APPARATUS FOR MANUFACTURING TEXTILE GRID WITH INCREASED ADHESION AND METHOD THEREOF

Abstract

Provided are an apparatus for manufacturing a textile grid with increased adhesion and a method thereof capable of integrating the textile grid with a concrete structure by increasing the adhesion of the textile grid when the concrete structure is built, repaired, or reinforced, increasing structural safety and durability of the concrete structure, increasing a working speed by coating a surface of the textile grid with an abrasive material powder that is a surface coating material in an automatic series of processes immediately after the textile grid is manufactured, and increasing coating performance by automatically inspecting and adjusting the amount of the coating material applied to the surface of the textile grid using a camera.

Claims

1. An apparatus for manufacturing a textile grid with increased adhesion, which is a manufacturing apparatus for manufacturing a textile grid for building, repairing, or reinforcing a concrete structure, the apparatus comprising: a fabric yarn supplying unit that supplies textile grid fabric yarn in a form of a bundle of yarn; a weaving-knitting machine that forms a woven-knitted textile grid in a lattice form through a manner in which the fabric yarn is woven and knitted so that wefts and warps cross to be coupled to each other; a resin impregnation tank that impregnates the woven-knitted textile grid with a resin to form a resin impregnated textile grid; a coating chamber that comprises a first coating material spraying nozzle and a second coating material spraying nozzle installed in the coating chamber, before the resin impregnated textile grid is cured, allows a surface of the resin impregnated textile grid to be coated with an abrasive material powder that is a surface coating material, and forms a coated textile grid; a camera that is installed at a rear end of the coating chamber and captures a coating-image to inspect a coating state of the coated textile grid; and a controlling device that adjusts a spraying amount of the surface coating material according to the coating-image captured by the camera, wherein adhesion of the textile grid to a concrete structure is increased by the abrasive material powder that is the surface coating material.

2. The apparatus for manufacturing a textile grid with increased adhesion of claim 1, wherein the coating chamber is formed as a closed space, and coating is performed using at least two coating material spraying nozzles to spray a coating material to both surfaces of the resin impregnated textile grid.

3. The apparatus for manufacturing a textile grid with increased adhesion of claim 2, wherein the spraying amount of the coating material sprayed on the surface of the resin impregnated textile grid is determined by a sprayed coating material directly sprayed from the first coating material spraying nozzle and the second coating material spraying nozzle and a scattered coating material scattered in the coating chamber.

4. The apparatus for manufacturing a textile grid with increased adhesion of claim 1, wherein the abrasive material powder that is the surface coating material comprises sand, silica sand, or alumina oxide powder.

5. The apparatus for manufacturing a textile grid with increased adhesion of claim 1, further comprising a surface coating material supplying unit that supplies a coating material to the first coating material spraying nozzle and the second coating material spraying nozzle in the coating chamber and adjusts the spraying amount of the coating material under control of the controlling device.

6. The apparatus for manufacturing a textile grid with increased adhesion of claim 5, further comprising: a resin curing chamber that allows the coated textile grid formed in the coating chamber to be cured to form a cured textile grid; and a winding unit that winds the cured textile grid of the resin curing chamber.

7. The apparatus for manufacturing a textile grid with increased adhesion of claim 1, wherein the controlling device comprises: a coating-image collecting part that collects a coating image, which is an image of a coated coating material, captured by the camera; a data processing part that processes data to analyze the coating image collected by the coating-image collecting part; a coating state determining part that determines whether a coating state of a surface of the coated textile grid is appropriate based on the data processed by the data processing part; and a coating material spray adjusting part that adjusts the spraying amount of the coating material supplied to the first coating material spraying nozzle and the second coating material spraying nozzle in the coating chamber when a state of the coating material applied on the surface of the coated textile grid is not appropriate as a result determined by the coating state determining part.

8. The apparatus for manufacturing a textile grid with increased adhesion of claim 7, wherein the controlling device further comprises a pull-out motor speed adjusting part that adjusts a speed of a pull-out motor installed in front of a winding unit to adjust a coating amount of the coating material applied to the surface of the resin impregnated textile grid.

9. A method for manufacturing a textile grid with increased adhesion, which is a manufacturing method for manufacturing a textile grid for building, repairing, or reinforcing a concrete structure, the method comprising: (a) supplying fabric yarn for a textile grid in a form of a bundle of yarn using a fabric yarn supplying unit; (b) weaving and knitting the bundle of yarn into a woven and knitted textile grid using a weaving-knitting machine; (c) impregnating the woven and knitted textile grid with a resin in a resin impregnation tank and forming a resin impregnated textile grid by removing an overabundant resin; (d) under control of a controlling device, applying an abrasive material powder, which comprises surface coating materials, to a surface of the resin impregnated textile grid using a first coating material spraying nozzle and a second coating material spraying nozzle in a coating chamber and forming a coated textile grid; and (e) capturing an image of the coated textile grid, which is coated with the surface coating materials, using a camera and inspecting a coating state, wherein, when the controlling device determines that a state of a coating material applied on a surface of the coated textile grid is not appropriate, the controlling device adjusts a spraying amount of the coating material supplied to the first coating material spraying nozzle and the second coating material spraying nozzle in the coating chamber so that adhesion of the textile grid to the concrete structure is increased by the abrasive material powder that comprises the surface coating material.

10. The method for manufacturing a textile grid with increased adhesion of claim 9, wherein, when the controlling device determines that the state of the coating material applied on the surface of the coated textile grid is not appropriate, the controlling device adjusts a speed of a pull-out motor installed in front of a winding unit to adjust a coating amount of the coating material applied to the surface of the resin impregnated textile grid.

11. The method for manufacturing a textile grid with increased adhesion of claim 9, further comprising: (f) curing the coated textile grid coated with the surface coating materials in a resin curing chamber to form a cured textile grid; and (g) winding the cured textile grid around a winding unit.

12. The method for manufacturing a textile grid with increased adhesion of claim 9, wherein the coating chamber in operation (d) is formed as a closed space and coating is performed using at least two coating material spraying nozzles to spray a coating material to both surfaces of the resin impregnated textile grid.

13. The method for manufacturing a textile grid with increased adhesion of claim 12, wherein the spraying amount of the coating material sprayed on the surface of the resin impregnated textile grid is determined by a sprayed coating material directly sprayed from the first coating material spraying nozzle and the second coating material spraying nozzle and a scattered coating material scattered in the coating chamber.

14. The method for manufacturing a textile grid with increased adhesion of claim 9, wherein the abrasive material powder in operation (d) comprises sand, silica sand, or alumina oxide powder.

15. The method for manufacturing a textile grid with increased adhesion of claim 9, wherein the controlling device in operation (d) comprises: a coating-image collecting part that collects a coating image, which is an image of a coated coating material, captured by the camera; a data processing part that processes data to analyze the coating image collected by the coating-image collecting part; a coating state determining part that determines whether a coating state of the surface of the coated textile grid is appropriate based on the data processed by the data processing part; and a coating material spray adjusting part that adjusts the spraying amount of the coating material supplied to the first coating material spraying nozzle and the second coating material spraying nozzle in the coating chamber when the state of the coating material applied on the surface of the coated textile grid is not appropriate as a determination result by the coating state determining part.

16. The method for manufacturing a textile grid with increased adhesion of claim 15, wherein the controlling device further comprises a pull-out motor speed adjusting part that adjusts a speed of a pull-out motor installed in front of a winding unit to adjust a coating amount of the coating material applied to the surface of the resin impregnated textile grid.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0062] The above and other objects, features and advantages of the present invention will become more apparent to those of ordinary skill in the art by describing exemplary embodiments thereof in detail with reference to the accompanying drawings, in which:

[0063] FIGS. 1a, 1b and 1c illustrate a general textile grid reinforcement and examples of structures reinforced thereby;

[0064] FIGS. 2a and 2b illustrate a textile grid reinforcement manufactured through a weaving method;

[0065] FIGS. 3a and 3b are views illustrating a weaving-knitting machine for manufacturing a textile grid;

[0066] FIG. 4 is a view for describing a coating part of an apparatus for manufacturing a grid according to a related art;

[0067] FIG. 5a is a configuration view illustrating an apparatus for manufacturing a grid with an improved coating function according to a related art, and FIG. 5b is a view illustrating a coating part of the apparatus of manufacturing a grid with an improved coating function;

[0068] FIG. 6 is a configuration view of an apparatus for manufacturing a textile grid with increased adhesion according to an embodiment of the present invention;

[0069] FIG. 7 is a specific configuration view illustrating a controlling device in the apparatus for manufacturing a textile grid with increased adhesion according to the embodiment of the present invention;

[0070] FIGS. 8a and 8b are views illustrating a textile grid with increased adhesion by the apparatus for manufacturing a textile grid with increased adhesion according to the embodiment of the present invention;

[0071] FIG. 9 is a view illustrating an inspection result that represents adhesive strengths before and after the textile grid with increased adhesion according to the embodiment of the present invention is coated; and

[0072] FIG. 10 is an operation flowchart of the method of manufacturing a textile grid with increased adhesion according to the embodiment of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0073] Hereinafter, embodiments that are easily performed by those skilled in the art will be described in detail with reference to the accompanying drawings. However, the embodiments of the present invention may be implemented in several different forms and are not limited to embodiments described herein. In addition, parts irrelevant to description will be omitted in the drawings to clearly explain the embodiments of the present invention. Similar parts are denoted by similar reference numerals throughout this specification.

[0074] Throughout the specification, when a portion includes an element, the portion may include the element or another element may be further included therein unless otherwise described.

[0075] [Apparatus 100 for Manufacturing a Textile Grid with Increased Adhesion]

[0076] FIG. 6 is a configuration view of an apparatus for manufacturing a textile grid with increased adhesion according to an embodiment of the present invention, and FIG. 7 is a specific configuration view illustrating a controlling device in the apparatus for manufacturing a textile grid with increased adhesion according to the embodiment of the present invention.

[0077] Referring to FIG. 6, the apparatus 100 for manufacturing a textile grid with increased adhesion according to the embodiment of the present invention, which is a manufacturing apparatus for manufacturing a textile grid for building, repairing, or reinforcing a concrete structure, includes a fabric yarn supplying unit 110, a weaving-knitting machine 120, an resin impregnation tank 130, a coating chamber 140, a camera 150, a controlling device 160, a surface coating material supplying unit 170, a resin curing chamber 180, and a winding unit 190.

[0078] The fabric yarn supplying unit 110 supplies textile grid fabric yarn in the form of a bundle of yarn.

[0079] The weaving-knitting machine 120 forms a woven-knitted textile grid 200 in a lattice shape through a method in which the fabric yarn is woven and knitted so that wefts and warps cross to be coupled to each other.

[0080] The resin impregnation tank 130 allows the woven-knitted textile grid 200 to be impregnated with a resin 210 to form a resin impregnated textile grid 220. In this case, as described below, coating is performed on the resin impregnated textile grid 220 that passes through the resin impregnation tank 130 is impregnated with the resin 210 while the uncured resin impregnated textile grid 220 enters and passes through the coating chamber 140, and the resin impregnated textile grid 220 is cured after the coating.

[0081] The coating chamber 140 includes a first coating material spraying nozzle 141 and a second coating material spraying nozzle 142 installed therein, and the resin impregnated textile grid 220 is coated with abrasive material powder, which is a surface coating material, before being cured to form a coated textile grid 250. Specifically, the coating chamber 140 is formed as a closed space, and coating is performed by spraying the coating material on both surfaces of the resin impregnated textile grid 220 using the at least two first and second coating material spraying nozzles 141 and 142, wherein the spraying amount of the coating material sprayed on the surface of the resin impregnated textile grid 220 is determined by a sprayed coating material 230 directly sprayed and a coating material 240 scattered in the coating chamber 140. In this case, the surface coating material including the sprayed coating material 230 and the scattered coating material 240 may be formed of abrasive material powders such as sand, silica sand, alumina oxide powder, or the like.

[0082] Particularly, the apparatus 100 for manufacturing a textile grid with increased adhesion according to the embodiment of the present invention is for continuously coating a surface of the textile grid with abrasive material powder, which is a surface coating material, to increase adhesive performance of the textile grid to concrete. In this case, the surface of the resin impregnated textile grid 220 is coated with the abrasive material powders in the coating chamber 140.

[0083] Further, the surface coating material is sprayed on both surfaces of the resin impregnated textile grid 220 by the at least two coating material spraying nozzles 141 and 142 in the coating chamber 140. In this case, the spraying amount of the coating material may be determined by the sprayed coating material 230 directly sprayed and the scattered coating material 240 scattered in the coating chamber 140.

[0084] The camera 150 is installed on a rear end of the coating chamber 140 and captures a coating image to inspect a coating state of the coated textile grid 250. That is, the coated textile grid 250 coated with the abrasive material powder that is surface coating material is captured by imaging equipment such as the camera 150. Thus, the amount of the coating material applied to the coated textile grid 250 can be precisely measured by the imaging equipment such as the camera 150, and therefore, the surface coating material can be uniformly applied to the surface of the resin impregnated textile grid 220.

[0085] As shown in FIG. 7, the controlling device 160 adjusts the spraying amount of the surface coating material according to a coating-image captured by the camera 150.

[0086] The surface coating material supplying unit 170 supplies the coating material to the first and second coating material spraying nozzles 141 and 142 in the coating chamber 140 and adjusts the spraying amount of the coating material under control of the controlling device 160.

[0087] The resin curing chamber 180 cures the coated textile grid 250 formed in the coating chamber 140 to form a cured textile grid 260.

[0088] The winding unit 190 winds the cured textile grid 260 of the resin curing chamber 180. In this case, the apparatus 100 for manufacturing a textile grid with increased adhesion according to the embodiment of the present invention adjusts the spraying amount of the coating material of the first and second coating material spraying nozzles 141 and 142 in the coating chamber 140 or adjusts a speed of a pull-out motor installed at a front end of the winding unit 190 to adjust a winding speed of the coated textile grid 250 so as to precisely adjust the amount of coating.

[0089] Specifically, referring to FIG. 7, the controlling device 160 includes a coating-image collecting part 161, a data processing part 162, a coating state determining part 163, a coating material spray adjusting part 164, and a pull-out motor speed adjusting part 165.

[0090] The coating-image collecting part 161 of the controlling device 160 collects a coating-image in which a coating material is applied and is captured by the camera 150, and the data processing part 162 of the controlling device 160 processes data to analyze the coating-image collected by the coating-image collecting part 161.

[0091] The coating state determining part 163 of the controlling device 160 determines whether the coating state of the surface of the coated textile grid 250 is appropriate according to the data processed by the data processing part 162, and, as a result of the determination of the coating state determining part 163, when the state of the coating material applied on the coated textile grid 250 is not appropriate, the coating material spray adjusting part 164 of the controlling device 160 adjusts the spraying amount of the coating material supplied to the first and second coating material spraying nozzles 141 and 142 in the coating chamber 140.

[0092] The pull-out motor speed adjusting part 165 of the controlling device 160 adjusts a speed of the pull-out motor M installed in front of the winding unit 190 to adjust the coating amount of the coating material applied to the surface of the resin impregnated textile grid 220.

[0093] Therefore, the apparatus 100 for manufacturing a textile grid with increased adhesion according to the embodiment of the present invention precisely measures and inspects the coating amount of the surface coating material applied to the coated textile grid 250 using the imaging equipment, such as the camera 150, immediately after the resin impregnated textile grid 220 coated with the surface coating material passes through the coating chamber 140. After the coating amount of the surface coating material is measured with the image, the spraying amount of the coating material is adjusted, and thus an initially targeted application of the coating material can be precisely performed. Meanwhile, another method of adjusting the coating amount of the coating material to be applied is to adjust a speed of the pull-out motor installed in front of the winding unit 190. Next, after the coating amount of the surface coating material is measured, the coated textile grid 250 is cured while passing through the resin curing chamber 180, and the cured textile grid 260 is wound by the winding unit 190. Therefore, the adhesion of the textile grid to the concrete structure can be increased by the abrasive material powder that is the surface coating material.

[0094] Meanwhile, FIGS. 8a and 8b are views illustrating a textile grid with increased adhesion by the apparatus for manufacturing a textile grid with increased adhesion according to the embodiment of the present invention, and FIG. 9 is a view illustrating an inspection result that represents adhesive strengths before and after the textile grid with increased adhesion according to the embodiment of the present invention is coated.

[0095] Typically, a noncorrosive high strength textile grid reinforcement, which is a textile grid reinforcement, is used as a concrete reinforcement bar replacement, and in this case, to manufacture the textile grid, high strength yarn, such as carbon yarn, aramid yarn, or the like may be woven or knitted into a lattice-shaped textile, and an epoxy, vinyl ester, styrene-butadiene rubber (SBR) resin, or the like may penetrate into the textile grid. However, as shown in FIG. 8a, since the textile grid has a lower adhesion to concrete than a reinforcement bar, as shown in FIG. 8b, the textile grid is coated with the surface coating material. That is, FIG. 8a illustrates the resin impregnated textile grid 220 before the textile grid is coated with the surface coating material, and FIG. 8b illustrates the coated textile grid 250 after the resin impregnated textile grid is coated with the surface coating material.

[0096] Further, as shown in FIG. 9, as an inspect result that presents adhesive strengths before and after the textile grid is coated by the apparatus for manufacturing a textile grid with increased adhesion according to the embodiment of the present invention, it is shown that, for example, when a surface of the textile grid is coated with alumina oxide powders, the adhesive strength can be maximally increased up to 220%.

[0097] Finally, in the case of the apparatus 100 for manufacturing a textile grid with increased adhesion according to the embodiment of the present invention, the surface of the textile grid is coated with abrasive material powder, which is surface coating material, in an automatic series of processes immediately after the textile grid is manufactured so that a working speed can be increased, and the amount of the coating material applied to the surface of the textile grid is automatically inspected using a camera and adjusted so that coating performance can be increased.

[0098] [Method of Manufacturing Textile Grid with Increased Adhesion]

[0099] FIG. 10 is an operation flowchart of a method of manufacturing a textile grid with increased adhesion according to the embodiment of the present invention.

[0100] Referring to FIG. 10, the method of manufacturing a textile grid with increased adhesion according to the embodiment of the present invention is as follows. The fabric yarn supplying unit 110 supplies fabric yarn for a textile grid in the form of a bundle of yarn (step S110).

[0101] Next, the weaving-knitting machine 120 weaves and knits the bundle of yarn into a lattice-shaped woven and knitted textile grid 200 through a method in which the wefts and the warps cross to be coupled to each other (step S120).

[0102] Next, the woven-knitted textile grid 200 is impregnated with the resin 210 in the resin impregnation tank 130, and an overabundant resin is removed so that the resin impregnated textile grid 220 is formed (step S130).

[0103] Next, under control of the controlling device 160, the surface of the resin impregnated textile grid 220 is coated with the abrasive material powders, which are the surface coating materials 230 and 240, in the coating chamber 140 so that the coated textile grid 250 is formed (step S140). In this case, the abrasive material powders may be sand, silica sand, or alumina oxide powder.

[0104] Specifically, the controlling device 160 may include a coating-image collecting part 161 that collects a coating-image which is an image of the applied coating material captured by the camera 150, a data processing part 162 that processes data to analyze the coating-image collected by the coating-image collecting part 161, a coating state determining part 163 that determines whether a coating state of the surface of the coated textile grid 250 is appropriate according to the data processed by the data processing part 162, a coating material spray adjusting part 164 that adjusts the spraying amount of the coating material supplied to the first and second coating material spraying nozzles 141 and 142 in the coating chamber 140 when a state of the coating material applied to the surface of the coated textile grid 250 is not appropriate as a determination result of the coating state determining part 163, and a pull-out motor speed adjusting part 165 that adjusts a speed of the pull-out motor M installed in front of the winding unit 190 to adjust the coating amount of the coating material applied to the surface of the resin impregnated textile grid 220.

[0105] In this case, when the controlling device 160 determines that the state of the coating material applied on the surface of the coated textile grid 250 is not appropriate, the controlling device 160 may adjust the spraying amount of the coating material supplied to the first and second coating material spraying nozzles 141 and 142 in the coating chamber 140. Further, when the controlling device 160 determines that the state of the coating material applied on the surface of the coated textile grid 250 is not appropriate, the controlling device 160 may adjust a speed of the pull-out motor M installed in front of the winding unit 190 to adjust the coating amount of the coating material applied to the surface of the resin impregnated textile grid 220.

[0106] In this case, the coating chamber 140 is formed as a closed space and allows the coating material to be sprayed on both surfaces of the resin impregnated textile grid 220 by using the at least two coating material spraying nozzles 141 and 142, and the spraying amount of the coating material sprayed on the surface of the resin impregnated textile grid 220 may be determined by the sprayed coating material 230 directly sprayed from the first and second coating material spraying nozzles 141 and 142 and the scattered coating material 240 scattered in the coating chamber 140.

[0107] Then, referring back to FIG. 10, the coated textile grid 250 coated with the surface coating materials 230 and 240 is captured by the camera 150 so that a coating state is inspected (step S150).

[0108] Next, the coated textile grid 250 coated with the surface coating materials 230 and 240 is cured in the resin curing chamber 180 so that the cured textile grid 260 is formed.

[0109] Next, the cured textile grid 260 is wound by the winding unit 190 (step S170).

[0110] In the case of the method of manufacturing a textile grid with increased adhesion according to the embodiment of the present invention, the textile grid may be coated in an automatic series of processes, and particularly, immediately after the textile grid according to the related art is woven and resin-impregnated, operations of coating and inspecting a surface coating material are serially added. In this case, the resin impregnated textile grid 220 that passes through the resin impregnation tank 130 is impregnated with the resin 210, enters and passes through the coating chamber 140 in an uncured state, and is coated and cured sequentially.

[0111] Finally, according to an embodiment of the present invention, when a concrete structure is built, repaired, or reinforced, adhesion of a textile grid is increased so that the textile grid integrates with the concrete structure, and thus structural safety and durability of the concrete structure can be increased.

[0112] According to the present invention, when a concrete structure is built, repaired, or reinforced, adhesion of a textile grid is increased so that the textile grid integrates with a concrete structure, and thus a structural safety and durability of the concrete structure can be increased.

[0113] According to the present invention, a surface of the textile grid is coated with abrasive material powder, which is a surface coating material, in an automatic series of processes immediately after the textile grid is manufactured, and thus a working speed can be increased.

[0114] According to the present invention, the amount of the coating material applied to the surface of the textile grid is automatically inspected and adjusted using a camera, and thus coating performance can be increased.

[0115] The above description of the present invention is only exemplary, and it should be understood by those skilled in the art that the invention may be performed in other concrete forms without changing the technological scope and essential features. Therefore, the above-described embodiments should be considered as only examples in all aspects and not for purposes of limitation. For example, each component described as a single type may be realized in a distributed manner, and similarly, components that are described as being distributed may be realized in a coupled manner.

[0116] The scope of the present invention is defined not by the detailed description but by the appended claims and encompasses all modifications or alterations derived from meanings, the scope, and equivalents of the appended claims.