Basalt fiber composite material aggregate, preparation method thereof and pipeline

Abstract

According to the basalt fiber composite material aggregate, the preparation method thereof and the pipeline, the HDPE resin has good impact strength, tensile strength and wear resistance, the antioxidant can prevent oxygenolysis of the HDPE resin in the processing process and long-term use, the service life of the basalt fiber composite material aggregate is prolonged, and the service life of the basalt fiber composite material aggregate is prolonged. Maleic anhydride groups of the compatilizer are combined with high-density polyethylene molecules, so that the tail end of the high-density polyethylene has rereactivity and strong polarity of maleic anhydride polar molecules, the interface affinity between the high-density polyethylene and the basalt fibers is improved, and the basalt fibers and a resin matrix can have relatively high bonding strength; the color master batch mainly endows the composite material with a color effect, so that granules formed by cutting can be used for manufacturing the pipeline, and the pipeline has the advantages of low cost, environmental protection, light weight, good rigidity, high strength, outstanding water resistance and corrosion resistance, excellent thermal insulation performance, acid and alkali resistance and the like, and the service life of the pipeline is longer.

Description

Technical Field

[0001] This application relates to the field of material preparation, and more specifically, to a basalt fiber composite material pellet, a preparation method thereof, and a pipeline. Background Art

[0002] As an important part of infrastructure construction, pipelines support the development of many key fields, including but not limited to major water conservancy projects, urban water supply and drainage, energy transportation (such as oil and gas), industrial production, and agricultural irrigation.

[0003] However, existing pipelines are relatively heavy in weight, consume a large amount of raw materials in production, and have high production costs. During the later use process, their corrosion resistance, tensile resistance, and compressive resistance are all poor, resulting in a short service life of the pipelines. Summary of the Invention

[0004] This application provides a basalt fiber composite material pellet, a preparation method thereof, and a pipeline, which can enable the pipeline to have many advantages such as low cost, environmental friendliness, light weight, good rigidity, high strength, outstanding water and corrosion resistance, excellent heat preservation performance, and acid and alkali resistance, and the pipeline has a longer service life.

[0005] The embodiments of this application are implemented as follows:

[0006] In a first aspect, the present invention provides a method for preparing a basalt fiber composite material pellet, including:

[0007] Preparing an immersion liquid: mixing HDPE resin and additives evenly, where the additives include an antioxidant, a compatibilizer, and a masterbatch; the compatibilizer includes HDPE grafted maleic anhydride;

[0008] Composite treatment: impregnating basalt fibers in the immersion liquid for composite and extrusion;

[0009] Sizing and cutting: cooling and sizing the extruded basalt fiber composite material and then cutting it into pellets.

[0010] In an alternative embodiment, the antioxidant includes a phenolic antioxidant and a phosphite antioxidant.

[0011] In an alternative embodiment, there are 50 - 70 parts of HDPE resin, 20 - 40 parts of basalt fibers, 0.05 - 0.2 parts of phenolic antioxidant, 0.1 - 0.4 parts of phosphite antioxidant, 4 - 8 parts of compatibilizer, and 1 part of masterbatch.

[0012] In an alternative embodiment, the phenolic antioxidant includes antioxidant 1010 (AT - 10), and the phosphite antioxidant includes antioxidant 168.

[0013] In an alternative embodiment, an immersion liquid is formed by uniformly mixing HDPE resin and additives through a mixer, and the immersion liquid and basalt fibers are fed into a twin-screw extruder together for extrusion.

[0014] In an alternative embodiment, the extruded basalt fiber composite material is cooled and shaped through a cooling water tank and a shaping roller respectively.

[0015] In an alternative embodiment, the shaped basalt fiber composite material is dried by a hair dryer and then cut into pellets of a set length by a pelletizer.

[0016] In an alternative embodiment, the pellets obtained by cutting with the pelletizer are screened through a vibrating screen;

[0017] The pellets that meet the size requirements after screening are fed into a drying mixer for drying.

[0018] In a second aspect, the present invention provides a basalt fiber composite material pellet, which is made by the method for preparing basalt fiber composite material pellets according to any one of the foregoing embodiments.

[0019] In a third aspect, the present invention provides a pipeline, which is made of the basalt fiber composite material pellets according to the foregoing embodiments.

[0020] The beneficial effects of the present invention include:

[0021] The basalt fibers, HDPE resin and additives are compounded and extruded, and a composite material can be formed after cooling and shaping. Among them, the HDPE resin has good impact strength, tensile strength and wear resistance. The antioxidant can prevent the oxidative decomposition of HDPE resin during processing and long-term use. The maleic anhydride group of the compatibilizer combines with the high-density polyethylene molecules, making the end of the high-density polyethylene have the re-reactivity and strong polarity of maleic anhydride polar molecules, improving the interfacial affinity between the high-density polyethylene and the basalt fibers, so that there can be a high bonding strength between the basalt fibers and the resin matrix. The masterbatch mainly imparts color to the composite material. In this way, the finally cut pellets can be used to make pipelines, so that the pipelines have many advantages such as low cost, environmental protection, light weight, good rigidity, high strength, outstanding water and corrosion resistance, excellent heat preservation performance, and acid and alkali resistance, and the service life of the pipelines is longer. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for use in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present application, and therefore should not be regarded as limiting the scope. For those of ordinary skill in the art, other related drawings can be obtained based on these drawings without creative efforts.

[0023] Figure 1 is the scanning electron microscope image of the BF / HDPE composite material in the comparative example;

[0024] Figure 2 is the scanning electron microscope image of the basalt fiber composite material in the embodiment of the present application. Detailed implementation manners

[0025] As used herein, the terms:

[0026] "prepared from" is synonymous with "comprising". As used herein, the terms "comprising", "including", "having", "containing" or any other variation thereof are intended to cover non-exclusive inclusion. For example, a composition, step, method, article or apparatus comprising the listed elements is not necessarily limited to those elements, but may include other elements not expressly listed or elements inherent to such composition, step, method, article or apparatus.

[0027] When an equivalent, concentration, or other value or parameter is expressed as a range, a preferred range, or a range defined by a series of upper preferred values and lower preferred values, this should be understood to specifically disclose all ranges formed by any pairing of any range upper limit or preferred value with any range lower limit or preferred value, whether or not the ranges are separately disclosed. For example, when the range "1 to 5" is disclosed, the described range should be interpreted to include the ranges "1 to 4", "1 to 3", "1 to 2", "1 to 2 and 4 to 5", "1 to 3 and 5", etc. When a numerical range is described herein, unless otherwise stated, the range is intended to include its end values and all integers and fractions within the range.

[0028] The existing pipelines are relatively heavy in their own weight, consume more raw materials in production, and have high production costs. In the later use process, their corrosion resistance, tensile resistance, and compressive resistance are all poor, resulting in a short service life of the pipelines.

[0029] Basalt Fiber (BF) is a continuous fiber made by melting basalt ore at a high temperature of 1450°C - 1500°C and using the high-tech wire drawing technology of platinum-rhodium alloy. It is an innovative material extracted from natural volcanic rocks. Basalt ore is a natural material, and its main components are oxides such as silicon dioxide, aluminum oxide, calcium oxide, magnesium oxide, iron oxide, and titanium dioxide. During its production process, no boron or other alkali metal oxides are discharged, so no harmful substances are released from its smoke and dust, and it will not cause pollution to the atmosphere. Basalt fiber as a whole has the characteristics of high strength, high modulus, high temperature resistance, good low-temperature performance, acid and alkali resistance, oxidation resistance, radiation resistance, etc. Products formed by basalt fiber have excellent mechanical properties, corrosion resistance, long service life, and reduce the later maintenance and replacement costs. It is a new type of green and active environmental protection material with high performance and ideal cleanliness.

[0030] Therefore, thermoplastic basalt fiber composites can be applied to water supply pipes, drainage pipes or other pipes; compared with steel pipes, they have many advantages such as low cost, green environmental protection, light weight (1 / 4 of steel), good rigidity, high strength, outstanding water and corrosion resistance (smooth surface, not rusting, not easy to scale and wax), and excellent heat preservation performance; compared with glass fiber pipes, they have the outstanding advantages of long service life and acid and alkali resistance, and the designed service life exceeds 50 years.

[0031] Specifically, in this application, a basalt fiber composite granule, its preparation method and a pipe are provided. The preparation method of the basalt fiber composite granule mainly includes the following steps 1) - 2):

[0032] 1) Prepare the dipping solution: Mix the HDPE resin and additives evenly, where the additives include antioxidants, compatibilizers, and masterbatch; the compatibilizer includes HDPE grafted maleic anhydride;

[0033] 2) Composite treatment: Immerse the basalt fiber in the dipping solution for composite and extrusion;

[0034] 3) Shape setting and cutting: Cool and shape the extruded basalt fiber composite material and then cut it into granules.

[0035] In this way, basalt fiber, high-density polyethylene (HDPE) resin and additives are compounded and extruded, and a composite material can be formed after cooling and shaping. Among them, HDPE resin has good impact strength, tensile strength and wear resistance. The antioxidant can prevent the oxidative decomposition of HDPE resin during processing and long-term use. The compatibilizer can increase the interfacial affinity between basalt fiber and HDPE resin, improve the adhesion between the two, and then enhance the overall performance of the composite material. The masterbatch mainly imparts color to the composite material. In this way, the finally formed pellets after cutting can be used to make pipes, making the pipes have many advantages such as low cost, environmental friendliness, light weight, good rigidity, high strength, outstanding water and corrosion resistance, excellent heat preservation performance, and acid and alkali resistance, and the service life of the pipes is longer.

[0036] Specifically, in step 1), the antioxidant includes phenolic antioxidants and phosphite antioxidants. Phenolic antioxidants usually contain one or more phenolic hydroxyl groups (-OH). The main function of phenolic antioxidants is to capture free radicals, interrupt the growth of the automatic oxidation reaction chain, and prevent further oxidative degradation. Phosphite antioxidants usually contain one or more phosphite groups (-O-P(=O)(OR)2). Phosphite antioxidants can effectively decompose peroxides such as hydrogen peroxide, reduce the generation of new free radicals, and have a certain metal passivation effect. When the two are used in combination, phenolic antioxidants are responsible for capturing free radicals, while phosphite antioxidants help decompose peroxides and inhibit the generation of new free radicals. The two complement each other to form a complete antioxidant system. That is, the combined use of phenolic antioxidants and phosphite antioxidants can produce a significant synergistic effect, thereby providing more comprehensive and effective antioxidant protection, significantly improving the long-term thermal stability and light stability of the material, extending its service life, and under high-temperature processing conditions (such as extrusion, injection molding), the combined use of phenolic and phosphite antioxidants helps prevent the thermal degradation of polymers during processing, can better protect the material from oxidative damage, and maintain the consistency of material properties.

[0037] For example, the phenolic antioxidant includes antioxidant 1010 (AT-10), with the chemical name of pentaerythritol tetra[β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], which is used as the main antioxidant; the phosphite antioxidant includes antioxidant 168, with the chemical name of tris(2,4-di-tert-butylphenyl) phosphite, which is used as the auxiliary antioxidant.

[0038] In addition, in some embodiments, the phenolic antioxidant can also be antioxidant 1076, with the chemical name of octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate. The phosphite antioxidant can also be antioxidant 626, with the chemical name of bis(2,4-di-tert-butylphenyl)pentaerythritol diphosphite.

[0039] The compatibilizer includes but is not limited to Maleic Anhydride Grafted HDPE (MAH-g-HDPE), with the product name of W1H compatibilizer, which is a functional polymer prepared by chemical modification. This material introduces maleic anhydride groups onto the main chain of high-density polyethylene (HDPE) through chemical reactions, endowing the high-density polyethylene with the re-reactivity and strong polarity of maleic anhydride polar molecules at the end; thus endowing it with new properties, enabling it to be better compatible or bonded with other polar materials. Therefore, using HDPE grafted maleic anhydride as an interfacial modifier can enhance the interfacial affinity and bonding force between basalt fibers and HDPE resin, and improve the strength and toughness of the composite material.

[0040] The color masterbatch includes but is not limited to Polyethylene Color Masterbatch (PE CM), also known as polyethylene color masterbatch, which is a high-concentration pigment pre-dispersion, usually composed of pigments, carrier resins (usually the same polymer type as the final product, such as PE), dispersants, and other additives. The color masterbatch is mainly used to color plastic products and ensure color consistency and stability, thereby ensuring the color consistency and stability of pipeline products and reducing color difference problems between batches.

[0041] Specifically, during compound extrusion, 50 - 70 parts of HDPE resin, 20 - 40 parts of basalt fibers, 0.05 - 0.2 parts of phenolic antioxidant, 0.1 - 0.4 parts of phosphite antioxidant, 4 - 8 parts of compatibilizer, and 1 part of color masterbatch are used. If the amount of basalt fibers is less than 20 parts, the reinforcing effect may not be achieved; if it is more than 40 parts, the fluidity will be significantly reduced, thereby affecting the performance. The remaining auxiliaries are formulated according to the fiber content.

[0042] Among them, the HDPE resin and auxiliaries are mixed evenly in a mixer to form an immersion liquid, and then the immersion liquid and basalt fibers are fed into a twin-screw extruder for extrusion, so that the basalt fiber filaments can be impregnated and coated with the molten HDPE resin.

[0043] The extruded basalt fiber composite material is successively cooled and shaped through a cooling water tank and a shaping roller respectively, then dried with a hair dryer to remove moisture, and then cut into pellets of a set length by a pelletizer. After the pellets cut by the pelletizer are screened by a vibrating screen, the pellets or debris with too long length are screened out, and the pellets that meet the size requirements after screening are fed into a drying mixer for drying. Thus, basalt fiber composite material pellets are obtained.

[0044] In addition, the present application also discloses a basalt fiber composite material pellet, which is made by the preparation method of the basalt fiber composite material pellet.

[0045] The present application also discloses a pipeline made of the above basalt fiber composite pellets.

[0046] The following will describe the implementation schemes of the present application in detail with reference to the embodiments. However, those skilled in the art will understand that the following embodiments are only used to illustrate the present application and should not be regarded as limiting the scope of the present application. For those not specified in the embodiments, they are carried out according to the conventional conditions or the conditions recommended by the manufacturer. For the reagents or instruments not specified by the manufacturer, they are all conventional products that can be obtained through commercial purchase.

[0047] In these embodiments, unless otherwise specified, the parts and dosage ratios are all by mass.

[0048] The following further describes in detail the preparation method of the basalt fiber composite pellets of the present application with reference to the embodiments.

[0049] Example 1

[0050] Weigh 62.7 parts of high-density polyethylene (HDPE) resin pellets, 0.1 part of AT-10 antioxidant, 0.2 part of 168 antioxidant, 6 parts of W1H compatibilizer, and 1 part of PE color masterbatch. Stir and mix the weighed raw materials evenly in a mixer, pour them into an extruder for melting, and set the extrusion temperature at 220°C. Weigh 30 parts of basalt fiber yarn (linear density of 1200 tex), enter it through the exhaust port of the extruder into the impregnation die, be coated and impregnated with the molten HDPE resin, then pass through the cooling water tank and the sizing roller for cooling and sizing in sequence. After that, use a hair dryer to dry the moisture of the basalt fiber strip, and then reach the pelletizer device to be cut into BF / HDPE composite pellets. The vibrating screen screens out the pellets or debris with too long length, and the qualified pellets are left to enter the drying stirrer for further drying, so as to obtain the basalt fiber composite pellets that meet the requirements. Bake the BF / HDPE composite pellets in a vacuum drying oven at 80°C for 4 hours, use the injection molding process to inject them into tensile, bending, and impact specimens at 220°C, measure their tensile strength and bending strength on an electronic universal testing machine, and measure their impact resistance on an electronic universal impact testing machine.

[0051] Example 2

[0052] Add a certain amount of HDPE resin to the BF / HDPE composite pellets in Example 1 to make the basalt fiber content 5%, use the injection molding process to inject them into tensile, bending, and impact specimens at 220°C, measure their tensile properties and bending properties on an electronic universal testing machine, and measure their impact resistance on an electronic universal impact testing machine.

[0053] Example 3

[0054] The BF / HDPE composite pellets in Example 1 were added with a certain amount of HDPE resin to make the basalt fiber content 7%. The tensile, flexural, and impact specimens were injection-molded at 220 °C using an injection molding process. The tensile and flexural properties were measured on an electronic universal testing machine, and the impact resistance was measured on an electronic universal impact testing machine.

[0055] Example 4

[0056] Weigh 62.7 parts of high-density polyethylene (HDPE) resin pellets, 0.1 part of AT-10 antioxidant, 0.2 part of 168 antioxidant, 6 parts of W1H compatibilizer, and 1 part of PE masterbatch. The weighed raw materials were stirred and mixed evenly in a mixer and then poured into an extruder for melting. The extrusion temperature was set at 220 °C. 30 parts of basalt fiber yarn (linear density of 2400 tex) were weighed and fed into the impregnation die through the exhaust port of the extruder. After being coated and impregnated with the molten HDPE resin, it passed through a cooling water tank and a sizing roller for cooling and sizing in sequence. Then, a hair dryer was used to dry the moisture of the basalt fiber strip. After that, it reached the pelletizer device and was cut into BF / HDPE composite pellets. The vibrating screen screened out the pellets or debris with too long length, and the qualified pellets were left and further dried in a drying mixer to obtain the basalt fiber composite pellets that meet the requirements.

[0057] Example 5

[0058] The BF / HDPE composite pellets in Example 4 were added with a certain amount of HDPE resin to make the basalt fiber content 5%. The tensile, flexural, and impact specimens were injection-molded at 220 °C using an injection molding process. The tensile and flexural properties were measured on an electronic universal testing machine, and the impact resistance was measured on an electronic universal impact testing machine.

[0059] Example 6

[0060] The BF / HDPE composite pellets in Example 4 were added with a certain amount of HDPE resin to make the basalt fiber content 7%. The tensile, flexural, and impact specimens were injection-molded at 220 °C using an injection molding process. The tensile and flexural properties were measured on an electronic universal testing machine, and the impact resistance was measured on an electronic universal impact testing machine.

[0061] Comparative Example 1

[0062] The basalt fiber and HDPE resin were compounded with the basalt fiber content of 30%. They were baked in a vacuum drying oven at 80 °C for 4 hours. The tensile, flexural, and impact specimens were injection-molded at 220 °C using an injection molding process. The tensile and flexural properties were measured on an electronic universal testing machine, and the impact resistance was measured on an electronic universal impact testing machine.

[0063] Comparative Example 2: A certain amount of HDPE resin was added to the BF / HDPE composite pellets in Comparative Example 1 so that the basalt fiber content was 5%. The tensile, bending, and impact specimens were injection-molded at 220°C using an injection molding process. The tensile and bending properties were measured on an electronic universal testing machine, and the impact resistance was measured on an electronic universal impact testing machine.

[0064] Comparative Example 3: A certain amount of HDPE resin was added to the BF / HDPE composite pellets in Comparative Example 1 so that the basalt fiber content was 7%. The tensile, bending, and impact specimens were injection-molded at 220°C using an injection molding process. The tensile and bending properties were measured on an electronic universal testing machine, and the impact resistance was measured on an electronic universal impact testing machine.

[0065] The test results of each example and comparative example are shown in Table 1 below:

[0066] Table 3 Comparison of Performance Parameters of Basalt Fiber Composite Pellets

[0067]

[0068] According to the performance test results in Table 1 above and Figure 1 and Figure 2 it can be seen that for the composite pellets with the same basalt fiber content in the examples and comparative examples, the comprehensive mechanical properties of the pellets in the examples are better than those of the pellets in the comparative examples. Among them, the tensile strength, bending strength, and bending modulus are the most obvious. This is because the maleic anhydride groups on the compatibilizer W1H combine with the high-density polyethylene molecules, making the end of the high-density polyethylene have the re-reactivity and strong polarity of maleic anhydride polar molecules, improving the interfacial affinity between the high-density polyethylene and the basalt fiber, enabling a relatively high bonding strength between the basalt fiber and the resin matrix. As a result, when the BF / HDPE composite is subjected to tensile and bending, the BF / HDPE composite shows relatively large tensile strength, bending strength, and bending modulus. The basalt fiber can not only transfer stress through the interface but also restrict the movement of the HDPE resin molecular chains to a certain extent, and can also improve the tensile and bending strength.

[0069] The beneficial effects of the present invention are as follows: The basalt fiber-reinforced high-density polyethylene composite material has excellent comprehensive mechanical properties, good chemical corrosion resistance, and a long service life, etc., expanding the applications of basalt fiber / HDPE composite materials in water supply pipes, drainage pipes, oil pipelines, petrochemical process pipes, etc. The basalt fiber composite material steel-plastic reinforced winding drainage and sewage pipe made of basalt fiber composite material pellets has the characteristics of light weight, excellent mechanical properties, good impact resistance, and convenient installation and laying. Table 2 shows the performance comparison between basalt fiber composite material pipes and other pipes.

[0070] Table 2 Performance Comparison of Various Pipes

[0071]

[0072]

[0073] The above are only specific embodiments of the present application and are not used to limit the present application. For those skilled in the art, various changes and modifications can be made to the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included within the protection scope of the present application.

Claims

1. A method for preparing basalt fiber composite pellets, characterized in that, Comprising: Preparing the impregnating solution: Mix HDPE resin and additives evenly, where the additives include antioxidants, compatibilizers, and masterbatches; the compatibilizer includes HDPE grafted maleic anhydride; Composite treatment: Immerse basalt fibers in the impregnating solution for composite and extrusion; Sizing and cutting: Cool and shape the extruded basalt fiber composite material and then cut it into pellets.

2. The method for preparing basalt fiber composite material pellets according to claim 1, characterized in that, The antioxidant includes phenolic antioxidants and phosphite antioxidants.

3. The method for preparing basalt fiber composite material pellets according to claim 2, wherein, 50 - 70 parts of HDPE resin, 20 - 40 parts of basalt fibers, 0.05 - 0.2 parts of phenolic antioxidant, 0.1 - 0.4 parts of phosphite antioxidant, 4 - 8 parts of compatibilizer, and 1 part of masterbatch.

4. The preparation method of the basalt fiber composite material pellets according to claim 2, characterized in that, The phenolic antioxidant includes antioxidant 1010 (AT - 10), and the phosphite antioxidant includes antioxidant 168.

5. The method for preparing basalt fiber composite material pellets according to claim 1, characterized in that, Mix HDPE resin and additives evenly through a mixer to form the impregnating solution, and feed the impregnating solution and basalt fibers into a twin - screw extruder for extrusion together.

6. The preparation method of the basalt fiber composite material granule according to claim 1, wherein, The extruded basalt fiber composite material is cooled and shaped through a cooling water tank and a sizing roller respectively.

7. The method for preparing basalt fiber composite material pellets according to claim 6, characterized in that, The shaped basalt fiber composite material is dried by a hair dryer and then cut into pellets of a set length by a pelletizer.

8. The method for preparing the basalt fiber composite material pellets according to claim 7, wherein The pellets cut by the pelletizer are screened through a vibrating screen; The pellets that meet the size requirements after screening are fed into a drying mixer for drying.

9. A basalt fiber composite granule, characterized in that, Made by the method for preparing basalt fiber composite material pellets according to any one of claims 1 - 8.

10. A pipeline, characterized in that, Made from the basalt fiber composite material pellets according to claim 9.

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