Composite material cover plate for bridge and manufacturing method thereof

Abstract

The present invention discloses a composite material cover plate for bridges and a manufacturing method thereof, the cover plate comprises a cover plate body, the cover plate body comprises a panel layer and a grille layer, the grille layer is located at the bottom of the panel layer, the cover plate body is provided with joints and interfaces at opposite ends, the joints are used to be plugged with the interfaces on the adjacent cover plate body, the interfaces are used to be plugged with the joints on the adjacent cover plate body, the panel layer is a short fiber reinforced resin-based composite material component or a particle reinforced resin-based composite material component, the grille layer, the joints and the interfaces are all fiber reinforced resin-based composite material components, the panel layer, the grille layer, the joints and the interfaces are an integrally formed structural part. The composite material cover plate described in the present invention is an integrally formed composite material structural part, which has light weight, high strength, is not easy to decay, can be produced quickly, and is conducive to weight reduction of bridges.

Description

Technical Field

[0001] The present invention relates to the field of bridge engineering, and particularly to a composite material cover plate for bridges and a manufacturing method thereof. Background Art

[0002] Grooves such as cable troughs and water ditches are usually provided on bridges, and cover plates need to be arranged thereon to form a flat surface. Taking railway bridges as an example, railway water ditch and cable trough cover plates, as indispensable auxiliary facilities for railway engineering, mainly bear the crowd load and small temporary loads during maintenance. With the rapid development of high-speed railways in China, heavy, easily rusted metal cover plates that are not easy to construct and maintain have been gradually phased out, and currently, ordinary C40 concrete and reactive powder concrete (RPC) cover plates are mainly used. The ordinary C40 concrete cover plate is lighter in mass than the metal cover plate, greatly reducing the secondary dead load on the bridge deck and the installation difficulty. However, it is brittle and has low load-bearing capacity; the RPC cover plate has higher bearing capacity and has made great progress compared with the ordinary C40 concrete cover plate. However, it still has large brittleness, low flexural capacity, and is prone to brittle fracture and chipping during construction and handling.

[0003] Both the existing ordinary C40 concrete cover plate and the RPC cover plate are concrete structural plates. On the one hand, they are prone to brittle fracture and chipping, and on the other hand, the self-weight of the concrete structural plate is still relatively heavy, which is not conducive to reducing the weight of the bridge. Summary of the Invention

[0004] The purpose of the present invention is to provide a composite material cover plate for bridges and a manufacturing method thereof, aiming at the problems existing in the prior art that both the existing ordinary C40 concrete cover plate and the RPC cover plate are concrete structural plates, which are prone to brittle fracture and chipping on the one hand, and on the other hand, the self-weight of the concrete structural plate is still relatively heavy, which is not conducive to reducing the weight of the bridge.

[0005] In order to achieve the above purpose, the technical solution adopted by the present invention is as follows:

[0006] A composite material cover plate for bridges includes a cover plate body. The cover plate body includes a panel layer and a grid layer. The grid layer is located at the bottom of the panel layer. Connectors and interfaces are respectively provided at opposite ends of the cover plate body. The connectors are used for plugging into the interfaces on adjacent cover plate bodies, and the interfaces are used for plugging into the connectors on adjacent cover plate bodies. The panel layer is a short fiber reinforced resin matrix composite material member or a particle reinforced resin matrix composite material member. The grid layer, the connectors, and the interfaces are all fiber reinforced resin matrix composite material members. The panel layer, the grid layer, the connectors, and the interfaces are integrally formed structural members.

[0007] Preferably, the thickness of the panel layer is 2 mm - 5 mm.

[0008] Preferably, the panel layer is a short fiber reinforced resin matrix composite member formed by doping short cut fiber yarns into one of fluorocarbon resin, unsaturated resin or epoxy resin;

[0009] Or the panel layer is a particle reinforced resin matrix composite member formed by doping quartz sand and / or calcium carbonate into one of fluorocarbon resin, unsaturated resin or epoxy resin.

[0010] Preferably, the grid layer is a pultruded grid layer or a molded grid layer.

[0011] Preferably, the grid layer, the joint and the interface are all fiber reinforced resin matrix composite members formed by doping one or more of glass fiber, basalt fiber or carbon fiber into one of unsaturated resin or epoxy resin.

[0012] Preferably, one or more of a reinforcing agent, a toughening agent, a flame retardant or an insulating agent are added to the unsaturated resin or the epoxy resin.

[0013] Preferably, a plurality of protrusions are provided on the top surface of the panel layer.

[0014] The present invention also provides a manufacturing method of the composite material cover plate for a bridge as described above in the claims. The cover plate body is pultruded in one step to form a semi-finished product, and then the semi-finished product is placed in a mold to form surface protrusions.

[0015] Preferably, it includes the following steps:

[0016] A. Lead out fiber yarns and reinforcing fabrics, pass through a yarn guide plate and enter a resin tank for impregnation. The yarn guiding shape of the yarn guide plate is the cross-sectional shape of the cover plate body;

[0017] B. The impregnated fiber yarns and reinforcing fabrics enter a preforming mold to be preformed into fiber tapes;

[0018] C. The fiber tapes enter a forming mold and are formed through preheating, gelling and curing;

[0019] D. When the fiber tapes reach the required production size, use a cutting component for fixed-length cutting to obtain a blank plate of the composite material cover plate.

[0020] Preferably, it includes the following steps:

[0021] a. Apply fluorocarbon resin on a surface mold, and the surface mold has grooves;

[0022] b. Buckle the blank plate into the surface mold so that the top surface of the blank plate is in complete contact with the fluorocarbon resin;

[0023] c. Wait for the fluorocarbon resin to cure to form the finished product of the composite material cover plate.

[0024] In summary, due to the adoption of the above technical solutions, the beneficial effects of the present invention are as follows:

[0025] 1. The composite material cover plate described in the present invention is an integrally formed composite material structural member, which has a light self-weight, high strength, is not easily decayed, and can be produced quickly, which is beneficial to the weight reduction of the bridge;

[0026] 2. The composite material cover plate described in the present invention is inserted through the joints and interfaces of adjacent cover plate bodies. The strength of the connection part is reliable, and it does not require connection methods such as bolts, which can facilitate paving, and has a high installation efficiency. When all the cover plates on the bridge are paved, all the cover plates are connected into a whole;

[0027] 3. The composite material cover plate described in the present invention uses the grid layer as the main bearing layer. On the one hand, it can be selected and designed according to the span of the cover plate, and on the other hand, it is designed according to the specification standards, which can meet the actual use requirements of the road;

[0028] 4. The composite material cover plate described in the present invention is provided with a number of fluorocarbon resin protrusions on the top surface of the panel layer. The protrusions can prevent slipping, and the protrusions are integrally formed with the cover plate body, which can have its own color (no need for secondary painting) and self-cleaning and maintenance-free. Description of the Drawings

[0029] Figure 1 is a three-dimensional structural schematic diagram of the cover plate described in the present invention;

[0030] Figure 2 is a planar structural schematic diagram of the cover plate described in the present invention;

[0031] Figure 3 is a schematic diagram of the connection relationship of multiple cover plates;

[0032] Figure 4 is a schematic diagram of the manufacturing equipment of the composite material cover plate for bridges described in the present invention.

[0033] Reference numerals: 1 - panel layer, 2 - grid layer, 3 - joint, 4 - interface, 5 - fiber yarn frame body, 6 - reinforcing fabric frame body, 7 - yarn guide plate, 8 - resin tank, 9 - forming die, 10 - traction component, 11 - cutting component. Detailed Embodiments

[0034] The present invention will be described in detail below with reference to the drawings.

[0035] In order to make the purpose, technical solutions and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0036] Example 1

[0037] As Figures 1-3 shown, a composite cover plate for a bridge according to the present invention includes a cover plate body.

[0038] The cover plate body includes a panel layer 1 and a grille layer 2. The grille layer 2 is located at the bottom of the panel layer 1. Connectors 3 and interfaces 4 are respectively provided at opposite ends of the cover plate body. The connector 3 is used for plugging into the interface 4 on an adjacent cover plate body, and the interface 4 is used for plugging into the connector 3 on an adjacent cover plate body.

[0039] The panel layer 1 is a short fiber reinforced resin matrix composite member or a particle reinforced resin matrix composite member; specifically, the panel layer 1 is a short fiber reinforced resin matrix composite member formed by doping chopped fiber yarns into one of fluorocarbon resin, unsaturated resin or epoxy resin, or the panel layer 1 is a particle reinforced resin matrix composite member formed by doping quartz sand and / or calcium carbonate into one of fluorocarbon resin, unsaturated resin or epoxy resin.

[0040] The grille layer 2, the connector 3 and the interface 4 are all fiber reinforced resin matrix composite members; specifically, the grille layer 2, the connector 3 and the interface 4 are all fiber reinforced resin matrix composite members formed by doping one or more of glass fiber, basalt fiber or carbon fiber into one of unsaturated resin or epoxy resin; one or more of a reinforcing agent, a toughening agent, a flame retardant or an insulating agent are added to the unsaturated resin or the epoxy resin to obtain functions such as reinforcement, toughening, flame retardancy and insulation.

[0041] The panel layer 1, the grille layer 2, the connector 3 and the interface 4 are integrally formed structural members.

[0042] Among them, the thickness of the panel layer 1 is 2 mm - 5 mm. A plurality of protrusions are provided on the top surface of the panel layer 1. The grille layer 2 is a pultruded grille layer or a molded grille layer.

[0043] Example 2

[0044] As Figures 1-4 shown, a manufacturing method of a composite cover plate for a bridge according to the present invention is used to manufacture a composite cover plate for a bridge as described in Example 1, and includes the following steps:

[0045] Step 1. Material preparation

[0046] Prepare a resin adhesive solution, and prepare fiber yarns and reinforcing fabrics;

[0047] The resin glue solution is an unsaturated resin glue solution, and its mass ratio is: 100 parts of unsaturated resin matrix, 20 parts of calcium carbonate powder, 5 parts of aluminum hydroxide powder, 3 parts of internal mold release agent, and 3 parts of curing agent;

[0048] The fiber yarn is E-glass continuous yarn, specifically 4800 TEX;

[0049] The reinforcing fabric is continuous glass mat, and the grammage of the continuous glass mat is 300 g / m 2 ;

[0050] Step Two: Yarn Arrangement and Mold Preparation

[0051] Place the fiber yarn on the fiber yarn rack 5, place the reinforcing fabric on the reinforcing fabric rack 6, lead out the fiber yarn and the reinforcing fabric, and enter the preform mold through the yarn guide plate 7;

[0052] Install a resin tank 8 on the equipment rack. The resin tank 8 is used to hold the unsaturated resin glue solution, and the resin tank 8 is located between the yarn guide plate 7 and the preform mold;

[0053] Install a forming mold 9 on the equipment rack. The forming mold 9 includes a front zone heating device, a middle zone heating device, and a rear zone heating device. The heating temperatures of the front, middle, and rear zone heating devices of the forming mold 9 should be stable within the designed temperature range;

[0054] Step Three: Preforming

[0055] The fiber yarn and the reinforcing fabric enter the resin tank 8 through the yarn guide plate 7, and after impregnation, enter the preform mold;

[0056] The yarn guiding shape of the yarn guide plate 7 is the cross-sectional shape of the cover plate body (as Figure 2 shown);

[0057] The function of preforming is to guide the flat strip-shaped fiber tape after impregnation to gradually evolve into the shape closest to the pultruded product, while squeezing out the excess resin in the fiber tape and removing the air bubbles brought into the fiber tape to obtain a structurally dense pultruded product;

[0058] Step Four: Forming

[0059] After being pulled out from the preforming die, the fiber tape enters the forming die 9, is cured and formed in the forming die 9, and then is pulled out from the forming die 9. The fiber tape sequentially passes through the front-zone heating device, the middle-zone heating device, and the rear-zone heating device in the forming die 9. The front-zone heating device is used for preheating at a temperature of 155 °C, the middle-zone heating device is used for gelling at a temperature of 185 °C, and the rear-zone heating device is used for curing and forming at a temperature of 210 °C;

[0060] The pulling of the fiber tape is powered by the traction component 10;

[0061] The length of the forming die 9 is 0.5 m - 1.55 m, and the specific length depends on factors such as the thickness of the required fiber tape product, the pultrusion speed, and the chemical reaction characteristics of the resin system;

[0062] Step Five: Cutting

[0063] When the fiber tape reaches the required production size, use the cutting component 11 for fixed-length cutting to obtain the composite cover plate blank;

[0064] Step Six: Setting the surface die

[0065] Apply at least two coats of Meguiar's - 005 release wax evenly on the surface of the surface die and polish it;

[0066] Step Seven: Pouring the glue

[0067] Pour the mixed fluorocarbon resin A and B components into the surface die and use a tool to apply it evenly;

[0068] The mass ratio of the fluorocarbon resin is Component A∶Component B∶quartz sand = 100∶100∶25;

[0069] The fluorocarbon resin covers the inner cavity grooves of the surface die pattern and protrudes 2 mm - 3 mm, and the total height of the fluorocarbon resin layer is 5 mm;

[0070] Step Eight: Forming the protrusion

[0071] Fasten the blank obtained in Step Five into the surface die so that the top surface of the blank is in full contact with the fluorocarbon resin and do not move before the fluorocarbon resin cures;

[0072] Step Nine: Curing at room temperature or by heating

[0073] After curing at room temperature for about 3 h, the composite cover plate can be demolded and taken out. If the temperature is raised, the process time can be shortened;

[0074] Step Ten: Post-treatment

[0075] Edge trimming and polishing are performed to obtain the finished composite material cover plate.

[0076] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention shall be included within the protection scope of the present invention.

Claims

1. A method for manufacturing a composite material cover plate for a bridge, characterized in that: A composite material cover plate for a bridge comprises a cover plate body, the cover plate body comprises a panel layer (1) and a grid layer (2), the grid layer (2) is located at the bottom of the panel layer (1), and two opposite ends of the cover plate body are respectively provided with a joint (3) and an interface (4), the joint (3) is used to be plugged with the interface (4) on the adjacent cover plate body, and the interface (4) is used to be plugged with the joint (3) on the adjacent cover plate body, the panel layer (1) is a short fiber reinforced resin-based composite material component or a particle reinforced resin-based composite material component, the grid layer (2), the joint (3) and the interface (4) are all fiber reinforced resin-based composite material components, the panel layer (1), the grid layer (2), the joint (3) and the interface (4) are integrally formed structural parts; the joint (3) is a flat plug, and the interface (4) is a flat socket; the top surface of the panel layer (1) is provided with a plurality of protrusions; The manufacturing method comprises pultruding the cover plate body into a semi-finished product at one time: A. Leading out the fiber yarn and the reinforcing fabric, passing through a yarn guide plate (7) and entering a resin tank (8) for resin dipping, wherein the yarn guide shape of the yarn guide plate (7) is the cross-sectional shape of the cover plate body; B. The fiber yarn and the reinforcing fabric after being dipped in glue enter into a preforming mold and are preformed into a fiber tape; C. The fiber tape enters the molding die (9), is preheated at 155°C, gelled at 185°C, and cured at 210°C; D. When the fiber strip reaches the size required for production, the fiber strip is cut to length using a cutting component (11) to obtain a composite material cover plate blank; Then the semi-finished product is placed in a mold to form a protrusion on the surface: a. Apply fluorocarbon resin on the surface mold, the surface mold has a groove, the fluorocarbon resin covers the groove and protrudes 2mm-3mm; b. buckling the blank into the surface mold so that the top surface of the blank is completely in contact with the fluorocarbon resin; c. Waiting for the fluorocarbon resin to solidify and form the finished composite material cover plate.

2. The method for manufacturing a composite material cover plate according to claim 1, characterized in that: The thickness of the panel layer (1) is 2 mm-5 mm.

3. The method for manufacturing a composite material cover plate according to claim 1, characterized in that: The panel layer (1) is a short fiber reinforced resin-based composite material component formed by mixing chopped fiber yarn with one of fluorocarbon resin, unsaturated resin or epoxy resin; Alternatively, the panel layer (1) is a particle-reinforced resin-based composite material component formed by doping quartz sand and / or calcium carbonate with one of fluorocarbon resin, unsaturated resin or epoxy resin.

4. The method for manufacturing a composite material cover plate according to claim 1, characterized in that: The grid layer (2) is a pultruded grid layer or a molded grid layer.

5. The method for manufacturing a composite material cover plate according to claim 1, characterized in that: The grid layer (2), the joint (3) and the interface (4) are all fiber-reinforced resin-based composite material components formed by doping one of unsaturated resin or epoxy resin with one or more of glass fiber, basalt fiber or carbon fiber.

6. The method for manufacturing a composite material cover plate according to claim 5, characterized in that: One or more of a reinforcing agent, a toughening agent, a flame retardant or an insulating agent is added to the unsaturated resin or the epoxy resin.

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