round wire can be formed by applying an appropriate tension to the resin-impregnated reinforcing fiber in which the reinforcing fiber is twisted at a certain level or more. . Further, in the system of this example, the resin-impregnated round fiber bundle only needs to be drawn into the flat plate mold, and the upper and lower sides thereof are protected by a thin cloth (high-density fabric) for release, and the metal Since the mold and the resin-impregnated fiber bundle were not in direct contact with each other, it was found that there was little damage to the resin-impregnated fiber bundle, there was almost no thread breakage during production, and the molding yield could be greatly increased.

(Fiber reinforced plastic wire)
Next, the fiber reinforced plastic wire 2 manufactured by this manufacturing method is demonstrated using FIG.

  In FIG. 5, the cross section of the fiber reinforced plastic wire 2 manufactured with the manufacturing method of a present Example is shown. The fiber reinforced plastic wire 2 has a flat cross section, that is, a rectangular shape, and a plurality of reinforcing fibers f are impregnated with a matrix resin R.

  In the fiber reinforced plastic wire 2 manufactured by the manufacturing method of the present embodiment, the twist is put in any of 5 to 20 times per 1 m. If it is less than 5 times / m, it is difficult to ensure a stable circular shape (round shape) even if tension is applied before resin curing, and if the twist exceeds 20 times / m, it becomes difficult to form a flat shape, It is not preferable to exceed 20 times / m. In particular, the twist is optimally in the range of 10 times / m to 15 times / m.

  The ratio of the reinforcing fiber f and the matrix resin R constituting the fiber reinforced plastic wire 2 is a volume ratio (Vf) of the matrix resin, and a range of 36% to 60% can be used. If it is less than 36%, the resin is insufficient, and physical properties such as strength of the fiber-reinforced plastic wire 2 after production are lowered. On the other hand, if it exceeds 60%, it becomes excessive, and resin sagging occurs when the resin is cured, making it difficult to ensure a round shape. In particular, the volume ratio of the matrix resin is optimally in the range of 40% to 50%.

  Further, regarding the tension force to be applied when the matrix resin is cured, it is appropriate that the tension is 500 g / strand to 3000 g / strand for the fiber bundle (strand) f1. If it is less than 500 g / piece, it will be difficult to secure a round shape, and if it exceeds 3000 g / piece, there will be a problem that the reinforcing fiber f breaks during production, resulting in a problem that stable production cannot be achieved. . In particular, the tension force is optimally in the range of 1000 g / line to 2000 g / line.

  As for the flat shape fiber reinforced plastic wire 2 manufactured by the manufacturing method of a present Example, thickness (t) 0.2mm-5.0mm and width (w) 1.0mm-10.0mm are appropriate. When the thickness (t) is less than 0.2 mm, the reinforcing fiber f frequently breaks during production. On the other hand, when the thickness (t) exceeds 5.0 mm, when the resin-impregnated reinforcing fiber f2 is wound up, the fiber f is folded back, and the physical properties such as strength of the fiber-reinforced plastic wire 2 after curing are significantly reduced. . In particular, the fiber reinforced plastic wire 2 preferably has a thickness (t) of 0.4 mm to 1.5 mm and a width (w) of 1.2 mm to 4.5 mm.

  On the other hand, in the production method of the present embodiment, glass fiber, carbon fiber, aramid fiber, PBO (polyphenylene benzbisoxazole) fiber, and polyester fiber can be used. Among these, carbon fiber is preferably used. Other fibers are used for special applications such as markets requiring electrical insulation, markets with electrical corrosion with metals.

  Moreover, in the manufacturing method of a present Example, although an epoxy resin, vinyl ester resin, MMA resin, unsaturated polyester resin, and a phenol resin can be used, an epoxy resin is used suitably especially. Other resins are used for special applications such as a market used at high temperatures and a market requiring special corrosion resistance.

(Experimental example)
Next, an experimental example will be described more specifically with respect to the method for producing the flat-shaped fiber-reinforced plastic wire 2 of the present embodiment.

Experimental example 1
In this experimental example, a flat fiber reinforced plastic wire 2 was manufactured as a basic product in the following manner using the apparatus shown in FIGS.

  Reinforcing fiber f uses PAN-based carbon fiber strand (carbon fiber bundle f1) (“TR50” (trade name) manufactured by Mitsubishi Rayon Co., Ltd.) having an average diameter of 7 μm and a converged number of 15000, and cured at 120 ° C. as matrix resin R. Epoxy resin (“Epomic R140P” (trade name) manufactured by Mitsui Chemicals, Inc.) was used.

  In this experimental example, the number of twists was 10 times / m, and the resin-impregnated strand (carbon fiber bundle f2) was produced with a resin volume ratio (Vf) of 45% as the resin impregnation amount. The distance between the two heating plates (t1) of the heating plate device 27a was 0.8 mm, the length in the strand running direction (L27a) was 1.5 m, and the width (W27a) was 300 mm. The temperature of the heating plates 27a1 and 27a2 was 120 ° C.

  The secondary heating furnace 27b had a width (W27b) of 400 mm, a length (L27b) of 10 m, and a curing furnace temperature of 140 ° C.

  The resin impregnated strand f2 was applied with a tension force of 2000 g / strand and was sandwiched between the upper surface and lower surface peel plies 63 and 64 and moved in the heating plate device 27a and the curing furnace 27b at a moving speed of 5 mm / sec.

  In this experimental example, “Release Ply F” (trade name), which is a high-density fabric manufactured by Airtech, was used as the upper and lower surface peel plies 63 and 64. The specifications of this high density fabric were as follows.

High density fabric Fiber Polyester fiber Weight 95g / m ²
Total of warp and weft: 230 / inch Thickness (t2) 0.15mm

  With the above configuration, the resin-impregnated strand f2 is made into a primary-cured (semi-cured) strand f3 having a rectangular cross section formed by the heating plate device 27a, and then completely in the secondary-curing furnace 27b. Thus, a fiber-reinforced plastic wire 2 cured in the above manner was obtained. The fiber reinforced plastic wire 2 was peeled off from the upper surface and lower surface peel plies 63 and 64 very smoothly and without any problems at the outlet of the secondary curing furnace 27b.

  The fiber reinforced plastic wire 2 thus obtained had a flat cross section with a thickness (t) of 0.6 mm and a width (w) of 1.7 mm.

  As a comparative material, a material in which the number of twists was 3 times / m, 5 times / m, 20 times / m, and 30 times / m was produced in the same manner as the above basic product under the other production conditions.

  Each of these fiber-reinforced plastic wires was compared in terms of cross-sectional shape. The results are shown in Table 1.

  As can be seen from the above table, if the number of twists is less than 5 times / m, the width variation exceeds the reference width ± 20%, and when used as a strand sheet, it is necessary to take a large gap between the strands, and the fiber content It becomes difficult to achieve the purpose of increasing

  On the other hand, if the number of twists starts to exceed 20 times / m, the thickness of the product starts to deviate from the set thickness of the mold, the control becomes ineffective, and it becomes difficult to obtain the target thickness. This is considered to be due to the fact that the resin is soft due to the high temperature during secondary curing, and that the fiber swells and returns to its thickness due to twisting.

  Next, the number of twists of 10 times / m was fixed, and the resin impregnation amount was changed to 45%, 36%, 30%, 60%, 65%, respectively, in the resin volume ratio. It was manufactured in the same manner as the basic product in this experimental example.

  Each of these fiber reinforced plastic wires was compared in terms of cross-sectional shape, and compared by performing a tensile test on the product. The results are shown in Table 2.

  As can be seen from the above table, if the resin impregnation amount is less than 36%, the surface is frequently rusted due to insufficient resin and the strength is reduced. If the resin impregnation amount exceeds 60%, the resin amount increases and the resin flow increases. It becomes clear that the product width varies and the shape is difficult to secure.

  As a result of measuring the amount of resin adhering to the high-density fabric, about 10% to 15% of the amount of resin contained in one strand adheres, and as a result, the cured strand has a lower resin content. I understood.

  Next, the number of twists was 10 times / m and the resin impregnation amount was fixed at 45%, and the tension force at the time of resin curing was changed to 2000 g / line, 400 g / line, 500 g / line, 3000 g / line, 3500 g / line. The other production conditions were the same as those of the basic product of this experimental example.

  Each of these fiber reinforced plastic wires was compared in terms of cross-sectional shape, and compared by performing a tensile test on the product. The results are shown in Table 3.

  As can be seen from the above table, when the tension force is less than 500 g / strand, the width variation exceeds ± 20% of the reference width, which is out of the purpose of increasing the fiber content within a certain thickness. No longer play a role. It can be seen that when the tension force exceeds 3000 g / piece, the carbon fiber breaks during production, making the production difficult, and at the same time reducing the strength of the product.

Example 2
Next, with reference to FIG.7 and FIG.8, the other manufacturing method and manufacturing apparatus of the fiber reinforced plastic wire which concern on this invention are demonstrated.

  The manufacturing apparatus according to the present embodiment has the same configuration as the manufacturing apparatus 100 according to the first embodiment, and includes a fiber feeding, resin impregnation, and winding section 100A, and a fiber tension, oblate shape, and heat curing section 100B. Yes.

  However, in this embodiment, the fiber feeding, resin impregnation, and winding section 100A is only an example in that the twisting of the fiber is performed after the resin impregnation as shown in FIGS. 1 different from the manufacturing apparatus 100 of FIG. Accordingly, members having the same configuration and the same function as those of the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

  Moreover, since the fiber tension of the manufacturing apparatus 100 in a present Example, oblate Heisei, and the heat-hardening section 100B are the same as that of the manufacturing apparatus 100 of Example 1, description of Example 1 is used and this example is used. Description is omitted.

  FIG. 7 shows the fiber feeding, resin impregnation, and winding section 100A of the manufacturing apparatus 100 in the present embodiment. In the drawing, reinforcing fiber strands (reinforcing fiber bundles) composed of a plurality of reinforcing fibers f from the left side to the right side. ) F1 moves, during which resin impregnation and twisting are performed.

  That is, referring to FIG. 7, in the fiber feeding, resin impregnation and winding section 100A of this embodiment, a plurality of unwinding bobbins (tubular bobbin) 11 for supplying reinforcing fibers are provided to the unwinding device 51. 11a, 11b) are prepared, and a reinforcing fiber strand (reinforced fiber bundle) f1 in which a predetermined number of reinforcing fibers f not impregnated with resin are converged is wound around each bobbin 11.

  The reinforcing fiber bundle f1 wound around each bobbin 11 is guided to the guide holes 15a and 15b of the guide 14 and continuously fed to the resin impregnation process (reinforcing fiber bundle supplying process).

The reinforcing fiber bundle f1 fed to the resin impregnation step is impregnated with resin in the resin impregnation tank 17.
The configuration of the resin impregnation step and the work contents are the same as those in the first embodiment.

  The resin-impregnated reinforcing fiber bundle f2 is wound around the winding bobbin 22 (22a, 22b) in the winding device 52.

  At this time, the winding bobbin 22 (22a, 22b) is attached to the rotary shaft 23 (23a, 23b) provided in the winding device 52, as can be better understood with reference to FIG. The rotating shaft 23 is rotatably attached to the rotating main shaft 32 (32a, 32b) of the winding device 52.

  Each bobbin 22 is rotated around the rotation shaft 23 of each bobbin 22 by the drive motor M and the gear transmission mechanism G to wind up the reinforcing fiber bundle f2 impregnated with the resin. At the same time, as described above, each bobbin 22 (22a, 22b) rotates around the rotary shaft 23 (23a, 23b) and rotates with the rotary shaft 23 (23a, 23b) 32 (32a, 32b). ).

  That is, the bobbin 22 rotates around the rotation shaft 23 and simultaneously rotates around the rotation main shaft 32 to wind up the reinforcing fiber bundle f2.

  Therefore, the reinforcing fiber bundle f2 guided from the resin impregnation tank 17 by the guide hole 21 (21a, 21b) formed in the outlet guide roller pair 19 (19a, 19b) and the guide 20 and wound by the bobbin 22, Twisting is performed.

  By adjusting the rotation speed of the bobbin 22 around the rotation main shaft 32 and the winding speed of the reinforcing fiber bundle f2, the number of twists per 1 m can be controlled.

  According to this example, as in Example 1, the wire diameter of the round fiber-reinforced plastic wire is preferably 0.5 mm to 8.0 mm. Accordingly, the reinforcing fiber bundle f1 supplied to the impregnation step is, for example, carbon in which 3000 to 320,000 carbon fibers (filaments) f having a wire diameter of 6 to 10 μm are converged when carbon fibers are used as reinforcing fibers. The fiber strand (carbon fiber bundle) f1 is used.

  The number of twists of the reinforcing fiber bundle f1 is preferably 5 times / m to 20 times / m.

  The bobbin 22 around which the reinforcing fiber bundle f2 impregnated with the resin is wound is removed and supplied to the heating and curing processes of the next process.

  Also in this embodiment, the fiber tension, oblate shape, and heat-curing section 100B shown in FIGS. 2 (a), 2 (b), and 3 are used.

  That is, referring to FIG. 2, the bobbin 22 (22a, 22b) around which the resin-impregnated reinforcing fiber bundle f2 is wound in the resin impregnation step is installed on the rotating shaft 24 (24a, 24b) of the unwinding device 53. . That is, the winding bobbin 22 functions as an unwinding bobbin in tension, oblate shape, and heat curing processes.

  The resin-impregnated uncured reinforcing fiber bundle f2 wound around the unwinding bobbin 22 is unwound by rotating the bobbin 22 around the rotation shaft 24 (24a, 24b). The reinforcing fiber bundle f2 passes through the heating plate device 27a and the heat curing furnace 27b, and is taken up by the take-up bobbins 30 (30a, 30b).

  Also in the present embodiment, the reinforcing fiber bundle f2 impregnated with resin and twisted is unwound from the bobbin 22 and molded into a flat shape by the heating plate device 27a in the same manner as in the first embodiment. Next cured. Next, it is introduced into the heat curing furnace 27b and heat cured (secondary curing) (reinforced fiber bundle tension, oblate shape, heat curing step). The reinforcing fiber bundle that has been heat-cured (secondarily cured), that is, the reinforcing fiber plastic wire 2 is wound on the winding bobbin 30.

  When the manufacturing method of Example 1 is compared with the manufacturing method of this example, the difference between the manufacturing methods of both examples is that according to the manufacturing method of Example 1, fiber feeding, resin impregnation, and winding section 100A It is possible to connect the fiber tension and heat-curing section 100B to make the manufacturing process continuous. On the other hand, according to the manufacturing method of the present embodiment, it is difficult to continue the manufacturing process.

  On the other hand, in the production method of Example 1, a twist was added when producing a large flat (rectangular cross-section) fiber reinforced plastic wire having a thickness (t) of 1.0 mm and a width (w) of 3.3 mm. When the post-resin impregnation is performed, there is a problem that it is difficult to sufficiently impregnate the resin into the reinforcing fiber bundle f1.

  Therefore, it is appropriate to use the manufacturing methods of Examples 1 and 2 depending on the kind to be manufactured.

(Experimental example)
Next, an experimental example will be described more specifically with respect to the method for producing the fiber-reinforced plastic wire 2 of the present embodiment.

Experimental example 2
In this experimental example, the fiber reinforced plastic wire 2 was manufactured using the apparatus of FIG. 7, FIG. 8, FIG. 2 and FIG.

  Similar to Experimental Example 1 described in Example 1, the reinforcing fiber f has an average diameter of 7 μm and a converged number of 15,000 PAN-based carbon fiber strands (carbon fiber bundle f1) (“TR50” manufactured by Mitsubishi Rayon Co., Ltd. (trade name). )) And a 120 ° C. epoxy resin (“Epomic R140P” (trade name) manufactured by Mitsui Chemicals, Inc.) was used as the matrix resin R.

  Further, the number of twists is 10 times / m, the resin impregnation amount is a resin volume ratio of 45%, oblate shape, a tension force of 2000 g / piece during resin curing, the temperature of the heating plate device 27a is 120 ° C., and the furnace temperature of the curing furnace 27b is 140 ° C. The fiber-reinforced plastic wire 2 was manufactured at a temperature of 5 ° C./sec and the moving speed of the upper and lower peel plies 63 and 64 and the fiber bundles f2 and f3.

  The configuration of the manufacturing apparatus 100 such as the heating plate device 27a and the curing furnace 27b was the same as that in Experimental Example 1.

  As a result, the cross-sectional shape of the product is almost the same as the fiber-reinforced plastic wire manufactured by the manufacturing method that is the basis of Experimental Example 1 of Example 1, and the breaking load of the product is almost experimental as shown in Table 4. Same as one.

From this, it was found that there is no difference in the products manufactured in Experimental Examples 1 and 2 as a method of manufacturing the fiber reinforced plastic wire 2.

Example 3
Next, with reference to FIG. 6, an example of a fiber reinforced sheet using the fiber reinforced plastic wire 2 produced in Examples 1 and 2 will be described.

  In FIG. 6, one Example of the fiber reinforced sheet | seat 1 of this invention is shown. The fiber reinforced sheet 1 is formed by aligning a plurality of continuous flat fiber reinforced plastic wires 2 prepared in Examples 1 and 2 in a slender shape in the longitudinal direction, and the wires 2 are fixed to each other as a fixing fiber material 3. Fixed.

  The fiber reinforced plastic wire 2 has an elongated shape in which a transverse cross section obtained by impregnating a matrix resin R with a plurality of continuous reinforcing fibers f oriented in one direction and curing is flat, and has elasticity. ing. Accordingly, the fiber reinforced sheet 1 in which the elastic fiber reinforced plastic wire 2 is formed in a sled shape, that is, a sheet shape in which the wires 2 are arranged close to and away from each other, has elasticity in its longitudinal direction. Yes. Therefore, for example, the fiber reinforced sheet 1 can be carried in a state of being wound at a predetermined radius during conveyance, and is extremely portable. Further, since the fiber reinforced sheet 1 is composed of the fiber reinforced plastic wire 2, the orientation of the reinforced fibers is disturbed at the time of conveyance, as in a conventional unimpregnated reinforced fiber sheet, or when tension is introduced. There is no concern that thread breakage may occur due to disordered orientation of the reinforcing fibers.

  As described above, the fiber reinforced plastic wire 2 used in this example has a flat cross section with a thickness (t) of 0.2 mm to 5.0 mm and a width (w) of 1.0 mm to 10.0 mm in the cross section. The shape (ie, rectangular shape) (FIG. 5).

  As described above, in the fiber reinforced sheet 1 that is aligned and slender in one direction, the wires 2 are closely spaced from each other by a gap (g) = 0.1 to 20.0 mm, and the fixing fiber 3 It is fixed with. In addition, the length (L) and width (W) of the fiber reinforced sheet 1 formed in this way are appropriately determined according to the size and shape of the structure to be reinforced, Generally, the total width (W) is 100 to 500 mm. Moreover, although a length (L) can manufacture a thing of 100 m or more, in use, it cuts and uses it suitably.

  In addition, as a method of fixing each wire 2 with the fixing fiber material 3, as shown in FIG. 6, for example, a plurality of fibers that are arranged in a unidirectional manner using wefts as the fixing fiber material 3 are arranged. It is possible to adopt a method of driving and knitting a wire rod in the form of a sheet composed of the wire rods 2, that is, a continuous wire rod sheet at a constant interval (P) perpendicular to the wire rod. The driving interval (P) of the weft yarn 3 is not particularly limited, but is usually selected in the range of 1 to 15 cm in consideration of the handleability of the produced fiber reinforced sheet 1.

  At this time, the weft 3 is, for example, a yarn obtained by bundling a plurality of glass fibers or organic fibers having a diameter of 2 to 50 μm. Moreover, nylon, vinylon, etc. are used suitably as an organic fiber.

  Next, experimental examples of the fiber reinforced sheet of the present invention will be described.

Experimental example 3
Using the fiber reinforced sheet 1 which is a sheet-like reinforcing material of the present invention, a concrete beam was reinforced in accordance with a tension bonding method.

  In this experimental example, the fiber reinforced sheet 1 having the configuration described with reference to FIG. 6 was used.

  As the fiber reinforced plastic wire 2 in the fiber reinforced sheet 1, the fiber reinforced plastic wire 2 produced in Experimental Examples 1 and 2 was used. The wire 2 had a flat cross section with a thickness (t) of 0.6 mm and a width (w) of 1.7 mm.

  The fiber reinforced plastic wire 2 obtained in this way was aligned in one direction and arranged in a slender shape, and the wires 2 were spaced apart from each other by a gap (g) and fixed with the fixing fiber material 3.

  The fiber reinforced sheet 1 thus produced had a width (W) of 200 mm and a length (L) of 100 m. The gap (g) between each wire 2 was 0.4 to 0.5 mm. In the experiment, the length of the fiber reinforced sheet 1 was cut into 500 cm and used.

  Next, concrete beams were reinforced by the tension bonding method using the fiber reinforced sheet 1 as follows.

  First, in this experimental example, prior to bonding the fiber reinforced sheet 1 to a concrete beam, a tension force of 100,000 N was introduced into the fiber reinforced sheet 1. When the tension force was introduced, no thread breakage occurred, and a sufficient tension force could be introduced to near the breaking strength of the carbon fiber.

  In a state where the fiber reinforced sheet 1 is maintained in a tension state, a matrix resin is applied to the fiber reinforced sheet 1 from the side facing the concrete beam sheet bonding surface, and then the fiber reinforced sheet 1 is applied to the concrete beam bonding surface. Glued. At this time, in order to increase the adhesive strength, the entire fiber reinforced sheet was covered with a bag film, the air in the bag film was evacuated with a vacuum pump, and bonded while pressing against the beam with vacuum pressure. It was possible to adhere to the concrete beam very well without generating any voids on the sticking surface of the fiber reinforced sheet 1.

  In the experimental example 3 described above, the reinforcement of the concrete structure has been described. However, the fiber reinforced sheet 1 of the present invention can be similarly applied to the reinforcement of the steel structure, and the same operational effects can be achieved.

  Further, the fiber reinforced sheet 1 of the present invention is not limited to the tension bonding method described in the above experimental example, but is simply applied to a reinforcing method in which the reinforcing material is bonded to a structure, and further in a fiber reinforced plastic structure such as glass fiber. It can be suitably used also for the method of embedding in and reinforcing.

DESCRIPTION OF SYMBOLS 1 Fiber reinforced sheet 2 Flat shape fiber reinforced plastic wire 3 Fixing fiber material 11 Unwinding bobbin 17 Resin impregnation tank 22 Rewinding bobbin (unwinding bobbin)
27a Heating plate device 27a1, 27a2 First and second heating plates 27a3, 27a4 Flat plates for molding 27a5, 27a6 Panel heater (heat source)
27b Heat curing furnace 32 Winding bobbin 63 Upper surface peel ply (high density fabric)
64 Bottom peel ply (high density fabric)

Claims (10)

(A) a step of continuously feeding a reinforcing fiber bundle composed of a plurality of reinforcing fibers arranged in one direction while twisting;
(B) impregnating a matrix resin into the reinforcing fiber bundle continuously fed;
(C) The reinforcing fiber bundle impregnated with the resin and twisted is tensed with a predetermined strength to make the reinforcing fiber bundle have a circular cross section, and then the cross section is made circular. With a high-density fabric having releasability from the resin placed on the upper and lower surfaces of the bundle, the resin is drawn in between the two heated flat plates and the cross section of the reinforcing fiber is molded into a flat shape. A primary curing step,
(D) a step of secondarily curing the reinforcing fiber bundle which has been flatly cured in the transverse cross section through a heated curing furnace;
A method for producing a continuous flat fiber reinforced plastic wire, characterized in that a fiber reinforced plastic wire having a flat cross-section is provided. (A) a step of continuously feeding a reinforcing fiber bundle composed of a plurality of reinforcing fibers arranged in one direction;
(B) impregnating a matrix resin into the reinforcing fiber bundle continuously fed;
(C) a step of twisting the resin-impregnated reinforcing fiber bundle,
(D) The reinforcing fiber bundle impregnated with the resin and twisted is tensed with a predetermined strength so that the cross section of the reinforcing fiber bundle has a circular shape, and then the cross section of the reinforcing fiber bundle has a circular shape. With a high-density fabric having releasability from the resin placed on the upper and lower surfaces of the bundle, the resin is drawn in between the two heated flat plates and the cross section of the reinforcing fiber is molded into a flat shape. A primary curing step,
(E) a step of secondarily curing the reinforced fiber bundle, which has a flat cross-sectional cross section, through a heated curing furnace;
A method for producing a continuous flat fiber reinforced plastic wire, characterized in that a fiber reinforced plastic wire having a flat cross-section is provided.   The flat fiber reinforced plastic according to claim 1 or 2, wherein the fiber reinforced plastic wire has a thickness (t) of 0.2 mm to 5.0 mm and a width (w) of 1.0 mm to 10.0 mm. A manufacturing method of a wire.   The method for producing a flat fiber-reinforced plastic wire according to any one of claims 1 to 3, wherein the number of twists of the reinforcing fiber bundle is 5 times / m to 20 times / m.   The flat fiber reinforced plastic wire according to any one of claims 1 to 4, wherein the resin-impregnated reinforcing fiber bundle is tensioned at a strength of 500 g / strand to 3000 g / strand. Production method.   The flat shape according to any one of claims 1 to 5, wherein an amount of the matrix resin impregnated with respect to the reinforcing fibers in the reinforcing fiber bundle is 36% to 60% in volume ratio (Vf). Manufacturing method of fiber reinforced plastic wire.   The flat shape according to any one of claims 1 to 6, wherein the reinforcing fiber is any one of glass fiber, carbon fiber, aramid fiber, PBO (polyphenylenebenzbisoxazole) fiber, and polyester fiber. Manufacturing method of fiber reinforced plastic wire.   The flat-shaped fiber reinforced fiber according to any one of claims 1 to 7, wherein the matrix resin is any one of an epoxy resin, a vinyl ester resin, an MMA resin, an unsaturated polyester resin, or a phenol resin. Manufacturing method of plastic wire.   The flat fiber reinforced plastic according to any one of claims 1 to 8, wherein the high-density fabric is a fabric in which a total number of warp yarns and weft yarns between inch lengths is 210 or more. A manufacturing method of a wire. The high-density fabric, polyester fiber, nylon fiber, or vinylon fiber continuous filament yarn of a single fabric Wei, or according to any one of claims 1-9, characterized in that either of mixed fabrics Manufacturing method of flat shape fiber reinforced plastic wire.

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