Manufacturing method of reinforcing mesh

Abstract

To provide a method for manufacturing a reinforcement mesh, capable of preventing curl from occurring when forming a wound body and excellent in workability.SOLUTION: A method for manufacturing a biaxial reinforcement mesh composed of a warp 4 and a weft 5 comprises the steps of: obtaining a mesh textile 1 by weaving so as to entangle thermally fusible yarn including thermoplastic resin fibers with at least one of the warp 4 and the weft 5; crimping the warp 4 and the weft 5 by subjecting the mesh textile 1 to heating and pressing; and obtaining a reinforcement mesh by applying a secondary binder to the crimped mesh textile 1.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a reinforcing mesh and a reinforcing mesh wound body. [Background technology]

[0002] Mortar used in cement products and building exterior walls is prone to cracking due to drying shrinkage, and if such cracks are left unattended for a long period of time, water may seep in and cause leakage, or the strength may decrease, causing the mortar to deteriorate. For this reason, attempts have been made to prevent the cracks from expanding by embedding reinforcing mesh in mortar or concrete.

[0003] As an example of such a reinforcing mesh, Patent Document 1 below discloses a crack suppression material for hardened cement paste, which is a net-like body formed by combining first threads and second threads that are shorter than the first threads. In Patent Document 1, the ratio (tensile stiffness of the first threads) / (tensile stiffness of the second threads) of the net-like body is set to 1.5 to 30. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2009-126730 Summary of the Invention [Problem to be solved by the invention]

[0005] The reinforcing mesh described in Patent Document 1 is intended to be inserted directly into the mortar, and the larger the mesh openings, the less susceptible they are to the effects of aggregate in the matrix, making installation easier. Furthermore, since mortar is poured using equipment such as a vibrator, a strong sealing treatment is required to prevent the warp and weft threads in the mesh from coming loose, even in such an environment. Protection of the fibers themselves is also necessary to prevent the fibers from unraveling and reducing tensile strength.

[0006] To solve these problems, it is usually considered to increase the amount of secondary binder applied for sealing treatment, but if the amount of secondary binder applied is increased, the mesh itself may become hard, or when used in the form of a wound body, it may become curled, making application difficult. Another method is to soften the composition of the secondary binder itself, but in this case, the secondary binder film becomes sticky, which may cause blocking when used in the form of a wound body, making it difficult to unwind from the wound body.

[0007] Furthermore, in the secondary binder application process for a mesh in which a large amount of fibers are arranged in one axial direction and the openings are large, as in Patent Document 1, the mesh may become unstable, causing the warp and weft yarns to meander and become blocked, making it impossible to obtain the desired tensile strength.

[0008] An object of the present invention is to provide a method for producing a reinforcing mesh that is less likely to develop a curl when wound and has excellent workability, and to provide a reinforcing mesh wound body formed by winding the reinforcing mesh. [Means for solving the problem]

[0009] The method for manufacturing a reinforcing mesh according to the present invention is a method for manufacturing a biaxial reinforcing mesh composed of warp threads and weft threads, and is characterized by comprising the steps of: obtaining a mesh fabric by weaving the fabric so that a heat-sealed thread containing a thermoplastic resin fiber is entangled with at least one of the warp threads and weft threads; heating and pressurizing the mesh fabric to pressurize the warp threads and weft threads; and applying a secondary binder to the mesh fabric after the pressing to obtain a reinforcing mesh.

[0010] In the present invention, in the step of obtaining the reinforcing mesh, the secondary binder is preferably applied so that the ignition loss of the reinforcing mesh is 0.5% by mass to 10.0% by mass.

[0011] In the present invention, in the step of obtaining the mesh fabric, it is preferable to entangle a first heat-sealed yarn containing a first thermoplastic resin fiber along at least one of the warp and weft yarns, and to entangle a second heat-sealed yarn containing a second thermoplastic resin fiber by winding it around at least one of the warp, weft, and first heat-sealed yarn. It is preferable that the second heat-sealed yarn further contains inorganic fibers. It is more preferable that the ratio of the content of the second thermoplastic resin fiber to the content of the inorganic fiber in the second heat-sealed yarn is 3:7 to 7:3 by mass.

[0012] In the present invention, in the process of obtaining the mesh fabric, it is preferable that the warp and weft threads are woven by plain weaving, and at the intersection of the warp and weft threads, the second heat-sealed thread is entangled from one main surface of the mesh fabric to the other main surface, and from the other main surface of the mesh fabric back to the one main surface.

[0013] The reinforcing mesh wound body of the present invention is a reinforcing mesh wound body formed by winding a biaxial reinforcing mesh composed of warp threads and weft threads, wherein the reinforcing mesh includes a secondary binder, and when the reinforcing mesh is cut out 500 mm in the winding direction from the reinforcing mesh wound body and placed on a flat surface, the shortest distance connecting both ends of the reinforcing mesh in the winding direction is 400 mm or more.

[0014] In the present invention, the ignition loss of the reinforcing mesh is preferably 0.5% to 10.0% by mass.

[0015] In the present invention, it is preferable that the maximum interval between the rows of warp or weft yarns is 20 mm or more and 60 mm or less.

[0016] In the present invention, it is preferable that the tensile strength of one row of the warp or weft yarns is 800 N / row or more. [Effects of the Invention]

[0017] According to the present invention, it is possible to provide a method for manufacturing a reinforcing mesh that is less likely to develop a curl when wound and has excellent workability, and a reinforcing mesh wound body made from the reinforcing mesh. [Brief explanation of the drawings]

[0018] [Figure 1] FIG. 1 is a schematic plan view showing a mesh fabric used in a method for producing a reinforcing mesh according to a first embodiment of the present invention. [Figure 2] FIG. 2 is a schematic plan view showing an enlarged portion of a mesh fabric used in the method for producing a reinforcing mesh according to the first embodiment of the present invention. [Figure 3] FIG. 3 is a schematic plan view showing an enlarged portion of a mesh fabric used in a method for producing a reinforcing mesh according to a second embodiment of the present invention. [Figure 4] FIG. 4 is a schematic plan view showing an enlarged portion of a mesh fabric used in a method for producing a reinforcing mesh according to a third embodiment of the present invention. [Figure 5] FIG. 5 is a schematic plan view showing a mesh fabric used in a method for manufacturing a reinforcing mesh according to a fourth embodiment of the present invention. [Figure 6] FIG. 6 is a schematic plan view showing an enlarged portion of a mesh fabric used in a method for producing a reinforcing mesh according to a fourth embodiment of the present invention. [Figure 7] FIG. 7 is a schematic diagram showing a reinforcing mesh wound body according to one embodiment of the present invention. [Figure 8] FIG. 8 is a schematic plan view showing a reinforcing mesh that constitutes a reinforcing mesh wound body according to one embodiment of the present invention. [Figure 9] FIG. 9 is a diagram for explaining a method for evaluating the curling tendency of a reinforcing mesh. [Figure 10] FIG. 10 is a diagram for explaining a method for evaluating the sealing strength of a reinforcing mesh. [Figure 11]FIG. 11 is a schematic diagram illustrating the structure of the mesh fabrics produced in Examples 1 and 2. [Figure 12] FIG. 12 is a schematic diagram illustrating the structure of the mesh fabrics produced in Examples 3 and 5. [Figure 13] FIG. 13 is a schematic diagram illustrating the structure of the mesh fabric produced in Example 4. [Figure 14] FIG. 14 is a schematic plan view showing an enlarged portion of a mesh fabric used in the manufacturing method of a reinforcing mesh in Comparative Example 1. As shown in FIG. [Figure 15] FIG. 15 is a schematic plan view showing an enlarged portion of a mesh fabric used in the manufacturing method of a reinforcing mesh in Comparative Example 2. As shown in FIG. [Figure 16] FIG. 16 is a schematic plan view showing an enlarged portion of a mesh fabric used in the manufacturing method of the reinforcing mesh in Comparative Example 3 and Comparative Example 4. As shown in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0019] Preferred embodiments will be described below. However, the following embodiments are merely examples, and the present invention is not limited to the following embodiments. In addition, in each drawing, components having substantially the same functions may be referred to by the same reference numerals.

[0020] [Manufacturing method of reinforcing mesh] In the method for manufacturing a reinforcing mesh of the present invention, first, a mesh fabric is obtained by weaving so that heat-sealed yarns containing thermoplastic resin fibers are entangled with at least one of the warp and weft yarns (mesh fabric formation process). Next, the mesh fabric is heated and pressurized to crimp the warp and weft yarns (crimping process). Next, a secondary binder is applied to the crimped mesh fabric (secondary binder application process). This allows for the production of a biaxial reinforcing mesh composed of the warp and weft yarns.

[0021] In the method for manufacturing a reinforcing mesh of the present invention, heat-sealing yarns containing thermoplastic resin fibers are entangled with at least one of the warp and weft yarns through weaving, followed by heating and pressure treatment. This increases the sealing strength of the warp and weft yarns and improves their mechanical strength. Furthermore, because the sealing strength of the warp and weft yarns is increased, the amount of secondary binder required in subsequent processes can be reduced. This increases the flexibility of the reinforcing mesh and reduces the likelihood of curling. Therefore, even when a uniaxially reinforced mesh with large openings and high tensile strength per row is used, workability can be improved. Furthermore, applying a secondary binder prevents damage to the fibers themselves during concrete pouring, thereby achieving the desired tensile strength.

[0022] (First embodiment) Fig. 1 is a schematic plan view showing a mesh fabric used in a manufacturing method of a reinforcing mesh according to a first embodiment of the present invention, and Fig. 2 is a schematic plan view showing an enlarged portion of the mesh fabric of Fig. 1.

[0023] <Mesh fabric forming process> In the process of forming the mesh fabric 1, first, warp threads 4 and weft threads 5 are prepared. In this embodiment, the fiber bundles constituting the warp threads 4 and weft threads 5 are both glass fiber bundles. The glass fiber bundles can be obtained by bundling several tens to several thousands of glass fiber monofilaments.

[0024] More specifically, the glass fiber bundle can be obtained by the following method. First, glass raw materials charged into a glass melting furnace are melted to form molten glass, and after the molten glass is made homogeneous, the molten glass is drawn out from a heat-resistant nozzle attached to a bushing. Then, the drawn molten glass is cooled to form glass fiber monofilaments (glass fibers).

[0025] Next, a sizing agent is applied to the surface of the glass fibers. With the sizing agent evenly applied, the glass fibers are aligned and bundled together in groups of several tens to several thousands, and then dried to obtain a glass fiber bundle.

[0026] The glass fiber monofilaments constituting the glass fiber bundle preferably each contain, as a glass composition, 12% by mass or more of ZrO2 and 10% by mass or more of R2O (R is at least one selected from Li, Na, and K). In this case, alkali resistance can be further improved and rigidity can be further increased. Incidentally, "10% by mass or more of R2O" means that the total content of Li2O, Na2O, and K2O in the glass fiber monofilament is 10% by mass or more.

[0027] Such glass fiber monofilaments may contain, for example, as a glass composition, in mass%, 54 to 65% SiO2, 12 to 25% ZrO2, 0 to 5% Li2O, 10 to 17% Na2O, 0 to 8% K2O, 0 to 10% R'O (where R' represents Mg, Ca, Sr, Ba, or Zn), 0 to 10% TiO2, and 0 to 2% Al2O3, and preferably contain, in mass%, 57 to 64% SiO2, 14 to 24% ZrO2, 0 to 3% Li2O, 10 to 17% Na2O, 0 to 5% K2O, 0.2 to 8% R'O (where R' represents Mg, Ca, Sr, Ba, or Zn), 0.5 to 9% TiO2, and 0 to 1% Al2O3.

[0028] The average diameter of the glass fiber monofilaments is preferably 10 μm or more, more preferably 15 μm or more, and preferably 30 μm or less, more preferably 25 μm or less. When the average diameter of the glass fiber monofilaments is equal to or greater than the above-mentioned lower limit, the rigidity can be further increased. When the average diameter of the glass fiber monofilaments is equal to or less than the above-mentioned upper limit, the surface area can be further increased, and the adhesiveness to cement, etc. can be further increased.

[0029] Examples of sizing agents used when bundling glass fiber monofilaments include polyester resins. The polyester resin may be a saturated polyester resin or an unsaturated polyester resin. It may also be a vinyl acetate resin, a urethane resin, an epoxy resin, or an acrylic resin. These may be used alone or in combination.

[0030] In addition to the above components, the sizing agent preferably further contains a silane coupling agent. Examples of the silane coupling agent that can be used include aminosilane, epoxysilane, vinylsilane, acrylicsilane, chlorosilane, mercaptosilane, and ureidosilane. The addition of a silane coupling agent can further enhance adhesion to the matrix, such as cement.

[0031] In addition to the silane coupling agent, the sizing agent may contain other components such as a lubricant, a nonionic surfactant, a water-soluble polymer, and an antistatic agent, and the blending ratio of each component may be determined as needed. Examples of water-soluble polymers that can be used include polyvinyl alcohol, polyoxyethylene polyoxypropylene glycol, and polyvinylpyrrolidone.

[0032] The amount of the sizing agent applied is preferably adjusted so that the ignition loss of the glass fiber bundle is 0.5% by mass to 2.0% by mass. The ignition loss can be measured in accordance with JIS R3420 (2013).

[0033] However, the fiber bundles constituting the warp threads 4 and the weft threads 5 are not limited to glass fiber bundles, and may be synthetic fiber bundles. Furthermore, the warp threads 4 and the weft threads 5 may be made of the same fiber bundles as in this embodiment, or may be made of different fiber bundles. Furthermore, they may be made of a combination of multiple fibers. For example, the warp threads 4 may be glass fiber bundles and the weft threads 5 may be synthetic fiber bundles. The warp threads 4 may be synthetic fiber bundles and the weft threads 5 may be glass fiber bundles. However, from the viewpoint of further increasing rigidity, it is preferable that at least one of the warp threads 4 and the weft threads 5 contains glass fiber bundles.

[0034] Examples of fibers constituting the synthetic fiber bundle include carbon fibers, aramid fibers, vinylon fibers, polyester fibers, and polyolefin fibers. These fibers may be used alone or in combination. Of these, carbon fibers, aramid fibers, vinylon fibers, and polyolefin fibers are preferred. From the viewpoint of further improving heat resistance, polyolefin fibers are preferably polypropylene fibers.

[0035] The count of the fiber bundles constituting the warp threads 4 and the weft threads 5 is not particularly limited, but is preferably 100 tex or more and 3000 tex or less. When the count of the fiber bundles is within the above range, the stiffness of the resulting reinforcing mesh can be further increased.

[0036] Next, the obtained fiber bundles are used as warp threads 4 and weft threads 5 to be woven by plain weaving. At this time, as shown in Figures 1 and 2, warp threads 4 consisting of two warp threads 4a and 4b are woven into one warp row 2, and one weft thread 5 is woven into one weft row 3. Thereafter, as shown in Figure 2, a first heat-sealing yarn 6 is aligned so as to extend parallel to the warp threads 4a and 4b. And weft 5 and The second heat-sealing yarn 7 is entangled with the two warp threads 4a and 4b constituting the warp threads 4 in the extending direction of the warp threads 4. , around the warp threads 4a and 4b The yarns are entangled and woven in a winding manner to obtain the mesh fabric 1. Note that the first heat-sealing yarns 6 and the second heat-sealing yarns 7 are not shown in FIG.

[0037] It is preferable that the second heat-sealed yarns 7 are entangled at the intersections 8 of the warp yarns 4 and the weft yarns 5 so as to move from one main surface of the mesh fabric 1 to the other main surface, and also so as to move from the other main surface back to one main surface of the mesh fabric 1. In this way, the second heat-sealed yarns 7 can be wound regularly around the warp yarns 4a and 4b, and the contact area between the weft yarns 5 and the second heat-sealed yarns 7 can be increased, further increasing the sealing strength of the warp yarns and weft yarns.

[0038] The first heat-sealing yarn 6 and the second heat-sealing yarn 7 are yarns that fuse when heated. While it is sufficient to provide either the first heat-sealing yarn 6 or the second heat-sealing yarn 7, it is preferable to provide both. In this case, the amount of secondary binder required in the subsequent process can be further reduced.

[0039] The melting points of the first heat-fusion yarn 6 and the second heat-fusion yarn 7 are preferably 70°C or higher and 160°C or lower, respectively. When the melting points of the first heat-fusion yarn 6 and the second heat-fusion yarn 7 are above the above-mentioned lower limit, sealing can be performed at a relatively low temperature. Furthermore, when the melting points of the first heat-fusion yarn 6 and the second heat-fusion yarn 7 are below the above-mentioned upper limit, flexibility of the mesh fabric 1 can be more reliably ensured.

[0040] The first heat-sealing yarn 6 and the second heat-sealing yarn 7 each contain a thermoplastic resin fiber. The first heat-sealing yarn 6 and the second heat-sealing yarn 7 may be made of the same thermoplastic resin fiber or different thermoplastic resin fibers.

[0041] The thermoplastic resin fiber may be made of, for example, polyester, polyamide, polyacrylonitrile, polyvinyl alcohol, polyolefin, etc. Among these, polyester, polyamide, or polyolefin is preferred because they have a lower melting point. These resins may be used alone or in combination.

[0042] The counts of the first heat-fusion yarn 6 and the second heat-fusion yarn 7 are not particularly limited, but are preferably 10 dtex or more, more preferably 50 dtex or more, and are preferably 600 dtex or less, more preferably 350 dtex or less. When the counts of the first heat-fusion yarn 6 and the second heat-fusion yarn 7 are within the above-mentioned ranges, the amount of secondary binder required in the subsequent process can be further reduced.

[0043] It is preferable that the second heat-sealing yarn 7 further contains inorganic fibers. The inorganic fibers are not particularly limited, but are preferably fibers that do not melt at the heating temperature of the second heat-sealing yarn 7. Such inorganic fibers are not particularly limited, and examples thereof include glass fibers, carbon fibers, and mineral fibers, with glass fibers being preferable. In this case, the sealing strength of the warp yarns 4 and weft yarns 5 can be further increased. Furthermore, inorganic fibers have a lower elongation (0.1% or more and 5% or less) than thermoplastic resin fibers, and are therefore more likely to become entangled with the warp yarns 4 and weft yarns 5.

[0044] When the second thermal adhesive yarn 7 also contains inorganic fibers, the inorganic fibers and thermoplastic resin fibers may be doubled or twisted together, or the inorganic fibers and thermoplastic resin fibers may simply be aligned.

[0045] Furthermore, the ratio of the content of the thermoplastic resin fiber to the content of the inorganic fiber in the second heat-bonding yarn 7 is preferably 3:7 to 7:3 by mass, which can further improve the sealing strength of the warp yarns 4 and the weft yarns 5.

[0046] The area of ​​the opening 9 in the mesh fabric 1 is, for example, 250 mm 2 More than 2500mm 2 The mesh fabric 1 may be woven so that the maximum spacing between the warp rows 2 is, for example, 20 mm or more and 60 mm or less. The mesh fabric 1 may be woven so that the maximum spacing between the weft rows 3 is, for example, 20 mm or more and 60 mm or less. The thickness of the mesh fabric 1 is not particularly limited, but may be woven so that the thickness is, for example, 0.2 mm or more and 1 mm or less.

[0047] <Crimping process> Next, the mesh fabric 1 is subjected to a heat and pressure treatment to thermocompress the warp threads 4 and the weft threads 5 .

[0048] The heating and pressure treatment can be carried out by a hot press such as a hot roll press or a hot mold press. The hot press is preferably carried out at a temperature that does not soften the fiber bundles (warp yarns 4 and weft yarns 5) that make up the mesh fabric 1. Note that the "non-softening temperature" refers to a temperature lower than the softening point for materials that have a softening point, and refers to a temperature equal to or lower than the softening point for materials that do not have a softening point.

[0049] The temperature of the heat press depends on the type of material constituting the fiber bundle, but is preferably 80° C. or higher, more preferably 100° C. or higher, and is preferably 250° C. or lower, more preferably 160° C. or lower. The pressure of the heat press is preferably 5 N / cm. 2 More preferably 7N / cm 2 or more, preferably 40N / cm 2 Less than or equal to 15N / cm 2 It can be as follows:

[0050] <Secondary binder application process> Next, a secondary binder is applied to the compressed mesh fabric 1 to obtain a reinforcing mesh. Examples of the secondary binder that can be used include acrylic resin, urethane resin, epoxy resin, vinyl acetate resin, urea resin, and PVC resin. One type of secondary binder may be used alone, or multiple types may be used in combination.

[0051] The glass transition temperature (Tg) of the secondary binder is not particularly limited, but is preferably -12°C or higher, more preferably -10°C or higher, and preferably 35°C or lower, more preferably 15°C or lower. In this case, when the secondary binder is wound, it is possible to further reduce the likelihood of curling. Note that it is preferable to use multiple types of compounds with different glass transition temperatures as the secondary binder.

[0052] The secondary binder is preferably applied so that the ignition loss of the resulting reinforcing mesh is 0.5% to 10.0% by mass. In this case, the flexibility of the resulting reinforcing mesh can be further increased, making it even less likely to become curled. Furthermore, even by applying a small amount of secondary binder, damage to the fibers themselves during concrete pouring can be prevented, and the desired tensile strength can be more reliably achieved.

[0053] The ignition loss of the secondary binder is preferably adjusted to be 1.0 mass% or more, more preferably 3.0 mass% or more, and preferably 8.0 mass% or less, more preferably 6.0 mass% or less. The ignition loss can be measured in accordance with JIS R3420 (2013).

[0054] In this embodiment, warp yarn 4 and weft 5 In contrast, the first thermal fusion yarn 6 and the second thermal fusion yarn 7 are woven so as to be entangled, and then heat and pressure treatment is performed, thereby increasing the sealing strength of the warp yarns 4 and the weft yarns 5 and improving mechanical strength. Furthermore, because the sealing strength of the warp yarns 4 and the weft yarns 5 can be increased, the amount of secondary binder required in subsequent processes can be reduced. This increases the flexibility of the resulting reinforcing mesh and also reduces the likelihood of curling. Therefore, even when a uniaxially reinforced mesh with large openings 9 and high tensile strength per row is used, workability can be improved. Furthermore, applying a secondary binder can prevent damage to the fibers themselves during concrete pouring, and the desired tensile strength can be achieved.

[0055] In addition , economics The first heat-sealing yarn 6 and the second heat-sealing yarn 7 are entangled with the yarn 4 by weaving. Also well Alternatively, the first heat-sealing yarn 6 and the second heat-sealing yarn 7 may be entangled with the weft yarn 5 during weaving.

[0056] More specifically, the first heat-sealed yarn 6 may be entangled along at least one of the warp yarn 4 and the weft yarn 5, and the second heat-sealed yarn 7 may be entangled with at least one of the warp yarn 4, the weft yarn 5, and the first heat-sealed yarn 6.

[0057] In the present invention, it is not necessary to provide one of the first heat-fusion yarn 6 and the second heat-fusion yarn 7, and it is sufficient to provide at least one heat-fusion yarn. Even in this case, the effects of the present invention can be enjoyed.

[0058] (Second embodiment) FIG. 3 is a schematic plan view showing an enlarged portion of a mesh fabric used in a method for producing a reinforcing mesh according to a second embodiment of the present invention.

[0059] In the manufacturing method of the second embodiment, in the mesh fabric forming step, as shown in Fig. 3, six warp threads 4a and 4b are arranged in one warp row 2, and one weft thread 5 is arranged in one weft row 3 to weave the mesh fabric 21. Also, as shown in Fig. 3, the first heat-sealing yarn 6 is arranged in such a way that it extends parallel to the warp threads 4a and 4b. And weft 5 and After the entanglement, the warp yarns 4a, 4b and the weft yarn 5 are plain woven, and the second heat-sealing yarn 7 is entangled with the warp yarns 4a, 4b. Around Therefore, in this embodiment, the warp threads 4a, 4b are wound around each other and entangled to weave the fabric. Therefore, in this embodiment, the warp thread row 2 is formed by providing three pairs of warp threads 4a, 4b each entangled with the second thermal adhesive yarn 7. Other points are the same as those in the first embodiment.

[0060] In the second embodiment, the warp yarn 4 and weft 5The first heat-sealing yarn 6 and the second heat-sealing yarn 7 are entangled in the reinforcing mesh, which is then woven and heated and pressurized. Therefore, the reinforcing mesh obtained is less likely to develop a curl when wound, has excellent workability, and is also excellent in mechanical strength.

[0061] Therefore, as in the second embodiment, the warp row 2 may be configured by providing a plurality of sets of warp threads 4a, 4b each entangled with the second thermal fusion thread 7. In this way, by almost simultaneously weaving the warp threads 4a, 4b and the weft thread 5 and winding the second thermal fusion thread 7, the time required for the mesh fabric formation process can be shortened.

[0062] (Third embodiment) FIG. 4 is a schematic plan view showing an enlarged portion of a mesh fabric used in a method for producing a reinforcing mesh according to a third embodiment of the present invention.

[0063] In the manufacturing method of the third embodiment, in the mesh fabric forming step, as shown in Fig. 4, one warp thread 4 is used as one warp thread row 2 and one weft thread 5 is used as one weft thread row 3 to weave a mesh fabric 31. Also, as shown in Fig. 4, a first heat-sealing yarn 6 is arranged so as to extend parallel to the warp thread 4. And weft 5 and The second heat-sealing yarn 7 is entangled with the warp yarn 4. Around The fibers are woven by wrapping them around each other. The other points are the same as those in the first embodiment.

[0064] In the third embodiment, the warp yarn 4 and weft 5 The first heat-sealing yarn 6 and the second heat-sealing yarn 7 are entangled in the reinforcing mesh, which is then woven and heated and pressurized. Therefore, the reinforcing mesh obtained is less likely to develop a curl when wound, has excellent workability, and is also excellent in mechanical strength.

[0065] Therefore, as in the third embodiment, one warp thread 4 2nd 2. Tangle the heat-sealed yarn 7 The first heat-sealing yarns 6 are arranged so as to extend parallel to the warp yarns 4. The warp row 2 may be formed by the above.

[0066] (Fourth embodiment) Fig. 5 is a schematic plan view showing a mesh fabric used in a manufacturing method for a reinforcing mesh according to a fourth embodiment of the present invention, and Fig. 6 is a schematic plan view showing an enlarged portion of the mesh fabric used in a manufacturing method for a reinforcing mesh according to the fourth embodiment of the present invention.

[0067] In the fourth embodiment, in the mesh fabric forming step, glass fiber bundles prepared in the same manner as in the first embodiment are used, and as shown in Fig. 5, a mesh fabric 41 is obtained by weaving using a leno weave. At this time, as shown in Figs. 5 and 6, a first strand 44a and a second strand 44b are entangled to form warp threads 44, and a weft thread 45 is woven into the warp threads 44 to form the mesh fabric. Also, as shown in Fig. 6, a first heat-sealing thread 46 is pulled and aligned along the first strand 44a. The second strand 44b and the weft 45 The second heat-sealing thread 47 is entangled with the second strand 44b, and the second heat-sealing thread 47 is pulled along the second strand 44b. The first strand 44a and the weft yarn 45 The yarns are entangled and woven. Other points are the same as those in the first embodiment. Note that the first heat-sealing yarn 46 and the second heat-sealing yarn 47 are omitted from Fig. 5.

[0068] In the fourth embodiment, the warp threads 44 (first strand 44a and second strand 44b) and weft yarn 45 The reinforcing mesh is woven so as to entangle the first heat-sealed yarn 46 and the second heat-sealed yarn 47, and then subjected to heat and pressure treatment. Therefore, the reinforcing mesh obtained is less likely to develop a curl when wound, has excellent workability, and is also excellent in mechanical strength.

[0069] Therefore, the mesh fabric 41 may be obtained by weaving using a leno weave as in the fourth embodiment. However, it is preferable to obtain the mesh fabric by weaving using a plain weave as in the first to third embodiments, since this allows for a larger surface area to be bonded using heat-sealing yarns.

[0070] [Reinforcing mesh roll] Fig. 7 is a schematic view showing a reinforcing mesh wound body according to one embodiment of the present invention, and Fig. 8 is a schematic plan view showing a reinforcing mesh constituting the reinforcing mesh wound body according to one embodiment of the present invention.

[0071] The reinforcing mesh wound body 10 shown in Fig. 7 is formed by winding up the reinforcing mesh 11 shown in Fig. 8. The reinforcing mesh 11 can be manufactured, for example, by the reinforcing mesh manufacturing method of the present invention described above. Therefore, the reinforcing mesh 11 contains a secondary binder. The reinforcing mesh 11 can be formed by appropriately using the materials described in the section on the reinforcing mesh manufacturing method. Note that the first heat-sealing yarn 6 and the second heat-sealing yarn 7 are omitted from Fig. 8.

[0072] When the reinforcing mesh 11 of the reinforcing mesh wound body 10 is cut out to a length of 500 mm in the winding direction and placed on a flat surface, the shortest distance connecting both ends of the reinforcing mesh 11 in the winding direction is 400 mm or more.

[0073] 9, when the reinforcing mesh 11 is placed on a flat surface 50, it is preferable that the distance L connecting both ends of the main surface 11a of the reinforcing mesh 11 on the flat surface 50 side in the winding direction X is 400 mm or more. In this case, when the reinforcing mesh 11 is wound, it is even less likely to develop a curl, and workability can be further improved.

[0074] From the viewpoint of further reducing the likelihood of curling when wound and further improving workability, the distance L is more preferably 420 mm or more, and further preferably 470 mm or more. Note that the distance L may be a maximum of 500 mm.

[0075] The ignition loss of the reinforcing mesh 11 is preferably 0.5% by mass or more, more preferably 3.0% by mass or more, and preferably 10.0% by mass or less, more preferably 8.0% by mass or less, and even more preferably 6.0% by mass or less. When the ignition loss of the reinforcing mesh 11 is within the above-mentioned range, curling is less likely to occur when the mesh is wound, which further improves workability. It also further improves mechanical strength.

[0076] The maximum spacing W between the rows formed by the warp row 2 or the weft row 3 is preferably 20 mm or more, more preferably 25 mm or more, and preferably 60 mm or less, more preferably 55 mm or less. In this case, the workability of the reinforcing mesh 11 can be further improved.

[0077] The tensile strength of one row formed by the warp row 2 or the weft row 3 is preferably 800 N / row or more, more preferably 1000 N / row or more, and preferably 1500 N / row or less. In this case, it is possible to further improve the mechanical strength of the reinforcing mesh 11. The tensile strength can be measured in accordance with JIS L1015 (2010).

[0078] According to the reinforcing mesh wound body 10 of this embodiment, it is possible to provide a reinforcing mesh 11 that is less prone to curling, has excellent workability, and is also excellent in mechanical strength.

[0079] Moreover, the reinforcing mesh wound body 10 and the reinforcing mesh 11 are preferably used by being embedded in concrete or mortar, and can be suitably used as a cement reinforcing mesh.

[0080] The present invention will be described in more detail below with reference to specific examples. The present invention is not limited to the following examples, and can be practiced with appropriate modifications within the scope of the present invention.

[0081] Example 1 First, raw materials were prepared to produce glass having a composition of 58.6 mass% SiO2, 17.3 mass% ZrO2, 0.1 mass% Li2O, 15.2 mass% Na2O, 0.4 mass% KO, 0.6 mass% CaO, 7.6 mass% TiO2, and 0.2 mass% Al2O3, and the molten glass was drawn out as glass fiber monofilaments from a bushing having several hundred to several thousand nozzles.

[0082] Next, a sizing agent prepared by dispersing aminosilane, epoxy resin, and lubricant in water was applied to the surface of the obtained glass fiber monofilament using an applicator, and the amount was adjusted so that the loss on ignition was 0.7% by mass. After bundling the glass fibers, the sizing agent was dried to produce a glass fiber bundle.

[0083] Next, a mesh fabric having the structure shown in Fig. 11 was produced. Specifically, as shown in Fig. 6, warp threads 44 were formed by intertwining first strands 44a and second strands 44b made of glass fiber bundles obtained by the above method, and three sets of these warp threads 44 were provided to form one warp row 2 shown in Fig. 11. In addition, one weft thread 45 was made into one weft row 3 shown in Fig. 11, and this weft row 3 was woven into the warp row 2 to form a leno weave. As shown in Fig. 6, a first heat-sealed yarn 46 was pulled and aligned along the first strands 44a. The second strand 44b and the weft 45 The second heat-sealing thread 47 is entangled with the second strand 44b, and the second heat-sealing thread 47 is pulled along the second strand 44b. The first strand 44a and the weft yarn 45 It was woven by intertwining.

[0084] The first heat-sealing yarn 46 and the second heat-sealing yarn 47 were made of a heat-sealing yarn (count: 330 dtex) made of nylon fiber as a thermoplastic resin fiber.

[0085] The count of the warp yarns 44 and weft yarns 45 was 1100 tex. The warp yarn density was 5.0 ends / inch, and the weft yarn density was 0.83 ends / inch. The number of heat-sealed yarns (warp heat-sealed yarns) in warp row 2 was 2 / row, and the number of heat-sealed yarns (weft heat-sealed yarns) in weft row 3 was 0 / row. The spacing a between the rows in warp row 2 and weft row 3 was 30 mm, and the width b of the mesh fabric was 210 mm.

[0086] The resulting mesh fabric was then heated at a temperature of 120°C and a pressure of 10 N / cm 2 The mesh fabric was then hot-pressed with a heated roller at 100°C for thermocompression bonding. The resulting mesh fabric was then immersed in a secondary binder. The secondary binder used was a mixture of an acrylic resin with a glass transition temperature of 14°C and an acrylic resin with a glass transition temperature of -10°C. After immersion, the mesh fabric was dried to obtain a reinforcing mesh. The secondary binder was applied so that the ignition loss of the reinforcing mesh was 3.0% by mass. The ignition loss was measured using the method described in JIS R3420 (2013). The basis weight of the resulting reinforcing mesh was 307 g / m 2 It was.

[0087] Example 2 In Example 2, a mesh fabric having the structure shown in Fig. 11 was produced using glass fiber bundles obtained in the same manner as in Example 1. Specifically, as shown in Fig. 3, three sets of warp threads 4 each consisting of two warp threads 4a and 4b were provided to form one warp thread row 2, and one weft thread 5 was provided to form one weft thread row 3, and the fabric was woven by plain weaving. Also, as shown in Fig. 3, a first heat-sealing yarn 6 was arranged so as to extend parallel to each of the warp threads 4a and 4b. And weft 5 and The second heat-sealing yarn 7 is intertwined with each warp yarn 4 Around The fabric was woven by wrapping it around and intertwining it.

[0088] A heat-sealing yarn (count: 330 dtex) made of nylon resin as a thermoplastic resin fiber was used as the first heat-sealing yarn 6. A heat-sealing yarn (count: 555 dtex) containing 69% by mass of nylon resin as a thermoplastic resin fiber and 31% by mass of glass fiber as an inorganic fiber was used as the second heat-sealing yarn 7.

[0089] The number of heat-sealed yarns (warp heat-sealed yarns) in warp row 2 was 3, and the number of heat-sealed yarns (weft heat-sealed yarns) in weft row 3 was 0. The secondary binder was applied so that the ignition loss of the reinforcing mesh was 2.0% by mass. A reinforcing mesh was obtained in the same manner as in Example 1 except for the above. The basis weight of the obtained reinforcing mesh was 298 g / m 2 It was.

[0090] The count of the warp yarn 4 and the count of the weft yarn 5 are the same as the count of the warp yarn 44 and the count of the weft yarn 45 in Example 1.

[0091] Example 3 In Example 3, a mesh fabric having the structure shown in Fig. 12 was produced using glass fiber bundles obtained in the same manner as in Example 1. Specifically, as shown in Figs. 1 and 2, a warp thread 4 consisting of two warp threads 4a and 4b was arranged as one warp thread row 2, and a weft thread 5 was arranged as one weft thread row 3, and the fabric was woven by plain weaving. In addition, as shown in Fig. 2, a first heat-sealing yarn 6 was aligned so as to extend parallel to the warp threads 4a and 4b. Weft 5 and The second heat-sealed yarn 7 is entangled with the warp yarns 4 constituting the warp row 2. Around The fabric was woven by wrapping it around and intertwining it.

[0092] The first heat-sealing yarn 6 and the second heat-sealing yarn 7 used were the same as the first heat-sealing yarn 6 and the second heat-sealing yarn 7 used in Example 2.

[0093] The warp yarn 4 had a count of 155 tex, and the weft yarn 5 had a count of 320 tex. The warp yarn density was 10 yarns / inch, and the weft yarn density was 5 yarns / inch. The number of heat-sealed yarns (warp heat-sealed yarns) in warp row 2 was 3 yarns / row, and the number of heat-sealed yarns (weft heat-sealed yarns) in weft row 3 was 0 yarns / row. The spacing a between the warp yarn row 2 and the weft yarn row 3 was 5 mm, and the width of the mesh fabric was 210 mm. The secondary binder was applied so that the ignition loss of the reinforcing mesh was 5.0 mass %. A reinforcing mesh was obtained in the same manner as in Example 1 except for the above. The basis weight of the obtained reinforcing mesh was 135 g / m 2It was.

[0094] Example 4 In Example 4, a mesh fabric having the structure shown in FIG. 13 was produced using glass fiber bundles obtained in the same manner as in Example 1. Specifically, as shown in FIG. 4, one warp thread 4 was used as one warp row 2, and one weft thread 5 was used as one weft row 3, and the fabric was woven by plain weaving. Also, as shown in FIG. 4, the first heat-sealing yarn 6 was aligned so as to extend parallel to the warp thread 4, and the first heat-sealing yarn 6 was aligned so as to extend parallel to the warp thread 4. Weft 5 and The second heat-sealing yarn 7 is entangled with the warp yarn 4. Around The fabric was woven by wrapping it around and intertwining it.

[0095] The first heat-sealing yarn 6 and the second heat-sealing yarn 7 used were the same as the first heat-sealing yarn 6 and the second heat-sealing yarn 7 used in Example 2.

[0096] The warp yarns 4 and weft yarns 5 had a count of 320 tex. The warp yarn density and weft yarn density were 5 yarns / inch. The number of heat-sealed yarns (warp heat-sealed yarns) in warp row 2 was 2 yarns / row, and the number of heat-sealed yarns (weft heat-sealed yarns) in weft row 3 was 0 yarns / row. The spacing a between the rows in warp row 2 and weft row 3 was 5 mm, and the width of the mesh fabric was 210 mm. The secondary binder was applied so that the ignition loss of the reinforcing mesh was 4.0% by mass. A reinforcing mesh was obtained in the same manner as in Example 1 except for the above. The basis weight of the obtained reinforcing mesh was 130 g / m 2 It was.

[0097] Example 5 In Example 5, a mesh fabric having the structure shown in Fig. 12 was produced using glass fiber bundles obtained in the same manner as in Example 1. Specifically, as shown in Figs. 1 and 2, a warp thread 4 consisting of two warp threads 4a and 4b was arranged as one warp thread row 2, and a weft thread 5 was arranged as one weft thread row 3, and the fabric was woven by plain weaving. In addition, as shown in Fig. 2, a first heat-sealing yarn 6 was aligned so as to extend parallel to the warp threads 4a and 4b. Weft 5 and The second heat-sealed yarn 7 is entangled with the warp yarns 4 constituting the warp row 2. Around The fabric was woven by wrapping it around and intertwining it.

[0098] The first heat-sealing yarn 6 and the second heat-sealing yarn 7 used were the same as the first heat-sealing yarn 6 and the second heat-sealing yarn 7 used in Example 2.

[0099] The warp yarn 4 had a count of 640 tex. The weft yarn 5 had a count of 1400 tex. The warp yarn density was 2.4 ends / inch. The weft yarn density was 1.2 ends / inch. The number of heat-sealed yarns (warp heat-sealed yarns) in warp row 2 was 3 / row, and the number of heat-sealed yarns (weft heat-sealed yarns) in weft row 3 was 1 / row. The spacing a between the warp yarn row 2 and the weft yarn row 3 was 20 mm, and the width of the mesh fabric was 210 mm. The secondary binder was applied so that the ignition loss of the reinforcing mesh was 8.0% by mass. A reinforcing mesh was obtained in the same manner as in Example 1 except for the above. The basis weight of the obtained reinforcing mesh was 132 g / m 2 It was.

[0100] (Comparative Example 1) In Comparative Example 1, a mesh fabric 71 shown in FIG. 14 was produced using glass fiber bundles obtained in the same manner as in Example 1. Specifically, one warp thread 74 was used as one warp row, and one weft thread 75 was used as one weft row, and the fabric was woven by plain weaving. Also, as shown in FIG. 14, cotton thread 76 was used as the warp thread 74. Around The fabric was woven by wrapping it around and intertwining it.

[0101] The warp density was 2.25 threads / inch, and the weft density was 1.88 threads / inch. The spacing between the warp and weft rows was 11 mm x 13 mm, and the width of the mesh fabric was 210 mm. The secondary binder was applied so that the ignition loss of the reinforcing mesh was 21.0 mass %. In Comparative Example 1, no heating or pressure treatment was performed. A reinforcing mesh was obtained in the same manner as in Example 1 except for the above. The basis weight of the obtained reinforcing mesh was 220 g / m 2 It was.

[0102] (Comparative Example 2) In Comparative Example 2, a mesh fabric 81 shown in FIG. 15 was produced using glass fiber bundles obtained in the same manner as in Example 1. Specifically, three warp threads 84 were used as one warp row, and one weft thread 85 was used as one weft row, and the fabric was woven by plain weaving. Also, as shown in FIG. 15, cotton thread 86 was used as the thread for each warp thread 84. Around The fabric was woven by wrapping it around and intertwining it.

[0103] The warp density was 5.0 threads / inch, and the weft density was 0.83 threads / inch. The interval between the warp and weft rows was 30 mm, and the width of the mesh fabric was 210 mm. The secondary binder was applied so that the ignition loss of the reinforcing mesh was 20.0 mass %. In Comparative Example 2, no heating or pressure treatment was performed. A reinforcing mesh was obtained in the same manner as in Example 1 except for the above. The basis weight of the obtained reinforcing mesh was 332 g / m 2 It was.

[0104] (Comparative Example 3) In Comparative Example 3, a mesh fabric 91 shown in Fig. 16 was produced using glass fiber bundles obtained in the same manner as in Example 1. Specifically, a first strand 94a and a second strand 94b made of the glass fiber bundles obtained as described above were entangled to form warp threads 94, and a weft thread 95 made of the glass fiber bundles obtained as described above was woven into the warp threads 94 by leno weaving. In addition, no thermally fused yarns or cotton yarns were used.

[0105] The warp yarn count 94 was 155 tex, and the weft yarn count 95 was 320 tex. The warp yarn density was 10 yarns / inch, and the weft yarn density was 5 yarns / inch. The interval between the warp yarn rows and the weft yarn rows was 5 mm, and the width of the mesh fabric was 210 mm. The secondary binder was applied so that the ignition loss of the reinforcing mesh was 20.0 mass %. In Comparative Example 3, no heating or pressure treatment was performed. A reinforcing mesh was obtained in the same manner as in Example 1 except for the above. The basis weight of the obtained reinforcing mesh was 153 g / m 2 It was.

[0106] Comparative Example 4 In Comparative Example 4, a reinforcing mesh was obtained in the same manner as in Comparative Example 3, except that a secondary binder was applied so that the ignition loss of the reinforcing mesh would be 8.7% by mass. The basis weight of the obtained reinforcing mesh was 137 g / m 2 It was.

[0107] [evaluation] (Evaluation of tensile strength) The tensile strength of one row composed of warp and weft yarns (one warp row and one weft row) was measured for each of the reinforcing meshes obtained in Examples 1 to 5 and Comparative Examples 1 to 4. The tensile strength was measured in accordance with JIS L1015 (2010).

[0108] (Evaluation of curling habits) The reinforcing meshes obtained in Examples 1 to 5 and Comparative Examples 1 to 4 were wound up to a diameter of 150 mm to obtain mesh wound bodies. The obtained reinforcing mesh wound bodies were stored at 40°C for one month. A piece 200 mm wide and 500 mm long was cut out from the outer layer of the stored reinforcing mesh wound body. The cut-out sample was designated the reinforcing mesh 11 shown in Fig. 9 and placed on a flat surface 50. After placement, the distance L connecting both ends of the main surface 11a of the reinforcing mesh 11 on the flat surface 50 side in the winding direction X was measured.

[0109] (Evaluation of sealing strength) The reinforcing meshes obtained in Examples 1 to 5 and Comparative Examples 1 to 4 were cut out so as to include the intersection points 8 of the warp row 2 and the weft row 3 as shown in Figure 10, and the warp row 2 and the weft row 3 were fixed to a backing sheet 60 with adhesive 61, and the adhesive strength at the intersection points 8 was measured.

[0110] The results are shown in Table 1 below.

[0111] [Table 1]

[0112] As is clear from Table 1, the reinforcing meshes of Examples 1 to 5 were confirmed to be less prone to curling and to have excellent workability compared to Comparative Examples 1 to 4. It was also confirmed that the reinforcing meshes of Examples 1 to 5 also had high sealing strength. Furthermore, when Examples 1 and 2 were compared with Comparative Example 2, which had substantially the same warp count and density, weft count and density, and basis weight, Examples 1 and 2 had higher tensile strength than Comparative Example 2. Furthermore, when Example 3 was compared with Comparative Example 3, which had substantially the same warp count and density, weft count and density, and basis weight, Example 3 had higher tensile strength. [Explanation of symbols]

[0113] 1, 21, 31, 41...Mesh fabric 2...Warp row 3...Weft row 4, 4a, 4b, 44...warp threads 5,45...weft 6,46...First heat-sealing yarn 7,47...Second heat-sealing thread 8...Intersection 9...Opening 10...Reinforcing mesh wound body 11...Reinforcing mesh 11a…main surface 44a...1st strand 44b...Second strand 50…Flat surface 60...Backing paper 61...Adhesive

Claims

1. A method for manufacturing a biaxial reinforcing mesh composed of warp yarns and weft yarns, A step of weaving a mesh fabric by entangling a heat-sealing yarn containing a thermoplastic resin fiber with at least one of a warp yarn and a weft yarn; a step of heating and pressurizing the mesh fabric to crimp the warp and weft yarns; Applying a secondary binder to the compressed mesh fabric to obtain a reinforcing mesh; Equipped with In the step of obtaining the mesh fabric, a first heat-sealing yarn containing a first thermoplastic resin fiber is arranged so as to extend along at least one of the warp yarns and the weft yarns; A method for manufacturing a reinforcing mesh, comprising weaving a second heat-sealed yarn containing a second thermoplastic resin fiber by wrapping it around at least one of the warp yarn, the weft yarn, and the first heat-sealed yarn to entangle them.

2. In the step of obtaining the reinforcing mesh, The method for producing a reinforcing mesh according to claim 1, wherein the secondary binder is applied so that the ignition loss of the reinforcing mesh is 0.5% by mass to 10.0% by mass.

3. The method for producing a reinforcing mesh according to claim 1 or 2, wherein the second heat-sealing yarn further contains inorganic fibers.

4. 4. The method for manufacturing a reinforcing mesh according to claim 3, wherein the ratio of the content of the second thermoplastic resin fiber to the content of the inorganic fiber in the second heat-fused yarn is 3:7 to 7:3 by mass.

5. In the step of obtaining the mesh fabric, The warp and weft yarns are woven by plain weaving, A method for manufacturing a reinforcing mesh as described in any one of claims 1 to 4, wherein at the intersection of the warp and weft threads, the second heat-sealed thread is entangled from one main surface of the mesh fabric to the other main surface, and from the other main surface of the mesh fabric back to the one main surface.

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