A method for preparing a low-cost structural beaded fiber and a structural beaded fiber prepared thereby

Abstract

The application provides a preparation method of a low-cost structural bead chain fiber, comprising the following steps: (1) bundling: bundling fiber filaments to obtain a fiber bundle; (2) impregnating: impregnating the fiber bundle in resin and standing; (3) beading: taking out the fiber bundle, determining a plurality of processing positions at equal intervals along the length direction of the fiber bundle, hammering the processing positions in a direction perpendicular to the length direction of the fiber bundle or extruding and dispersing from top to bottom in a direction perpendicular to the length direction of the fiber bundle; (4) curing: impregnating the fiber bundle in another resin and standing to form a glue bead, taking out the fiber bundle for curing, and drying and forming; and (5) segmenting: segmenting the fiber bundle to form a mini muscle, and the mini muscle is the structural bead chain fiber. The application also provides the structural bead chain fiber prepared by the method. The structural bead chain fiber prepared by the method has a round particle shape, high forming efficiency and low bead chain manufacturing cost.

Description

Technical Field

[0001] This invention relates to the field of cement product reinforcing fiber technology, and more specifically, to the field of beaded fiber technology, particularly to a low-cost method for preparing structural beaded fibers and the structural beaded fibers prepared therefrom. Background Technology

[0002] Existing cement products are usually reinforced with composite reinforcing fibers, such as basalt fiber and carbon fiber.

[0003] Composite reinforcing fibers, also known as structural composite fibers, resemble small steel bars and are sometimes called "mini-reinforcements." They are typically prepared by spirally bonding raw fiber filaments, followed by twisting, resin impregnation, drying, and cutting into segments. Their bond strength in concrete products is provided by three factors: chemical bonding, mechanical friction, and mechanical anchoring.

[0004] Traditional methods for preparing composite reinforced fibers: Taking basalt fiber as an example, basalt fiber is a continuous fiber made by melting basalt ore at high temperatures and then drawing it into filaments. It possesses excellent properties such as high strength, temperature resistance, and corrosion resistance. The traditional preparation method of basalt fiber (including twisting) mainly involves the following steps:

[0005] 01 Raw Material Preparation: Basalt ore with stable chemical composition is selected as raw material to ensure the consistency of fiber performance.

[0006] 02 Melting: Basalt ore is melted at a high temperature of 1450℃~1500℃ to form a homogeneous melt.

[0007] 03 The molten material is drawn into fine filaments by passing through a platinum-rhodium alloy spinneret and a high-speed drawing machine to obtain basalt fiber precursor.

[0008] 04. Twisted basalt fiber filaments are twisted using a twisting machine to form woven yarn with a certain degree of twist. Twisting can improve the compactness and strength of the fiber bundle, increase the friction between fibers, and improve the stability and performance of the yarn.

[0009] 05 Post-treatment: Twisted basalt fiber yarns may require post-treatment processes such as impregnation and drying to enhance their performance in specific applications.

[0010] 06. Chopped fibers: In some applications, such as reinforced concrete, twisted basalt fiber yarns are chopped to form chopped fibers.

[0011] 07 Surface Modification In order to improve the bonding between basalt fibers and other materials, surface modification treatments, such as coating modification technology, may be carried out to improve their mechanical properties and environmental anti-aging properties.

[0012] Insufficient traditional materials: When fiber-reinforced cement products are subjected to external forces, the composite reinforcing fibers are prone to slippage and cannot coordinate with the deformation of the cement matrix. The failure mode of high-strength composite reinforcing fibers (basalt fibers, carbon fibers, etc.) prepared by this synthesis method is mostly "pull-out failure", which is far from reaching the tensile strength and can only improve the post-cracking properties of cement products.

[0013] To further enhance cement products, a novel material called structural beaded fiber has emerged. This material consists of multiple spherical beads spaced apart along the length of a continuous fiber, forming a beaded chain. Existing composite fiber beading technology involves dripping resin onto continuous fibers at fixed points one by one. However, the structural beaded fibers prepared by this method have insufficiently rounded particle shapes, low forming efficiency, and high manufacturing costs.

[0014] Therefore, it is desirable to provide a method for preparing structural beaded fibers, which produces structural beaded fibers with rounded particle shape, high forming efficiency, and low bead manufacturing cost. Summary of the Invention

[0015] In order to overcome the shortcomings of the prior art, one object of the present invention is to provide a low-cost method for preparing structural beaded fibers, wherein the prepared structural beaded fibers have rounded particle shape, high forming efficiency, and low bead manufacturing cost, and are suitable for large-scale promotion and application.

[0016] Another objective of this invention is to provide a low-cost structural beaded fiber, which is prepared by the above-mentioned low-cost structural beaded fiber preparation method. The granules are round, the forming efficiency is high, the manufacturing cost is low, and it is suitable for large-scale promotion and application.

[0017] To achieve the above objectives, in a first aspect of the present invention, a method for preparing low-cost structural beaded fibers is provided, characterized by comprising the following steps:

[0018] (1) Bundling: Bundling the original fiber filaments to obtain fiber bundles;

[0019] (2) Impregnation: The fiber bundle is impregnated in resin and left to stand;

[0020] (3) Bead making: Take out the fiber bundle, determine multiple processing positions on the fiber bundle, the multiple processing positions are equally spaced along the length direction of the fiber bundle, and hammer or squeeze and disperse from top to bottom along the length direction of the fiber bundle.

[0021] (4) Curing: The fiber bundle is immersed in another resin and left to stand to form glue beads. The fiber bundle is then taken out, cured, and dried to form a shape.

[0022] (5) Cutting: The fiber bundle is cut into segments to form mini ribs, which are structural beaded fibers.

[0023] Preferably, in step (1), the specific steps of bundling are: to spin and bond the fiber filaments, or to bundle them without twisting or with weak twisting.

[0024] Preferably, in step (2), the settling time is 5 to 60 seconds.

[0025] Preferably, in step (3), the distance between two adjacent processing positions is 5 mm to 10 mm.

[0026] Preferably, in step (3), the hammering is performed using intermittent micro-water jets or electromagnetic relay hammers, and the squeezing is performed using rib plates.

[0027] Preferably, in step (4), the settling time is 5 to 10 seconds.

[0028] Preferably, in step (4), the curing time is 5 minutes to 30 minutes, the drying temperature is 40°C to 60°C, and the drying time is 12 hours to 48 hours.

[0029] Preferably, in step (5), the length of the miniature rib is 30mm to 50mm.

[0030] Preferably, the method for preparing the low-cost structural beaded fiber further includes:

[0031] (6) Surface modification: The surface of the miniature rib is subjected to surface modification treatment.

[0032] In a second aspect of the present invention, a structural beaded fiber is provided, characterized in that it is prepared by the above-described low-cost structural beaded fiber preparation method.

[0033] The beneficial effects of this invention are as follows:

[0034] 1. The method for preparing low-cost structural beaded fiber of the present invention includes the following steps: (1) Bundling: Bundling the fiber filaments to obtain fiber bundles; (2) Impregnation: Impregnating the fiber bundles in resin and letting them stand; (3) Bead making: Taking out the fiber bundles, determining multiple processing positions on the fiber bundles, the multiple processing positions being equally spaced along the length direction of the fiber bundles, hammering the processing positions along the length direction perpendicular to the length direction of the fiber bundles or squeezing and dispersing them from top to bottom along the length direction perpendicular to the length direction of the fiber bundles; (4) Curing: Impregnating the fiber bundles in another resin and letting them stand to form glue beads, taking out the fiber bundles to cure, and drying and shaping; (5) Segmentation: Segmenting the fiber bundles to form mini ribs, the mini ribs being structural beaded fibers. Therefore, the structural beaded fibers prepared by this method have rounded particle shape, high forming efficiency, and low bead manufacturing cost, making them suitable for large-scale promotion and application.

[0035] 2. The low-cost structural beaded fiber of the present invention is prepared by the above-mentioned low-cost structural beaded fiber preparation method. The particles are round, the forming efficiency is high, the manufacturing cost is low, and it is suitable for large-scale promotion and application.

[0036] These and other objects, features and advantages of the present invention will be fully realized by the following detailed description and claims, and may be achieved by the means, apparatus and combinations thereof specifically pointed out in the appended claims. Attached Figure Description

[0037] Figure 1 This is a top view schematic diagram of the shape change of the fiber bundle before and after hammering dispersion, which is a specific embodiment of the preparation method of low-cost structural beaded fiber of the present invention. In this diagram, 1 is the fiber bundle; 2 is the fiber dispersion point; and 3 is the glue bead.

[0038] Figure 2 This is another specific embodiment of the method for preparing low-cost structural beaded fiber of the present invention. It is a top view schematic diagram of the shape change of the fiber bundle before and after extrusion and dispersion, wherein 1 is the fiber bundle; 2 is the fiber dispersion point; and 4 is the rib plate.

[0039] Figure 3 These are photos of a spider web reconstructed after being wet, with 5 representing the spider web and 6 representing water droplets. Detailed Implementation

[0040] In order to achieve rounded particle shape, high forming efficiency, and low manufacturing cost of the prepared structural beaded fiber, the inventors have proposed a low-cost method for preparing structural beaded fiber through in-depth and extensive research. The structural beaded fiber prepared by this low-cost method has rounded particle shape, high forming efficiency, and low manufacturing cost.

[0041] This invention provides a low-cost method for preparing structural beaded fibers, comprising the following steps:

[0042] (1) Bundling: Bundling the original fiber filaments to obtain fiber bundles;

[0043] (2) Impregnation: The fiber bundle is impregnated in resin and left to stand to enhance the bonding force between the fiber filaments;

[0044] (3) Bead making: Take out the fiber bundle, determine multiple processing positions on the fiber bundle, the multiple processing positions are equally spaced along the length direction of the fiber bundle, and hammer or squeeze and disperse from top to bottom along the length direction of the fiber bundle.

[0045] (4) Curing: The fiber bundle is immersed in another resin and left to stand to form glue beads. The fiber bundle is then taken out, cured, and dried to form a shape.

[0046] (5) Cutting: The fiber bundle is cut into segments to form mini ribs, which are structural beaded fibers.

[0047] In step (1), the bundling can be carried out by any suitable specific steps. Preferably, in step (1), the specific steps of bundling are: to spin and bond the fiber filaments, or to bundle them without twisting or with weak twisting.

[0048] In step (2), the settling time can be determined as needed. Preferably, in step (2), the settling time is 5 to 60 seconds.

[0049] In step (3), the spacing between two adjacent processing positions can be determined as needed. Preferably, in step (3), the spacing between two adjacent processing positions is 5 mm to 10 mm.

[0050] In step (3), the hammering and the squeezing can be performed using any suitable tool. Preferably, in step (3), the hammering is performed using intermittent micro-water jets or electromagnetic relay hammers, and the squeezing is performed using rib plates.

[0051] In step (4), the settling time can be determined as needed. Preferably, in step (4), the settling time is 5 to 10 seconds.

[0052] In step (4), the curing time can be determined as needed. Preferably, in step (4), the curing time is 5 to 30 minutes.

[0053] In step (4), the drying temperature and temperature can be determined as needed. Preferably, in step (4), the drying temperature is 40°C to 60°C and the drying time is 12 hours to 48 hours.

[0054] In step (5), the length of the miniature rib can be determined as needed. Preferably, in step (5), the length of the miniature rib is 30mm to 50mm.

[0055] The method for preparing the low-cost structural beaded fiber may also include any other suitable composition; preferably, the method for preparing the low-cost structural beaded fiber further includes:

[0056] (6) Surface modification: The surface of the miniature ribs is subjected to surface modification treatment. In order to improve the chemical bonding between the structural beaded fibers and other materials, surface modification treatment, such as coating modification technology, may be performed to improve its mechanical properties and environmental anti-aging properties.

[0057] The present invention also provides a structural beaded fiber, which is prepared by the above-described low-cost structural beaded fiber preparation method.

[0058] This invention involves impregnating the fiber bundles with resin after they are bundled together. The fiber bundles are then continuously hammered and dispersed along their length perpendicular to the bundle's length, or compressed and dispersed from top to bottom along the same direction, forming a periodic spindle-shaped structure. A second impregnation is then performed. After a period of settling, the surface energy gradient causes the impregnating agent to spontaneously migrate in a directional manner, forming bead chains. The fibers are then cured, dried, and cut into segments to complete the preparation. This method produces beaded fibers that solve the problem of poor interfacial properties between fibers and cement, fully utilizing the high tensile strength of the main chain.

[0059] Periodic spindle segment structure: Referencing the "wet remodeling" phenomenon in spider webs (see...) Figure 3 (As shown). The fibers of the "wet-reconstructed" system are characterized by periodic spindle nodes, which are composed of random nanofibers separated by neatly arranged nanoscale fiber nodes. This structure creates a surface energy gradient between the spindle nodes and the nodes, resulting in a difference in pressure acting on water droplets in contact with the spindle nodes or nodes. This ensures that water continuously condenses around the nodes and is then transported to the spindle nodes, where water molecules can accumulate into large, suspended droplets. Through this "wet-reconstruction," the spider web rapidly condenses atmospheric moisture into droplets, keeping the overall structure dry and accelerating the directional migration of moisture, forming an orderly arrangement on the spider web chain.

[0060] Microfluidics is the science and technology involved in systems that use microchannels (tens to hundreds of micrometers in size) to process or manipulate tiny fluids (volumes from nanoliters to attoliters). The "micro" in microfluidics refers to the miniaturization of experimental instruments (tens to hundreds of micrometers in size); "fluid" refers to the fact that the experimental object is a fluid (volume from nanoliters to attoliters); and "control" represents the control, manipulation, and processing of fluids on miniaturized devices. It is a fundamental technology, an interdisciplinary field encompassing biology, chemistry, medicine, semiconductors, materials science, and mechanics.

[0061] This invention utilizes spider silk biomimicry to design a microfluidic surface for the impregnation liquid of fiber bundles, achieving directional and efficient driving of small-scale droplets. Specifically, periodic fiber dispersion points are introduced onto the fiber bundles to generate spindle nodes, which drive the impregnation liquid to form beads.

[0062] Before secondary impregnation, the fiber bundles are rapidly hammered or squeezed to transform them into a loose mass of nano / micron-sized fine fibers and their interconnecting structures. During secondary impregnation, this structure transforms into periodic spindle-knot structures and delicate joint structures. Randomly distributed nano / micron-sized fiber structures form on the spindle-knots, while ordered nano / micron-sized fiber structures form on the joints. These structural characteristics create a surface energy gradient between the spindle-knots and joints, while a Laplace pressure difference is also generated due to the curvature gradient. This coupling of microscopic multistructures allows the forces of the two gradients to act synergistically on small-scale droplets, enabling the fiber bundles to transport liquid from the joints to the spindle-knots. As a result, larger impregnation droplets can be rapidly and efficiently concentrated and stably attached to the fiber bundles, producing ultra-high-quality, uniform bead chains.

[0063] Compared with the prior art, the present invention has the following advantages:

[0064] 1. High-quality beads: The tiny droplets are round and evenly spaced.

[0065] 2. High molding efficiency: Spindle segments are used as positioning points for resin droplets. Spindle segments can be formed by simple hammering / rolling (extrusion) in one go for impregnation.

[0066] 3. Low energy consumption and wear: The material is spontaneously formed by using a periodic spindle joint structure, which reduces wear from mechanical movement.

[0067] 4. Excellent application effect: Structural beaded fibers can provide stronger bonding force for composite reinforcing fibers, thereby improving the mechanical properties of cement products.

[0068] Therefore, this invention proposes a low-cost method for preparing structural beaded fibers, which can be used to reinforce cement products. The preparation method involves forming beaded chains from fiber filaments by bundling the filaments into fiber bundles. Resin is then applied to these fiber bundles using the low-cost method specifically described in this invention to form droplets. After the resin cures, a fiber-resin beaded chain is formed, which is then cut into miniature rods. This beaded chain can increase the coordination between the fiber body and the cement matrix during deformation, improve the stress distribution at both ends of the fiber, and enhance mechanical properties.

[0069] In summary, the low-cost structural beaded fiber preparation method of the present invention produces structural beaded fibers with rounded particle shape, high forming efficiency, and low beaded manufacturing cost, making it suitable for large-scale promotion and application.

[0070] In this specification, the invention has been described with reference to specific embodiments thereof. However, it will be apparent that various modifications and variations can be made without departing from the spirit and scope of the invention. Therefore, this specification should be considered illustrative rather than restrictive.

Claims

1. A method for preparing a low-cost structural beaded fiber, characterized in that, Includes the following steps: (1) Bundling: Bundling the original fiber filaments to obtain fiber bundles; (2) Impregnation: The fiber bundle is impregnated in resin and left to stand; (3) Bead making: Take out the fiber bundle, determine multiple processing positions on the fiber bundle, the multiple processing positions are equally spaced along the length direction of the fiber bundle, and hammer or squeeze and disperse from top to bottom along the length direction of the fiber bundle. (4) Curing: The fiber bundle is immersed in another resin and left to stand to form glue beads. The fiber bundle is then taken out, cured, and dried to form a shape. (5) Cutting: The fiber bundle is cut into segments to form mini ribs, which are structural beaded fibers.

2. The method for preparing low-cost structural beaded fiber according to claim 1, characterized in that, In step (1), the specific steps of bundling are: to spin and bond the fiber filaments, or to bundle them without twisting or with weak twisting.

3. The method for preparing low-cost structural beaded fiber according to claim 1, characterized in that, In step (2), the settling time is 5 to 60 seconds.

4. The method for preparing low-cost structural beaded fiber according to claim 1, characterized in that, In step (3), the distance between two adjacent processing positions is 5 mm to 10 mm.

5. The method for preparing low-cost structural beaded fiber according to claim 1, characterized in that, In step (3), the hammering is performed using intermittent micro-water jets or electromagnetic relay hammers, and the squeezing is performed using rib plates.

6. The method for preparing low-cost structural beaded fiber according to claim 1, characterized in that, In step (4), the settling time is 5 to 10 seconds.

7. The method for preparing low-cost structural beaded fiber according to claim 1, characterized in that, In step (4), the curing time is 5 minutes to 30 minutes, the drying temperature is 40°C to 60°C, and the drying time is 12 hours to 48 hours.

8. The method for preparing low-cost structural beaded fiber according to claim 1, characterized in that, In step (5), the length of the miniature rib is 30mm to 50mm.

9. The method for preparing low-cost structural beaded fiber according to claim 1, characterized in that, The method for preparing low-cost structural beaded fibers further includes: (6) Surface modification: The surface of the miniature rib is subjected to surface modification treatment.

10. A structural beaded fiber, characterized in that, It is prepared by the low-cost structural beaded fiber preparation method according to any one of claims 1 to 9.

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