Basalt fiber mortar three-dimensional woven blanket and preparation method thereof

Abstract

The invention discloses a basalt fiber mortar three-dimensional woven blanket and a preparation method thereof. The woven blanket sequentially comprises a waterproof thin film layer, a basalt fiber woven mesh, a magnesium phosphate mortar filler, a fiber skeleton, a flexible base layer and a second waterproof thin film layer from top to bottom. The magnesium phosphate mortar filler is prepared from the following components in parts by weight: 35 to 45 parts of magnesium oxide, 35 to 45 parts of monopotassium phosphate, 35 to 45 parts of ammonium dihydrogen phosphate, 90 to 100 parts of sea sand, 15 to 20 parts of seawater, 0.1 to 0.15 part of graphene and 3 to 5 parts of borax. The ultra-high-strength anti-compression concrete has ultra-high-strength anti-compression performance and can be hardened in an extremely short time. The thermal expansion coefficient of the magnesium phosphate filling mortar is lower, so that the magnesium phosphate filling mortar is not easy to crack or deform in the hardening process, and the later maintenance cost of a project is reduced.

Description

Technical Field

[0001] The present invention relates to a three-dimensional braided blanket of basalt fiber mortar and a preparation method thereof, belonging to the technical field of airport runway material repair. Background Art

[0002] In the emergency repair and construction of tropical island airport runways, more stringent requirements are faced. It is necessary to restore the use function of the runway within an extremely short time to ensure the continuity and efficiency of takeoff and landing. However, most traditional building materials for marine engineering use silicate concrete, which has a slow setting speed, poor resistance to marine erosion, and its strength is greatly affected by external conditions such as temperature and humidity. Factors such as high temperature, high humidity, strong ultraviolet rays, and salt spray erosion in the wartime environment make it difficult for traditional repair methods to meet the requirements of rapid and high efficiency. Traditional runway repair technologies have a long curing time and insufficient compressive strength. Especially in emergency conditions, frequent maintenance is required, which affects efficiency.

[0003] In the special environment of tropical island airports, the fast-hardening and early-strength characteristics of magnesium phosphate-based composites enable them to rapidly form a stable structure within 2 hours and reach a strength of 85 MPa, meeting the timeliness requirements of airport emergency repair and construction; their hydration products have high stability in a high-salt environment, and the dense structure formed can prevent the intrusion of moisture and ions, thereby improving the durability of airport runways, extending their service life, reducing the probability of cracks and damage in airport runways, and enhancing the stability of the entire runway airport structure; magnesium phosphate-based composites have high temperature resistance and can maintain a stable hydration reaction within the environmental temperature range of 30°C to 50°C, providing guarantee for construction under extreme climate conditions.

[0004] In addition, considering the surrounding environment of tropical islands and the wartime emergency environment, the acquisition and transportation costs of fresh water and river sand are extremely high. Seawater and sea sand, as local ready-made resources, can greatly reduce the overall construction cost and project cycle. In terms of adaptability to the marine environment, the cement blanket can still be shaped 2 hours after watering, which cannot meet the technical requirements of rapid repair. It only reaches 80% of the strength after hardening in 1 day, with a compressive strength of 50 MPa, and the pH value after hardening > 12, with a strong alkaline environment, which will promote the chemical reaction activity with salts. Ca(OH)2 in the cement blanket reacts with SO4 in seawater 2- to form ettringite, resulting in structural cracking and making it difficult to meet the durability requirements.

[0005] In the current situation of extreme climate in tropical islands and the low efficiency of traditional repair materials, the prior art has not developed high-performance materials that meet the rapid repair requirements of airport runways. Therefore, we propose a three-dimensional braided blanket of basalt fiber mortar and a preparation method to solve the problem. Summary of the Invention

[0006] Objective of the Invention: To overcome the deficiencies in the prior art, the present invention provides a three-dimensional woven blanket of basalt fiber mortar and a preparation method thereof, which can be compatible with seawater and sea sand, and utilize seawater to activate the curing process of the mortar, so that it shows higher stability and corrosion resistance in high-salt and high-humidity environments.

[0007] Technical Solution: To solve the above technical problems, a three-dimensional woven blanket of basalt fiber mortar of the present invention has, from top to bottom, a first waterproof film layer, a basalt fiber woven mesh, a fiber skeleton, a flexible base layer, and a second waterproof film layer. The fiber skeleton is provided with a number of grooves, and the grooves are filled with magnesium phosphate mortar filler. The materials of each layer of the woven blanket are connected by gluing.

[0008] Preferably, the magnesium phosphate mortar filler includes the following components by weight: 45 - 55 parts of magnesium oxide, 45 - 55 parts of potassium dihydrogen phosphate, 20 - 30 parts of ammonium dihydrogen phosphate, 160 - 175 parts of sea sand, 25 - 30 parts of seawater, 0.1 - 0.2 parts of graphene, and 3 - 5 parts of borax.

[0009] Preferably, the material of the waterproof film is polyvinyl chloride.

[0010] Preferably, the basalt fiber woven mesh is provided with cutting lines coinciding with the fiber grids.

[0011] Preferably, the material of the fiber skeleton is polyvinyl alcohol.

[0012] Preferably, the material of the flexible base layer is polyurethane foam.

[0013] A preparation method of a three-dimensional woven blanket of basalt fiber mortar, the preparation process includes the following steps:

[0014] S1: Lay the second waterproof film layer at the bottommost and brush glue on the surface, and lay the flexible base layer on the surface of the second waterproof film layer;

[0015] S2: Brush glue on the surface of the flexible base layer and lay the fiber skeleton on its surface;

[0016] S3: Stir the filler raw materials of magnesium oxide, ammonium dihydrogen phosphate, potassium dihydrogen phosphate, sea sand, seawater, graphene, and borax, with a stirring speed of 80 - 120 r / min and a stirring time of 2 - 4 min. After stirring evenly, fill the mixed dry materials into the grooves;

[0017] S4: Brush glue on the surface of the basalt fiber woven mesh and lay it on top of the fiber skeleton;

[0018] S5: Brush glue on the first waterproof film layer and lay it on top of the entire woven blanket.

[0019] By adopting the above technical solutions, these magnesium phosphate compounds have a very fast crystallization rate and can rapidly form a stable and dense solid network. Due to the rapid reaction, the magnesium phosphate compounds rapidly crystallize in the mortar and fill the pores of the material, resulting in the mortar obtaining a relatively high strength in a short period of time. In addition, the formation of these compounds is accompanied by an exothermic reaction, and the released heat further accelerates the hydration and curing processes, enabling the mortar to rapidly cure within a few hours and exhibiting excellent early strength.

[0020] Overall, the early strength performance of magnesium phosphate mortar not only depends on the rapid reaction between magnesium oxide and phosphate, but is also affected by the rapid crystallization of the generated magnesium phosphate compounds and their dense structure. These factors work together to enable the mortar to rapidly reach a relatively high strength in the early stage.

[0021] The present invention is further configured such that: the magnesium oxide in the mortar filler is dead-burned magnesia.

[0022] By adopting the above technical solutions, dead-burned magnesia is added. After calcination, the release of magnesium ions from magnesia is slower, avoiding shrinkage and cracks caused by rapid reactions, making the generated magnesium phosphate hydrate more stable and having higher strength. Its dense crystal structure also ensures uniform progress of the hydration reaction, reducing the risk of stress concentration and crack formation. In addition, the high-temperature calcination of dead-burned magnesia endows it with excellent fire resistance and corrosion resistance, further enhancing the durability of the mortar in harsh environments. In contrast, ordinary magnesia has too fast a reaction rate, which easily leads to uneven hardening and performance degradation.

[0023] The present invention is further configured such that: the retarder is preferably borax.

[0024] By adopting the above technical solutions, the addition of borax temporarily passivates the active part of magnesia. It forms a complex boromagnesium complex with magnesium ions, making the hydration of magnesia and the formation of magnesium phosphate more uniform, effectively preventing local stress concentration and excessive heat release during the early hardening process. This reaction makes the early-generated magnesium phosphate hydrate more dense and stable, contributing to the stable growth of the early strength of the mortar. By smoothing the reaction rate, borax optimizes the formation process of the hydrate, reduces the risk of stress concentration and cracks, and enables the magnesium phosphate mortar to exhibit more stable and durable early strength performance.

[0025] The present invention is further configured such that: the mortar filler is a self-healing material.

[0026] By adopting the above technical solutions, the rapid hardening and self-healing characteristics of magnesium phosphate mortar can significantly shorten the runway closure time. This performance is further enhanced when exposed to moisture or humidity, and the unreacted components can undergo a secondary reaction to form a new bonding layer, effectively improving the adhesion between the material and the substrate. Its self-healing ability generates phosphate products through chemical reactions to fill microcracks and extend the service life of the runway. In addition, this self-healing bonding ability also enables the magnesium phosphate mortar to form a firm bond with the surface of the old runway during the repair process, preventing peeling or interfacial failure between the new and old materials.

[0027] The present invention is further configured such that: graphene nanomaterials are added to the mortar filler.

[0028] By adopting the above technical solutions, after the high strength and unique two-dimensional sheet structure of graphene are dispersed in the mortar, a uniform reinforcement network is formed, which enables the external load to be evenly dispersed, effectively avoiding stress concentration, and thus improving the compressive and flexural strengths of the material. In addition, through the conductive path of the graphene network, the change in the internal resistance of the repair material can be monitored. Microcracks or structural damages inside the material will cause changes in the conductive path and the resistance will change accordingly. This characteristic enables the military airport runway to achieve real-time health monitoring, timely detect potential problems, and ensure the long-term safety and service efficiency of the runway.

[0029] The present invention is further configured such that: the fiber skeleton is made of polyvinyl alcohol material.

[0030] By adopting the above technical solutions, the outstanding advantage of polyvinyl alcohol (PVA) fibers in the cement blanket lies in their excellent flexibility, which can maintain a certain elasticity after the cement solidifies. This flexibility makes the cement blanket not prone to breakage or damage when bent or under local stress, especially in the case of unevenness or large dynamic stress during the repair of airport runways. The PVA fibers can effectively disperse the stress, thus preventing premature failure of the material. In addition, its flexibility also makes the cement blanket easier to operate during the construction and laying process in case of urgent military situations.

[0031] The present invention is further configured such that: the flexible base layer has a self-leveling function.

[0032] By adopting the above technical solutions, the low density and excellent adhesion of the polyurethane foam material enable it to form a tight bond with the repair substrate during the curing process, preventing peeling. Its expansion characteristic during the curing process can also help the material automatically adapt to the surface shape after application, achieving a self-leveling effect. In addition, the elasticity of its structure enables the material to adapt to the minor deformations of the substrate and effectively disperse the load to reduce stress concentration.

[0033] A technology of mortar woven blanket designed for rapid repair and construction during wartime has been invented. This technology combines high-performance repair mortar and fiber-reinforced materials, which can not only cure in a short time but also provide extremely high compressive strength, up to 90 MPa, and can withstand the huge pressure during the takeoff and landing of fighter jets. This mortar woven blanket can be simply activated by adding water during use and can quickly cure, ensuring that the runway can be restored for use in the shortest time, greatly shortening the time required for runway repair during wartime. Moreover, the mortar woven blanket can be compatible with seawater and sea sand, and even use seawater to activate the curing process of the mortar, making it show higher stability and corrosion resistance in high-salt and high-humidity environments. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a schematic three-dimensional structure diagram of the present invention.

[0035] Figure 2 It is a schematic diagram of self-leveling of the flexible base layer of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0036] The present invention will be further described below with reference to the accompanying drawings.

[0037] A three-dimensional woven blanket of basalt fiber mortar of the present invention, the woven blanket from top to bottom is successively the first waterproof film layer 1, basalt fiber woven mesh 2, fiber skeleton 3, flexible base layer 4, and the second waterproof film layer. The fiber skeleton 3 is provided with a plurality of grooves, and the grooves are filled with magnesium phosphate mortar filler. The materials of each layer of the woven blanket are connected by gluing.

[0038] In the present invention, the magnesium phosphate mortar filler includes the following components by weight: 45-55 parts of magnesium oxide, 45-55 parts of potassium dihydrogen phosphate, 20-30 parts of ammonium dihydrogen phosphate, 160-175 parts of sea sand, 25-30 parts of seawater, 0.1-0.2 parts of graphene, and 3-5 parts of borax.

[0039] A preparation method of a three-dimensional woven blanket of basalt fiber mortar, the preparation process includes the following steps:

[0040] S1: Lay the second waterproof film layer at the bottommost end and brush glue on the surface, and lay the flexible base layer on the surface of the second waterproof film layer;

[0041] S2: Brush glue on the surface of the flexible base layer and lay the fiber skeleton on its surface;

[0042] S3: Stir the filler raw materials of magnesium oxide, ammonium dihydrogen phosphate, potassium dihydrogen phosphate, sea sand, seawater, graphene and borax, the stirring speed is 80-120 r / min, and the stirring time is 2-4 min. After stirring evenly, fill the mixed dry materials into the grooves;

[0043] S4: Brush glue on the surface of the basalt fiber woven mesh and lay it on top of the fiber skeleton;

[0044] S5: Brush glue on the first waterproof film layer and lay it on top of the entire woven blanket.

[0045] Example 1 is a magnesium phosphate repair mortar woven blanket and its preparation method disclosed by the present invention. The magnesium phosphate repair mortar includes the following components by weight:

[0046] Component Parts by weight Component Parts by weight Dead-burned magnesia 45 Sea sand 160 Potassium dihydrogen phosphate 45 Seawater 25 Ammonium dihydrogen phosphate 20 Graphene 0.1 Borax 3

[0047] The preparation method of the magnesium phosphate repair mortar specifically includes the following steps:

[0048] S1: Lay the waterproof film at the bottommost layer and brush glue on its surface, then lay the flexible base layer on the surface of the waterproof film.

[0049] S2: Brush glue on the surface of the flexible base layer and lay the fiber grid on its surface.

[0050] S3: Stir the filler raw materials: magnesium oxide, ammonium dihydrogen phosphate, potassium dihydrogen phosphate, sea sand, seawater, and graphene at a stirring speed of 80 - 120 r / min for 2 - 4 min. After stirring evenly, fill the mixed dry materials into the grid.

[0051] S4: Brush glue on the surface of the basalt fiber woven mesh and lay it on top of the fiber grid.

[0052] S5: Brush glue on the last waterproof film and lay it on top of the entire woven blanket.

[0053] Example 2 is a magnesium phosphate repair mortar and its preparation method disclosed by the present invention. The magnesium phosphate repair mortar includes the following components by weight

[0054] Component Parts by weight Component Parts by weight Dead-burned magnesia 47 Sea sand 163 Potassium dihydrogen phosphate 47 Seawater 25 Ammonium dihydrogen phosphate 22 Graphene 0.1 Borax 3

[0055] Example 3 is a magnesium phosphate repair mortar and its preparation method disclosed by the present invention. The magnesium phosphate repair mortar includes the following components by weight:

[0056] Component Parts by weight Component Parts by weight Dead-burned magnesia 40 Sea sand 172 Potassium dihydrogen phosphate 50 Seawater 28 Ammonium dihydrogen phosphate 25 Graphene 0.15 Borax 3

[0057] Example 4 is a magnesium phosphate repair mortar and its preparation method disclosed by the present invention. The magnesium phosphate repair mortar includes the following components by weight:

[0058] Component Parts by weight Component Parts by weight Dead-burned magnesia 42 Sea sand 172 Potassium dihydrogen phosphate 53 Seawater 28 Ammonium dihydrogen phosphate 27 Graphene 0.15 Borax 4

[0059] Example 5 is a magnesium phosphate repair mortar and its preparation method disclosed by the present invention. The magnesium phosphate repair mortar includes the following components by weight:

[0060] Component Parts by weight Component Parts by weight Dead-burned magnesia 45 Sea sand 175 Potassium dihydrogen phosphate 55 Seawater 30 Ammonium dihydrogen phosphate 30 Graphene 0.2 Borax 4

[0061] Comparative Example 1 is a magnesium phosphate repair mortar and its preparation method disclosed in the present invention. The magnesium phosphate repair mortar includes the following components by weight:

[0062] Component Parts by weight Component Parts by weight Magnesium oxide 42 Standard sand 172 Potassium dihydrogen phosphate 53 Fresh water 28 Ammonium dihydrogen phosphate 27 Borax 4

[0063] The difference from Example 1 is that in step S3, seawater is replaced with fresh water and sea sand is replaced with standard sand.

[0064] Comparative Example 2 is a magnesium phosphate repair mortar and its preparation method disclosed in the present invention. The magnesium phosphate repair mortar includes the following components by weight:

[0065] Component Parts by weight Component Parts by weight Magnesium oxide 42 Standard sand 172 Potassium dihydrogen phosphate 53 Fresh water 28 Ammonium dihydrogen phosphate 27 Borax 4

[0066] The difference from Example 1 is that in step S3, dead-burned magnesia is replaced with magnesia and graphene is not added.

[0067] Performance detection test

[0068] Samples of the magnesium phosphate repair mortar prepared from Examples 1-6 and Comparative Examples 1-2 were taken, and the following performance tests were carried out on the samples.

[0069] Compressive strength test: According to JTGE30-2005, the 2-hour compressive strength and 2-day flexural strength of the samples in Examples 1-5 and Comparative Examples 1-2 were tested.

[0070] Table 1 - Compressive strength test data of the samples in Examples 1-6 and Comparative Examples 1-3

[0071] Table 1

[0072]

[0073]

[0074] From the sample test data of Examples 1-5 and Comparative Example 1 in Table 1, it can be seen that compared with standard sand and fresh water, seawater and sea sand have a certain promoting effect on the early strength of the repair mortar, but the strength gap between the two is not large.

[0075] From the sample test data of Examples 1-5 and Comparative Example 2 in Table 1, it can be seen that dead-burned magnesia has an obvious promoting effect on the early strength of the repair mortar compared with ordinary magnesia.

[0076] From the sample test data of Examples 1-5 in Table 1, it can be seen that changing the addition amount of each raw material of the mortar within a suitable range has little effect on the compressive strength of the alkali-activated repair mortar.

[0077] It can be seen from the sample test data of Examples 1-5 and Comparative Example 2 in Table 1 that the repair material can solidify within 3 minutes, meeting the timeliness requirements for emergency repair and rapid construction at the airport.

[0078] It can be seen from the sample test data of Examples 1-5 and Comparative Example 2 in Table 1 that the 2-hour compressive strength of the repair material all exceeds 85 MPa, and the 2-hour flexural strength all exceeds 16 MPa, meeting the service function of the runway and ensuring the continuity of fighter takeoff and landing and the combat effectiveness of the airport.

[0079] The above are only the preferred embodiments of the present invention. It should be pointed out that for those of ordinary skill in the art, without departing from the principle of the present invention, several improvements and refinements can be made, and these improvements and refinements should also be regarded as the protection scope of the present invention.

Claims

1. A three-dimensional braided blanket of basalt fiber mortar, characterized in that: The woven blanket from top to bottom is in turn the first waterproof film layer (1), basalt fiber woven mesh (2), fiber skeleton (3), flexible base layer (4), and the second waterproof film layer. The fiber skeleton (3) is provided with a number of grooves, and the grooves are filled with magnesium phosphate mortar filler. Each layer of materials of the woven blanket is connected by gluing.

2. The three-dimensional braided blanket of basalt fiber mortar according to claim 1, characterized in that: The magnesium phosphate mortar filler includes the following components by weight: 45 - 55 parts of magnesium oxide, 45 - 55 parts of potassium dihydrogen phosphate, 20 - 30 parts of ammonium dihydrogen phosphate, 160 - 175 parts of sea sand, 25 - 30 parts of seawater, 0.1 - 0.2 parts of graphene, and 3 - 5 parts of borax.

3. A three-dimensional woven blanket of basalt fiber mortar according to claim 1, characterized in that: The material of the waterproof film is polyvinyl chloride.

4. A three-dimensional woven blanket of basalt fiber mortar according to claim 1, characterized in that: The basalt fiber woven mesh is provided with cutting lines that coincide with the grooves.

5. A three-dimensional braided blanket of basalt fiber mortar according to claim 1, characterized in that: The material of the fiber skeleton is polyvinyl alcohol.

6. A three-dimensional braided blanket of basalt fiber mortar according to claim 1, characterized in that: The material of the flexible base layer is polyurethane foam.

7. A method for preparing a three-dimensional braided blanket of basalt fiber mortar according to any one of claims 1 to 6, characterized in that, The preparation process includes the following steps: S1: Lay the second waterproof film layer at the bottommost and brush glue on its surface, and then lay the flexible base layer on the surface of the second waterproof film layer; S2: Brush glue on the surface of the flexible base layer and lay the fiber skeleton on its surface; S3: Stir the filler raw materials of magnesium oxide, ammonium dihydrogen phosphate, potassium dihydrogen phosphate, sea sand, seawater, graphene, and borax, with a stirring speed of 80 - 120 r / min and a stirring time of 2 - 4 min. After stirring evenly, fill the mixed dry material into the grooves; S4: Brush glue on the surface of the basalt fiber woven mesh and lay it on top of the fiber skeleton; S5: Brush glue on the first waterproof film layer and lay it on top of the entire woven blanket.

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