Separation protective sleeve with prestress guiding function and process thereof

Abstract

The invention relates to the technical field of material packaging and protection, and discloses a precise isolation sheath with a prestress buffering function and a preparation process thereof, the sheath comprises a structural layer made of a high-strength rigid material and a functional layer which coats the structural layer and is made of a high-elasticity buffering material; a prestress buffering structure with a guiding function is integrally formed on the outer surface of the functional layer. By means of the composite structure combining rigidity and softness, when the protective sleeve is installed or internal materials are subjected to external impact and vibration, the external prestress buffering structure can efficiently absorb energy and generate elastic deformation, continuous and self-adaptive clamping force is provided for the internal materials, and therefore accurate positioning and damping protection are achieved, and meanwhile the service life of the protective sleeve is prolonged. Multidirectional sealing formed by the sheath structure can effectively isolate external moisture, pollutants and corrosive media, cement paste and water are prevented from invading, and the problems that in an existing packaging or protection scheme, protection is not sufficient, fixation is not stable, and environmental erosion is likely to happen are solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of concrete construction, in particular to a separated protective sleeve with prestress guide and its process. BACKGROUND

[0002] In modern construction engineering, especially in the construction of complex concrete structures, it is often necessary to temporarily fix some components that need to be removed later, such as pull rods or temporary reinforcing steel in formwork engineering. To achieve this purpose, a sleeve is usually provided outside these components to prevent them from being bonded with concrete.

[0003] The sleeve structure in the prior art is mainly made of a single material, such as a common polyvinyl chloride pipe, a high-density polyethylene pipe or a steel sleeve. The design idea of this kind of sleeve mainly relies on the structural strength of the material itself to resist external geotechnical pressure, and the standardized cylindrical outer wall is used to define the protection space. During installation, the sleeve is usually pushed or pulled directly into the pre-set hole to achieve the protection of the internal space.

[0004] However, in actual engineering applications, due to the complexity of geological conditions and the limitations of construction technology, the underground hole formed often has irregular conditions such as uneven diameter, uneven inner wall or curved axis. The traditional rigid sleeve has a fixed shape and a smooth outer wall, and the smooth polyvinyl chloride pipe or steel pipe outer wall will produce firm chemical and physical bonding with the concrete. After the concrete solidifies, heavy machinery is needed to knock, drill or forcibly twist and pull to remove it, which is not only low in efficiency and labor-intensive, but more seriously, it can easily cause irreversible damage to the main concrete structure, such as micro-cracks, edge collapse and corner drop. At the same time, during the concrete pouring and vibrating process, the high-flowability cement slurry and water can easily invade from the gap between the sleeve and the temporary component or the two ends of the sleeve, polluting or rusting the internal steel bars or components, affecting their subsequent use or recycling. SUMMARY

[0005] In view of the shortcomings of the prior art, the present application provides a separated protective sleeve with prestress guide and its process, which aims to solve the problems of difficult removal of traditional rigid sleeves, damage to concrete structures, and inability to block the invasion of cement slurry.

[0006] To achieve the above purpose, the present application realizes the following technical scheme: A separated protective sleeve with prestress guide, comprising a structure layer and a functional layer, the structure layer is made of a first material, the functional layer is made of a second material; the functional layer is coated outside the structure layer, and the outer surface of the functional layer is provided with a prestress guide structure; the prestress guide structure comprises at least one guide surface, the guide surface is specifically provided as one of a plane and a curved surface.

[0007] Preferably, the first material is selected from one of polyvinyl chloride, ABS engineering plastic, high-density polyethylene, rubber-plastic composite material, metal, soft foam, synthetic material.

[0008] Preferably, the second material is selected from one of polyurethane foam, polyethylene foam, ethylene-vinyl acetate copolymer foam.

[0009] Preferably, the outer surface of the functional layer is further provided with a sealing layer.

[0010] Preferably, the sealing layer is specifically one of a water-swelling rubber layer, a thermoplastic polyurethane elastomer layer.

[0011] Preferably, the prestressed guide structure comprises a plurality of independent polyhedral protrusions, and the guide surface is arranged on the outer surface of the polyhedral protrusions.

[0012] A process for manufacturing a separate protective sleeve with prestressed guide, comprising the following steps: Preparation of a structural layer: a structural layer is prepared by injection molding or machining using a first material; Preparation of a functional layer: the structural layer is used as a substrate, and a functional layer made of a second material is formed on the outside of the structural layer by in-mold foaming process, and a prestressed guide structure is formed on the outer surface of the functional layer.

[0013] Before the in-mold foaming process, the step of coating an adhesive on the outer surface of the structural layer is further included After the functional layer is formed, the step of compounding a sealing layer on the outer surface of the functional layer is further included The parameters of the in-mold foaming process are as follows: The mold temperature is 45-60℃, the foaming pressure is 2-4MPa, and the pressure maintaining time is 3-8 minutes.

[0014] The present application provides a separate protective sleeve with prestressed guide and a process thereof. The following beneficial effects are achieved: 1、The present application integrally forms a functional layer and a prestressed guide structure composed of an elastic material on the outside of a rigid structural layer, which helps to utilize the prestress generated by the elastic structure after installation to tightly seal the gap between the sleeve and the components and the external environment, realizes reliable blocking of the intrusion of cement slurry and moisture, and achieves the core purpose of protecting the internal components such as reinforcing steel from being contaminated and corroded.

[0015] 2、The present application adopts the elastic foam material with low surface adhesion as the functional layer, compared with the rigid sleeve and the concrete firm adhesion, violent removal and the deficiency of damaging the main body, which helps to break the bonding surface by the stress shrinkage characteristics of the elastic layer after the concrete solidification, realizes the easy and complete separation of the sleeve, achieves the key purpose of non-destructive removal and protecting the integrity of the main concrete structure.

[0016] 3、The present application sets the prestressed guide structure with guide surface on the outer surface of the functional layer, compared with the smooth outer wall of the sleeve in the traditional technology, which is difficult to install in the complex reinforcement cage, which helps to guide and reduce resistance during installation, and realizes stable self-positioning by elastic extrusion cooperation with the surrounding components, realizes the convenient and efficient installation process and accurate and reliable positioning, and provides protection for the preset isolation and protection function.

[0017] 4、The present application adopts the efficient in-mold foaming integrated molding process, compared with the complex multi-component assembly process in the prior art, which improves the production efficiency and product integrity, helps to accurately form the functional layer and the prestressed guide structure at one time and firmly combine with the structure layer, realizes the high consistency and stable and reliable product quality, and helps to ensure that the product plays the preset excellent anti-pollution performance. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 It is a three-dimensional structure schematic diagram of the present application; Figure 2 It is a functional layer schematic diagram of the present application; Figure 3 It is a prestressed guide structure schematic diagram of the present application; Figure 4 It is a process flow schematic diagram of the present application; Figure 5 It is a structure schematic diagram of another embodiment (spiral rib) of the prestressed guide structure of the present application; Figure 6 It is a working state and sealing principle schematic diagram of the present application in irregular holes; Figure 7 It is an in-mold foaming process principle schematic diagram of the present application.

[0019] Among them, 1, structure layer; 2, functional layer; 3, sealing layer; 4, prestressed guide structure; 401, polyhedral protrusion; 402, guide surface; 5, spiral rib. DETAILED DESCRIPTION

[0020] With reference to the drawings of the present application, the technical solutions in the embodiments of the present application will be clearly and completely described. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments of the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the scope of the present application.

[0021] Embodiment 1 This embodiment details the structure of a separated protective sleeve with prestressed guiding.

[0022] Please refer to the drawings of the present application Figure 1 - the drawings of the present application Figure 3 The separated protective sleeve with prestressed guiding provided by the embodiments of the present application has a multi-layer composite pipe body, and the sleeve comprises a structure layer 1 and a functional layer 2 from inside to outside.

[0023] The structure layer 1 is the rigid skeleton of the sleeve, and its core function is to provide basic compressive strength and shape stability to resist the impact force of high static pressure and mechanical vibration in the concrete pouring process, so as to ensure that the sleeve channel will not be crushed or deformed.

[0024] In this embodiment, the structure layer 1 is made of polyvinyl chloride (PVC) material through extrusion process, and its cross section is hollow circular, and the wall thickness can be selected between 5mm and 20mm according to the application scene.

[0025] In order to meet the needs of different working conditions, the first material constituting the structure layer can also be other materials, for example, ABS engineering plastic or high-density polyethylene (HDPE) can be selected to be made by injection molding to obtain higher impact toughness and low temperature resistance.

[0026] This structure composed of multiple polyhedral protrusions 401 and guiding surfaces 402 thereon provides the sleeve with multi-dimensional, non-continuous guiding ability and multiple prestressed support points, enhancing the positioning stability The functional layer 2 is completely and tightly coated on the outer surface of the structure layer 1 through in-mold foaming process, and a firm combination is formed between the two, and the core function of the functional layer 2 is to provide elasticity and form a special shape, and its thickness (excluding the protrusion part) is usually 10mm to 50mm.

[0027] In this embodiment, the second material constituting the functional layer 2 is polyurethane (PU) foam, specifically a high-elasticity PU foam with a closed-cell structure, whose density range is 60-120kg / m³, and the Shore A hardness is 30-50. This material has excellent compression resilience (compression permanent set is less than 10%), which is an ideal choice to realize the sealing function and easy disassembly function.

[0028] Similarly, to achieve a similar function, the second material can also be polyethylene (PE) foam or ethylene-vinyl acetate copolymer (EVA) foam, which also have the property of generating elastic recovery force after being compressed.

[0029] The key innovation of this invention is that the outer surface of the functional layer 2 is not a smooth cylindrical surface, but is provided with an array of prestressed guiding structures 4.

[0030] like Figure 3 As shown, in this embodiment, the prestressed guide structure 4 is composed of multiple independent polyhedral protrusions 401 arranged in an alternating matrix along the circumference and axial direction of the sleeve. The height (radial dimension) of each polyhedral protrusion 401 is 5 mm to 30 mm, and each has at least one or more guide surfaces 402. These guide surfaces 402 can be planes or curved surfaces with a certain radius of curvature designed to reduce friction.

[0031] This structure, consisting of multiple polyhedral protrusions 401 and their guide surfaces 402, provides the sleeve with multidimensional, discontinuous guiding capabilities and allows mud and sand to pass through the grooves between the protrusions, reducing installation resistance.

[0032] To further enhance its protective performance, a sealing layer 3 can be further provided on the outer surface of the functional layer 2.

[0033] In this embodiment, the sealing layer 3 is a water-swellable rubber layer with a thickness of approximately 1-3 mm, which is completely covered on the outer surface of the functional layer 2 and all the polyhedral protrusions 401 by a spraying process. As a preferred embodiment, the sealing layer 3 can also be a thermoplastic polyurethane elastomer (TPU) layer to provide stronger wear resistance and chemical corrosion resistance.

[0034] Example 2 This embodiment details the process for preparing the separation protective sleeve of Example 1.

[0035] Please see Figure 4 The process flow diagram shows that the process specifically includes the following steps: Step S1: Prepare structural layer 1 using the aforementioned first material, manufactured by injection molding or machining. For example, when using ABS engineering plastic, it is prepared by injection molding; when using metal materials (such as aluminum alloy or stainless steel pipe), it can be prepared by machining methods such as cutting, welding, or turning.

[0036] Step S2: Surface pretreatment. To ensure a strong bond between the functional layer 2 made of the second material and the structural layer 1, and to prevent delamination during the subsequent high-pressure foaming process, this step is preferably included in this process.

[0037] Before the in-mold foaming process, a layer of two-component reactive polyurethane adhesive is evenly coated on the outer surface of the structural layer 1. The adhesive can chemically bond with the foam material of the structural layer 1 and the functional layer 2 under the high-temperature and high-pressure environment of foaming, forming strong interfacial bonding force.

[0038] Step S3: In-mold foaming molding. The pretreated structural layer 1 is fixed as a substrate (or insert) in the central cavity of the foaming mold through positioning tooling.

[0039] The inner wall of the mold cavity is precisely engraved with a reverse cavity corresponding to the prestressed guiding structure 4 (for example, a plurality of polyhedral protrusions 401). After closing the mold, the prepared second material (such as a mixture of polyurethane A and B) is injected into the mold cavity through a high-pressure injection device.

[0040] During this process, the process parameters are strictly controlled: the mold temperature is controlled between 45-60℃ by circulating the heat conduction oil of the mold temperature machine, the foaming pressure is realized between 2-4MPa by controlling the injection amount and the volume of the mold cavity, and the holding time (from the completion of injection to the opening of the mold) is maintained for 3-8 minutes.

[0041] Reasons for parameter selection: If the mold temperature is lower than 45℃, the foaming reaction is not sufficient, the foam density is uneven, and the elasticity is poor; if it is higher than 60℃, the foam material will be locally scorched or degraded, affecting the performance. The foaming pressure in this range can ensure that the foaming material completely fills every corner of the mold cavity, so that the profile of the prestressed guiding structure 4 is clear and the structure is dense. The holding time ensures that the foam is fully matured and shaped.

[0042] After the reaction is completed, the mold is opened to obtain a semi-finished product in which the functional layer 2 and the structural layer 1 are combined into one and the outer surface has simultaneously formed the prestressed guiding structure 4.

[0043] Step S4: Composite sealing layer 3. After the formation of the functional layer 2, in order to obtain a product with a sealing layer, this process preferably provides this step. An automatic spraying device is used to uniformly spray liquid water-swelling rubber or TPU paint on the outer surface of the semi-finished product to form the sealing layer 3. Then, heat drying treatment (such as drying in an oven at 60-80℃ for 30-60 minutes) is performed to obtain the final product.

[0044] Example 3 See Figure 5This embodiment demonstrates another specific form of the prestressed guiding structure 4. Its main difference from Embodiment 1 is that the prestressed guiding structure 4 consists of one or two continuous spiral ribs 5. These spiral ribs are also integrally molded from the foam material of the functional layer 2, and their cross-section can be trapezoidal or semi-circular. Their surface also forms a guiding surface 402, which offers unique advantages in situations requiring rotational installation or the provision of specific fluid flow channels.

[0045] like Figure 6 As shown, in concrete construction, the isolation sleeve of the present invention is first placed on the reinforcing steel (or other components) that need to be temporarily fixed, and then concrete is poured.

[0046] During pouring, the external prestressed guiding structure 4 is under pressure and fits tightly with the reinforcing bars and surrounding formwork, effectively preventing cement slurry from seeping in. After the concrete has fully cured, due to the elasticity of the functional layer 2, there is almost no adhesion between it and the concrete.

[0047] At this point, the elastic layer will shrink when the sleeve is slightly twisted or pulled out directly with a tool, allowing the sleeve to easily detach from the concrete and be completely removed, leaving a clean, regularly sized channel. The protected reinforcing steel is also free from contamination and easy to handle later.

[0048] The guide surface 402 plays a guiding role and reduces installation resistance during this process. After installation, the elastic potential energy stored in the compressed prestressed guide structure 4 is converted into a continuous, outward elastic restoring force (i.e., prestress), causing it to fit tightly against the hole wall, thereby physically sealing the irregular gaps. If a sealing layer 3 (such as water-swellable rubber) is present, it will further expand in a humid environment, achieving a microscopic chemical-physical dual seal. This perfectly solves the problems of poor sealing and poor adaptability in the prior art.

[0049] In summary, this invention, through a unique composite design of a rigid inner skeleton, an elastic functional outer layer, and a prestressed guiding structure, combined with a highly efficient in-mold foaming integrated molding process, successfully solves the shortcomings of existing technologies in concrete construction applications, such as difficulty in removal, damage to the main body, and poor sealing and anti-fouling effects.

[0050] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A separate protective sleeve with prestressed guidance, characterized in that The application relates to a structure layer (1) and a functional layer (2), the structure layer (1) is made of a first material, the functional layer (2) is made of a second material; the functional layer (2) is coated on the outside of the structure layer (1), and the outer surface of the functional layer (2) is provided with a prestress guide structure (4); the prestress guide structure (4) comprises at least one guide surface (402), and the guide surface (402) is specifically one of a plane and a curved surface.

2. A separation protection jacket pipe with prestressed guidance according to claim 1, characterized in that The first material is selected from one of polyvinyl chloride, ABS engineering plastic, high-density polyethylene, rubber-plastic composite material, metal, soft foam and synthetic material.

3. A separation protection jacket pipe with prestressed guidance according to claim 1, characterized in that The second material is selected from one of polyurethane foam, polyethylene foam and ethylene-vinyl acetate copolymer foam.

4. A separation protection jacket pipe with prestressed guidance according to claim 1, characterized in that The outer surface of the functional layer (2) is further provided with a sealing layer (3).

5. A separation protection jacket pipe with prestressed guidance according to claim 4, characterized in that The sealing layer (3) is specifically one of a water-swelling rubber layer and a thermoplastic polyurethane elastomer layer.

6. A separation protection jacket pipe with prestressed guidance according to claim 1, characterized in that The prestress guide structure (4) comprises a plurality of independent polyhedral protrusions (401), and the guide surface (402) is arranged on the outer surface of the polyhedral protrusions (401).

7. A process for the production of a separate protective jacket with prestressed guidance, applied to a separate protective jacket with prestressed guidance according to any one of claims 1 to 6, characterized in that The application further discloses a preparation method of the structure layer (1) and the functional layer (2). The structure layer (1) is prepared by adopting the first material through injection molding or machining; The functional layer (2) is prepared by adopting the in-mold foaming process to form the functional layer (2) made of the second material on the outside of the structure layer (1) with the structure layer (1) as a base body, and the prestress guide structure (4) is formed on the outer surface of the functional layer (2).

8. The process of claim 7, wherein, Before the in-mold foaming process, the structure layer (1) is further coated with an adhesive on the outer surface.

9. The process of claim 7, wherein, After the functional layer (2) is formed, the functional layer (2) is further compounded with the sealing layer (3) on the outer surface.

10. The process of claim 7, wherein, The parameters of the in-mold foaming process are as follows: The mold temperature is 45-60 DEG C, the foaming pressure is 2-4 MPa, and the pressure maintaining time is 3-8 minutes.

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