A method of manufacturing and installing a composite fender

Abstract

The application relates to a bridge anti-collision technology field, in particular to a composite fender manufacturing method, which comprises the following steps: cleaning a mold and coating a release agent, coating a gel coat after the release agent is dried; laying dry fiber reinforced material, sandwich material, release cloth, flow guide cloth, flow guide pipe and air guide pipe on the mold in sequence; then laying a vacuum bag and an inflation bag, and checking air tightness; vacuumizing the vacuum bag, introducing resin glue solution into the flow guide pipe, simultaneously vibrating and heating the mold until the resin glue solution completely soaks the mold; after complete soaking, inflating and pressurizing the inflation bag, and compacting the fiber reinforced material to the mold; after the resin glue solution is solidified, removing the vacuum bag and the inflation bag, and obtaining the composite fender from the mold. The application can keep the temperature of the resin glue solution and the mold consistent by inflating and pressurizing the inflation bag, heating the resin glue solution and the mold, and can avoid the problems of too low local glue content of the fiber reinforced material, uneven overall thickness of the prefabricated part and fiber layering.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of bridge anti-collision technology, in particular to a composite fender manufacturing and installation method. BACKGROUND

[0002] In order to prevent the overall or partial damage of the bridge when the ship collides with the bridge, the bridge anti-collision system generally prevents the ship impact force from being transmitted to the bridge structure, or prolongs the collision time of the ship and reduces the ship impact force to improve the safety of the bridge.

[0003] When the vacuum introduction process is used to manufacture the bridge anti-collision fender, due to the uneven resin impregnation and inconsistent resin glue curing time in the vacuum introduction manufacturing process, there are problems of local incomplete resin impregnation, uneven thickness of the prefabricated part and fiber layering.

[0004] The existing repair means are usually restoration and repair, the restoration is to remove the defects and perform secondary fiber laying and pouring in the defect area according to the original structure, the repair is to keep the original defects and increase the fiber laying in the defect area, both of which cannot achieve the original effect, and the above technical problems are also new requirements for fender manufacturing. SUMMARY

[0005] In view of this, the present application provides a composite fender manufacturing and installation method, which is mainly used to solve the problems of incomplete resin impregnation, uneven thickness of the prefabricated part and fiber layering in the manufacturing process of the anti-collision fender in the prior art.

[0006] In one aspect, the present application provides a composite fender manufacturing method, which comprises:

[0007] cleaning the mold and coating a release agent, and then coating a gel coat after the release agent is dried;

[0008] laying dry fiber reinforced materials, sandwich materials, release cloth, flow guide cloth, flow guide pipe and air guide pipe on the mold in sequence;

[0009] then laying a vacuum bag and an inflation bag, and checking the air tightness;

[0010] vacuumizing the vacuum bag to introduce resin glue from the flow guide pipe, and at the same time, vibrating and heating the mold until the resin glue completely impregnates the mold;

[0011] after complete impregnation, inflating and pressurizing the inflation bag to compact the fiber reinforced materials towards the mold;

[0012] after the resin glue is cured, removing the vacuum bag and the inflation bag to obtain the composite fender from the mold.

[0013] In some embodiments of the present application, the flow guide pipe is directly fixed on the flow guide cloth.

[0014] In some embodiments of the present application, the fiber reinforced material includes glass fiber material and carbon fiber material.

[0015] In some embodiments of the present application, the core material is preferably hard polyurethane closed-cell foam.

[0016] In some embodiments of the present application, the resin glue solution is preheated and kept at a constant temperature of 25-28°C.

[0017] In some embodiments of the present application, an inflation pipe is connected to the inflatable bag, and the inflatable bag is inflated and pressurized by using the inflation pipe.

[0018] In some embodiments of the present application, the resin glue solution curing further includes: maintaining vacuum negative pressure, and allowing the resin glue solution to undergo curing cross-linking reaction under room temperature or heating condition to obtain a preform of the fender.

[0019] In another aspect, the present application provides a composite fender installation method, comprising:

[0020] Setting up a construction platform and a support;

[0021] Exploring the position of the reinforcing steel bars of the bridge pier structure, positioning and drilling holes at the anchor bolt position according to the position of the reinforcing steel bars of the bridge pier structure, and the distance P between the drilling position and the reinforcing steel bars is P>5cm;

[0022] Drilling holes based on the drilling position, the drilling hole diameter d is 36mm≤d≤40mm, and the drilling depth h is 380mm≤h≤400mm;

[0023] After the drilling is completed, the reinforcing steel bars are planted, the reinforcing steel bolt passes through the mounting hole of the corresponding anchor bolt position on the fender, and is fixed by a nut.

[0024] In some embodiments of the present application, the positioning and drilling holes at the anchor bolt position according to the position of the reinforcing steel bars of the bridge pier structure further includes that when the force-bearing reinforcing steel bars are encountered, the installation position is moved upward, downward, leftward or rightward as a whole.

[0025] In some embodiments of the present application, the anchoring adhesive used when the reinforcing steel bars are planted is an epoxy product.

[0026] Compared with the prior art, the application has the beneficial effect that the pressure generated by inflating the air bag is used to uniformly compact the fiber reinforced material in the mold, so that the fiber layer is kept flat and uniform in thickness, and when the preheated constant-temperature resin glue solution is introduced, vibration heating is performed at the bottom of the mold, the resin glue solution is uniformly and completely impregnated into the fiber reinforced material through vibration, and the first poured resin glue solution is prevented from being prematurely cured through heating, thereby avoiding fiber delamination, partial incomplete impregnation of the fiber material, uneven overall thickness of the prefabricated part, and fiber delamination caused by time difference in resin glue solution curing. BRIEF DESCRIPTION OF DRAWINGS

[0027] Various other advantages and benefits will become apparent to those of ordinary skill in the art upon reading the following detailed description of the preferred embodiments. The accompanying drawings are included to provide a description of the preferred embodiments and are not intended to limit the scope of the application.

[0028] Figure 1 Flow chart of the composite fender manufacturing method of the application;

[0029] Figure 2 Flow chart of the composite fender installation method of the application. DETAILED DESCRIPTION

[0030] Exemplary embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Although exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. Rather, these embodiments are provided so that the present disclosure can be more thoroughly understood and the scope of the present disclosure can be accurately conveyed to those skilled in the art. It should be noted that the embodiments in the present application and the features in the embodiments can be combined with each other without conflict. The present application will be described in detail below with reference to the accompanying drawings and in conjunction with the embodiments.

[0031] With the increase of the operating time and the vehicle passing density, the carrying capacity of the bridge itself will decrease, which will affect the overall stress performance of the bridge structure to some extent. In addition, with the increase of the navigation density in the bridge area, the risk of ship collision with the pier will also increase. Therefore, appropriate anti-collision measures should be taken for the bridge pier to protect the bridge structure and reduce the impact force of the ship. At the same time of protecting the bridge, the damage to the ship can also be reduced.

[0032] In bridge protection engineering, the anti-collision fender is usually installed on the pier body and the bearing platform of the bridge pier to reduce the impact force on the pier body through the anti-collision fender, so as to improve the safety performance of the bridge pier and avoid local scratching of the pier body. In the manufacturing process of the anti-collision fender, the vacuum introduction process is often used. The resin glue solution is impregnated into the entire mold by using the vacuum negative pressure generated by vacuum bagging of the mold and the laying material. After the resin glue solution is solidified, the required product is obtained. However, the resin glue solution may be unevenly impregnated, the local glue content may be too low, and the fiber may be layered after the resin glue solution is solidified.

[0033] Referring to Figure 1 The embodiment provides a composite fender manufacturing method, which comprises the following steps:

[0034] Step S101: cleaning the mold and coating a release agent, and then coating a glue skin after the release agent is dried;

[0035] Step S102: laying dry fiber reinforced material, sandwich material, release cloth, flow guide cloth and flow guide pipe on the mold in sequence;

[0036] Step S103: laying a vacuum bag and an inflation bag, and checking the air tightness;

[0037] Step S104: vacuumizing the vacuum bag, introducing the resin glue solution from the flow guide pipe, and simultaneously vibrating and heating the mold until the resin glue solution completely impregnates the mold;

[0038] Step S105: after the impregnation is completed, inflating and pressurizing the inflation bag to compact the fiber reinforced material towards the mold;

[0039] Step S106: after the resin glue solution is solidified, removing the vacuum bag and the inflation bag to obtain the composite fender from the mold.

[0040] It can be seen that, by vibrating and heating, the resin glue solution is uniformly and fully impregnated into the entire mold, and the time difference in the solidification of the resin glue solution is avoided. By the inflation pressure of the inflation bag, uniform force is applied to the fiber reinforced material towards the mold, so that the impregnated fiber reinforced material is compacted towards the mold, the resin glue solution is further promoted to flow, the glue content of the fiber reinforced material in each region is consistent, the fiber layering caused by the inconsistent solidification time of the resin glue solution is effectively avoided, and the problems of the low local glue content and the uneven thickness of the prefabricated part caused by the incomplete and insufficient impregnation of the resin glue solution are also avoided.

[0041] Specifically, in the embodiment, the mold is cleaned and the release agent and the glue skin are coated on the surface of the mold, and the mold is a single-sided rigid mold, so that the fender can be smoothly demolded after the preparation of the fender is completed.

[0042] Specifically, in the embodiment, after the release agent and the gel coat are applied, the dry fiber reinforced material and the core material are laid, the dry fiber reinforced material includes glass fiber material and carbon fiber material, and the core material is preferably rigid polyurethane closed-cell foam; the composite fender synthesized by introducing the resin glue solution through the vacuum introduction process has the advantages of high strength, corrosion resistance, impact cutting resistance, light weight and the like, thereby improving the crashworthiness of the fender.

[0043] Specifically, in the embodiment, the release cloth, the flow guide cloth, the flow guide pipe and the air guide pipe are sequentially laid on the core material layer, the flow guide pipe is preferably a spiral flow guide pipe, the flow guide pipe is arranged on the flow guide cloth and fixed, the inlet of the flow guide pipe is provided with a sealing clamp, and the sealing clamp is opened when the resin glue solution is poured, so that the resin glue solution can quickly and uniformly spread under the vacuum negative pressure generated when the vacuum bag is pumped, thereby achieving rapid impregnation of the entire mold.

[0044] Specifically, in the embodiment, the mold is bagged by the vacuum bag, the vacuum bag is sealed and checked for air tightness after being laid, and the vacuum bag is pumped through the air guide pipe under the condition that there is no air leakage, the sealing clamp of the inlet is opened after the vacuum bag is pumped, the resin glue solution is introduced from the flow guide pipe, the resin glue solution is preheated and kept at a constant temperature of 25-28℃, and the mold is vibrated and heated by the vibration heating plate under the mold at the same time when the resin glue solution is introduced, so that the heating temperature of the mold is consistent with the temperature of the resin glue solution, which is a constant temperature of 25-28℃, so that the resin glue solution will not solidify during the introduction process, and the vibration operation promotes the rapid and uniform flow of the resin glue solution, so that the resin glue solution fully and completely impregnates the entire mold.

[0045] Specifically, in the embodiment, after the resin glue solution is fully impregnated, the air in the air bag is inflated and pressurized by the inflation pipe, so that the material in the vacuum bag is subjected to uniform pressure, thereby compacting the material in the direction of the mold, and the resin glue solution is further uniformly dispersed, so that the resin content of the fiber reinforced material in each region is consistent.

[0046] As can be seen, in the embodiment, the resin glue solution is preheated and kept at a constant temperature of 25-28℃ before being introduced, and the mold is vibrated and heated at the same time during the introduction process, so that the heating temperature of the mold is consistent with the temperature of the resin glue solution, so that the resin glue solution will not solidify in advance during the introduction process, the mold is vibrated during the introduction process, the vibration force promotes the rapid and uniform flow of the resin glue solution, and after the resin glue solution is introduced, the air bag is inflated to generate uniform pressure in the direction of the mold, thereby avoiding the problems of uneven impregnation of the resin glue solution and too low resin content in some areas.

[0047] Specifically, in the embodiment, when the resin glue solution is in the curing reaction, the uniform pressure applied in the inflatable bag and the vacuum pressure in the vacuum bag are maintained, after the curing reaction is completed, the vacuum bag, the inflatable bag, the release cloth, the flow guide cloth, the flow guide pipe, the air guide pipe and the inflation pipe are removed, and the product is separated from the mold to obtain the composite fender.

[0048] Referring to Figure 2 As shown in the embodiment, the composite fender installation method comprises the following steps.

[0049] Step S201: erecting a construction platform and a support;

[0050] Step S202: finding out the reinforcement position of the bridge pier structure, positioning and drilling the anchor bolt position according to the reinforcement position of the bridge pier structure, and the distance P between the drilling position and the reinforcement is P>5cm.

[0051] Step S203: drilling based on the drilling position, the drilling diameter d is 36mm≤d≤40mm, and the drilling depth h is 380mm≤h≤400mm.

[0052] Step S204: after the drilling is completed, the reinforcement is planted, the reinforcement bolt passes through the mounting hole of the corresponding anchor bolt position on the fender, and is fixed by a nut.

[0053] Specifically, the embodiment first erects a construction platform and a support, preferably a ship as a construction platform or builds a construction platform, then uses a reinforcement detection mechanism to find out the reinforcement position of the bridge pier structure, positions and drills the anchor bolt position according to the drilling design position, moves the overall installation position upward or downward when encountering a horizontal reinforcement, and moves the overall installation position left or right when encountering a vertical reinforcement, the distance P between the actual drilling position and the drilling design position is in the range of P<5cm, and the distance Q between the actual drilling position and the nearest reinforcement position is in the range of Q<5cm.

[0054] Specifically, in the positioning and drilling of the anchor bolt position in the embodiment, the drilling diameter d is in the range of 36mm≤d≤40mm, and the drilling depth h is in the range of 380mm≤h≤400mm.

[0055] Specifically, after the positioning and drilling are completed in the embodiment, the bridge pier body is polished and leveled, and cleaned and dried, then the reinforcement is planted, an epoxy injection type anchoring adhesive is used, the reinforcement glue type is preferably RE100-HC, after the reinforcement glue reaches the design strength, the fender to be installed is lifted from the countersunk hole to the cargo ship, transported to the lifting site, lifted to the installation position by using a lifting belt passing through the installation lifting ring on the fender to be installed, the position of the fender to be installed is adjusted, the reinforcement bolt passes through the corresponding mounting hole, and is fixed by a nut. The lifting facility is transferred, and the next fender installation can be continued.

[0056] It can be seen that, in the embodiment, the actual drilling position is determined by building a construction platform, according to the steel bar position of the bridge pier structure and the drilling position of anchoring, the drilling diameter d is 36mm≤d≤40mm, the drilling depth h is 380mm≤h≤400mm, the fender is fixed on the bridge pier by using the anchoring glue and the anchoring bolt, so that the fender is installed quickly and conveniently.

[0057] Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the present application, but not to limit it, although the present application has been described in detail with reference to the above embodiments, those skilled in the art should understand that: the specific embodiments of the present application can still be modified or replaced by the same, without departing from the spirit and scope of the present application, any modification or equivalent replacement, which should be covered within the protection scope of the claims of the present application.

Claims

1. A method of manufacturing a composite fender, characterized by, The application relates to a method for manufacturing a composite material fender. Cleaning the mold and applying a release agent, and then applying a gel coat after the release agent is dried; Laying dry fiber reinforced material, sandwich material, release cloth, flow guide cloth, flow guide pipe and air guide pipe on the mold in sequence; The sandwich material is hard polyurethane closed-cell foam; Then, a vacuum bag and an inflation bag are laid, and air tightness is checked; The vacuum bag is vacuumized to introduce resin glue into the flow guide pipe, and meanwhile, the mold is vibrated and heated until the resin glue completely soaks the mold; The resin glue is preheated and kept at a constant temperature of 25-28 DEG C; After complete soaking, the inflation bag is inflated and pressurized to compact the fiber reinforced material towards the mold; The fiber reinforced material comprises glass fiber material and carbon fiber material; After the resin glue is solidified, the vacuum bag and the inflation bag are removed, and the composite material fender is obtained from the mold; The resin glue solidification further comprises: maintaining vacuum negative pressure, and making the resin glue undergo solidification and cross-linking reaction under room temperature or heating condition to obtain a preform of the fender.

2. The method of claim 1, wherein The flow guide pipe is directly fixed on the flow guide cloth.

3. The method of claim 1, wherein The inflation bag is connected with an inflation pipe, and the inflation pipe is used to inflate and pressurize the inflation bag.

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