Substrate for pipe lining material and pipe lining material

Abstract

To provide a base material for a pipe lining material further excellent in mechanical strength, and the pipe lining material containing a curable resin in the base material for the pipe lining material.SOLUTION: In the base material for the pipe lining material, the glass fabric and the porous base material are integrally laminated only by the fusion of the thermoplastic resin contained in the constituent component of the porous base material and the glass fabric is reinforced by the porous base material. Therefore, the occurrence of yarn slippage in the glass fabric is suppressed. The base material for the pipe lining material is obtained by reinforcing the glass fabric with the nonwoven fabric in spite of being not subjected to the needle punching treatment. Therefore, the presence of broken portions of the glass fibers in the glass fabric due to the needle punching treatment is prevented, so that the base material for a pipe lining material is further excellent in mechanical strength.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a substrate (substrate for pipe lining material) constituting a pipe lining material used for repairing or reinforcing pipelines such as water supply and sewerage pipes, and to a pipe lining material containing the substrate for pipe lining material and a curable resin. [Background technology]

[0002] Conventionally, existing pipelines, such as aging water supply and sewerage pipes, have been repaired or reinforced by placing a sheet coated with a photocurable resin or a thermosetting resin on the inner surface of the existing pipeline, and allowing the photocurable resin or thermosetting resin (hereinafter sometimes collectively referred to as "curable resin") to harden on the inner surface of the existing pipeline.

[0003] For example, Patent Document 1 (JP 2012-86386 A) discloses a substrate for pipe lining material that includes a laminated member formed by laminating glass fabric and nonwoven fabric containing a thermoplastic resin, such as polyester spunbond nonwoven fabric, and integrating them by needle-punching.

[0004] The substrate for a pipe lining material according to prior art such as Patent Document 1 has high strength due to the inclusion of a glass fabric. Furthermore, the glass fabric and nonwoven fabric are laminated together by needle punching, and the glass fabric is reinforced by the nonwoven fabric. Therefore, even when an external force acts on the substrate for a pipe lining material, the presence of the nonwoven fabric reinforcing the glass fabric prevents the glass fabric from becoming misaligned. Note that areas where misalignment occurs in the glass fabric are areas where strength is locally reduced. Therefore, the occurrence of misalignment causes the rigidity of the substrate for a pipe lining material to become non-uniform, leading to a decrease in mechanical strength.

[0005] From the above, it is considered that by adopting a pipe lining material substrate according to conventional technology such as that of Patent Document 1 as the base material for pipe lining material, and by using a pipe lining material in which the base material for pipe lining material contains a curable resin, it is possible to form a uniform lining layer with high mechanical strength on the inner surface of the pipeline, thereby making it possible to repair and reinforce existing pipelines. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2012-86386 Summary of the Invention [Problem to be solved by the invention]

[0007] However, in the substrate for pipe lining material according to the prior art such as Patent Document 1, broken portions of the glass fibers are unevenly present in the glass fabric due to the needle punching treatment. As a result, the mechanical strength of the substrate for pipe lining material according to the prior art such as Patent Document 1 is still insufficient due to the uneven presence of broken portions of the glass fibers in the glass fabric.

[0008] This problem was particularly pronounced when the basis weight of the nonwoven fabric reinforcing the glass fabric was reduced in order to provide a substrate for a pipe lining material that was easy to handle, as this caused the glass fabric to break more easily during needle punching.

[0009] Therefore, an object of the present invention is to provide a pipe lining substrate having even greater mechanical strength, and a pipe lining material in which the pipe lining substrate contains a curable resin. [Means for solving the problem]

[0010] The invention of claim 1 of the present invention is "a substrate for a pipe lining material comprising a glass fabric and a porous substrate containing a thermoplastic resin as a constituent component, wherein the glass fabric and the porous substrate are laminated and integrated only by fusion of the thermoplastic resin."

[0011] The invention according to claim 2 of the present invention is "a pipe lining material comprising the substrate for a pipe lining material according to claim 1 and a curable resin." [Effects of the Invention]

[0012] In the pipe lining substrate according to claim 1 of the present invention, the glass fabric and the porous substrate are laminated together only by fusion of the thermoplastic resin contained in the porous substrate, and the glass fabric is reinforced by the porous substrate, thereby preventing misalignment of the glass fabric.

[0013] Furthermore, although the substrate is not needle-punched, the glass fabric is reinforced with a nonwoven fabric, which prevents the glass fabric from having broken glass fibers that would otherwise be present in the glass fabric if needle-punched, resulting in a substrate for pipe linings with even greater mechanical strength.

[0014] The pipe lining material according to claim 2 of the present invention is a pipe lining material obtained by further incorporating a curable resin into a pipe lining base material having excellent mechanical strength, and therefore, by using this pipe lining material, it is possible to form a uniform lining layer with high mechanical strength on the inner surface of a pipeline, thereby enabling repair or reinforcement of existing pipelines. DETAILED DESCRIPTION OF THE INVENTION

[0015] The substrate for a pipe lining material of the present invention comprises a glass fabric and a porous substrate containing a thermoplastic resin as a constituent component.

[0016] The porous substrate may be, for example, a sheet having voids, such as a nonwoven fabric, a woven fabric, a knitted fabric, or a porous film.

[0017] The constituent resin of the porous substrate is not particularly limited as long as it contains a thermoplastic resin, and can be, for example, polyamide, polyester, nylon, acrylic, vinylon, rayon, etc. Among these, it is preferable that the constituent resin of the porous substrate contains polyamide or polyester, which has excellent heat resistance, light resistance, stain resistance, etc.

[0018] Furthermore, when the porous substrate is composed of fibers, the constituent fibers may be single fibers or composite fibers containing two or more types of resin, such as core-sheath or side-by-side fibers. Furthermore, the cross section of the constituent fibers may be circular or irregular, such as elliptical, rectangular, or Y-shaped. In addition, the porous substrate may contain fibrillated fibers.

[0019] Furthermore, when the porous substrate is a nonwoven fabric, the nonwoven fabric may be any known type, such as a dry nonwoven fabric, a wet nonwoven fabric, or a directly spun nonwoven fabric such as a spunbond or meltblown nonwoven fabric.

[0020] The fineness of the constituent fibers of this nonwoven fabric is preferably 1.0 dtex or more, more preferably 1.5 dtex or more, and even more preferably 2.0 dtex or more, so that the mechanical strength of the pipe lining substrate and the pipe lining material is excellent. On the other hand, if the constituent fibers of the nonwoven fabric have a fineness that is too large, the bonding between the nonwoven fabric and the glass fabric becomes insufficient, and it may become difficult to efficiently prevent misalignment of the glass fabric. Therefore, a fineness of 20 dtex or less is practical, and 10 dtex or less is more practical.

[0021] The weight of the porous substrate is set to 5 g / m2 so that the porous substrate is firmly fused to the glass fabric and the glass fabric can be efficiently prevented from slipping. 2 More than 10g / m is preferable. 2 More preferably, 15 g / m 2On the other hand, if the basis weight of the porous substrate is too large, the porous substrate tends to be difficult to impregnate with the curable resin, which may result in a decrease in the strength of the pipe lining material containing the porous substrate and the curable resin, and may also result in a deterioration in the handleability of the substrate for the pipe lining material. 2 Less than 65 g / m 2 Less than 60 g / m is more preferable. 2 The following is more preferable. The "weight" of the present invention is the weight per square meter of the main surface, which is the widest surface. 2 This refers to the mass per unit mass.

[0022] The thickness of the porous substrate is preferably 0.03 mm or more, more preferably 0.04 mm or more, and even more preferably 0.05 mm or more, so that the thermoplastic resin contained in the porous substrate is firmly fused to the glass fabric, preventing misalignment of the glass fabric and preventing damage to the constituent fibers of the glass fabric due to external forces. On the other hand, if the thickness of the porous substrate is too thick, when the substrate for a pipe lining material is impregnated with resin, the resin does not penetrate well into the porous substrate constituting the substrate for a pipe lining material, requiring a long time for the resin to penetrate the entire substrate for a pipe lining material. Furthermore, the handleability of the substrate for a pipe lining material may be impaired. Therefore, the thickness 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 this specification refers to the value at a load of 2.0 kPa. When measuring the thickness of the porous substrate constituting the substrate for a pipe lining material, the thickness of the substrate for a pipe lining material is first measured. The thickness of the glass fabric is then measured after removing the porous substrate from the pipe lining substrate, and the difference between the two thicknesses is regarded as the thickness of the porous substrate in the pipe lining substrate.

[0023] The porous substrate may be composed of a single sheet having voids, or may be a combination of multiple sheets having the same type of voids (e.g., multiple nonwoven fabrics stacked together), or may be a combination of multiple sheets having different types of voids (e.g., woven fabric and nonwoven fabric stacked together).

[0024] The glass fabric constituting the pipe lining substrate of the present invention is made of glass, and this glass fabric gives the pipe lining substrate and the pipe lining high mechanical strength. Furthermore, this glass fabric may be made of only one type of glass fiber or may be made of multiple types of glass fibers.

[0025] The type of glass fabric is appropriately selected, and known fabrics such as plain weave, twill weave, plain tatami weave, etc. can be used.

[0026] The fineness of the glass fibers (warp and weft) constituting the glass woven fabric is not particularly limited, but may be 1.7 to 5.0 tex, 2.0 to 4.0 tex, or 2.2 to 3.3 tex. The constituent fibers of the glass woven fabric may be in the form of a bundle of multiple constituent fibers like a roving cloth, or may be a single constituent fiber that is not in a bundle but exists independently.

[0027] The weight of the glass fabric is set to 200 g / m2 so that the base material for pipe lining has sufficient mechanical strength. 2 More than 250g / m 2 More preferably, 300 g / m 2 On the other hand, if the weight of the glass fabric is too large, the handling of the substrate for the pipe lining material may be deteriorated. 2 The following is realistic.

[0028] The thickness of the glass fabric is preferably 0.20 mm or more, more preferably 0.25 mm or more, and even more preferably 0.35 mm or more so that the pipe lining substrate has sufficient mechanical strength. On the other hand, if the glass fabric is too thick, the handleability of the pipe lining substrate may be deteriorated, so a thickness of 2.1 mm or less is practical.

[0029] The weight of the pipe lining base material is set to 250 g / m2 so that the pipe lining base material has sufficient mechanical strength. 2 More than 300g / m2 More preferably, 330 g / m 2 On the other hand, if the basis weight of the substrate for a pipe lining material is too large, the handling of the substrate for a pipe lining material may be deteriorated. 2 The following is realistic.

[0030] The thickness of the pipe lining substrate is preferably 0.3 mm or more, more preferably 0.5 mm or more, and even more preferably 0.7 mm or more so that the pipe lining substrate has sufficient mechanical strength. On the other hand, if the thickness of the pipe lining substrate is too thick, the pipe lining substrate may become difficult to handle, so a realistic thickness is 10 mm or less.

[0031] Next, an example of the method for producing the substrate for a pipe lining material of the present invention will be described.

[0032] First, a glass fabric is prepared.

[0033] Next, a porous substrate containing a thermoplastic resin as a constituent component (for example, a nonwoven fabric, fiber web, woven fabric, knitted fabric, or porous film made of a thermoplastic resin, each containing a thermoplastic resin as a constituent fiber) is prepared. The fiber web can be prepared, for example, by feeding fibers to a carding machine and opening them. The nonwoven fabric can be prepared by subjecting the above-mentioned fiber web to a hydroentanglement process or needle punching process to entangle the constituent fibers, or by melting the surfaces of the constituent fibers of the fiber web to bond the constituent fibers of the fiber web together.

[0034] Next, the porous substrate provided with the thermoplastic resin and the glass fabric are superimposed and heated to fuse at least a portion of the porous substrate to the glass fabric, and then cooled by, for example, standing to cool. In this way, the substrate for a pipe lining of the present invention is produced, in which the glass fabric and the porous substrate are laminated and integrated only by the fusion of the thermoplastic resin. The heating method at this time can be a known method, such as heating in an oven or heating under pressure using a reliant press or the like.

[0035] Another method for manufacturing a substrate for a pipe lining material, different from the above-mentioned method, is to directly spin fibers onto a glass fabric by a spunbonding method or a meltblowing method, and then accumulate the spun fibers directly on the glass fabric to form a porous substrate.

[0036] The pipe lining substrate of the present invention can be cylindrical or flat, impregnated with a thermosetting resin or a photocurable resin, and used as a pipe lining material for repairing or reinforcing pipelines such as water and sewerage pipes. When the pipe lining material is used to repair or reinforce pipelines such as water and sewerage pipes, if a glass fabric is present on the surface where the pipe lining material comes into contact with the water and sewerage (e.g., the innermost surface when the pipe lining material is used in a cylindrical shape), glass fibers detached from the glass fabric may be mixed into the water and sewerage. Therefore, it is preferable that a porous substrate be present on the surface where the pipe lining material comes into contact with the water and sewerage. The pipe lining material may be composed of only a thermosetting resin or a photocurable resin and the pipe lining substrate, or it may be used in combination with other components, such as other fabrics or films, to make it more suitable for pipeline repair or reinforcement. In this case, for example, a film for protecting the pipe lining substrate can be provided on the innermost or outermost surface when the pipe lining is used in a cylindrical form. In addition, to further improve the mechanical strength of the pipe lining substrate, multiple pipe lining substrates can be laminated together. [Example]

[0037] Examples of the present invention will be described below, but the present invention is not limited to the following examples.

[0038] (Preparation of Nonwoven Fabric A) The molten polyamide resin was spun by the melt-blowing method, and the spun fibers were accumulated on a release nonwoven fabric. Next, the nonwoven fabric was treated with a far-infrared heater at 70°C, and then the release nonwoven fabric was peeled off to obtain nonwoven fabric A (basis weight: 20 g / m 2 ) was formed.

[0039] (Preparation of nonwoven fabric laminate) The molten polyamide resin was spun by the melt-blowing method, and the spun fibers were accumulated on a release nonwoven fabric. Next, the nonwoven fabric was treated with a far-infrared heater at 150°C, and then the release nonwoven fabric was peeled off to obtain Nonwoven Fabric B (basis weight: 30 g / m 2 ) was formed. Next, nonwoven fabric A and nonwoven fabric B were simply stacked together to form a nonwoven fabric laminate (basis weight: 50 g / m 2 ) was formed.

[0040] (Preparation of glass fabric) A plurality of glass fabrics (roving cloths) having the following physical properties were prepared. Weight: 320g / m 2 Thickness: 0.37mm Warp: 3.1 tex Weft: 3.1 tex Weave: Plain weave In order to evaluate the substrate for pipe lining material, which will be described later, one main surface of each prepared glass fabric was visually observed using a stereomicroscope (magnification: 20x), and a rectangular area measuring 8.4 mm in length and 15.0 mm in width, in which no cross-sections of the warp or weft yarns were exposed, was marked with oil-based ink. In the same manner, rectangular marks were made in two more places on one main surface of the prepared glass fabric (a total of three rectangular marks were made).

[0041] Example 1 Nonwoven fabric A was placed over the main surface of the glass fabric that did not have the rectangular markings, and the glass fabric was placed in a Reliant press where it was heated and pressurized (speed: 10 m / min, pressure: 0.1 MPa, temperature: 90°C), thereby fusing part of the polyamide resin that makes up the constituent fibers of nonwoven fabric A to the glass fabric. This resulted in the nonwoven fabric A and the glass fabric being integrated into a base material for pipe lining (basis weight: 340 g / m 2 , thickness of the substrate for pipe lining material: 0.41 mm, thickness of nonwoven fabric A in the substrate for pipe lining material: 0.15 mm) were produced.

[0042] Example 2 In the same manner as in Example 1, except that a nonwoven fabric laminate was used instead of nonwoven fabric A and the nonwoven fabric A side of the nonwoven fabric laminate was overlapped with the glass fabric, at least a part of the nonwoven fabric laminate was fused to the glass fabric, and the nonwoven fabric laminate and the glass fabric were integrated to form a substrate for a pipe lining material (basis weight: 370 g / m 2 , thickness of the pipe lining substrate: 0.41 mm, thickness of the nonwoven fabric laminate in the pipe lining substrate: 0.17 mm) were produced. In the pipe lining material substrates of Examples 1 and 2, the glass fabric and the porous substrate were laminated together only by fusion bonding of the thermoplastic resin contained in the porous substrate.

[0043] (Comparative Example 1) Polyethylene terephthalate fiber (fineness: 3.3 dtex, fiber length: 64 mm) was used at 100 mass%, and the fiber was opened by a carding machine to prepare fiber web A (basis weight: 20 g / m 2 ) was formed. Next, the fiber web A was placed on the main surface of the glass fabric on which the rectangular markings were not made, and needle punching (needle density: 10.3 needles / cm) was performed from the fiber web A side. 2 , process conveying speed: 1.25 m / min, needle type: stainless steel) to integrate the fiber web A and the glass fabric to form a base material for pipe lining material (basis weight: 340 g / m 2 A substrate for pipe lining material (thickness: 0.89 mm) was manufactured.

[0044] (Comparative Example 2) Polyethylene terephthalate fiber (fineness: 3.3 dtex, fiber length: 64 mm) was used at 100 mass%, and the fiber was opened by a carding machine to prepare fiber web B (basis weight: 50 g / m 2 ) was formed. Next, in a state where the fiber web B is superimposed on the main surface of the glass fabric on the side where the rectangular markings are not made, needle punching is performed from the fiber web B side in the same manner as in Comparative Example 1, thereby integrating the fiber web B and the glass fabric to form a substrate for a pipe lining material (basis weight: 370 g / m 2 A substrate for pipe lining material (thickness: 1.24 mm) was manufactured. In the substrates for pipe lining materials of Comparative Examples 1 and 2, the glass fabric and the porous substrate were laminated and integrated only by entanglement of the constituent fibers by needle punching.

[0045] The pipe lining substrates of the Examples and Comparative Examples were evaluated as follows.

[0046] (Method for determining the number of broken glass fabric constituent fibers present on the main surface derived from the glass fabric) (1) A photograph was taken using a stereomicroscope (magnification: 20x) of the three rectangular marks remaining on the main surface of the substrate for pipe lining material, which was made from glass fabric, and the photograph was observed visually. (2) The number of warp and weft threads with exposed cross sections present within the rectangular marks in the micrographs was visually counted. The average of the numbers counted for each area in each micrograph was then calculated. When calculating the average, the number was rounded to the nearest tenth. The number of warp and weft threads with exposed cross sections is considered to be twice the number of constituent fibers of the broken glass fabric. A pipe lining substrate with a small number of warp and weft threads with exposed cross sections is a pipe lining substrate with less breakage of the glass fibers that make up the glass fabric.

[0047] The physical properties and evaluation results of the pipe lining material substrates of the Examples and Comparative Examples are shown in Table 1 below.

[0048] [Table 1]

[0049] In the substrate for pipe lining material of the examples, no breakage of the constituent fibers of the glass fabric was observed. This is thought to be because the glass fabric and the porous substrate were laminated and integrated only by fusion of the thermoplastic resin contained in the porous substrate, without undergoing needle punching treatment.

[0050] On the other hand, in the pipe lining substrate of the comparative example, breakage of the constituent fibers of the glass fabric was observed. The reason for this is thought to be that the glass fabric and the porous substrate were laminated and integrated by the needle punching treatment.

[0051] Therefore, the present invention provides a pipe lining substrate having excellent mechanical strength. By using a pipe lining material containing a curable resin as the pipe lining substrate of the present invention, a uniform lining layer with high mechanical strength can be formed on the inner surface of a pipeline, making it possible to repair or reinforce an existing pipeline. [Industrial Applicability]

[0052] The base material for pipe lining of the present invention can be used as a pipe lining material when repairing or reinforcing pipelines such as water supply and sewerage pipes by impregnating the base material for pipe lining with a thermosetting resin or a photocurable resin and then curing the resin inside the pipeline.

Claims

1. A substrate for a pipe lining material comprising a glass fabric and a porous substrate containing a thermoplastic resin as a constituent component, The glass fabric and the porous substrate are laminated and integrated only by fusion of the thermoplastic resin. Base material for pipe lining material.

2. A pipe lining material comprising the substrate for a pipe lining material according to claim 1 and a curable resin.

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