JPH0365549A - Reinforced three-dimensional structure and production thereof - Google Patents

Abstract

PURPOSE:To inexpensively obtain three-dimensional structures reinforced with fibers having high modulus of elasticity in excellent operation efficiency by making a great number of spherical structural units extending fibers having high modulus of elasticity from the center in a three-dimensional way in a matrix and setting the matrix. CONSTITUTION:Fibers (e.g. carbon fiber or Vinylon(R)) having high modulus of elasticity are used to form nonwoven fabric having large meshes of warp pitch, wefts are cut in width of one-several warps into a thin ribbon-state, the warps are shrunk by heat and the cut nonwoven fabric is made into a spherical state to produce a spherical structure 3 extending fibers 1a, 1b, 1c, etc., having high modulus of elasticity in a three-dimensional way. Then a great number of the prepared spherical structures 3a and 3b are arranged in a frame 6 and a matrix (e.g. epoxy resin or concrete) is added to the frame 6. Then the matrix is set to give a three-dimensional structure reinforced with the fibers 1a, 1b, 1c, etc., having high modulus of elasticity. Cylindrical structures may be used of the spherical structures.

Description

DETAILED DESCRIPTION OF THE INVENTION a. Field of Industrial Application The present invention relates to a three-dimensional structure reinforced with high modulus 1a fibers and a method for manufacturing the same, and is used in the production of strong FRP, concrete, etc.

b. Prior art and problems to be solved by the present invention Conventionally, as a means of reinforcing a matrix such as plastic or concrete, short fibers such as glass fiber or carbon fiber are mixed in, or the matrix is impregnated into a woven fabric. There is also. The reinforcing efficiency of short fibers is poor considering the TA fiber mixing rate;
With textiles, plane reinforcement is possible, but three-dimensional reinforcement is difficult. As a method of three-dimensional reinforcement, three-dimensional textiles (for example, Journal of the Textile Machinery Society, January issue, 1985, pages 56-61) have been actively studied in recent years. However, these 3
Dimensional textiles have an extremely slow production speed, require complicated equipment, and require high installation costs to manufacture large products.
It is unsuitable for use in large quantities and cheaply as an industrial material.

In addition, the resulting product has yarns entwined in a complicated manner, making it impossible to maintain the straightness of the yarn, and even if J# fibers, which have a high modulus of elasticity, are used, they have little effect on the bending elastic modulus.

Furthermore, even if large-scale three-dimensional textile products can be manufactured,
It is extremely inconvenient and difficult to transport it to the II site, store it, or perform on-site construction.

In order to make three-dimensional fabrics, short 1aii, m products, etc. compatible with FRP and concrete, it is often necessary to anchor the fiber surface. For this purpose, an anchoring agent is applied at the yarn or product stage. A coating process is required,
Conversion is complicated and manufacturing costs are high.

C6 Means for Solving Problems The present invention provides a hardened matrix structure with good three-dimensional reinforcement efficiency even for large three-dimensional structures, and a manufacturing method that allows for simple, high-speed, low-cost mass production of the same with good workability. As a result of intensive research, we were able to invent a structure by first manufacturing the following simple basic structural units and then combining them and hardening them in a matrix.

There are two basic structural eye positions, one of which is a spherical structural unit in which high elastic modulus ml1i radiates three-dimensionally from the center. 'The length of the radiating fibers is preferably in the range of several tens of millimeters to several hundred millimeters, but the lengths of the &*fibers radiating from one structural unit do not have to be the same.0 Spherical shape is strictly Not only those with a circular cross section, but also elliptical or slightly deformed cross sections are included in the spherical official seal of the present invention. Another basic structural unit is a rod-like structural unit, which is a structure in which fibers with a high elastic modulus protrude horizontally from a support object disposed in a linear manner in a direction substantially perpendicular to the support object.

The rod shape does not necessarily have to be rigid in the length direction.The cross section of the long axis of the rod shape is not limited to a circle, but may also be linear, triangular, rectangular, or elliptical.The length of the protruding a-fibers is a number. It is selected appropriately from the range of ten millimeters to several hundred millimeters, but as expected,
It is not necessary that all the protruding lengths are the same.As the supporting object, metal wires, organic and inorganic fibers, etc. can be used, but it is desirable that the supporting object has a high elastic modulus.

It is desirable that the high elastic modulus fiber has an elastic modulus of 300 kg/ms2 or more, ideally 2000 kg/1
It is desirable that the fiber is 112 m or more, specifically, carbon fiber, glass fiber, aramid 1alt11 (Kevlar, etc.), ultra-stretched fiber of ultra-high molecular weight polyethylene, high elastic modulus polyvinyl alcohol fiber (vinylon, etc.), steel fiber. , amorphous metal fibers, ceramic fibers such as alumina fibers, etc. are used alone or in combination. As the form of the m-fiber, monofilament, multifilament, spun yarn, flat yarn, roving, string, lobe, etc. can be used.

The present invention consists in combining the above basic structural units in a matrix and curing the matrix to form a three-dimensional structure. First, let us describe an example of combining spherical structural units.
A large number of high elastic modulus fibers are arranged so close to each other that they cross each other, and the matrix is hardened. The spherical structures contained in this matrix do not have to all have the same size or shape; in fact, it is often better to have a variety of different shapes. It was confirmed that it exhibited a remarkable reinforcing effect against stresses such as , impact, and creep.

Next, there are roughly two methods for combining rod-like structural units in a matrix.

The first structure is made by arranging a plurality of rod-like structural units in parallel, or by arranging long structures (by folding the 111th position and arranging them in parallel, and also by arranging them so that the fibers protruding from the support object cross each other). This is a thick three-dimensional reinforcing structure.It can be arranged in parallel to reinforce a floor, vertically to reinforce a wall, or arranged in a cone shape to form a cylindrical reinforcement.

Further perpendicular to the structure of the present invention arranged in parallel, there is another linear object having a high elastic modulus, such as a steel rod, an iron wire, etc.
By arranging laths, high elastic modulus materials, fabrics, etc., reinforcement can be achieved three-dimensionally in the vertical, horizontal, and height directions. This three-dimensional structure is impregnated with a matrix to form a three-dimensionally reinforced structure.

The second example of the combination is to combine and arrange a plurality of rod-like structural units orthogonally or obliquely to each other.
Further, to give concrete examples of IA combinations that create three-dimensional structures, there are methods that combine logs and square timbers, such as log cabins, Yokura-zukuri, and Gassho-zukuri.

In addition, these basic structural units and the prior invention (patent application 1986-
It is also possible to form a three-dimensional structure by combining it with a coarse tubular body made of high elastic modulus fiber of No. 186079.

These three-dimensional structures can be made from resins (polyolefins, polyesters, epoxy resins, phenolic resins, etc.), soil,
By impregnating plaster, carbon, metal such as aluminum, or matrix such as concrete and post-curing, it becomes a reinforced three-dimensional structure object. The method of impregnating the basic structural unit into the matrix may be by impregnating the matrix into a structure in which basic structural units are sterically combined, or by adding the basic structural unit into the matrix,
There is also a method of gradually increasing the size of the structure. When impregnating, it is desirable to vibrate with a vibrator or the like so that the core is thoroughly impregnated.

The surface of the matrix reinforced with these basic structure types IQ may have protruding high modulus fibers that make it inconvenient or unsafe to form a flat surface; in such cases, the surface By placing laths or net-like objects on the surface of the matrix, it is possible to prevent high elastic modulus fibers from coming out on the surface of the matrix, and at the same time increase the density of high elastic modulus fibers on the surface.
It is also possible to improve the surface quality by arranging the fibers parallel to the surface.

As a manufacturing method for the structure of the basic structural unit, an orthogonal nonwoven fabric with a coarse warp (or weft) pitch made of high elastic modulus all male yarns [earlier invention by the present applicant (Japanese Patent Application No. 53-38783
There is a method of using a IR product produced by a NI machine such as No. 1). A thin ribbon-like flat surface with high elastic modulus fibers protruding in multiple stages in the weft direction by cutting the weft yarn at the width of one to several warp yarns using a weft-orthogonal nonwoven fabric with a coarse warp pitch. The structure is easy to manufacture. Spherical and rod-like structures can be manufactured from such ribbon-like planar structures. First, the spherical structure can utilize the reaction heat of the concrete hardening process, where the warp threads are hot, or a solvent or swelling agent (water or steam is often used).
The warp threads are made of a filament made of a shape memory substance, and the warp threads are greatly deformed by heat, etc., so that they can be gathered into small pieces.
It can be changed into a spherical shape. In addition, as a manufacturing method for a rod-shaped structural unit, tension or rotational force is applied to the supporting object of the above-mentioned planar ribbon-like structure, or one of the two (or more than one) warp threads (or more is okay). By applying a contractile force, a rod-shaped three-dimensional structure including a three-dimensional helical structure can be manufactured using all fibers with a high elastic modulus protruding horizontally from a supporting object.The explanation for 0 or more is as a ribbon-shaped structure! ! The explanation was given using the example of cross-graft nonwoven fabric, but there are also m-type products made of Karami fiber,
Or you can knit vertically or horizontally, but
In the case of weft/warp orthogonal nonwoven fabrics, the adhesive used to bond the warp and weft yarns is an adhesive that increases affinity with the matrix, which not only has the advantage of eliminating the need for anchor coating treatment, but also Since the rigidity of the thread can be increased with adhesive, it is possible to create a rigid structure when it is made into a three-dimensional structure.

In addition, as a manufacturing method for rod-shaped structural units, as in the manufacturing method for industrial rod-shaped brushes, in the process of twisting together several wires (linear support objects), the desired high elastic modulus ALL is sandwiched between the wires. It can also be manufactured by twisting them together.

Explanation with 60 drawings An example of the structure of the present invention will be specifically explained with reference to the drawings.

Figure 1 shows an example of a spherical structural unit, and (A) shows a high elastic modulus of 1
This is an example in which the a fibers 1 a, 1 b, IC... protrude roughly in a 44-shape from the center, and are converged at the core 2 to form a spherical body 3.
Configure. (B), (C), and (D) are perspective views of cross sections of spherical bodies. (B) High elastic modulus edge I! This is an example in which l is densely protruding radially.

(C) is a ring-shaped high elastic modulus lJi fiber 1x, 1y, 1
This is an example where z is focused near core 2. The focusing point 2 may be adhesive or mechanically bound. (D) is an example in which high elastic modulus fibers 1 radiate three-dimensionally from the core portion 2 bundled into a bundle.

Fig. 2 is a perspective view showing various types of specific structures of rod-like structural units, and (a) shows a support object with two (more may be possible, but two are shown for simplicity). This is an example in which a high elastic modulus fiber 1 is sandwiched between certain high elastic modulus fibers (IW wires may also be used) 4a and 4b being twisted together. In this figure, the high modulus fibers are short fibers, but
Continuous high elastic modulus fibers may be sandwiched one after another. (
A) is an example in which high elastic modulus fibers are sandwiched intermittently, but (b) is an example in which high elastic modulus fibers are sandwiched intermittently, but by sandwiching the fibers continuously without any gaps, a high elastic modulus edge is created in the shape of two strokes! 1] is an example of a prominent structure.

31st! 1 is the spherical structure 3a, 3b... in FIG.
In this example, a large number of 3a are combined in a matrix (existing inside the rectangular frame 6), and one of 3a is shown in a cross-sectional view.
Other spheroids are indicated by circles.

FIG. 4 shows an example in which the rod-like structures 5 of FIG. 2 are combined to form a three-dimensional structure, and the high elastic modulus fibers l protruding in a cylindrical shape from the support object 4 of each rod-like body 5 are arranged in parallel. The rod-shaped bodies 5 intertwine and intersect with each other at the overlapping portion. In order to further strengthen this in the horizontal direction, the high elastic modulus material shown by the dotted line in the figure (the structure shown in Figure 2 may be used, or other high elastic modulus materials such as steel rods or carbon fiber strands) )
If 7 is passed horizontally, it becomes a structure that is thick and can be reinforced in a plane. If these layers are further stacked in the thickness direction, a structure that can be reinforced three-dimensionally will be created.

FIG. 5 shows an example in which the rod-like structures 5 of FIG. 2 are orthogonally crossed and combined. To simplify the diagram and make it easier to understand,
The structure in Fig. 2 is shown as a cylinder, and only a small part of the materials to be combined is shown. - Fig. 6 shows an example of manufacturing the structure of the present invention, and (A) shows the structure of the present invention. The weft yarns 8 made of high elastic modulus fibers and arranged in parallel in the weft direction in the weft/weft orthogonal nonwoven fabric with a coarse warp pitch interval according to the applicant's previous invention are as follows:
These are fixed in contact with two groups of vertical threads 9 and 10 at an interval of several tens of millimeters in the vertical direction so that they overlap each other with the front and back sides sandwiched between them. By cutting and separating the weft yarn between adjacent warp yarns at the position shown by chain line 11,
As shown in FIG. 6(B), it becomes a planar and elongated structure. If the upper end of this structure (B) is fixed and the lower end is twisted by applying a rotational force, the structure shown in Fig. 2 will be obtained.For example, the structure shown in Fig. 6 (B) will be transported in and the second one at the construction site.
The structure shown in the figure can also be made into the structures shown in Figs. 4 and 5 and used as a three-dimensional reinforcement structure for concrete.

e. Effects The three-dimensional structure of the present invention is based on a very simple basic structural unit, so this structural unit can be mass-produced at low cost.

■Since the basic structure is simply combined, even large structures can be made into three-dimensional structures with good workability on site.

■The basic structural unit can be manufactured more easily than with inexpensive, mass-produced orthogonal nonwoven fabrics.

■High elastic modulus edge'! Since the ram is incorporated into the structure in a form with less deflection + DI, the elastic modulus of 81 can be effectively utilized.

■Easy to create a structure with affinity and rigidity with the matrix.

The above cannot be expected with conventional three-dimensional fabrics.

[Brief explanation of drawings]

Figures 11 (A), (B), (C), and (D) are examples of spherical structural units that are the basic structural units of the present invention. FIGS. 2(a) and 2(b) are perspective views of a rod-shaped structural unit which is the basic structural unit of the present invention. FIG. 3 is an example of a structure in which the spherical structures shown in FIG. 1 are combined in a matrix and further combined into a three-dimensional structure. FIGS. 4 and 5 are examples of structures in which the rod-like structures shown in FIG. 2 are combined in a matrix to form a three-dimensional structure. FIGS. 6(A) and 6(B) show an example of a method for manufacturing the basic structural units shown in FIGS. 1 and 2 from orthogonal nonwoven fabrics. Explanation of symbols 1% Ia, lb, lc, lx, Iy, 1z, 8 are high elastic modulus woven yarns. 2 is the core of the spherical structure. 3.3a and 3b are spherical structures made of high elastic modulus fibers. 4a and 4b are linear support objects for the core of a rod-like structure. 5 is a rod-shaped structure. 6 is the frame containing the matrix. 7 is a material with high elastic modulus. 9.10 is the warp in the orthogonal nonwoven fabric. Cut along the chain line No. 11. Departing person Polymer Processing Research Institute Co., Ltd.

Claims (5)

[Claims] (1) A reinforced three-dimensional structure in which a large number of spherical structural units in which high-modulus fibers radiate three-dimensionally from the center are present in a hardened matrix. (2) With respect to a linearly arranged support object, fibers with a high elastic modulus are arranged in a hardened matrix in which a large number of rod-shaped structural units protrude horizontally and almost perpendicularly to the support object.
A reinforced three-dimensional structure that exists in combination dimensionally or three-dimensionally. (3) A method for manufacturing a reinforced three-dimensional structure by curing a matrix in which a large number of spherical and rod-shaped structural units according to claims (1) and (2) are present. (4) Applying a contractile force to a linear support object or deforming the ribbon-like structure in which high elastic modulus fibers protrude in multiple stages in a direction substantially perpendicular to the linear support object, A method for manufacturing a three-dimensional structure for reinforcing a matrix, in which supporting objects are grouped together into a spherical structure in which fibers with a high elastic modulus radiate from the center. (5) Apply tension, rotational force, or contractile force to a linear support object on a ribbon-like structure in which high elastic modulus fibers protrude in multiple stages in a direction substantially perpendicular to the linear support object. A method for producing a three-dimensional structure for reinforcing a matrix, in which fibers with a high elastic modulus protruding from a support object are formed into a rod-like structure including a three-dimensional helical structure.