REINFORCING STRUCTURAL MATERIAL AND REINFORCED STRUCTURE REINFORCED THEREWITH

Abstract: There is disclosed a reinforcing structural material (1) comprising a plurality of fibre cords (3), each comprising a plurality of fibres (2) formed into a braid (4), the braid (4) being impregnated with a bonding agent (5). The reinforcing structural material (1) can be used to reinforce a moulded inorganic composite.

Description: This invention relates to a reinforcing structural material to be used, for example, in place of a reinforcing steel bar, a PC steel wire or the like for reinforcing a construction or building by being embedded in a structural material such as concrete, plastic or the like, which is weak in tensile strength, and to a reinforced fibre-containing inorganic structure reinforced with the foregoing reinforcing structural material. It is known to use a steel bar as a reinforcing structural material. However, the bending and arranging of such bars is difficult, and increases the weight of the construction. In GB-A-917147, there is disclosed a process for the construction of fibreglass twisted and non-twisted rope for concrete reinforcement comprising the saturation of heavy duty fibreglass yarns, cords or combined rovings, with an epoxy resin compound composed of a flexible epoxy resin plus a rigid epoxy resin in proportion of thirty parts of flexible epoxy resin to seventy parts of rigid epoxy resin plus a diluent of allyl glycidyl ether, plus an anhydride curing agent composed of methylbicyclo(2.2.1)heptene-2,3-dicarboxylic anhydride isomers, then an application to the exterior rope surface having uncured epoxy resin compound thereon of a liberal coating of medium grade of rocky grit for the purpose of bonding with concrete, followed by the necessary heat curing of the saturated grit coated rope. According to the present invention, there is provided a reinforcing structural material comprising a plurality of fibre cords, each comprising a plurality of fibres, formed into a braid, characterised in that the braid is impregnated with a bonding agent. The present invention also provides a reinforced structure comprising a moulded inorganic composite having fibres embedded therein and having at least one reinforcing structural material embedded therein, the reinforcing structural material being a reinforcing structural material as defined above. The invention will now be described, by way of example, with reference to the accompanying drawings in which Fig. 1 shows a reinforced inorganic structure reinforced with the reinforcing structural material shown in Fig. 2. Referring to the Figures, there is shown a reinforcing structural material 1. The reinforcing structural material 1 is constructed of eight fibre assembly cords 3, each comprising a plurality of fibres 2 made of, for example, aromatic polyamide, interwoven into a braid 4. Additionally, according to this invention, the braid 4 is impregnated with a bonding agent 5 so that the bonding agent 5 bonds not only the cords 3 together, but also the fibres 2 of each cord 3 together. Examples of the aromatic polyamide constituting the fibres 2 are straight coordinated aromatic polyamide, aromatic polyether amide, aromatic polysulphide amide, aromatic polysulphone amide, aromatic polymethylene amide, aromatic polyketone amide, aromatic polyamine amide, and copolymers thereof. Furthermore, the fibres 2 are not limited to fibres of the foregoing aromatic polyamides. Instead, there may be used carbon fibres, glass fibres, ceramic fibres or other desired inorganic fibres; polyester fibres, high strength polyolefin fibres, strong polyvinyalcohol fibres or any other desired organic fibre; and cold drawn steel wire, steel wire for prestressing or any other desired metallic fibres. The foregoing fibres may be used singly or in combination. If the fibre 2 is so formed as to be different in its sectional shape in its longitudinal direction, the friction force between the fibres is increased, so that stress applied to each fibre is easier to transmit to the whole of the reinforcing material 1. Thus, where the reinforcing material 1 is embedded in an inorganic compsite 6 as shown in Fig. 1, the close contact between the reinforcing structural material 1 and the inorganic composite 6 can be improved. The diameter of the fibre 2 is in general in the range of from several microns to several tens of microns. As for the shape of the braid formed by the fibre cords 3, besides the round braid as mentioned above, the cords 3 may be interwoven into a flat braid, a square braid or a braid of any other desired shape. The braid 3 may also be one which is different in its sectional shape in the longitudinal direction thereof, so that close contact between the same and the inorganic composite 6 can be improved. As for the bonding agent 5, there may be used a coldsetting or thermosetting resin such as of epoxy type, polyester type, vinylester type, phenolic type, polyimide type, etc.; a coldsetting or thermosetting inorganic bonding agent such as of alkali metal silicate type, collidal silica type, or phosphate type; or a mixture of a coldsetting or thermosetting organic resin and an inorganic bonding agent. For bonding the fibres 2 of the braid 4 one to another by means of the bonding agent 5, there may be carried out a process wherein, after the braid is formed by braiding the fibre cords 3, the braid is immersed in an uncured bonding agent in a liquid form so that the fibres 2 of each of the fibre cords 3 is impregnated with the liquid bonding agent, and thereafter the impregnated braid is subjected to a curing treatment. Alternatively, there may be carried out a process wherein each fibre cord is impregnated with a liquid bonding agent 5, thereafter a plurality of fibre cords are braided to form a braid, and then the bonding agent 5 is subjected to a curing treatment. The reinforcing structural material 1 may be not only in the form of a straight material, but also in the form of any desired curved material. In addition, the reinforcing structural material 1 may be produced not only at a factory, but also at the site of construction of a building, for instance. In a case where the reinforcing structural material 1 is used as a reinforcing member such as a shearing reinforcing bar which is required to be bent (for instance for coiling around main reinforcing bars in the case of bar arrangement work), it is preferable that the reinforcing structural material 1 be coiled round the main reinforcing bars while the bonding agent 5 impregnated therein is not completely cured, whereby the bar arrangement work can be performed firmly and reliably. In addition, if a coating film of a hydrophilic material such as a wettable and underwater settable type epoxy resin or the like is formed on the peripheral surface of the reinforcing structural material 1, the integrality thereof with an inorganic compsite 6 can be improved. Furthermore, the reinforcing structural material 1 of braid type may be also used as it is, or in a net or fabric form obtained by interweaving several braids of the reinforcing structual material 1. Fig. 1 shows one reinforced fibre-containing inorganic structure of this invention comprising a moulded inorganic composite 6 formed into a hollow square tubular body, short fibres 7 being uniformly mixed therein and eight reinforcing structure materials 1 each in the form of a round braid being embedded therein at regular intervals in the peripheral direction thereof and parallel to the longitudinal direction thereof. The inorganic composite 6 comprises, in general, cement, sand and water. However, instead of cement as a main component, plaster may be used. As for the cement, there may be used any kind of cement, for example Portland cement, aluminous cement, Portland blast-furnace cement, silica cement, and flyash cement. In the inorganic composite 6, there may be selectively present one or more of milling aids, retarders, accelerators, water reducing agents, coagulants, thickeners, builders such as an air entraining agents, and suitably-sized aggregates. The short fibres 7 are used to improve the toughness of the reinforced inorganic structure. As for the kind of material of the short fibres 7, there may be used one or more of any desired fibre such as the various fibres as enumerated above for the fibres 2. In general, there are used short fibres 7 ranging from several microns to several ten of microns in diameter and 5 to 15 mm in length. These fibres are preferably present in the inorganic composite in an amount of up to 2% by volume relative to the inorganic composite. As for the content of the reinforcing structural material 1, this is in general 5% by volume at the maximum. The invention will now be illustrated by the following Example. EXAMPLE Thirty six fibre cords, each cord being made of total aromatic polyamide ("Kevlar 49") and having a diameter of 1420 denier, were interwoven into a round braid 3mm in diameter, and the braid was impregnated with a bonding agent composed of 100 parts by weight of bisphenol A/epichlorohydrin type epoxy resin ("DER 332 Dow Chemical") and 14 parts by weight of triethylenetetramine in an impregnation ratio of 40 parts of the bonding agent to 100 parts of the braid. Thereafter, the braid impregnated with the bonding agent was heated for 3 hours at 100°C while the shape of the braid was retained by coiling a tape thereround, so that the bonding agent was cured completely. After the curing thereof, the tape was uncoiled. Thus there was produced a reinforcing structural material of a braid type. Next, eight reinforcing structural materials produced as above were embedded in an inorganic composite composed of a mixture of 911 kg/m³ of Portland cement, 310 kg/m³ of water, 1,002 kg/m³ of sand and 13.67 kg/m³ of thickener and containing 1.5% by volume of short fibres ("Kevlar 49") each 15 mm in length, in an arrangement wherein two lines of four of the reinforcing structural materials were disposed above and below in the inorganic composite. Thereafter, the inorganic compsite including the short fibres and the reinforcing structural materials were extruded under a vacuum of 75 mm Hg, under an extrusion pressure of 10 kg/cm², and at an extruding speed of 1.5 m/minute, so that there was formed an extruded moulded body, i.e. a reinforced fibre-containing inorganic structure having a rectangular sectional shape of 50 mm by 100 mm. Thereafter, the reinforced structure was cured for 14 days at 20°C, so that there was produced a moulded reinforced fibre-containing inorganic structure. The bending strength thereof was 205 kg/cm². For comparison, there was produced a reinforced fibre-containing inorganic structure by the same process, except that no bonding agent was impregnated into the reinforcing structure material of braid type. The bending strength of the product was 110 kg/cm². Thus, according to a first feature of this invention, a reinforcing structural material of braid type is impregnated with a bonding agent, so that the respective mutual bondings between the fibre cords and between the fibres of each fibre cord can be performed, and accordingly stress applied to each of the fibres can be transmitted relaibly to the whole of the reinforcing structural material, and the tensile strength of the reinforcing structural material is excellent. According to a second feature of this invention, there is provided reinforced fibre-containing inorganic structure comprises a moulded inorganic composite having short fibres mixed therein and having at least one of the foregoing reinforcing structural materials of the invention embedded therein, the being excellent in toughness and light in weight.

Claims: A reinforcing structural material (1) comprising a plurality of fibre cords (3), each comprising a plurality of fibres (2), formed into a braid (4), characterised in that the braid (4) is impregnated with a bonding agent (5). A material as claimed in claim 1, wherein the fibres (2) are aromatic polyamide fibres or other organic fibres, inorganic fibres, or metallic fibres. A material as claimed in claim 1 or 2, wherein the bonding agent (5) is a coldsetting or thermosetting organic resin or a coldsetting or thermosetting inorganic bonding agent. A reinforced structure comprising a moulded inorganic composite (6) having fibres (7) embedded therein and having at least one reinforcing structural material (1) embedded therein, the reinforcing structural material (1) being a reinforcing structural material (1) as claimed in any of claims 1 to 3.

Inventors: HANDA, MASAHISA C/O MITSUI KENSETSU K.K., MATSUBARA, SUMIYUKI C/O MITSUI KENSETSU K.K., OKAMOTO, TADASHI C/O MITSUI KENSETSU K.K.
Applicants: MITSUI KENSETSU KABUSHIKI KAISHA
Application year: 1986
Main classification: E04C5
IPC codes: B28B23, E04C5, B28B3, D04C1