Pipe lining material substrate and pipe lining material

Abstract

To provide a pipe lining material substrate having excellent mechanical strength and a pipe lining material comprising this pipe lining material substrate impregnated with a hardening resin.SOLUTION: A pipe lining material substrate is obtained by bonding a nonwoven fabric and a glass fabric by water-jet intertwining by using water which is a material softer than a glass as compared to those obtained by bonding a nonwoven fabric and a glass fabric by using a substance harder than a glass (e.g., stainless steel needle, etc.), such as a needle punch treatment disclosed in, e.g., patent literature 1. Thus, breakage in a glass fabric is difficult to occur. Further, as displacement of stitches in a case where an external force is applied to the pipe lining material substrate is inhibited, this pipe lining material substrate has excellent mechanical strength.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to a pipe lining material base material that constitutes a pipe lining material used for repairing and reinforcing pipelines such as water and sewage pipes, and a pipe lining material in which a curable resin is impregnated into the pipe lining material base material.

Background Art

[0002] Conventionally, a sheet impregnated with a photocurable resin liquid or a thermosetting resin liquid has been installed on the inner surface of an existing pipeline such as an aging water and sewage pipe, and these resin liquids have been cured on the inner surface of the existing pipeline to repair and reinforce the existing pipeline. For example, Patent Document 1 (Japanese Patent Application Laid-Open No. 2012-86386) discloses a pipe lining material including a laminated member in which a non-woven fabric (hereinafter sometimes abbreviated as non-woven fabric) made of an organic resin and a glass fabric are overlapped and joined by needle punching.

[0003] This pipe lining material (hereinafter referred to as a pipe lining material base material) has high strength because it includes a glass fabric. Furthermore, since the non-woven fabric and the glass fabric are joined by needle punching, the glass fabric is in a state of being reinforced by the constituent fibers of the non-woven fabric. Therefore, even when an external force acts on the pipe lining material base material, the occurrence of displacement caused by the movement of the glass fibers constituting the glass fabric is suppressed, and the presence of the non-woven fabric also prevents the glass fabric from fraying. In addition, since the portion where displacement occurs in the glass fabric becomes a portion where the strength is locally reduced, the occurrence of displacement causes the rigidity of the pipe lining material base material to become non-uniform and leads to a decrease in mechanical strength.

[0004] From the above, it was considered that by using the pipe lining material base material disclosed in the prior art such as Patent Document 1, it was possible to form a uniform and highly mechanically strong lining layer on the inner surface of the pipeline.

Prior Art Documents

Patent Documents

[0005] [Patent Document 1] JP 2012-86386 A Summary of the Invention [Problem to be solved by the invention]

[0006] However, the glass fabrics of the pipe lining substrates according to the prior art such as Patent Document 1 have broken glass fibers. As a result, when an external force acts on the pipe lining substrate, the glass fabric may be misaligned, resulting in a decrease in mechanical strength. This problem is particularly noticeable when the basis weight of the nonwoven fabric is reduced to improve the handling of the pipe lining substrate.

[0007] Therefore, another object of the present invention is to provide a pipe lining material base material having excellent mechanical strength, and a pipe lining material obtained by impregnating the pipe lining material base material with a curable resin. [Means for solving the problem]

[0008] The invention according to claim 1 of the present invention is "a substrate for a pipe lining material, comprising a hydroentangled laminated member in which a nonwoven fabric made of organic fibers and a glass fabric are overlapped and joined."

[0009] The invention according to claim 2 of the present invention is "a pipe lining material obtained by impregnating the pipe lining base material according to claim 1 with a curable resin." Effect of the Invention

[0010] The pipe lining base material according to claim 1 of the present invention is a material in which a nonwoven fabric and a glass fabric are bonded together by hydroentanglement using water, which is a material softer than glass, as opposed to, for example, the needle punching process disclosed in Patent Document 1, in which a nonwoven fabric and a glass fabric are bonded together using a material harder than glass (such as stainless steel needles). Therefore, the glass fabric is less likely to break. Therefore, since the occurrence of further displacement is suppressed when an external force acts on the in-pipe lining material base material, it is an in-pipe lining material base material having excellent mechanical strength.

[0011] The in-pipe lining material according to claim 2 of the present invention is an in-pipe lining material having excellent mechanical strength because a curable resin such as a thermosetting resin or a photocurable resin is impregnated into an in-pipe lining base material having excellent mechanical strength.

Embodiments for Carrying Out the Invention

[0012] The non-woven fabric composed of organic fibers constituting the in-pipe lining material base material of the present invention reinforces the glass fabric and prevents the displacement and fraying of the glass fabric.

[0013] The resin constituting the non-woven fabric is not particularly limited, but for example, it can be polyester fiber, nylon fiber, acrylic fiber, vinylon fiber, rayon fiber, etc. Among these, it is preferable to contain polyester fiber excellent in heat resistance, light resistance, stain resistance, etc. Further, the constituent fibers of the non-woven fabric may be single fibers or composite fibers containing two or more kinds of resins such as core-sheath type or side-by-side type. For example, using latent crimp fibers (such as side-by-side type composite fibers) is preferable because the fibers exhibit crimp due to heat, and the structure of the non-woven fabric becomes dense by using the fibers with crimp developed. Furthermore, the cross-section of the constituent fibers may be circular, or may be a deformed shape such as an ellipse, a square, or a Y-shaped cross-section. In addition, fibrillated fibers may be included.

[0014] Regarding the form of the non-woven fabric, known non-woven fabrics such as dry non-woven fabrics, wet non-woven fabrics, and direct spinning non-woven fabrics such as spunbond and meltblown can be used. However, since it has a certain thickness with respect to the amount of constituent fibers of the non-woven fabric and the constituent fibers of the non-woven fabric can easily enter the weave of the glass fabric, a dry non-woven fabric is preferable.

[0015] Regarding the fineness of the constituent fibers of the nonwoven fabric, in order for the nonwoven fabric to have excellent mechanical strength, it is preferably 1.0 dtex or more, more preferably 1.5 dtex or more, and even more preferably 2.0 dtex or more. On the other hand, if the fineness of the constituent fibers of the nonwoven fabric is too large, the constituent fibers of the nonwoven fabric may not easily penetrate into the weave of the glass fabric, and the bonding between the nonwoven fabric and the glass fabric may become insufficient. Therefore, it is realistic to be 50 dtex or less.

[0016] Regarding the basis weight of the nonwoven fabric, in order for the constituent fibers of the glass fabric and the nonwoven fabric to be intertwined and prevent the glass fabric from shifting and fraying, it is preferably 5 g / m 2 or more, more preferably 10 g / m 2 or more, and even more preferably 15 g / m 2 or more. On the other hand, if the basis weight of the nonwoven fabric is too large, there is a risk that the handleability of the pipe inner lining material substrate will deteriorate, and there is a risk that the bonding between the nonwoven fabric and the glass fabric due to water flow entanglement will become insufficient. Therefore, it is preferably 80 g / m 2 or less, more preferably less than 70 g / m 2 and even more preferably 60 g / m 2 or less. Note that the "basis weight" of the present invention refers to the mass per 1 m 2 of the main surface, which is the widest surface.

[0017] Regarding the thickness of the non-woven fabric, in order for the constituent fibers of the glass fabric and the non-woven fabric to be intertwined to prevent the glass fabric from shifting and fraying, and also to make it difficult for the constituent fibers of the glass fabric to be damaged by external forces, it is preferably 0.3 mm or more, more preferably 0.4 mm or more, and even more preferably 0.5 mm or more. On the other hand, if the thickness of the non-woven fabric is too thick, there is a risk that the handleability of the pipe lining material base material will deteriorate, and there is a risk that the joining of the non-woven fabric and the glass fabric due to water flow entanglement will be insufficient. Therefore, it is preferably 1.8 mm or less, more preferably 1.6 mm or less, and even more preferably 1.4 mm or less. Note that the "thickness" in the present invention refers to the value at a load of 2.0 kPa. When measuring the thickness of the non-woven fabric from the pipe lining base material, first measure the thickness of the pipe lining base material. Then, remove the non-woven fabric from the pipe lining base material, measure the thickness of the material after removing the non-woven fabric, and the thickness of the non-woven fabric in the pipe lining base material can be calculated from the difference value.

[0018] The glass fabric constituting the pipe lining material base material of the present invention is composed of glass, and due to this glass fabric, the pipe lining material base material and the pipe lining material have high mechanical strength. Further, this glass fabric may be composed of only one type of glass or may be composed of a plurality of types of glass.

[0019] The type of the glass fabric can be appropriately selected. For example, known fabrics such as plain weave, twill weave, and plain tabby weave can be used.

[0020] Regarding the fineness of the constituent fibers (warp and weft) of the glass fabric, although it is not particularly limited, it can be 1.7 to 5.0 tex, can be 2.0 to 4.0 tex, and can be 2.2 to 3.3 tex. Note that the constituent fibers of the glass fabric may exist in a bundle of a plurality of constituent fibers like roving cloth, or a single constituent fiber may exist independently without forming a bundle.

[0021] Regarding the basis weight of the glass fabric, in order for the pipe lining material base material to have sufficient mechanical strength, it is preferably 200 g / m 2 or more, and preferably 250 g / m 2The above is more preferable, 300 g / m 2 The above is even more preferable. On the other hand, if the basis weight of the glass fabric is too large, the handleability of the base material for the inner lining material may deteriorate. Therefore, 1800 g / m 2 or less is realistic.

[0022] Regarding the thickness of the glass fabric, 0.20 mm or more is preferable, 0.25 mm or more is more preferable, and 0.35 mm or more is even more preferable so that the base material for the inner lining material has sufficient mechanical strength. On the other hand, if the thickness of the glass fabric is too thick, the handleability of the base material for the inner lining material may deteriorate. Therefore, 2.1 mm or less is realistic.

[0023] Regarding the basis weight of the base material for the inner lining material, 200 g / m 2 or more is preferable, 300 g / m 2 or more is more preferable, 400 g / m 2 or more is even more preferable so that the base material for the inner lining material has sufficient mechanical strength. On the other hand, if the basis weight of the base material for the inner lining material is too large, the handleability of the base material for the inner lining material may deteriorate. Therefore, 1880 g / m 2 or less is realistic.

[0024] Regarding the thickness of the base material for the inner lining material, 0.3 mm or more is preferable, 0.5 mm or more is more preferable, and 0.7 mm or more is even more preferable so that the base material for the inner lining material has sufficient mechanical strength. On the other hand, if the thickness of the base material for the inner lining material is too thick, the handleability of the base material for the inner lining material may deteriorate. Therefore, 3.0 mm or less is realistic.

[0025] Next, the manufacturing method of the base material for the inner lining material of the present invention will be described.

[0026] First, prepare a glass fabric.

[0027] Next, a non-woven fabric or fiber web composed of organic fibers is prepared. The fiber web can be prepared, for example, by feeding fibers to a carding machine and opening the fibers. The non-woven fabric can be prepared by subjecting the above-described fiber web to a water entanglement treatment or a needle punching treatment to entangle the constituent fibers, or by melting the surfaces of the constituent fibers of the fiber web and bonding the constituent fibers of the fiber web to each other.

[0028] Next, a non-woven fabric or fiber web composed of organic fibers and a glass fabric are overlapped and subjected to a water entanglement treatment to produce a water entanglement laminated member in which the non-woven fabric composed of organic fibers and the glass fabric are overlapped and joined. By subjecting the laminate of the fiber web and the glass fiber to a water entanglement treatment, breakage of the glass fabric is less likely to occur. The water pressure during this water entanglement is preferably 1 to 10 MPa, more preferably 2 to 9 MPa, and even more preferably 3 to 8 MPa so that the constituent fibers of the non-woven fabric enter the weave of the glass fabric and breakage of the glass fabric is less likely to occur. Further, at this time, it is preferable to perform water entanglement from the side having the non-woven fabric or fiber web composed of organic fibers so that the constituent fibers of the non-woven fabric are sufficiently entangled with the weave of the glass fabric and the non-woven fabric and the glass fabric can be sufficiently joined.

[0029] The base material of the in-pipe lining material of the present invention can be impregnated with a thermosetting resin or a photocurable resin and used as an in-pipe lining material for repairing or reinforcing pipelines such as water supply and drainage pipes. At this time, the in-pipe lining material may be composed of only one of a thermosetting resin or a photocurable resin and the base material of the in-pipe lining material, or may be used in combination with other members such as other fabrics and films in order to be in a form more suitable for repairing or reinforcing pipelines. Further, in order to further improve the mechanical strength of the base material of the in-pipe lining material, a plurality of layers of the base materials of the in-pipe lining material may be laminated and used.

Examples

[0030] Examples of the present invention will be described below, but the present invention is not limited to the following examples.

[0031] (Preparation of Fiber Web A) Using 100 mass% of polyethylene terephthalate fibers (fineness: 3.3 dtex, fiber length: 64 mm), the fibers were opened by a carding machine to form a fiber web (basis weight: 20 g / m 2 ).

[0032] (Preparation of Fiber Web B) Using 100 mass% of the same polyethylene terephthalate fibers as in Fiber Web A, the fibers were opened by a carding machine to form a fiber web (basis weight: 50 g / m 2 ).

[0033] (Preparation of Glass Fabric) A glass fabric (roving cloth) having the following physical properties was prepared. Basis weight: 320 g / m 2 Thickness: 0.37 mm Warp: 3.1 tex Weft: 3.1 tex Weave pattern: Plain weave

[0034] (Example 1) The fiber web A and the glass fabric were overlapped, and a water flow entanglement treatment was performed by applying water flow from the fiber web A side (water pressure: 5 - 8 MPa, process conveyance speed: 5.3 m / min) to entangle and integrate the fiber web A and the glass fabric. Then, it was dried to remove water, and a pipe inner lining base material (basis weight: 340 g / m 2 , thickness of the pipe inner lining base material: 0.85 mm, thickness of the nonwoven fabric: 0.48 mm) in which a dry nonwoven fabric made of organic fibers and the glass fabric were overlapped and joined was manufactured.

[0035] (Comparative Example 1) Instead of the water flow entanglement treatment, a needle punching treatment (needle density: 10.3 needles / cm 2 , process conveyance speed: 1.25 m / min, type of needle: made of stainless steel) was applied from the fiber web A side to integrate the fiber web A and the glass fabric. Otherwise, in the same manner as in Example 1, a pipe inner lining base material (basis weight: 340 g / m 2, a tube-lining base material with a thickness of 0.89 mm and a non-woven fabric with a thickness of 0.52 mm was manufactured.

[0036] (Example 2) The fiber web B and the glass fabric were overlapped, and a water flow entanglement treatment was performed by applying a water flow from the side of the fiber web B (water pressure: 5 - 8 MPa, process conveyance speed: 5.3 m / min), and the fiber web B and the glass fabric were entangled and integrated. Then, it was dried to remove water, and a tube-lining base material (basis weight: 370 g / m 2 , with a thickness of the tube-lining base material of 1.2 mm and a thickness of the non-woven fabric of 0.83 mm) was manufactured.

[0037] (Comparative Example 2) Instead of the water flow entanglement treatment, a needle punching treatment (needle density: 20.6 needles / cm 2 , process conveyance speed: 1.25 m / min, type of needle: made of stainless steel) was applied from the side of the fiber web B to integrate the fiber web B and the glass fabric. Otherwise, in the same manner as in Example 2, a tube-lining base material (basis weight: 370 g / m 2 , with a thickness of the tube-lining base material of 1.4 mm and a thickness of the non-woven fabric of 1.03 mm) was manufactured.

[0038] The tube-lining materials of the examples and comparative examples were evaluated as follows.

[0039] (Confirmation of breakage points of glass fibers constituting the main surface derived from the glass fabric) (1) One main surface of the glass fabric before manufacturing the tube-lining material was observed with a stereomicroscope (magnification: 20 times), and three regions where no breakage points where the cross-sections of the constituent fibers of a rectangular glass fabric with a length of 8.4 mm in the vertical direction and 15.0 mm in the horizontal direction were exposed were visually confirmed and marked. (2) A tube inner lining material base was manufactured from the glass fabric of (1) by the methods of the examples / comparative examples. At this time, a fiber web was overlaid on the main surface opposite to the main surface of the glass fabric observed with a stereomicroscope, and the fiber web and the glass fabric were intertwined and integrated to manufacture the tube inner lining material bases of the examples and comparative examples. (3) The main surface derived from the glass fabric in the tube inner lining material base in a rectangular region of 8.4 mm in length × 15.0 mm in width marked in (1) was observed with a stereomicroscope (magnification: 20 times), and a micrograph of this region was taken. Similarly, micrographs were taken for the other two locations on the main surface. (4) In the three micrographs obtained in (3), the number of breakage points where the cross-sections of the constituent fibers of the glass fabric were exposed was counted visually. Since the number of breakage points of the constituent fibers of the glass fabric in the region where it was confirmed in (1) that the constituent fibers of the glass fabric were not broken was counted, the number of broken constituent fibers of the glass fabric during the intertwining and integration by water flow intertwining / needle punching can be counted thereby. (5) The number of breakage points was counted for each of the three micrographs, and the average value of the numbers was calculated. At that time, the second decimal place was rounded off.

[0040] The various physical properties and evaluation results of the tube inner lining material bases of the examples and comparative examples are shown in Table 1 below.

[0041]

Table 1

[0042] When the tube inner lining material base of the example, which is a water flow intertwining laminated member, was compared with the tube inner lining material base of the comparative example, which is a needle punch laminated member with the same nonwoven fabric basis weight, the number of breakage points of the constituent fibers of the glass fabric was small. From the above, according to the present invention, furthermore, a tube inner lining material base excellent in mechanical strength and a tube inner lining material in which the tube inner lining material base is impregnated with a curable resin can be provided.

Industrial Applicability

[0043] The base material of the in-pipe lining material of the present invention can be used as an in-pipe lining material that, when repairing or reinforcing pipelines such as water and sewage pipes, impregnates the base material of the in-pipe lining material with a thermosetting resin or a photocurable resin and then cures the resin inside the pipeline.

Claims

1. An in-pipe lining material substrate including a water flow complex laminated member in which a nonwoven fabric made of organic fibers and a glass fabric are overlapped and joined.

2. An in-pipe lining material obtained by impregnating the in-pipe lining material substrate according to Claim 1 with a curable resin.

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