Method for manufacturing a resin wire and resin wire

Abstract

The present invention provides a resin wire with excellent adhesion to other materials and a method for manufacturing the same. [Solution] The core has a covering layer 3 made of thermoplastic resin around it, and the area of ​​the cross-section perpendicular to the length direction is 25 mm². 2 In manufacturing the following resin wire 1, the process involves coating the outer circumference of the wire constituting the core 2 with a thermoplastic resin to form a resin-coated wire, and then heating the resin-coated wire while pressurizing it at 0.1 to 1.6 MPa and 80 to 200°C after bringing water and / or steam into contact with the surface of the resin-coated wire, thereby forming minute irregularities on more than one-third of the outer surface of the coating layer 3.

Description

[Technical Field]

[0001] The present invention relates to a resin wire having a coating layer made of thermoplastic resin around its core, and to a method for producing the same. [Background technology]

[0002] Fiber-reinforced plastic linear bodies (hereinafter referred to as FRP linear bodies), which consist of a core material made by bonding bundles of long reinforcing fibers such as aramid fibers and carbon fibers with thermosetting resin and then coating the periphery with thermoplastic resin, are used in a wide range of fields, including tensioning materials for prestressed concrete (PC tensioning materials), reinforcing bars for NOMST (Novel Material Shieldcuttable Tunnel-wall system), rock bolts for tunnel construction, earth anchors for slope and ground reinforcement, and various components such as tension members for optical cables.

[0003] Conventionally, in order to improve productivity and economic efficiency while ensuring sufficient quality, carbon fiber reinforced plastic composites have been proposed in which a core is formed by binding bundles of long, unidirectional carbon fibers with a thermosetting resin that has a minimum curing time of 3.5 minutes or less in the JIS high-temperature curing characteristics test (measurement temperature 100°C), and then coating the core with a thermoplastic resin (see Patent Document 1).

[0004] Furthermore, for thermoplastic resin-coated FRP wires having a substantially rectangular shape with a short side of less than 0.3 mm, which can be used as tension members for drop optical cables, a method has also been proposed in which the tension applied to the reinforcing fiber bundle is controlled to open the reinforcing fibers and guide them into a thermosetting resin impregnation tank, the resin-impregnated reinforcing fibers are drawn into a predetermined rectangular shape, and then, in the thermoplastic resin coating process, the inner circumference of the coated cone portion discharged from the annular die is coated under reduced pressure. (See Patent Document 2) [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2000-351858 [Patent Document 2] Japanese Patent Publication No. 2011-37133 [Overview of the project] [Problems that the invention aims to solve]

[0006] On the other hand, the conventional FRP linear materials mentioned above have problems with adhesion to other materials. As a method to improve the surface adhesion of FRP linear materials, for example, Patent Document 1 describes that by forming irregularities of a predetermined depth on the surface of a coating layer made of thermoplastic resin, the adhesive strength between concrete or mortar and carbon fiber reinforced plastic composite material can be increased or adjusted to the required strength due to the anchoring effect of the irregularities.

[0007] However, since a dry heat curing furnace and embossing roller are used to create a textured surface on the FRP linear material, it can only be manufactured at a low take-up speed of 1.0 m / min. Furthermore, while embossing is possible if the cross-sectional dimensions of the FRP linear material are approximately 19.0 mm wide x 4.0 mm thick, the area of ​​the cross-section perpendicular to the length direction is 25 mm². 2 For the following small diameter linear materials, it is difficult to create minute irregularities on the surface by embossing, and furthermore, there is a possibility of breakage due to buckling during the embossing process.

[0008] Therefore, the present invention aims to provide a thin resin wire with excellent adhesion to other materials and a method for manufacturing the same. [Means for solving the problem]

[0009] The present invention relates to a method for manufacturing a resin wire, which has a coating layer made of thermoplastic resin around the core, and a cross-sectional area perpendicular to the length direction of 25 mm². 2A method for manufacturing a resin wire, comprising the steps of: coating the outer circumference of a wire constituting the core with a thermoplastic resin to form a resin-coated wire; and bringing water and / or steam into contact with the surface of the resin-coated wire, and then heating the resin-coated wire under pressure at 0.1 to 1.6 MPa and 80 to 200°C. In the method for manufacturing a resin wire of the present invention, the core portion may be a fiber-reinforced resin wire. In this case, before coating the fiber-reinforced resin wire with the thermoplastic resin, the method includes impregnating a reinforcing fiber bundle with an uncured thermosetting resin, and shaping the reinforcing fiber bundle impregnated with the thermosetting resin into a predetermined shape to obtain a fiber-reinforced resin wire.

[0010] The resin wire according to the present invention is a resin wire having a coating layer made of thermoplastic resin around a core, and having a cross-sectional area perpendicular to the length direction of 25 mm². 2 The coating layer has minute irregularities formed on more than one-third of its outer surface. Each recess formed on the outer circumferential surface of the coating layer of the resin linear body of the present invention has a size, for example, 0.01 to 2.0 mm in plan view. 2 The depth can be set to 0.001 to 0.4 mm. Furthermore, the core portion may contain a thermosetting resin. Furthermore, the core portion may be a fiber-reinforced resin wire in which a reinforcing fiber bundle is impregnated with resin. [Effects of the Invention]

[0011] According to the present invention, it is possible to realize a thin resin wire with superior adhesion to other materials compared to conventional products. [Brief explanation of the drawing]

[0012] [Figure 1] Figures A and B show examples of the structure of a resin linear body according to an embodiment of the present invention, where A is a cross-sectional view perpendicular to the length direction and B is an enlarged view of the surface. [Figure 2] This is a flowchart showing a method for producing a resin linear body according to an embodiment of the present invention. [Figure 3]It is a schematic diagram showing a configuration example of an apparatus for implementing a method for manufacturing a resin linear body according to an embodiment of the present invention.

Embodiments for Carrying Out the Invention

[0013] Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the accompanying drawings. Note that the present invention is not limited to the embodiments described below.

[0014] [Configuration of Resin Linear Body] FIGS. 1A and 1B are diagrams showing a configuration example of a resin linear body according to an embodiment of the present invention. FIG. 1A is a cross-sectional view perpendicular to the length direction, and FIG. 1B is an enlarged view of the surface. As shown in FIGS. 1A and 1B, the resin linear body of the present embodiment has a coating layer 3 made of a thermoplastic resin provided around a core portion 2. Further, the resin linear body 1 of the present embodiment is a resin linear body with a small diameter as described below, and minute irregularities are formed in an area of 1 / 3 or more of the outer peripheral surface of the coating layer 3. 2 The resin linear body has a small diameter as described below, and minute irregularities are formed in an area of 1 / 3 or more of the outer peripheral surface of the coating layer 3.

[0015] [Core Portion 2] The material and configuration of the core portion 2 are not particularly limited. For example, a linear material containing a thermoplastic resin or a thermosetting resin, or a fiber-reinforced resin linear body in which a thermosetting resin is impregnated into a reinforcing fiber bundle such as carbon fiber, glass fiber or organic synthetic fiber can be used. In particular, a fiber-reinforced resin linear body is preferable.

[0016] The thermoplastic resin used in the core 2 is not particularly limited, but examples include polyolefin resins such as polypropylene (PP), polyethylene (PE), and polyisobutylene (PB); polyester resins such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), polyethylene naphthalate (PENp), and liquid crystal polyester (LCP); styrene resins such as polystyrene (PS), acrylonitrile-styrene resin (AS), acrylonitrile-butadiene-styrene resin (ABS), acrylonitrile-acrylic-styrene resin (AAS), and acrylonitrile-ethylene propylene rubber-styrene (AES); urethane resins; and nylon 6.

[0017] Other thermoplastic resins include polyvinyl alcohol (PVA), polyoxymethylene (POM), polyamide (PA), polycarbonate (PC), polymethyl methacrylate (PMMA), polyvinyl chloride (PVC), polyphenylene sulfide (PPS), polyphenylene ether (PPE), modified PPE, polyimide (PI), polyamide-imide (PAI), polyetherimide (PEI), polysulfone (PSU), modified polysulfone (modified PSU), polyethersulfone (PES), polyketone (PK), polyetherketone (PEK), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyarylate (PAR), and polyethernitrile (PEN). These thermoplastic resins may be used individually or in combination of two or more. Furthermore, when a thermoplastic resin is used for the core 2, it is preferable to use one whose melting point is 20°C or more higher than the heating temperature in the heating process described later.

[0018] The thermosetting resin is not particularly limited, and examples include terephthalic acid-based and isophthalic acid-based unsaturated polyester resins, vinyl ester resins such as epoxy acrylate resins, and epoxy resins. Vinyl ester resins, which have excellent heat resistance, are particularly preferred. These thermosetting resins may contain curing catalysts or the like.

[0019] When the core 2 is a fiber-reinforced resin wire, examples of organic synthetic fibers include aromatic polyamide fibers (aramid fibers), polyarylate fibers, poly(p-phenylenebenzobisoxazole) (PBO) fibers, and poly(p-phenylenebenzobisthiazole) (PBT) fibers. The volume content of reinforcing fibers in the resin wire 1 can be appropriately set according to the required physical properties, but it is preferably 25 to 75 volume%. This makes it possible to manufacture a small-diameter resin wire without reducing yield or mechanical properties. The core 2 may consist of a single wire or multiple wires.

[0020] [Coating layer 3] The coating layer 3 can be formed from a thermoplastic resin. From the viewpoint of adhesion to the core 2, it is preferable that the thermoplastic resin used for the coating layer 3 melts or softens in the portion that comes into contact with the core 2 during the heating process after the coating layer 3 is formed. Specifically, it is preferable to use low-density polyethylene (LDPE) or linear low-density polyethylene (LLDPE). Furthermore, if the core 2 contains a thermosetting resin, it is preferable that the coating layer 3 be formed from a thermoplastic resin containing styrene as a component. This improves the chemical affinity with the thermosetting resin constituting the core 2, and when the thermosetting resin of the core 2 is cured by the heating process after the coating layer 3 is formed, the core 2 and the coating layer 3 can adhere to each other and become one.

[0021] Furthermore, the coating layer 3 is preferably formed from a thermoplastic resin having a melting point or softening temperature in the range of 80 to 200°C, and more preferably from a thermoplastic resin having a melting point or softening temperature in the range of 80 to 200°C. If a thermoplastic resin with a melting point or softening temperature lower than this temperature range is used, deformation or damage to the coating layer 3 may occur during the manufacturing process. If a thermoplastic resin with a melting point or softening temperature higher than this temperature range is used, the design of the manufacturing equipment may become difficult.

[0022] Furthermore, the coating layer 3 may also have a structure in which two or more layers made of the same or different thermoplastic resins are laminated. When a laminated structure is made using the same type of thermoplastic resin, the resin composition of each layer may be the same or different.

[0023] [Recess 3a] The outer surface of the coating layer 3a has minute irregularities formed over more than one-third of its area, and the size of each recess 3a is, for example, 0.01 to 2.0 mm in a plan view. 2 These recesses have a depth of 0.001 to 0.4 mm. By forming numerous such minute recesses, the specific surface area of ​​the coating layer 3 can be increased, and the adhesive strength can be improved by the anchoring effect while maintaining the mechanical properties of the resin linear body 1.

[0024] Here, the size of the recess 3a formed on the outer surface of the coating layer 3 can be measured, for example, using a microscope. In this invention, the major and minor axes of the substantially circular recess 3a were measured, and the area was calculated as an ellipse or a circle. The depth of the recess 3a was determined by observing the cross-section of the resin wire 1 with a microscope and measuring the distance from the straight line connecting the edges of the recess 3a to the deepest part of the recess.

[0025] [cross section] The resin wire 1 of this embodiment has a cross-section perpendicular to its length that is, for example, circular, elliptical, or flattened, but is not limited to these and can have any shape. Furthermore, the resin wire 1 of this embodiment has a cross-sectional area perpendicular to its length of 25 mm². 2 The following applies: The cross-sectional area perpendicular to the length is 25 mm². 2In the case of a resin linear body having a normal diameter or a large diameter exceeding this, since unevenness can be formed on the surface by physical processing, the usefulness of the present invention is lost. That is, the present invention relates to a resin linear body having a cross-sectional area perpendicular to the length direction of 25 mm 2 or less in particular is preferably a resin linear body having a small diameter.

[0026] [Other configurations] The resin linear body 1 of the present embodiment may have a structure in which a hollow portion is provided at the center and a core portion 2 is disposed around it.

[0027] [Method for manufacturing the resin linear body 1] Next, the method for manufacturing the resin linear body 1 of the present embodiment will be described. FIG. 2 is a flowchart showing the method for manufacturing the resin linear body of the present embodiment, and FIG. 3 is a schematic diagram showing a configuration example of an apparatus for implementing the method for manufacturing the resin linear body of the present embodiment.

[0028] As shown in FIG. 2, in the method for manufacturing the resin linear body 1 of the present embodiment, a coating layer forming step S1 of coating the outer periphery of the linear body constituting the core portion 2 with a thermoplastic resin to form a resin-coated linear body, and water and / or After bringing water vapor into contact with the surface of the resin-coated linear body, a heating step S2 of heating the resin-coated linear body while applying pressure under conditions of 0.1 to 1.6 MPa and 80 to 200 ° C. is at least performed.

[0029] When the core portion 2 is a fiber-reinforced resin linear body, before the coating layer forming step S1, an impregnation step S11 of impregnating the reinforcing fiber bundle with an uncured thermosetting resin, and a reinforcing fiber bundle impregnated with the thermosetting resin may be formed into a predetermined shape to obtain a fiber-reinforced resin linear body. A molding step S12 may be performed.

[0030] [Impregnation step S11] As shown in FIG. 3, in the impregnation step S11, the reinforcing fiber bundle 20 wound around a paper tube or the like is unwound, and the reinforcing fiber bundle 20 is immersed in an impregnation tank 11 in which the uncured thermosetting resin 21 is stored, and the reinforcing fiber bundle 20 is impregnated with the uncured thermosetting resin 21. At that time, the reinforcing fiber bundle 20 may be pressed by a pressing jig 17.

[0031] [Molding process S12] In molding step S12, for example, a rectangular nozzle 12 is used to mold a reinforcing fiber bundle 22 impregnated with thermosetting resin into a predetermined shape to obtain a fiber-reinforced resin linear object 23.

[0032] [Coating layer formation step S1] In the coating layer formation step S1, for example, a coating die 13 is used to coat the outer circumference of the fiber-reinforced resin wire 23 constituting the core 2 with thermoplastic resin to form a resin-coated wire 24. The resin-coated wire 24 can also be processed by passing it through a pair of press rollers 14 to create a flattened cross-section.

[0033] [Heating process S2] In the heating step S2, first, the resin-coated linear body 24 is brought into contact with water and / or steam by passing it through the cooling water tank 15. Then, for example, the resin-coated linear body 24 is heated under pressure in a steam curing tank 16 at conditions of 0.1 to 1.6 MPa and 80 to 200°C. As a result, a resin linear body 1 is obtained in which minute irregularities are formed on more than one-third of the outer surface of the coating layer 3.

[0034] Here, if the pressurization condition is less than 0.1 MPa, the amount of water vapor cannot be maintained, resulting in insufficient irregularities formed on the outer surface of the coating layer. Furthermore, pressurizing above 1.6 MPa requires a very large steam curing tank 16, making equipment design and maintenance difficult. Moreover, if the heating condition is less than 80°C, the thermoplastic resin constituting the coating layer does not melt sufficiently, and heating above 200°C requires a larger steam curing tank 16, making equipment design and maintenance difficult.

[0035] Through the above process, a resin wire is produced in which a coating layer made of thermoplastic resin is provided around the core without reducing the manufacturing speed, and the area of ​​the cross-section perpendicular to the length direction is 25 mm². 2 The following conditions make it possible to manufacture a resin linear body in which minute irregularities are formed on more than one-third of the outer surface of the coating layer. Because minute irregularities are formed on more than one-third of the outer surface of the coating layer of this resin linear body, the area of ​​the cross-section perpendicular to the length direction is 25 mm². 2Even with the smallest diameters, excellent adhesion to other materials and high adhesive strength can be achieved.

[0036] Furthermore, the present invention may also take the following forms. [1] The core has a coating layer made of thermoplastic resin around it, and the area of ​​the cross-section perpendicular to the length is 25 mm². 2 A method for producing a resin wire, wherein the following A step of coating the outer circumference of the linear material constituting the core with a thermoplastic resin to form a resin-coated linear body, The process involves bringing water and / or steam into contact with the surface of the resin-coated linear body, and then heating the resin-coated linear body under pressure at 0.1 to 1.6 MPa and 80 to 200°C. A method for producing a resin linear body having the properties of a resin. [2] The core portion is a fiber-reinforced resin wire, Before coating the fiber-reinforced resin wire with the thermoplastic resin, A process of impregnating the reinforcing fiber bundle with uncured thermosetting resin, A step of forming a reinforcing fiber bundle impregnated with the thermosetting resin into a predetermined shape to obtain a fiber-reinforced resin wire. A method for producing a resin linear body as described in [1], which involves performing the following: [3] A resin wire having a coating layer made of thermoplastic resin around its core, The area of ​​the cross-section perpendicular to the length is 25 mm². 2 The following: The coating layer is a resin linear body in which minute irregularities are formed on more than one-third of the outer surface. [4] Each recess formed on the outer surface of the coating layer has a size of 0.01 to 2.0 mm in plan view. 2 A resin linear body as described in [3], wherein the depth is 0.001 to 0.4 mm. [5] The core portion is a resin wire body according to [3] or [4], comprising a thermosetting resin. [6] The core portion is a fiber-reinforced resin linear material obtained by impregnating a reinforcing fiber bundle with resin, as described in any of [3] to [5]. [Explanation of Symbols]

[0037] 1. Resin wire 2 core 3 Covering layer 3a Recess 11 Impregnation tank 12 Rectangular Nozzles 13 Coated die 14 Press Roller 15 Cooling water tank 16. Steam curing tank 17. Pressing jig 20 Reinforcement fiber bundles 21 Uncured thermosetting resin 22 Reinforcement fiber bundles impregnated with thermosetting resin 23 Fiber-reinforced resin linear body 24 Resin-coated linear body

Claims

1. The core has a coating layer made of thermoplastic resin around it, and the area of ​​the cross-section perpendicular to the length is 25 mm². ２ A method for producing a resin wire, wherein the following A step of coating the outer circumference of the linear material constituting the core with a thermoplastic resin to form a resin-coated linear body, The process involves bringing water and / or steam into contact with the surface of the resin-coated linear body, and then heating the resin-coated linear body under pressure at 0.1 to 1.6 MPa and 80 to 200°C. A method for producing a resin linear body having the properties of a resin.

2. The core portion is a fiber-reinforced resin wire, Before coating the fiber-reinforced resin wire with the thermoplastic resin, A process of impregnating the reinforcing fiber bundle with uncured thermosetting resin, A step of forming a reinforcing fiber bundle impregnated with the thermosetting resin into a predetermined shape to obtain a fiber-reinforced resin wire. A method for producing a resin wire according to claim 1, wherein the method is carried out as described in claim 1.

3. A resin wire having a coating layer made of thermoplastic resin around its core, The area of ​​the cross-section perpendicular to the length is 25 mm². ２ The following: The coating layer is a resin linear body in which minute irregularities are formed on more than one-third of the outer surface.

4. Each recess formed on the outer surface of the coating layer has a size of 0.01 to 2.0 mm in plan view. ２ The resin wire body according to claim 3, wherein the depth is 0.001 to 0.4 mm.

5. The core portion comprises a resin wire according to claim 3, wherein the core portion comprises a thermosetting resin.

6. The resin linear body according to claim 3, wherein the core portion is a fiber-reinforced resin linear material obtained by impregnating a reinforcing fiber bundle with resin.

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