Wire for carbon fiber-reinforced plastic stranded cable, stranded cable comprising said wire, and apparatus and method for manufacturing said cable

Abstract

One embodiment of the present invention provides a wire for a carbon fiber-reinforced plastic stranded cable, a stranded cable comprising the wire, and an apparatus and method for manufacturing the cable. The wire for a carbon fiber-reinforced plastic stranded cable comprises: a main body including a carbon fiber bundle cured by a thermosetting resin; a thermosetting resin layer formed to surround the outer circumferential surface of the main body; and a friction layer including friction particles adhered to the thermosetting resin layer. One effect of the present invention is to provide a wire for a carbon fiber-reinforced plastic stranded cable, a stranded cable comprising the wire, and an apparatus and method for manufacturing the cable, in which a frictional force can be imparted to the surface of the carbon fiber-reinforced plastic stranded cable, thereby improving a bonding force between the carbon fiber-reinforced plastic stranded cable and a fixing device or a support member.

Description

A strand for a carbon fiber reinforced plastic stranded cable, a stranded cable having the strand, an apparatus for manufacturing the cable, and a method for manufacturing the cable.

[0001] The present invention relates to a strand for a stranded cable, a stranded cable having the strand, an apparatus for manufacturing the cable, and a method for manufacturing the cable. More specifically, the invention relates to a strand for a carbon fiber reinforced plastic stranded cable, a stranded cable having the strand, an apparatus for manufacturing the cable, and a method for manufacturing the cable.

[0002] A stranded-pair cable is structured such that multiple side wires are arranged to twist around a core wire. The wires can be made of steel or fiber bundles. Recently, wires for stranded-pair cables are being made of carbon fiber reinforced plastic (CFRP), which is carbon fiber bundles reinforced with a material such as resin.

[0003] Stranded cables made of carbon fiber reinforced plastic wires are used in various fields such as the aerospace, automotive, sporting goods, construction, and bridges, as they possess high lightness and elasticity compared to stranded cables made of steel wires, while also exhibiting high strength, heat resistance, corrosion resistance, and electrical conductivity.

[0004] Stranded cables made of carbon fiber reinforced plastic wires are secured to a specific target by a fixing device or support member during use. In order for a stranded cable made of carbon fiber reinforced plastic wires to be stably secured to a specific target, it needs to be firmly connected to the fixing device.

[0005] Japanese Patent Publication No. 5913085 discloses a fiber-reinforced plastic stranded cable in which a filler wire with abrasive particles attached to its surface is wound along a spiral groove on the surface of the cable, an abrasive sheet with abrasive particles attached to its surface and back surface is wound over it, and a net tube made of metal wires is covered over it to ensure sufficient fixing performance in a high-temperature environment. However, this conventional technology has the problem that the fixing performance is inferior compared to when there are friction particles on the surface of the cable because there are no friction particles on the surface of the fiber-reinforced plastic stranded cable. Additionally, as tensile force is applied to the fiber-reinforced plastic stranded cable, the filler wire wound along the spiral groove on the surface of the cable detaches from the spiral groove, resulting in a decrease in fixing performance.

[0006] Conventionally, Japanese Patent Publication No. JP 1-272889 discloses a method of forming a thermosetting resin in a cylindrical shape at the end portion of an assembly to connect a fixing device or a supporting member. However, this conventional technology also has the problem that the fixing performance is inferior compared to cases where friction particles are present on the surface of the end portion of the assembly because there are no friction particles on the surface of the end portion of the assembly, and there is the problem that time is required for the cylindrical thermosetting resin formed at the end portion of the assembly to cure.

[0007] One problem that the present invention aims to solve is to provide a strand for a carbon fiber reinforced plastic stranded cable, a stranded cable equipped with said strand, an apparatus for manufacturing said cable, and a method for manufacturing said cable, which can improve the bonding strength between a carbon fiber reinforced plastic cable and a fixing device or a supporting member by imparting frictional force to the surface of the carbon fiber reinforced plastic cable.

[0008] The problems that the present invention aims to solve are not limited to those mentioned above, and other unmentioned problems will be clearly understood by a person skilled in the art from the description below.

[0009] A wire for a carbon fiber reinforced plastic stranded cable according to one embodiment of the present invention comprises: a main body comprising a bundle of carbon fibers cured by a thermosetting resin; a thermosetting resin layer formed to surround the outer surface of the main body; and a friction layer comprising friction particles attached to the thermosetting resin layer.

[0010] A stranded cable having carbon fiber reinforced plastic wires according to another embodiment of the present invention comprises a core wire; and a plurality of side wires surrounding the core wire, wherein the wire comprises a main body comprising a bundle of carbon fibers cured by a thermosetting resin; a thermosetting resin layer formed to surround the outer surface of the main body; and a friction layer comprising friction particles attached to the thermosetting resin layer.

[0011] A manufacturing apparatus for a stranded cable having a carbon fiber reinforced plastic wire according to another embodiment of the present invention comprises: a supply device for supplying a carbon fiber bundle impregnated with a thermosetting resin so that a thermosetting resin layer is formed on the outer surface of the carbon fiber bundle; a first curing device for partially curing the thermosetting resin layer so that the thermosetting resin layer formed on the outer surface of the carbon fiber bundle supplied by the supply device is cured within a viscosity range to which friction particles can be attached; a friction layer forming device for forming a friction layer so that a wire including a friction layer is formed on the thermosetting resin layer partially cured by the first curing device; a stranding device for stranding a plurality of wires so that a stranded cable including a friction layer formed by the friction layer forming device is formed; a second curing device for fully curing the thermosetting resin layer of a stranded cable including a plurality of wires stranded by the stranding device; and a winding device for winding a stranded cable having a thermosetting resin layer fully cured by the second curing device.

[0012] A method for manufacturing a stranded cable having a carbon fiber reinforced plastic wire according to another embodiment of the present invention comprises: a supply step of supplying a carbon fiber bundle impregnated with a thermosetting resin so that a thermosetting resin layer is formed on the outer surface of the carbon fiber bundle; a first curing step of partially curing the thermosetting resin layer so that the thermosetting resin layer formed on the outer surface of the carbon fiber bundle supplied by the supply step is cured within a viscosity range to which friction particles can be attached; a friction layer forming step of forming a friction layer so that a wire including a friction layer is formed on the thermosetting resin layer partially cured by the first curing step; a stranding step of stranding a plurality of wires so that a stranded cable including a friction layer formed by the friction layer forming step is formed; a second curing step of fully curing the thermosetting resin layer of the stranded cable including a plurality of wires stranded by the stranding step; and a winding step of winding a stranded cable having a thermosetting resin layer fully cured by the second curing step.

[0013] One effect of the present invention is to provide a strand for a carbon fiber reinforced plastic stranded cable, a stranded cable equipped with the strand, a manufacturing apparatus for the cable, and a manufacturing method, which can improve the bonding strength between the carbon fiber reinforced plastic cable and a fixing device or a supporting member by imparting frictional force to the surface of the carbon fiber reinforced plastic cable.

[0014] The effects of the present invention are not limited to those mentioned above, and other unmentioned effects will be clearly understood by a person skilled in the art from the description below.

[0015] FIG. 1 is a cross-sectional view showing a wire for a carbon fiber reinforced plastic stranded cable according to one embodiment of the present invention.

[0016] FIG. 2 is a cross-sectional view showing a stranded cable having a wire for a carbon fiber reinforced plastic stranded cable according to another embodiment of the present invention.

[0017] FIG. 3 is a schematic diagram showing a manufacturing apparatus for a stranded cable having carbon fiber reinforced plastic wires according to another embodiment of the present invention.

[0018] FIG. 4 is a flowchart illustrating a method for manufacturing a stranded cable having carbon fiber reinforced plastic wires according to another embodiment of the present invention.

[0019] Specific details for implementing the invention are explained based on examples. These examples are provided as illustrative examples to enable a person skilled in the art to understand specific details for implementing the invention and may be modified in various other forms; therefore, the scope of the invention is not limited by the following examples.

[0020] Furthermore, the terms used in this specification are used merely to describe specific embodiments and are not intended to limit the invention. The singular expression includes the plural expression unless the context clearly indicates otherwise.

[0021] In this specification, terms such as “comprising” or “having” are intended to specify the existence of the features, numbers, steps, actions, components, parts, or combinations thereof described in the specification, and should not be understood as precluding the existence or addition of one or more other features, numbers, steps, actions, components, parts, or combinations thereof.

[0022] 1. Wires for carbon fiber reinforced plastic stranded cables

[0023] The present embodiment relates to a wire for a carbon fiber reinforced plastic stranded cable. As illustrated in FIG. 1, the wire (100) for a carbon fiber reinforced plastic stranded cable according to the present embodiment may include a main body (110), a thermosetting resin layer (120), and a friction layer (130).

[0024] The main body (110) includes a carbon fiber bundle cured by a thermosetting resin. The carbon fiber bundle may consist of 3,000 to 24,000 strands of carbon fiber. The thermosetting resin may be an epoxy resin, an amino resin, a phenolic resin, a polyester resin, a polyurethane resin, etc. The carbon fiber bundle may be cured by heat treatment after being impregnated with the thermosetting resin, thereby curing the thermosetting resin.

[0025] The thermosetting resin layer (120) is a layer formed to surround the outer surface of the main body (110). The thermosetting resin layer (120) being formed to surround the outer surface of the main body (110) can be achieved by various methods. For example, the thermosetting resin layer (120) can be formed on the outer surface of the carbon fiber bundle by sufficiently impregnating the carbon fiber bundle with the thermosetting resin so that the thermosetting resin is exposed to the outer surface of the carbon fiber bundle.

[0026] The friction layer (130) is a layer containing friction particles attached to the thermosetting resin layer (120). The average diameter of the friction particles can vary. For example, the average diameter of the friction particles may be 0.063 mm to 2.0 mm. If the average diameter of the friction particles is less than 0.063 mm, it cannot perform a friction function, and if the average diameter of the friction particles is greater than 2.0 mm, it cannot be attached to the thermosetting resin layer (120). The hardness of the friction particles may vary. For example, the hardness of the friction particles may be 3 to 10. If the hardness of the friction particles is less than 3, it cannot perform a friction function, and if the hardness of the friction particles is greater than 10, it may damage the thermosetting resin layer (120) or the main body (110) when friction force is applied. The thickness of the friction layer may vary. For example, the thickness of the friction layer may be 0.1 mm to 2.0 mm. If the thickness of the friction layer is less than 0.1 mm, it cannot perform the friction function, and if the thickness of the friction layer is greater than 2.0 mm, the thermosetting resin layer (120) or the main body (110) may be damaged when the friction force is applied.

[0027] According to such a carbon fiber reinforced plastic stranded cable wire, frictional force is applied to the outer surface of the wire, and since frictional force is improved compared to when frictional force is not applied to the surface of the wire, it can contribute to improving the bonding strength between the carbon fiber reinforced plastic stranded cable equipped with such a wire and a fixing device or support member.

[0028] 2. Stranded cable having carbon fiber reinforced plastic wires

[0029] The present embodiment relates to a stranded cable having carbon fiber reinforced plastic wires. As illustrated in FIG. 2, the stranded cable (200) having carbon fiber reinforced plastic wires according to the present embodiment may include a core wire (100'') and a plurality of side wires (100').

[0030] The core wire (100'') is a wire arranged at the center of the stranded cable (200).

[0031] A plurality of side wires (100') surround a core wire (100'') and consist of six. Although six side wires (100) are shown in FIG. 2, this embodiment is not necessarily limited to this, and seven or more side wires (100) may be arranged. A plurality of side wires (100') are arranged to wrap around a core wire (100'') while twisting spirally around a single core wire (100'').

[0032] The wire (100', 100''), including the core wire (100'') and the side wire (100'), may include a main body (110) comprising a carbon fiber bundle cured by a thermosetting resin, a thermosetting resin layer (120) formed to surround the outer surface of the main body (110), and a friction layer (130) comprising friction particles attached to the thermosetting resin layer (120).

[0033] In this embodiment, the wires (100', 100'') are identical to the wires for the carbon fiber reinforced plastic stranded cable described above, so redundant descriptions regarding the main body (110), the thermosetting resin layer (120), and the friction layer (130), etc. are omitted.

[0034] Each of the plurality of side wires (100') has a portion of the surface that forms the outer surface of the stranded cable (200). Each side wire (100') has a friction layer (130) on its outer surface. Accordingly, the outer surface of the stranded cable (200) is formed by the friction layer (130) of the plurality of side wires (100').

[0035] According to a stranded cable equipped with such carbon fiber reinforced plastic wires, frictional force is applied to the outer surface of the stranded cable by a friction layer of multiple side wires, and since frictional force is improved compared to when no frictional force is applied to the surface of the stranded cable, the bonding strength between the stranded cable equipped with such carbon fiber reinforced plastic wires and a fixing device or a supporting member can be improved.

[0036] 3. Manufacturing apparatus for stranded cables equipped with carbon fiber reinforced plastic wires

[0037] The present embodiment relates to a manufacturing apparatus for a stranded cable having carbon fiber reinforced plastic wires. As illustrated in FIG. 3, the manufacturing apparatus (300) for a stranded cable having carbon fiber reinforced plastic wires according to the present embodiment may include a supply device (310), a first curing device (320), a friction layer forming device (330), a stranding device (340), a second curing device (350), and a winding device (360).

[0038] The supply device (310) is a device for supplying a carbon fiber bundle impregnated with a thermosetting resin so that a thermosetting resin layer is formed on the outer surface of the carbon fiber bundle. The carbon fiber bundle may consist of 3,000 to 24,000 strands of carbon fiber. The thermosetting resin may be an epoxy resin, an amino resin, a phenolic resin, a polyester resin, a polyurethane resin, etc.

[0039] The first curing device (320) is a device that partially cures a thermosetting resin layer so that the thermosetting resin layer formed on the outer surface of a carbon fiber bundle supplied by the supply device (310) is cured within a viscosity range to which friction particles can be attached.

[0040] The friction layer forming device (330) is a device for forming a friction layer such that a wire including a friction layer is formed in a thermosetting resin layer partially cured by the first curing device (320). The average diameter of the friction particles can vary. For example, the average diameter of the friction particles can be from 0.063 mm to 2.0 mm. If the average diameter of the friction particles is less than 0.063 mm, it cannot perform a friction function, and if the average diameter of the friction particles is greater than 2.0 mm, it cannot be attached to the thermosetting resin layer (120). The hardness of the friction particles can vary. For example, the hardness of the friction particles can be from 3 to 10. If the hardness of the friction particles is less than 3, it cannot perform a friction function, and if the hardness of the friction particles is greater than 10, it may damage the thermosetting resin layer (120) or the main body (110) when a frictional force is applied. The thickness of the friction layer can vary. For example, the thickness of the friction layer can be from 0.1 mm to 2.0 mm. If the thickness of the friction layer is less than 0.1 mm, it cannot perform the friction function, and if the thickness of the friction layer is greater than 2.0 mm, the thermosetting resin layer (120) or the main body (110) may be damaged when the friction force is applied.

[0041] The friction layer forming device (330) can form a friction layer on a thermosetting resin layer partially cured by the first curing device (320) in various ways. For example, a friction layer can be formed by spraying friction particles onto a thermosetting resin layer partially cured by the first curing device (320) using a solid spray device.

[0042] When friction particles are attached to the thermosetting resin layer, the degree of curing of the thermosetting resin layer can be adjusted to be 70% or more and less than 100%, and the viscosity of the thermosetting resin layer can be adjusted to be 10,000 cps or more. Such adjustment can be achieved by the first curing device (320). For example, the viscosity of the thermosetting resin layer impregnated with carbon fiber bundles can be adjusted to within a predetermined range, and by adjusting the heat treatment temperature, time, etc. of the thermosetting resin layer by the first curing device (320), the degree of curing of the thermosetting resin layer when friction particles are attached to the thermosetting resin layer can be adjusted to be within the above range. When friction particles are attached to the thermosetting resin layer, if the degree of curing of the thermosetting resin layer is less than 70%, it is difficult for the friction particles to be uniformly attached to the thermosetting resin layer, and if the degree of curing of the thermosetting resin layer is 100%, the friction particles cannot be attached to the thermosetting resin layer.

[0043] The stranding device (340) is a device for stranding a plurality of wires so that a stranded cable including a friction layer formed by the friction layer forming device (330) is formed.

[0044] The second curing device (350) is a device that completely cures the thermosetting resin layer of a stranded cable comprising a plurality of strands stranded by the stranding device (340). By doing so, friction particles attached to the thermosetting resin layer can be fixed to the thermosetting resin layer.

[0045] The winding device (360) is a device for winding a stranded cable having a thermosetting resin layer that is fully cured by the second curing device (350).

[0046] According to the manufacturing device for a stranded cable equipped with such carbon fiber reinforced plastic wires, frictional force is applied to the outer surface of the stranded cable, thereby enabling the cable to be manufactured with improved frictional force compared to a case where no frictional force is applied to the surface of the stranded cable. Consequently, the bonding strength between the stranded cable equipped with such carbon fiber reinforced plastic wires and a fixing device or a supporting member can be improved.

[0047] 4. Method for manufacturing a stranded cable having carbon fiber reinforced plastic wires

[0048] The present embodiment relates to a method for manufacturing a stranded cable having carbon fiber reinforced plastic wires. As illustrated in FIG. 4, the method (S400) for manufacturing a stranded cable having carbon fiber reinforced plastic wires according to the present embodiment may include a supply step (S410), a first curing step (S420), a friction layer forming step (S430), a stranding step (S440), a second curing step (S450), and a winding step (S460).

[0049] The supply step (S410) is a step of supplying a carbon fiber bundle impregnated with a thermosetting resin so that a thermosetting resin layer is formed on the outer surface of the carbon fiber bundle. The carbon fiber bundle may consist of 3,000 to 24,000 strands of carbon fiber. The thermosetting resin may be an epoxy resin, an amino resin, a phenolic resin, a polyester resin, a polyurethane resin, etc.

[0050] The first curing step (S420) is a step of partially curing a thermosetting resin layer so that the thermosetting resin layer formed on the outer surface of the carbon fiber bundle supplied by the supply step (S410) is cured within a viscosity range to which friction particles can be attached.

[0051] The friction layer formation step (S430) is a step of forming a friction layer such that a wire including a friction layer is formed in the thermosetting resin layer partially cured by the first curing step (S420). The average diameter of the friction particles can vary. For example, the average diameter of the friction particles can be from 0.063 mm to 2.0 mm. If the average diameter of the friction particles is less than 0.063 mm, it cannot perform a friction function, and if the average diameter of the friction particles is greater than 2.0 mm, it cannot adhere to the thermosetting resin layer. The hardness of the friction particles can vary. For example, the hardness of the friction particles can be from 3 to 10. If the hardness of the friction particles is less than 3, it cannot perform a friction function, and if the hardness of the friction particles is greater than 10, it may damage the thermosetting resin layer or the main body when a frictional force is applied. The thickness of the friction layer can vary. For example, the thickness of the friction layer can be from 0.1 mm to 2.0 mm. If the thickness of the friction layer is less than 0.1 mm, it cannot perform the friction function, and if the thickness of the friction layer is more than 2.0 mm, the thermosetting resin layer or the main body may be damaged when frictional force is applied.

[0052] The friction layer formation step (S430) can form a friction layer by spraying friction particles onto a thermosetting resin layer partially cured by the first curing step (S420). The friction layer formation step (S430) can form a friction layer on the thermosetting resin layer partially cured by the first curing step (S420) in various ways. For example, a friction layer can be formed by spraying friction particles onto the thermosetting resin layer partially cured by the first curing step (S420) using a solid spray device.

[0053] When friction particles are attached to the thermosetting resin layer, the degree of curing of the thermosetting resin layer can be adjusted to be 70% or more and less than 100%, and the viscosity of the thermosetting resin layer can be adjusted to be 10,000 cps or more. Such adjustment can be achieved by the first curing device (320). For example, the viscosity of the thermosetting resin layer impregnated with carbon fiber bundles can be adjusted to within a predetermined range, and by adjusting the heat treatment temperature, time, etc. of the thermosetting resin layer by the first curing device (320), the degree of curing of the thermosetting resin layer when friction particles are attached to the thermosetting resin layer can be adjusted to be within the above range. When friction particles are attached to the thermosetting resin layer, if the degree of curing of the thermosetting resin layer is less than 70%, it is difficult for the friction particles to be uniformly attached to the thermosetting resin layer, and if the degree of curing of the thermosetting resin layer is 100%, the friction particles cannot be attached to the thermosetting resin layer.

[0054] The stranding step (S440) is a step of stranding a plurality of wires so that a stranded cable including a friction layer formed by the friction layer forming step (S430) is formed.

[0055] The second curing step (S450) is a step of completely curing the thermosetting resin layer of a stranded cable comprising a plurality of strands stranded by the stranding step (S440).

[0056] The winding step (S460) is a step of winding a stranded cable having a thermosetting resin layer that has been fully cured by the second curing step (S450).

[0057] According to the method for manufacturing a stranded cable equipped with carbon fiber reinforced plastic wires as described above, frictional force is applied to the outer surface of the stranded cable, thereby improving the frictional force compared to when no frictional force is applied to the surface of the stranded cable. Consequently, the bonding strength between the stranded cable equipped with carbon fiber reinforced plastic wires manufactured by this method and a fixing device or a supporting member can be improved.

[0058] The present invention can be used for a stranded wire for a stranded cable, a stranded cable having the stranded wire, an apparatus for manufacturing the cable, and a method for manufacturing the cable.

Claims

1. A main body comprising a carbon fiber bundle cured by a thermosetting resin; A thermosetting resin layer formed to surround the outer surface of the main body; and A friction layer comprising friction particles attached to a thermosetting resin layer; A wire for a carbon fiber reinforced plastic stranded cable, comprising 2. A wire for a carbon fiber reinforced plastic stranded cable according to claim 1, wherein the average diameter of the friction particles is 0.063 mm to 2.0 mm.

3. A wire for a carbon fiber reinforced plastic stranded cable according to claim 1, wherein the hardness of the friction particles is 3 to 10.

4. A wire for a carbon fiber reinforced plastic stranded cable according to claim 1, wherein the thickness of the friction layer is 0.1 mm to 2.0 mm.

5. Core wire; and Multiple side wires surrounding the core wire; Includes, So-seon is, A main body comprising carbon fiber bundles cured by a thermosetting resin; A thermosetting resin layer formed to surround the outer surface of the main body; and A friction layer comprising friction particles attached to a thermosetting resin layer; A stranded cable comprising carbon fiber reinforced plastic wires.

6. A supply device for supplying a carbon fiber bundle impregnated with a thermosetting resin so as to form a thermosetting resin layer on the outer surface of the carbon fiber bundle; A first curing device for partially curing a thermosetting resin layer formed on the outer surface of a carbon fiber bundle supplied by a supply device, so that the thermosetting resin layer is cured within a viscosity range where friction particles can be attached; A friction layer forming device that forms a friction layer such that a wire including a friction layer is formed in a thermosetting resin layer partially cured by a first curing device; A stranding device for stranding a plurality of wires to form a stranded cable including a friction layer formed by a friction layer forming device; A second curing device for fully curing a thermosetting resin layer of a stranded cable comprising a plurality of strands stranded by a stranding device; and A winding device for winding a stranded cable having a thermosetting resin layer that is fully cured by a second curing device; A manufacturing apparatus for a stranded cable having carbon fiber reinforced plastic wires.

7. An apparatus for manufacturing a stranded cable having a carbon fiber reinforced plastic wire, wherein the friction layer forming apparatus of claim 6 forms a friction layer by spraying friction particles onto a thermosetting resin layer partially cured by a first curing apparatus.

8. A supply step of supplying a carbon fiber bundle impregnated with a thermosetting resin so as to form a thermosetting resin layer on the outer surface of the carbon fiber bundle; A first curing step for partially curing a thermosetting resin layer formed on the outer surface of a carbon fiber bundle supplied by a supply step, so that the thermosetting resin layer is cured within a viscosity range where friction particles can be attached; A friction layer forming step for forming a friction layer such that a wire including a friction layer is formed in a thermosetting resin layer partially cured by a first curing step; A stranding step of stranding a plurality of wires to form a stranded cable including a friction layer formed by a friction layer forming step; A second curing step for completely curing a thermosetting resin layer of a stranded cable comprising a plurality of strands stranded by a stranding step; and A winding step for winding a stranded cable having a thermosetting resin layer that is fully cured by a second curing step; A method for manufacturing a stranded cable having carbon fiber reinforced plastic wires having a carbon fiber reinforced plastic wire.

9. A method for manufacturing a stranded cable having carbon fiber reinforced plastic wires, wherein the friction layer forming step of claim 8 involves forming a friction layer by spraying friction particles onto a thermosetting resin layer partially cured by a first curing step.

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