A method of manufacturing a composite tensile grid panel for gabion manufacture
By performing embossing and indentation treatments during the preparation of composite tensile mesh plates, the problems of difficult bending and forming and reduced tensile strength were solved, thus achieving shape consistency and improved tensile strength of gabion products.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- SHANDONG UNIV
- Filing Date
- 2023-10-23
- Publication Date
- 2026-07-14
AI Technical Summary
Existing composite tensile mesh panels are difficult to maintain shape consistency during bending and forming, and their tensile strength decreases after bending, affecting the performance of gabion products.
In the preparation process of composite tensile mesh plate, straight indentations are formed by pressing at a set position on the plate after punching, and indentation is performed at a second set position to facilitate bending and forming, while improving the tensile strength of the ribs.
This technology enables easy bending and forming of composite tensile mesh panels and improves tensile strength, ensuring the standardization of the shape, consistency of dimensions, and stability of the overall tensile strength of gabion products.
Smart Images
Figure CN117341256B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of composite material gabion technology, and more specifically to a method for preparing a composite material tensile mesh plate for preparing gabions. Background Technology
[0002] The information disclosed in this background section is intended only to enhance understanding of the overall background of the invention and is not necessarily to be construed as an admission or in any way implying that such information constitutes prior art known to those skilled in the art.
[0003] Currently, commercially available gabions are all assembled from wire mesh structures. Because they are made of metal, they are quite heavy, resulting in high labor intensity during construction. Furthermore, the anti-corrosion coating on the wire mesh is easily worn away and damaged during the stacking of stones and construction, leading to a loss of the gabion's corrosion resistance. Composite materials such as polypropylene (PP) and polyethylene terephthalate (PET) offer advantages such as light weight, acid and alkali resistance, and corrosion resistance. Gabion products made from these materials can significantly reduce the labor intensity during construction and ensure stable and excellent overall performance during service.
[0004] Composite tensile mesh panels are made from composite material sheets through punching and biaxial stretching. According to the inventors' research, during the manufacturing process of gabions, the composite tensile mesh panels need to be bent and deformed at certain dimensional positions to ensure the dimensional specifications of the gabion products. Because the tensile ribs in the stretched composite mesh panels have significant elasticity in all directions after stretching, bending them is difficult, and maintaining the bent state is challenging. Furthermore, the tensile strength of the ribs decreases after bending, adversely affecting the performance of the gabion products made from them. Summary of the Invention
[0005] To address the shortcomings of existing technologies, the present invention aims to provide a method for preparing composite tensile mesh plates for gabions. The composite tensile mesh plates prepared by the present invention are not only easy to bend and form, but also avoid excessive reduction in tensile strength, thus ensuring the requirements for use are met.
[0006] To achieve the above objectives, the technical solution of the present invention is as follows:
[0007] On one hand, a method for preparing a composite material stretched mesh plate for gabions involves punching holes in an extruded composite material sheet, then imprinting a straight indentation at a first predetermined position on the punched sheet; then biaxially stretching a precursor mesh plate, and then indenting a crease at a second predetermined position on the precursor mesh plate to form a fold at the second predetermined position; finally, unfolding the indented precursor mesh plate along the planar direction to obtain the desired product.
[0008] The first set position includes the intended bending position, which is the position on the biaxially stretched sheet corresponding to the transverse rib that needs to be bent. The formed imprint connects the adjacent holes in the longitudinal and transverse directions. The second set position is the position where the longitudinal and transverse ribs need to be bent.
[0009] This invention aims to facilitate the bending of composite tensile mesh plates for gabion assembly. Indentation is performed at the locations where bending of the longitudinal and transverse reinforcing bars is required. In actual production, automated and large-scale indentation can be achieved mechanically, ensuring all indentation positions are neat and consistent, thus guaranteeing the standardized shape and dimensional consistency of the finished gabion products. However, directly bending the tensile mesh plate presents the following problems: the bendability of the transverse reinforcing bars is lower than that of the longitudinal reinforcing bars, and the mechanical properties decrease significantly, failing to meet requirements. Through research and analysis, this invention identifies the main reason as follows: during bidirectional stretching, longitudinal stretching occurs first, followed by transverse stretching. The transverse reinforcing bars experience completely different properties during longitudinal stretching due to transverse contraction and the tension generated during longitudinal stretching, resulting in different performance characteristics compared to the longitudinal reinforcing bars.
[0010] Before stretching, this invention performs an embossing treatment on the punched sheet material. During the stretching process, the transverse ribs at the embossed locations show a significant reduction in transverse width and a corresponding increase in thickness. The degree of fibrous development within the ribs also increases, thereby enhancing their tensile strength. This increased fibrous development facilitates bending and shaping without compromising tensile strength, thus ensuring the overall serviceability of the gabion product.
[0011] In addition, the invention unexpectedly discovered through experiments that the embossed mesh plate, after being indented, not only does not have its mechanical properties reduced, but its mechanical properties are slightly improved.
[0012] On the other hand, a composite tensile mesh plate for preparing gabions is obtained by the above-described preparation method.
[0013] Thirdly, a gabion is formed by assembling a composite material stretched mesh plate used to prepare the gabion after bending it along the indentation.
[0014] The beneficial effects of this invention are as follows:
[0015] The preparation method provided by this invention solves the problems of the reinforcing bars being difficult to bend and the bending affecting tensile strength by performing an imprinting treatment before stretching. The gabion products assembled by bending are effectively guaranteed to have consistent overall tensile strength (i.e., no load-bearing gaps). At the same time, the products have a neat and uniform appearance and consistent dimensions, which can well meet the requirements of aesthetics, standardization and consistency in gabion construction. Attached Figure Description
[0016] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.
[0017] Figure 1 This is a schematic diagram showing the location of the straight indentation after the perforated sheet metal is embossed in Embodiment 1 of the present invention;
[0018] Figure 2 This is a schematic diagram showing the location of the straight indentation after the perforated sheet metal is embossed in Embodiment 2 of the present invention;
[0019] Figure 3 This is a schematic diagram showing the location of the straight indentation after the perforated sheet metal is embossed in Embodiment 3 of the present invention;
[0020] Among them, 1 is a perforated sheet material, and 2 is a straight indentation. Detailed Implementation
[0021] It should be noted that the following detailed descriptions are exemplary and intended to provide further illustration of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.
[0022] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.
[0023] Given that existing processes for producing composite tensile mesh plates have problems such as difficulty in bending, difficulty in ensuring the cost and consistency of subsequent bending operations, and excessive reduction in the tensile strength of the ribs after bending, this invention proposes a method for preparing composite tensile mesh plates for gabions.
[0024] A typical embodiment of the present invention provides a method for preparing a composite material stretched mesh plate for preparing gabions. The method involves punching holes in an extruded composite material sheet, then imprinting a straight indentation at a first predetermined position on the punched sheet; then biaxially stretching the sheet to form a precursor mesh plate, followed by indentation at a second predetermined position on the precursor mesh plate to form a fold; finally, unfolding the indented precursor mesh plate along a planar direction to obtain the final product.
[0025] The first set position includes the intended bending position, which is the position on the biaxially stretched sheet corresponding to the transverse rib that needs to be bent. The formed imprint connects the adjacent holes in the longitudinal and transverse directions. The second set position is the position where the longitudinal and transverse ribs need to be bent.
[0026] After biaxial stretching, the punched holes in the composite material sheet form a mesh. The solid material remaining between adjacent holes in the longitudinal and transverse directions of the punched sheet can form the longitudinal and transverse ribs of the composite material mesh plate. In some embodiments, the holes on the composite material sheet after punching are rhomboid, and the diagonal of the rhomboid hole is consistent with the stretching direction. Preferably, the rhomboid has an included angle of 90 degrees between adjacent sides, i.e., a square.
[0027] Specifically, the two ends of the straight indentation are located at the apex of the rhomboid hole. The apex of the rhomboid hole forms a sharp corner, which will be preferentially stretched during the heating and stretching process, and a highly fibrous area will be formed at this location, in which it is easier to perform indentation treatment without affecting the tensile strength of the rib.
[0028] The embossing process of this invention can be performed after punching or simultaneously during punching. The embossing process can be achieved by setting up a suitable embossing device or mold.
[0029] The embossing process can be performed on one side of the composite material sheet or on both sides simultaneously. In some embodiments, the embossing process is performed on both sides of the composite material sheet simultaneously. This process is more conducive to improving the tensile strength and bending deformation performance of the ribs.
[0030] In some embodiments, the axial cross-section of the straight indentation is V-shaped. This configuration is more conducive to improving the tensile strength of the reinforcing bar. Specifically, the depth of the straight indentation is 0.4–0.65 mm. Specifically, the included angle between the two side walls of the V-shaped straight indentation is 9–11°.
[0031] In some embodiments, the first designated position includes the position on the sheet material before stretching corresponding to the transverse stiffeners. This helps increase the tensile strength of all transverse stiffeners, thereby helping to reduce the weight per square meter of the composite tensile mesh sheet and lower costs.
[0032] In some embodiments, the first designated position includes the position on the sheet material before stretching corresponding to the longitudinal stiffeners. This arrangement helps to increase the tensile strength of all longitudinal stiffeners, thereby further improving the performance of the composite tensile mesh plate.
[0033] In some embodiments, the first designated position includes the positions on the sheet material before stretching corresponding to the longitudinal and transverse stiffeners. This arrangement is more conducive to increasing the tensile strength of all longitudinal stiffeners, and can further improve the performance of the composite tensile mesh plate.
[0034] Biaxial stretching of composite mesh sheets involves first stretching along the longitudinal axis under heating conditions, followed by stretching along the transverse axis. Generally, the stretched composite mesh sheets are placed in rolls, with the roll length direction as the longitudinal axis and the roll width direction as the transverse axis. In some embodiments, the longitudinal stretching in biaxial stretching is a roller-surface heat conduction type winding stretching method, where the sheet is wound around the surface of multiple heat-conducting rollers and heated and stretched. The heating method involves adding heat-conducting oil to the heat-conducting rollers to heat the sheet surface.
[0035] In some embodiments, in biaxial stretching, the transverse stretching method is a hot air convection planar involute stretching method, that is, the sheet is stretched by clamps at both ends, and the heating method is to heat both sides of the sheet by hot air.
[0036] During the stretching process, the temperature control accuracy of this invention is ±2℃.
[0037] In some embodiments, after stretching, the ribs are cut and then indented at the middle. The cutting accuracy is ±2mm.
[0038] In the indentation process, the accuracy of the indentation position is ±2mm; the air pressure deviation of the indentation cylinder is ±0.1kg.
[0039] Another embodiment of the present invention provides a composite material tensile mesh plate for preparing gabions, which is obtained by the above-described preparation method.
[0040] A third embodiment of the present invention provides a gabion, which is formed by assembling a composite material stretched mesh plate used to prepare the gabion after bending along the indentation.
[0041] To enable those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention will be described in detail below with reference to specific embodiments and comparative examples.
[0042] In the following examples, polypropylene sheets are provided using conventional methods.
[0043] Example 1
[0044] A method for preparing a composite tensile mesh plate for gabions includes the following steps:
[0045] 1. Punching: A square punch is rotated 45°, with the edges of the punch parallel to its length axis, in the longitudinal and transverse planes where the length axis of the punch is located.
[0046] 2. Embossing treatment: At the location of the perforated plate 1 corresponding to the transverse ribs of the composite tensile mesh plate that need to be bent, such as... Figure 1 As shown, a corresponding mold is used for embossing to form a straight indentation 2. The depth of the straight indentation 2 is 0.65mm, and the V-shaped angle of the axial section of the straight indentation 2 is 10°.
[0047] 3. Bidirectional stretching treatment: First, longitudinal stretching is carried out using a roller surface heat conduction type winding stretching method at a temperature of 130±3℃ and a stretching speed of 10 meters per minute; then, transverse stretching is carried out using a hot air convection type planar involute stretching method at a temperature of 145±5℃ and a stretching speed of 5 meters per minute.
[0048] 4. Cut to size with a cutting accuracy of ±2mm.
[0049] 5. Indentation forming: The indentation forming work is completed by a CNC bending machine. The indentation position accuracy is ±2mm, and the air pressure deviation of the indentation cylinder is ±0.1kg.
[0050] 6. Packaging: After the product is molded, it is flattened and stacked flat. Each group consists of 25 pieces. At the four corners of each group, the group is tied together with wire.
[0051] 7. Mark and store in the database.
[0052] Example 2
[0053] A method for preparing a composite tensile mesh plate for gabions includes the following steps:
[0054] 1. Punching: A square punch is rotated 45°, with the edges of the punch parallel to its length axis, in the longitudinal and transverse planes where the length axis of the punch is located.
[0055] 2. Embossing treatment: At the positions of the perforated plate 1 corresponding to the transverse ribs of the composite tensile mesh plate, such as... Figure 2 As shown, a corresponding mold is used for embossing to form a straight indentation 2. The depth of the straight indentation 2 is 0.65mm, and the V-shaped angle of the axial section of the straight indentation 2 is 10°.
[0056] 3. Bidirectional stretching treatment: First, longitudinal stretching is carried out using a roller surface heat conduction type winding stretching method at a temperature of 130±3℃ and a stretching speed of 10 meters per minute; then, transverse stretching is carried out using a hot air convection type planar involute stretching method at a temperature of 145±5℃ and a stretching speed of 5 meters per minute.
[0057] 4. Cut to size with a cutting accuracy of ±2mm.
[0058] 5. Indentation forming: The indentation forming work is completed by a CNC bending machine. The indentation position accuracy is ±2mm, and the air pressure deviation of the indentation cylinder is ±0.1kg.
[0059] 6. Packaging: After the product is molded, it is flattened and stacked flat. Each group consists of 25 pieces. At the four corners of each group, the group is tied together with wire.
[0060] 7. Mark and store in the database.
[0061] Example 3
[0062] A method for preparing a composite tensile mesh plate for gabions includes the following steps:
[0063] 1. Punching: A square punch is rotated 45°, with the edges of the punch parallel to its length axis, in the longitudinal and transverse planes where the length axis of the punch is located.
[0064] 2. Embossing treatment: At the locations of the perforated sheet 1 corresponding to the transverse and longitudinal ribs of the composite tensile mesh plate, such as... Figure 3 As shown, a corresponding mold is used for embossing to form a straight indentation 2. The depth of the straight indentation 2 is 0.65mm, and the V-shaped angle of the axial section of the straight indentation 2 is 10°.
[0065] 3. Bidirectional stretching treatment: First, longitudinal stretching is carried out using a roller surface heat conduction type winding stretching method at a temperature of 130±3℃ and a stretching speed of 10 meters per minute; then, transverse stretching is carried out using a hot air convection type planar involute stretching method at a temperature of 145±5℃ and a stretching speed of 5 meters per minute.
[0066] 4. Cut to size with a cutting accuracy of ±2mm.
[0067] 5. Indentation forming: The indentation forming work is completed by a CNC bending machine. The indentation position accuracy is ±2mm, and the air pressure deviation of the indentation cylinder is ±0.1kg.
[0068] 6. Packaging: After the product is molded, it is flattened and stacked flat. Each group consists of 25 pieces. At the four corners of each group, the group is tied together with wire.
[0069] 7. Mark and store in the database.
[0070] The tensile strength of the product prepared in Example 2 was tested, and the testing process is as follows:
[0071] 1. Bulk Sampling: Open the roll of the grid product, and along the length of the roll, after avoiding the ends by at least two meters, cut a 1-meter length of the full-width grid product for use as a sample.
[0072] 2. Sample Cutting: Avoiding the 20cm section along both sides of the width of the large sample, select five sampling positions evenly along the width of the large sample. Cut two longitudinal and two transverse samples from each sampling position and mark the positions, forming five sets of samples to be tested in both the longitudinal and transverse directions (a total of ten sets of samples in both directions). In accordance with the requirements of GB / T 17689-2008, retain three complete nodes for each sample.
[0073] 3. Pressing: For one of the samples in each group, bend it at the middle of any one of its ribs (the three nodes include two complete ribs, choose one of them) to achieve the degree of folding. At the folded position, press it with a 1Kg weight or pressure to ensure that the folded position does not spring back.
[0074] 4. Handling: All samples (including molded and unmolded samples) should be placed in a standard laboratory environment (temperature 20±2℃) for at least 24 hours before testing.
[0075] 5. Testing: Mechanical properties of each sample shall be tested in accordance with the testing methods of GB / T 17689-2008.
[0076] 6. Data processing: The test results of samples from the same sampling location in the same direction (longitudinal or transverse) are compared one by one.
[0077] The test results are shown in Tables 1 to 4.
[0078] Table 1 Tensile strength of longitudinal stiffeners
[0079]
[0080]
[0081] Table 2 Tensile strength of transverse stiffeners
[0082]
[0083] Table 3 Differences in average tensile strength
[0084]
[0085] The data in Tables 1-3 show that the ribs after pressing all conform to the GB / T 17689-2008 standard. Furthermore, it also shows that the mechanical properties of the ribs in the grid plate produced by the embossing process of this invention not only do not decrease after pressing, but actually increase. Weight testing showed that the unit area weight of the biaxially stretched grid plate in Example 2 was 7-10% less than that of the grid plate produced without embossing.
[0086] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.
Claims
1. A method for preparing a composite tensile mesh plate for preparing gabions, characterized in that, The extruded composite material sheet is punched, and then an impression is made at the first predetermined position of the punched sheet to form a straight indentation; then it is biaxially stretched to form a front mesh plate, and then an impression is made at the second predetermined position of the front mesh plate to form a crease at the second predetermined position; then the impression-treated front mesh plate is unfolded along the plane to obtain the final product. The first set position also includes the position on the sheet metal before stretching corresponding to the transverse and longitudinal ribs; The biaxial stretching of composite mesh plates involves first stretching along the longitudinal axis under heating conditions, followed by stretching along the transverse axis. The first set position includes the intended bending position, which is the position on the plate before biaxial stretching corresponding to the transverse rib that needs to be bent. The formed imprint connects the adjacent holes in the longitudinal and transverse directions. The second designated location is the position where the longitudinal and transverse reinforcing bars need to be bent. The depth of the straight-line indentation is 0.4~0.65mm.
2. The method for preparing composite tensile mesh plates for preparing gabions as described in claim 1, characterized in that, After punching, the holes on the composite material sheet are diamond-shaped, and the diagonal of the diamond-shaped hole is in the same direction as the stretching; or, the two ends of the straight indentation are located at the apex of the diamond-shaped hole.
3. The method for preparing composite tensile mesh plates for preparing gabions as described in claim 1, characterized in that, The embossing process is performed simultaneously on both sides of the composite material sheet.
4. The method for preparing composite tensile mesh plates for preparing gabions as described in claim 1, characterized in that, The straight indentation is V-shaped.
5. The method for preparing composite tensile mesh plates for preparing gabions as described in claim 1, characterized in that, In biaxial stretching, the longitudinal axis stretching method is a roller surface heat conduction type winding stretching method; Alternatively, in biaxial stretching, the transverse stretching method is a hot air convection type planar involute stretching method.
6. The method for preparing composite tensile mesh plates for preparing gabions as described in claim 1, characterized in that, After stretching, cut the ribs and then indent them in the middle.
7. A composite tensile mesh plate for preparing gabions, characterized in that, Obtained by the preparation method according to any one of claims 1 to 6.
8. A gabion, characterized in that, It is formed by assembling the composite material tensile mesh plate used for preparing gabions as described in claim 7 after bending along the indentation.