Water-filled rubber dam bag and integrated vulcanization method thereof

Abstract

The invention relates to the technical field of water conservancy projects, in particular to a water-filled rubber dam bag and an integrated vulcanization method thereof. The dam bag comprises a dam bag piece, a bottom gasket and a spine strip, the dam bag piece, the bottom gasket and the spine strip are integrally formed, and the spine strip is located on the dam bag piece; the downstream of the bottom gasket is fixed to a ground foundation through an anchoring assembly, the anchoring assembly comprises an anchoring bottom plate, an anchoring pressing plate, an anchoring bolt and a protection piece, the protection piece is rolled into a cylindrical structure, the anchoring bottom plate is embedded into the ground foundation and is flush with the top face of the ground foundation, the anchoring pressing plate is pressed on the bottom side of the protection piece and the bottom gasket, and the anchoring bolt is arranged on the anchoring pressing plate. The anchoring bolt is connected with the anchoring bottom plate and the anchoring pressing plate, and the top of the anchoring bolt is located in the cylindrical structure of the protection piece. The problems of leakage and damage caused by a split structure and a construction mode in the prior art are solved.

Description

Technical Field

[0001] This invention relates to the field of water conservancy engineering technology, and in particular to a water-filled rubber dam bag and its integrated vulcanization method. Background Technology

[0002] A water-filled rubber dam is a flexible hydraulic structure that forms a water-blocking structure by filling a dam bag with water. It is widely used in scenarios such as river water storage, landscape creation, and flood control. The basic working principle is to anchor the rubber dam bag to the foundation plate and control the expansion and collapse of the dam bag through the filling and drainage system, thereby realizing the functions of water blocking and discharge.

[0003] The most common structure of water-filled rubber dams currently includes dam bags, bottom gaskets, and anchoring components. The dam bags and bottom gaskets are separate structures, sealed by overlapping with additional dimensional allowances beyond their designed dimensions. Because the dam bags and bottom gaskets are not integral and have different thicknesses, coupled with the impact and tearing of water flow during operation, leakage is prone to occur at the joints. Secondly, the separate dam bags and bottom gaskets are susceptible to frictional damage from water flow within the anchoring grooves, leading to common dam bag wear, leakage, and shortened service life. Furthermore, traditional water-filled rubber dam bags are prone to resonance when filled with water, also affecting their service life and operational safety. Summary of the Invention

[0004] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a water-filled rubber dam bag to solve the leakage and damage problems caused by the split structure and construction method in the existing technology.

[0005] To achieve the above objectives, the embodiments of the present invention provide the following technical solutions: A water-filled rubber dam bag includes: a dam bag sheet, a bottom pad, and a spine strip, wherein the dam bag sheet, the bottom pad, and the spine strip are integrally formed, and the spine strip is located on the dam bag sheet; the downstream of the bottom pad is fixed to the ground foundation by an anchoring assembly, the anchoring assembly including an anchoring base plate, an anchoring pressure plate, an anchoring bolt, and a protective sheet, wherein the protective sheet is rolled into a cylindrical structure, the anchoring base plate is embedded in the ground foundation and flush with the top surface of the ground foundation, the anchoring pressure plate presses on the bottom side of the protective sheet and the bottom pad, and the anchoring bolt connects the anchoring base plate and the anchoring pressure plate, with the top of the anchoring bolt located inside the cylindrical structure of the protective sheet.

[0006] Optionally, the protective sheet is a rectangular sheet with two edges forming joints. After bending the rectangular sheet, the protective sheet is rolled into a cylindrical structure through the joints. The axis of the cylindrical structure is parallel to the length direction of the dam bag, and the cylindrical structure forms a drainage channel. A drainage groove is provided at the joint of the cylindrical structure.

[0007] Optionally, the spine strip is provided with a flow-dispersing block. Multiple flow-dispersing blocks are provided along the length of the spine strip. The multiple flow-dispersing blocks have different shapes and there is a gap between two adjacent flow-dispersing blocks. The multiple flow-dispersing blocks are installed in a staggered manner in the direction of water flow.

[0008] Optionally, among the multiple flow-dispersing blocks, the ends of some flow-dispersing blocks along the water flow direction are flush with the ends of the spine strip, while the ends of some flow-dispersing blocks along the water flow direction protrude beyond the ends of the spine strip.

[0009] Optionally, the spoiler is bolted to the spine strip, or the spoiler is glued to the spine strip.

[0010] Optionally, the spine strip has an intermediate vulcanized aramid reinforcing strip, which is disposed along the entire length of the spine strip.

[0011] Optionally, the spine strip has an intermediate vulcanized steel wire rope, which is arranged along the entire length of the spine strip.

[0012] Optionally, a vulcanized base fabric reinforcement layer is added at the junction of the bottom pad and the dam bag.

[0013] Optionally, the base fabric reinforcement layer is clad with a polyurethane coating.

[0014] This invention also provides an integrated vulcanization method for the water-filled rubber dam bag as described above, comprising the following steps: The spine area is heated to the first preheating temperature, while the dam bag area is heated to the second preheating temperature, which is lower than the first preheating temperature. The temperature of the transition zone is between the two and is maintained for a period of time. When the core temperature of the spine area is close to the vulcanization initiation temperature, a first pressure is applied to the upstream area of ​​the dam bag, and a second pressure lower than the first pressure is applied to the downstream area, forming a static pressure gradient that decreases from upstream to downstream. Adjust all zone temperatures to the main vulcanization temperature and perform periodic pressure fluctuations at a set frequency and amplitude; After the main vulcanization time is completed, the temperature of the spine area is lowered first to stop the crosslinking reaction, and then the entire area is cooled to a safe range before demolding.

[0015] One or more technical solutions provided in the embodiments of the present invention have at least the following technical effects or advantages: 1. In the rubber dam bag of the present invention, the dam bag sheet, the bottom pad, and the spine strip adopt an integral molding structure. The dam bag sheet and the bottom pad are not produced separately and then spliced, but are formed into a complete whole through a one-time molding process. The spine strip provides basic airflow disturbance function. In the anchoring assembly, the anchoring base plate is embedded inside the ground foundation and its top surface is flush with the top surface of the ground foundation. The anchoring pressure plate directly presses on the bottom side of the protective sheet and the bottom pad. The protective sheet is rolled into a cylindrical structure. The anchoring bolt passes through the anchoring pressure plate and the anchoring base plate to achieve connection, and the top of the anchoring bolt is located inside the cylindrical structure formed by the protective sheet, without direct contact with other parts of the dam bag. The integral molding structure first solves the problem of joint leakage caused by the separate setting of the dam bag sheet and the bottom pad. Since there is no splicing seam, it is not necessary to achieve the overall splicing of the dam bag sheet through secondary vulcanization, avoiding the strength loss caused by secondary vulcanization, and improving the overall load-bearing capacity of the dam bag. The spine strip design lays the foundation for subsequent resonance suppression, breaking the stable flow pattern formed by water tightly adhering to the dam bag plate. This solves the problem of resonance easily generated by traditional single-sided dam bags. Simultaneously, the various shapes and installation positions of the deflector strips enhance the aesthetic appeal of the dam bag as water flows through it. The anchoring base plate is flush with the ground foundation, reducing the need for creating grooves in the ground foundation as in traditional anchoring. This not only lowers the cost and difficulty of civil construction but also avoids the risk of damage caused by the bottom pad rubbing against the foundation surface with the water flow within the groove. The protective cylindrical structure isolates the anchor bolts from other components of the dam bag, preventing bolt wear. Furthermore, the internal space of the cylinder can serve as an auxiliary drainage channel, eliminating the need for additional drainage pipes and avoiding the risk of dam bag damage caused by protruding traditional drainage pipes.

[0016] 2. The integrated vulcanization method of the present invention precisely manages the heat input of different thickness areas through zoned and stepped temperature control, ensuring that the optimal degree of vulcanization is achieved from the surface to the core and from the thin area to the thick area, avoiding local over-vulcanization or under-vulcanization, resulting in good consistency of the overall mechanical properties of the product, extending its service life, fundamentally improving the uniformity of vulcanization, and achieving a match between mechanical morphology and service condition.

[0017] Advantages of additional aspects of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. In addition, the dimensions or spacing between the components are exaggerated to show the position of each component, and the schematic diagrams are for illustrative purposes only.

[0019] Figure 1 This is a schematic diagram of the dam bag in an unfilled state provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the water-filled state of the dam bag provided in an embodiment of the present invention; Figure 3 This is a partial enlarged view of the protective sheet provided in an embodiment of the present invention; Figure 4 This is a side view of the protective sheet joint end provided in an embodiment of the present invention; Figure 5 This is a schematic diagram of the aramid reinforcing belt provided in an embodiment of the present invention; Figure 6 This is a schematic diagram of a steel wire rope provided in an embodiment of the present invention; Figure 7 These are schematic diagrams of various turbulence blocks provided in embodiments of the present invention; In the diagram: 1. Dam bag sheet; 2. Spine strip; 3. Bottom pad; 4. Protective sheet; 5. Anchoring pressure plate; 6. Anchoring bolt; 7. Anchoring base plate; 8. Drainage channel; 9. Aramid reinforcing strip; 10. Steel wire rope; 11. Turbulence block; 12. Protective filler block; Detailed Implementation It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0020] As described in the background section, existing technologies have several technical problems: First, the repeated splicing and secondary vulcanization cause a significant loss of strength in the adhesive tape material, making the seams weak points in the structure, which are prone to leakage and damage.

[0021] Secondly, the anchoring of water-filled rubber dams typically involves creating grooves in the ground foundation, bending the bottom gasket and embedding it into the grooves, and then anchoring it using an anchoring base plate, anchoring pressure plate, and bolts. After installation, the grooves are sealed and smoothed with cement. This increases construction costs and difficulty, and the bottom gasket's repeated friction with the foundation surface within the groove, along with the water flow, increases the risk of damage.

[0022] Furthermore, when the dam drains water, it is forcefully pumped out. When the pump draws water from inside the dam bag, excessive suction can cause the dam bag panels and bottom pads at the water cap to stick together, hindering drainage and causing the dam to collapse. Typically, a drainage pipe needs to be laid inside the dam bag. If the diameter of the suction pipe is too large, it will cause the surface of the dam bag to bulge, increasing costs. A bulging suction pipe also increases the risk of additional damage in the event of a dam collapse. If the diameter of the suction pipe is too small, the drainage speed will be slow.

[0023] Finally, both pillow-type and sloping-type rubber dam bags are single-sided dam bags made from a single sheet. When water flows through them, the water flow is very close to the dam bag sheet, making them prone to resonance. If resonance occurs in these types of rubber dams, additional control measures are needed to compensate for the inherent deficiencies. See section 6.4.5 of GB / T50979-2014 "Technical Specification for Rubber Dam Engineering" (page 79, Operation Control) for details on vibration reduction measures. The anti-vibration devices such as flow deflectors or diverters installed on the dam bag as described in the specification are only compensatory measures. They involve secondary vulcanization or clamping at fixed intervals along the length of the dam bag and cannot completely eliminate resonance. Furthermore, in actual use, these secondary components are easily washed away by strong water flow.

[0024] Example 1 like Figure 1 , Figure 2 , Figure 3 As shown, this embodiment proposes a water-filled rubber dam bag, including a dam bag piece 1, a bottom pad 3, and a spine strip 2. The dam bag piece 1, the bottom pad 3, and the spine strip 2 are integrally formed. The spine strip 2 is located on the curved surface S of the downstream dam bag piece 1, specifically at the center line of the overall unfolded width of the dam bag, that is, on the downstream length line of the dam bag piece when the dam collapses after installation. The downstream of the bottom pad 3 is fixed to the ground foundation by an anchoring assembly. The anchoring assembly includes an anchoring base plate 7, an anchoring pressure plate 5, an anchoring bolt 6, and a protective plate 4. The protective plate 4 is rolled into a cylindrical structure. The anchoring base plate 7 is embedded in the ground foundation and flush with the top surface of the ground foundation. The anchoring pressure plate 5 presses on the bottom side of the protective plate 4 and the bottom pad 3. The anchoring bolt 6 connects the anchoring base plate 7 and the anchoring pressure plate 5, and the top of the anchoring bolt 6 is located inside the cylindrical structure of the protective plate 4.

[0025] This structure avoids the material strength loss and joint leakage risks caused by splicing and secondary vulcanization in traditional split-type dam bags, improving the integrity and sealing reliability of the dam bag. In the downstream anchoring assembly, the protective plate 4 is rolled into a cylindrical structure, and the anchoring base plate 7 is flush with the top surface of the ground foundation, reducing the need to open anchoring grooves in the foundation, reducing construction complexity and wear on the dam bag from the foundation. The top of the anchoring bolt 6 is accommodated within the cylindrical space formed by the protective plate 4, preventing the bolt from directly contacting the upper dam bag plate 1. At the same time, this structure forms a continuous channel inside the dam bag, which helps drainage and prevents the dam bag from closing up in the event of a dam collapse, replacing the traditional method of laying internal drainage pipes, reducing costs and damage risks.

[0026] In addition, the one-piece molded dam bag piece 1, bottom pad 3, and spine strip 2 make the dam bag structure versatile, adaptable to both straight-wall and sloping-wall types of inflatable rubber dams. The straight-wall type is treated as a special sloping-wall type with a 90-degree slope, eliminating the need for separate dam head plugs for straight-wall type abutments. This unifies the production process and anchoring scheme for both pillow-type and sloping-wall type dam bags, solving the problems of complex production management and construction coordination caused by the inconsistency in the structure and process of the two traditional dam bag types. It also avoids common drawbacks of traditional pillow-type inflatable rubber dams, such as cracking of the dam bag plug joints at both ends, impact wear between the plugs and the abutment, and collapse of the shoulders at both ends of the rubber dam.

[0027] Traditional inflatable rubber dams have upstream and downstream anchoring components. For projects with low dam height, because the dam bag panels and bottom gaskets are separate designs, a downstream anchoring component is necessary to anchor and compact them for sealing. The construction cost of this anchoring component accounts for a large proportion of the overall cost. For low-height inflatable rubber dams, the unfolded width of the dam bag panels and bottom gaskets is small, and the overlap between them and the anchoring component is also significant. This results in a large proportion of the overall construction cost and material surplus cost, but this cannot be avoided due to the design structure.

[0028] Therefore, by integrating the bottom gasket and the dam bag into one unit, the downstream anchoring components can be omitted for water-filled rubber dams with a low design height. The anchoring and sealing of the dam bag can be achieved through the upstream anchoring components, saving material and construction costs.

[0029] The protective sheet 4 is a rectangular sheet, with its two sides forming joint ends. After bending the rectangular sheet, the protective sheet 4 is rolled into a cylindrical structure through the joint ends. The axis of the cylindrical structure is parallel to the length direction of the dam bag, forming a drainage channel. A drainage groove 8 is provided at the joint end of the cylindrical structure. Figure 4 As shown.

[0030] The initial form of the protective plate 4 is a rectangular piece with specially designed joint ends on both sides. By bending the rectangular piece and connecting the two joint ends, the protective plate 4 is rolled into a cylindrical structure by bonding or binding with cable ties. The axis of the cylindrical structure is parallel to the length of the dam bag, ensuring that the cylindrical structure is distributed along the entire length of the dam bag. A through drainage channel is formed inside the cylindrical structure. At the same time, drainage grooves 8 are set at the joint ends on both sides. The drainage grooves 8 are connected to the drainage channel, which can guide water flow into the drainage channel, avoid the problem of dam collapse caused by local water accumulation, and ensure that water can be quickly discharged along the drainage channel when the dam bag collapses. This optimizes the water flow guidance effect, allows water in the dam bag to enter the drainage channel more smoothly, improves drainage efficiency, and eliminates the need for additional drainage structure design. At the same time, the cylindrical structure of the protective plate 4 also protects the anchor bolts 6.

[0031] Traditional water-filled rubber dam bags consist of an upstream curved surface S1 and a downstream curved surface S, both with the same thickness and strength. When water flows over the dam bag, the downstream curved surface S experiences greater external force damage. Water flowing along this surface can also create resonance, further increasing the damage to the dam bag. When branches, debris, small stones, glass bottles, etc., fall along the S-curve into the concrete foundation with the water flow, there is a risk of scratching and abrading the dam bag. When these debris hit the ground, glass bottles may break, and the impact of the water flowing down the dam bag can cause further damage to the bottom of the dam bag near the downstream anchorage, exacerbating the damage to the bottom of the dam bag.

[0032] In this embodiment, the rubber dam bag is designed with different thicknesses, strengths, and cost materials for its three parts: the dam bag sheet, the bottom pad, and the spine strip, based on the stress on its location, the risk of external damage, and the function of each component. Specifically, the bottom pad is thinner than the dam bag sheet, and the spine strip is more than twice the thickness of the dam bag sheet. The reduced thickness and lower manufacturing cost of the bottom pad reasonably lower the cost of the dam bag, while the increased thickness of the spine strip increases the overall resistance to damage and the service life of the dam bag.

[0033] To enhance the visual appeal of water flowing through the dam, book-spine-style air dams typically feature spaced grooves (convex and concave) cut into the spine. This creates a waterfall effect with water flowing in different directions up and down the spine. However, this design has several drawbacks: the spine strips are usually 7-10cm wide, and the groove openings must be at least 1cm, compromising the overall strength of the spine strips. Furthermore, creating the grooves is a one-time operation, and any errors are irreparable. Additionally, the visual effect varies depending on the water level and flow rate; if the desired effect is unsatisfactory, it is irreversible.

[0034] In this embodiment, a baffle 11 is provided on the spine strip 2, such as... Figure 7 As shown, various shapes of the flow disturbance blocks 11 are given. When water passes through the dam bag, landscape water flow with different spatial shapes is generated. Multiple flow disturbance blocks 11 are arranged along the length direction of the spine strip 2, and there is a gap between two adjacent flow disturbance blocks 11. The gap size can be adjusted according to the flow velocity and head parameters of the water area used in the dam bag design to ensure that the water flow can partially pass through the gap and avoid excessive force on the flow disturbance blocks 11.

[0035] The arrangement of multiple disturbance blocks 11 can break the stable flow state formed by the water flow closely adhering to the dam bag 1. Through the obstruction and guidance of the water flow by the disturbance blocks 11, the water flow is made into a turbulent flow state, which weakens the conditions for resonance and solves the resonance problem caused by the stable water flow in traditional dam bags. The gap between adjacent disturbance blocks 11 can balance the water flow pressure and avoid excessive local impact caused by excessive accumulation of water flow in front of the disturbance blocks 11. At the same time, it prevents the disturbance blocks 11 from being washed away by the water flow. The disturbance blocks 11 can also make the water flow form multiple layers of water splashes when it passes through, which improves the landscape effect when the dam bag is filled with water. Moreover, there is no need to cut grooves on the spine strip 2, which ensures the overall strength of the spine strip 2.

[0036] The combination of the baffle block 11 and the spine strip 2 provides a stable installation base for the baffle block 11. The one-piece molded spine strip 2 has higher strength, which can ensure the long-term stable installation of the baffle block 11. The synergy between multiple baffle blocks 11 with gaps and the spine strip 2 makes the water flow disturbance more uniform, which not only achieves the anti-resonance effect, but also takes into account the landscape requirements. At the same time, the presence of the baffle block 11 can help the spine strip 2 disperse the water flow impact force, reduce the stress load on the spine strip 2 itself, and extend the service life of the spine strip 2.

[0037] In addition, the added baffles on the spine strip can further protect the spine strip and enhance its resistance to damage. When branches, debris, small stones, glass bottles, etc. flow past the spine strip, they can be lifted diagonally upwards along the arc of the baffles. When branches, debris, small stones, glass bottles, etc. fall to the ground, they will be far away from the anchor at the bottom of the dam and be carried downstream by the water flow.

[0038] like Figure 7 As shown, among the multiple flow-dispersing blocks 11, the ends of some flow-dispersing blocks 11 along the water flow direction are flush with the ends of the spine strip 2, while the ends of some flow-dispersing blocks 11 along the water flow direction protrude from the ends of the spine strip 2.

[0039] In terms of position, the multiple flow-disrupting blocks 11 arranged along the length of the spine 2 are divided into two categories. One type of flow-disrupting block 11 has its end along the water flow direction flush with the end of the spine 2 along the water flow direction, while the other type of flow-disrupting block 11 has its end along the water flow direction protruding from the end of the spine 2. The two types of flow-disrupting blocks 11 can be distributed alternately or according to a specific pattern. The specific distribution method is determined according to the hydrological conditions of the water area.

[0040] The positional difference between the two types of turbulence blocks 11 can create a more complex water flow disturbance state, avoiding the regularization of water flow caused by a single turbulence block 11 and the occurrence of resonance, so that the water flow forms multiple layers of flow in different directions and at different speeds at the spine 2, further enhancing the anti-resonance effect.

[0041] In terms of connection methods, the deflector block 11 and the spine strip 2 are connected in several ways. One method is bolt connection, where bolts are used to fix the deflector block 11 and the spine strip 2. The specific bolt type is selected according to the size of the deflector block 11 and the stress requirements. Bolted connection is detachable. When the deflector block 11 wears or ages due to long-term use, or when the specifications of the deflector block 11 need to be adjusted according to actual needs, it can be easily disassembled and replaced without damaging the spine strip 2 itself, solving the problem that traditional spine grooving is a one-time operation with irreparable errors. The second method is adhesive connection, where a water-resistant and aging-resistant adhesive is used to directly bond the deflector block 11 to the surface of the spine strip 2. The adhesive must be compatible with the rubber material to ensure bonding strength.

[0042] Currently, the base fabric of rubber dams is made of nylon or polyester. When applied to dams, the tensile and shear strength of the spine strip 2 is insufficient when the water flow impact is too great.

[0043] Based on this, the intermediate vulcanized aramid reinforcing strip 9 of the spine strip 2 thickness described in this embodiment, such as Figure 5 As shown, the aramid reinforcing strip 9 is disposed along the entire length of the spine strip 2. The elongation rate of aramid fiber is only 20%–25% of that of nylon or polyester fiber. Its low elongation characteristic effectively reduces the overall elongation of the dam bag during operation or collapse, making the deformation of the dam bag more controllable and avoiding strength loss due to excessive stretching. This solves the problem of insufficient tensile strength of the spine strip 2 in the prior art. The aramid reinforcing strip 9 is located in the middle of the spine strip 2's thickness, allowing it to evenly bear the shear and tensile forces acting on the spine strip 2, avoiding stress concentration on the surface or edges of the spine strip 2, which could lead to localized cracking. The aramid reinforcing strip 9 is distributed along the entire length of the spine strip 2, ensuring consistent resistance to damage at every location, eliminating weak points, and improving the overall load-bearing capacity of the spine strip 2. This makes it suitable for scenarios with high dam height and strong water flow impact.

[0044] In another embodiment, the intermediate vulcanized steel wire rope 10 of the spine strip 2 thickness, such as... Figure 6 As shown, the steel wire rope 10 is arranged along the entire length of the spine strip 2.

[0045] The steel wire rope 10 helps the dam bag to lay flat on the base plate when the dam bag collapses, preventing the dam bag from piling up due to its own elasticity. This solves the problems of uneven piling, water obstruction, and vibration after the collapse of traditional pillow-type dam bags. The high strength of the steel wire rope 10 further enhances the shear and tensile strength of the spine strip 2. Compared with the aramid reinforcing belt 9, it has stronger support and can better resist the deformation of the spine strip 2 caused by water flow impact. It is suitable for scenarios with larger dam bags and more complex stress. The vulcanized connection between the steel wire rope 10 and the spine strip 2 ensures that it will not fall off during long-term use, avoiding the problem of easy loosening of added metal parts and improving the long-term reliability of the spine strip 2.

[0046] Furthermore, a vulcanized base fabric reinforcement layer is added at the junction of the bottom pad 3 and the dam bag piece 1. Specifically, the vulcanized base fabric reinforcement layer is applied at the overlapping area of ​​the bottom pad and the dam bag piece, and in a length section extending 100-150mm outward from the dam bag, to increase the resistance to wear, puncture, and tearing at the bottom of the curved surface S downstream of the dam bag. The junction of the bottom pad 3 and the dam bag piece 1 is a stress concentration area of ​​the dam bag. When the dam bag is filled with water, the dam bag piece 1 expands and is subjected to force, while the bottom pad 3 remains stationary. The junction is prone to tearing force due to the difference in force. The addition of the base fabric reinforcement layer can significantly improve the strength and tear resistance of this area, avoiding damage caused by water flow impact and tearing at the junction, thus solving the problem of easy damage at the junction. The base fabric reinforcement layer is vulcanized, which improves the friction resistance when the dam bag piece is in contact with the ground and the tear resistance during water filling and operation.

[0047] Furthermore, the base fabric reinforcement layer is clad with a polyurethane coating. Polyurethane material possesses excellent wear resistance and corrosion resistance, preventing the base fabric fibers from being worn and broken. It also resists the corrosion of the base fabric by chemicals in the water when the dam bag wears and leaks, extending the service life of the base fabric reinforcement layer. This solves the problem of traditional base fabric reinforcement layers being easily worn and corroded. The cladding process ensures a tight bond between the polyurethane coating and the base fabric reinforcement layer, preventing coating peeling.

[0048] In summary, the dam bag 1, bottom pad 3, and spine spoiler strip are integrally formed in one step: the outline of the water-filled rubber dam bag after inflation is divided into four parts: S1, S, n, and X0. S1 and S are the curved parts of the dam bag, and n and X0 are the upstream and downstream straight sections of the bottom pad 3.

[0049] First, calculate the design unfolded length of the dam bag and bottom pad 3 according to the standard, using the formula: (S1+S)×H1, (n+X0)×H1. Then, add the anchoring allowance of the anchor to form the combined width of the two. Finally, lay the dam bag 1 and bottom pad 3 flat as a whole. The dam bag part is laid according to the dam bag production process and design strength standard, and the bottom pad 3 part is laid according to the bottom pad 3 production process and design strength standard. At the junction of the two integral moldings, that is, the fastening area of ​​the anchor plate 5, it is laid and formed according to the dam bag material standard requirements. After the overall width and length directions are formed, vulcanized release paper is laid on the inner rubber layer. The center line is drawn in the width direction. The dam bag piece 1 and the bottom pad 3 integral molding are folded in half along the center line in the length direction. The spine deflector strip is connected to the overall length at the fold line. In this way, the dam bag, bottom pad 3 and spine deflector strip are formed in one piece without joints. The increased thickness and strength of the spine deflector strip can be achieved independently of the dam bag.

[0050] Due to the improved process of combining the dam bag and bottom pad 3 into one unit, the abutment plate of the pillow-type rubber dam can be eliminated accordingly. The sealing function can be replaced by extending the combined dam bag and bottom pad 3 to the design height of the abutment wall. This unifies the anchoring method of the straight-wall pillow-type rubber dam and the anchoring of the sloping rubber dam into a single design structure. That is, the anchors that seal the abutment head of the pillow-type rubber dam at the bottom plate of the abutment wall are moved to the vertical abutment wall slope surface according to the anchoring method of the sloping abutment wall structure. The vertical abutment wall is understood as the slope ratio of the sloping abutment wall.

[0051] This invention changes the traditional methods of structure, production molding, vulcanization, installation, and maintenance of water-filled rubber dam bags and bottom pads 3. It integrates the three parts of the water-filled rubber dam—the dam bag 1, the bottom pad 3, and the spine-shaped baffle strip—into a single unit during molding and vulcanization, achieving a seamless, one-time molding and vulcanization process. This seamless, one-time molding of the water-filled rubber dam bag can be applied regardless of whether the end walls are straight or sloping, ensuring structural uniformity, consistent manufacturing processes, and uniform anchoring designs. The dam bag is easy to install and operates smoothly, achieving standardized molding, production, installation, and operation of water-filled rubber dam bags. Through design and process changes, overall costs are reduced, and potential risks during production and construction are minimized.

[0052] After a rubber dam is inflated, due to gravity and the inflation pressure, a section of the dam bag downstream of the anchoring components will adhere to the concrete foundation. Over long-term operation, the concrete of a rubber dam may crack, bulge, burst, and release concrete debris. Furthermore, the constant flow of water can carry small stones, glass shards, branches, bamboo strips, etc., into the bottom, posing a risk. If the dam bag near the downstream anchoring components is punctured or worn, requiring repair, the limited working space and lack of allowance for expansion and bonding of the repair patch at the damaged area make repair difficult. Therefore, the anchoring components are usually removed, and the length of the removed components must be sufficient to flatten the repaired area of ​​the dam bag. This process is difficult and costly, and in the case of a hydroelectric power station, it can significantly reduce power generation efficiency.

[0053] Based on this, in this embodiment, a protective filler block 12 is added between the rear dam bag and the ground foundation of the anchoring component. The protective filler block is teardrop-shaped to match the gap shape between the dam bag and the ground foundation. The protective filler block includes an elastic protective sleeve and a filler inside it. The elastic protective sleeve is a wear-resistant thin film or other wear-resistant polymer material sheet, and the filler is a rubber-plastic sponge or other polymer elastic foam with large compression space. After the rubber dam is inflated, a section of the dam bag is gently lifted, and the thin end of the protective filler block is tucked under the dam bag. The weight of the dam bag itself presses down on the protective sleeve. Once the dam bag is inflated, one end of the protective filler block rests on the bottom of the dam bag, while the other end, within a certain length and following the direction of water flow, naturally inflates against the dam bag sheet. This protects the dam bag sheet from wear and tear, and more importantly, prevents debris from entering the bottom of the dam bag, and also isolates concrete debris that has fallen from the foundation due to aging from direct contact with the dam bag sheet. If the dam bag collapses, the elastic protective sleeve will be flattened by the dam bag sheet.

[0054] Example 2 Traditional static vulcanization processes using constant temperature and pressure cannot simulate the dynamic water flow impact and pressure distribution experienced by water-filled dam bags during actual operation. This results in the molecular chain orientation of the internal materials and the stress state of the reinforcing materials after vulcanization not matching the actual stress environment. Consequently, in practical use, problems such as localized stress concentration, accelerated material fatigue, and latent cracking in critical areas such as the spine root are prone to occur.

[0055] In addition, the dam bag area is thinner than the spine strip area, resulting in a difference in cross-sectional thickness. Under uniform heating conditions, the thin area is prone to over-sulfurization, while the thick area, especially the core of the spine strip, is prone to under-sulfurization, which seriously affects the overall performance and lifespan of the product.

[0056] This embodiment proposes an integrated vulcanization method based on water flow simulation pressing and zoned stepped temperature control, which is applied to a one-time single-width double-layer integral vulcanization process, especially for the vulcanization molding process of water-filled rubber dam bags with a spine structure, and is carried out on a large flat vulcanizing machine.

[0057] The integrated vulcanization method includes the following steps: controlling the spine area to rise to a first preheating temperature, while simultaneously raising the dam bag area to a second preheating temperature lower than the first preheating temperature, with the transition zone temperature between the two, and maintaining this temperature for a period of time; when the core temperature of the spine area approaches the vulcanization initiation temperature, applying a first pressure to the upstream area of ​​the dam bag and a second pressure lower than the first pressure to the downstream area, forming a static pressure gradient decreasing from upstream to downstream; adjusting the temperature of all zones to the main vulcanization temperature and performing periodic pressure fluctuations at a set frequency and amplitude; after the main vulcanization time is completed, preferentially lowering the temperature of the spine area to stop the crosslinking reaction, and then cooling the entire area to a safe range before demolding.

[0058] First, preheating is performed in zones, with different preheating temperatures set for the spine zone and the dam bag zone. The spine zone is heated to the first preheating temperature, while the dam bag zone is heated to a second preheating temperature lower than the first preheating temperature. The temperature of the transition zone is between the two and is maintained for a set time. When the core temperature of the spine zone is monitored to be close to the vulcanization initiation temperature, a first pressure is applied to the upstream area of ​​the dam bag, and a second pressure lower than the first pressure is applied to the downstream area, forming a static pressure gradient that decreases from upstream to downstream. Then, all zone temperatures are uniformly adjusted to the main vulcanization temperature, and periodic pressure fluctuations are performed at a set frequency and amplitude. After the main vulcanization time is reached, the temperature of the spine zone is reduced first to quickly stop the crosslinking reaction. After the overall temperature of the dam bag drops to a safe range, the demolding operation is performed.

[0059] The zoned preheating process solves the problems of insufficient sulfurization in thick areas and excessive sulfurization in thin areas in the traditional static vulcanization process. The spine area accumulates sufficient heat through the first preheating temperature to ensure that its core reaches the vulcanization temperature. The lower second preheating temperature in the dam bag area prevents it from entering the excessive sulfurization state too early, ensuring uniform vulcanization in all areas of the dam bag. The static pressure gradient setting simulates the pressure distribution of the upstream water flow with high pressure and the downstream pressure with low pressure in the actual operation of the dam bag. This puts the dam bag under prestress, which is close to the working state, during the vulcanization process, optimizing the orientation of the material molecular chains and solving the problem of the material stress state after vulcanization not matching the actual stress environment. The problem of local stress concentration caused by the pressure fluctuations is simulated by the periodic pressure fluctuations, which mimic the pulsating characteristics of river flow. This allows the rubber molecular chains and reinforcing materials to undergo micro-adaptive movements and arrangements during the cross-linking and curing process, forming a more stable structure that adapts to dynamic loads. This improves the fatigue resistance of the dam bag, reduces the risk of latent cracking, and prioritizes reducing the temperature of the spine area after vulcanization. By utilizing the thickness and heat storage capacity of the spine area, the cross-linking reaction is quickly stopped, avoiding performance degradation caused by over-vulcanization. The entire dam bag is cooled to a safe range before demolding, which prevents deformation of the dam bag due to excessive temperature during demolding and ensures the dimensional accuracy of the dam bag after vulcanization.

[0060] The four steps of zoned preheating, static pressure gradient, periodic pressure fluctuation, and priority cooling form a synergistic system: zoned preheating lays the foundation for subsequent uniform vulcanization, static pressure gradient ensures a reasonable initial stress state of the material, periodic pressure fluctuation optimizes the internal structure of the material, and priority cooling ensures accurate vulcanization endpoint. The four work together to ensure uniform vulcanization in all areas of the dam bag, good consistency of mechanical properties, and that the material stress state matches the actual operating environment. This method allows for one-time vulcanization molding without subsequent splicing, avoiding the strength loss of secondary vulcanization. At the same time, the aramid reinforcing strip, steel wire rope, and base fabric reinforcement layer in the spine can be tightly bonded to the rubber material during vulcanization, ensuring that their reinforcement effect is fully utilized, ultimately improving the overall quality and service life of the dam bag.

[0061] Detailed steps: I. Preparations and parameter settings before vulcanization.

[0062] 1. Install dedicated vulcanizing pressure plates and sensors: Install independently temperature-controlled zone heating modules on the upper and lower hot plates of the vulcanizing machine, corresponding to the spine strip direction of the dam bag. Simultaneously, embed temperature sensors inside the pressure plates, with at least two temperature measurement points set for each zone. The zone heating modules are the foundation for achieving stepped temperature control, and the temperature sensors are used to monitor the temperature of each zone's hot plate in real time, providing data feedback for closed-loop control.

[0063] 2. Laying a dynamic pressure simulation system: On the surface of the hot plate under the vulcanizing machine, along the upstream to downstream direction of the dam bag, lay an array of independently adjustable dynamic pressing units. This array consists of multiple small hydraulic or pneumatic actuators, covering the entire vulcanizing area of ​​the dam bag. This array is used to simulate the pressure distribution of actual water flow impacting the dam bag from upstream and attenuating downstream, as well as the fluctuation characteristics of the water flow, to achieve gradient pressure and dynamic pressing.

[0064] 3. Input process parameters: Input two sets of core process parameters into the vulcanizing machine control system: Based on the rubber compound formulation and the thickness of each part of the dam bag, the zoned stepped temperature parameters are set to determine the target temperature values ​​and time-temperature change curves for the three temperature zones (spine zone S, transition zone T, and dam bag zone D) throughout the vulcanization process.

[0065] Water flow simulation pressure parameters: Based on the hydrological data of the water area used in the dam bag design, such as maximum head and flow velocity, the pressure gradient of the dynamic pressure unit array is set, and the target pressure value P of the upstream unit is set. h Downstream unit target pressure value P l And the fluctuation frequency f.

[0066] II. Zoned stepped heating and preheating of rubber compound.

[0067] Initiate zoned heating and perform the first stage of temperature control: Start the vulcanizing machine heating system, and the control system, according to the set curve, prioritizes and rapidly raises the temperature of the spine area S to a higher preheating temperature T. s1 For example, 100℃, and maintained for a period of time t1. Simultaneously, the temperature in the dam bag area D slowly rises to a lower preheating temperature T. d1 For example, 80℃, the transition zone temperature T is between the two. Since the spine rubber is the thickest, more heat is needed for its core temperature to reach the vulcanization initiation temperature. This stage aims to allow the thick rubber to accumulate enough heat, reduce the core temperature difference with the thin rubber, and prepare for subsequent synchronous vulcanization.

[0068] III. Dynamic pressure simulation and primary vulcanization.

[0069] 1. Applying gradient static pressure and entering the main vulcanization stage: When the model detects that the temperature of the spine core is close to the vulcanization initiation temperature, the vulcanizing machine closes the mold, and the dynamic pressing unit array applies high pressure P to the upstream area of ​​the dam bag according to the settings.h For example, 1.7-1.9 MPa, applying low pressure P to the downstream area. l For example, 1.4-1.6 MPa, forming a static pressure gradient from upstream to downstream. Simultaneously, all zone temperatures are adjusted to the main vulcanization temperature T. main For example, 150℃. Pressure is applied by closing the mold, causing the rubber compound to flow and fill the cavity, expelling air bubbles. Gradient pressure places each layer of the dam bag material under a pre-stress close to the working state in the early stage of vulcanization and cross-linking, optimizing the stress distribution inside the material.

[0070] 2. Initiate dynamic pressure fluctuation simulation: while maintaining temperature T main Based on the pressure gradient, the control system commands the dynamic pressing unit array to periodically pressurize and depressurize at a frequency f (0.5–1 Hz) and a certain amplitude (e.g., ±0.1 MPa). Simulating the pulsating characteristics of river flow, the micro-dynamic pressure prevents the rubber molecular chains and reinforcing materials from remaining static during cross-linking and curing. Instead, they undergo micro-adaptive movement and arrangement, resulting in a more stable structure that can better adapt to dynamic loads and reduces stress concentration.

[0071] IV. Cooling and Demolding.

[0072] Zoned Cooling and Pressure Relief: After the main vulcanization time, the heating system is shut down. The control system first lowers the temperature of the spine area S, rapidly cooling it to stop the cross-linking reaction and prevent over-vulcanization. Simultaneously, the dynamic pressure simulation system stops fluctuations and releases pressure. Once the overall temperature has dropped to a safe range, the mold is opened and the product is removed. By preferentially cooling the thicker areas, performance degradation due to excessive heat accumulation is prevented, and smooth pressure relief avoids the generation of new internal stresses within the product.

[0073] This integrated vulcanization method uses zoned, stepped temperature control to precisely manage heat input in areas of varying thicknesses, ensuring optimal vulcanization from the surface to the core, and from thin to thick areas. This avoids localized over- or under-vulcanization, resulting in consistent overall mechanical properties and extended service life. Water flow simulation pressing ensures that the dam bag is not static during the final vulcanization stage, but rather in a dynamic environment simulating actual major loads. This generates beneficial prestress distribution and material orientation within the product, enhancing resistance to water flow impact, reducing localized stress concentration, improving fatigue resistance, and effectively lowering the risk of latent cracking and sudden breakage.

[0074] A good degree of vulcanization is a prerequisite for materials to withstand simulated loads without plastic deformation, while the simulated loads promote the optimized arrangement of molecular chain structures after full vulcanization. The synergistic effect of zoned stepped temperature control and water flow simulation pressing produces dam bags that are not only internally uniform in quality, but also have a macroscopic structural morphology that is better adapted to complex real hydraulic environments, thus improving overall quality.

[0075] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A water-filled rubber dam bag, characterized in that, include: The dam bag sheet, the bottom pad sheet, and the spine strip are integrally formed, with the spine strip located on the dam bag sheet; The downstream of the bottom pad is fixed to the ground foundation by an anchoring assembly, which includes an anchoring base plate, an anchoring pressure plate, an anchoring bolt, and a protective plate. The protective plate is rolled into a cylindrical structure. The anchoring base plate is embedded in the ground foundation and is flush with the top surface of the ground foundation. The anchoring pressure plate presses on the bottom side of the protective plate and the bottom pad. The anchoring bolt connects the anchoring base plate and the anchoring pressure plate, and the top of the anchoring bolt is located inside the cylindrical structure of the protective plate.

2. The water-filled rubber dam bag as described in claim 1, characterized in that, The protective sheet is a rectangular sheet with two joint ends on both sides. After bending the rectangular sheet, the protective sheet is rolled into a cylindrical structure through the joint ends. The axis of the cylindrical structure is parallel to the length direction of the dam bag. The cylindrical structure forms a drainage channel, and a drainage groove is provided at the joint end of the cylindrical structure.

3. The water-filled rubber dam bag as described in claim 1, characterized in that, The spine strip is provided with a flow-dispersing block. Multiple flow-dispersing blocks are arranged along the length of the spine strip. The multiple flow-dispersing blocks have different shapes and there is a gap between two adjacent flow-dispersing blocks. The multiple flow-dispersing blocks are installed in a staggered manner in the direction of water flow.

4. The water-filled rubber dam bag as described in claim 3, characterized in that, Among the multiple flow-dispersing blocks, the ends of some flow-dispersing blocks along the water flow direction are flush with the ends of the spine strip, while the ends of some flow-dispersing blocks along the water flow direction protrude beyond the ends of the spine strip.

5. The water-filled rubber dam bag as described in claim 3, characterized in that, The deflector block is bolted to the spine strip, or the deflector block is glued to the spine strip.

6. The water-filled rubber dam bag as described in claim 1, characterized in that, The spine strip has a central vulcanized aramid reinforcing strip of intermediate thickness, the aramid reinforcing strip being disposed along the entire length of the spine strip.

7. The water-filled rubber dam bag as described in claim 1, characterized in that, The spine strip has a central vulcanized steel wire rope of intermediate thickness, the steel wire rope being arranged along the entire length of the spine strip.

8. The water-filled rubber dam bag as described in claim 1, characterized in that, The base fabric reinforcement layer is located at the junction of the bottom pad and the dam bag.

9. The water-filled rubber dam bag as described in claim 8, characterized in that, The base fabric reinforcement layer is clad with a polyurethane coating.

10. An integrated vulcanization method for a water-filled rubber dam bag as described in any one of claims 1-9, characterized in that, Includes the following steps: The spine area is heated to the first preheating temperature, while the dam bag area is heated to the second preheating temperature, which is lower than the first preheating temperature. The temperature of the transition zone is between the two and is maintained for a period of time. When the core temperature of the spine area is close to the vulcanization initiation temperature, a first pressure is applied to the upstream area of ​​the dam bag, and a second pressure lower than the first pressure is applied to the downstream area, forming a static pressure gradient that decreases from upstream to downstream. Adjust all zone temperatures to the main vulcanization temperature and perform periodic pressure fluctuations at a set frequency and amplitude; After the main vulcanization time is completed, the temperature of the spine area is lowered first to stop the crosslinking reaction, and then the entire area is cooled to a safe range before demolding.

Images