Novel polyurethane composite material protective fence and forming process thereof

Abstract

The invention provides a novel polyurethane composite material protective fence and a forming process thereof, and relates to the field of protective fence equipment. According to the novel polyurethane composite material protective fence, a reinforcing material based on modified basalt fibers is compounded with novel polyurethane resin, a flame retardant and a nano inhibitor for inhibiting growth of weed vines are added, and the environment-friendly protective fence is integrally formed through dip dyeing, pultrusion, winding, weaving and cutting. The novel polyurethane composite material protective fence structurally comprises a foundation, stand columns, meshes, connecting pieces and a top cover. The polyurethane composite material has the advantages of being light in weight, high in strength and free of maintenance in the later period, the strength of the polyurethane composite material is twice that of a twisted steel bar with the same diameter, the weight of the polyurethane composite material is only 1 / 4 that of the steel bar, and the polyurethane composite material is light, so that the labor intensity of field workers is reduced, occupational hazards in the construction process are reduced; and the problems of paint peeling, fading and the like are avoided.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of protective fence equipment, in particular to a novel polyurethane composite protective fence and a forming process thereof. BACKGROUND

[0002] The current railway protective fence is mainly reinforced concrete protective fence and metal protective fence. In combination with the actual use effect in recent years, the current reinforced concrete protective fence and metal protective fence have the following problems. The existing protective fence generally has a short service life, which is more obvious in extreme climate zones. The service life in dry and less corrosive areas is about 10-15 years, about 8-10 years in coastal areas, only 3-5 years in industrial pollution areas, and the average service life is about 8-10 years. In high-altitude and strong-sunlight areas, the metal mesh protective fence has insufficient ultraviolet resistance, and after 2-3 years, the protective fence net coating is seriously aged and powdered, losing the protection effect. In addition, the on-site pouring of the reinforced concrete protective fence produces a large amount of waste: the traditional method requires on-site formwork, binding of steel bars, and pouring of concrete, which produces waste formwork, waste binding wire, and concrete residue, and the recovery rate is less than 30%. At the same time, the electroplating process in the production process of the metal mesh protective fence also emits acidic or alkaline gas, which stimulates the respiratory tract of the human body, causes respiratory diseases, and may also form acid rain, which is harmful to the ecological system.

[0003] At the same time, the existing protective fence has many inconveniences in installation and maintenance. The single piece of galvanized metal mesh weighs up to 40 kg, and the self-weight of the reinforced concrete protective fence reaches 1.2 tons, which greatly increases the difficulty of carrying and installation and greatly increases the labor cost. Therefore, in order to solve the above problems, the present application provides a novel polyurethane composite protective fence, thereby effectively solving the above problems and difficulties. SUMMARY

[0004] In view of the deficiencies of the prior art, the present application provides a novel polyurethane composite protective fence and a forming process thereof. The polyurethane composite material has the advantages of light weight, high strength, and maintenance-free in the later period. The strength is twice that of the same diameter of steel bar, but the weight is only 1 / 4 of the steel bar. The light weight reduces the labor intensity of the workers on site and reduces the occupational hazards in the construction process. The equipment and process are simplified from transportation, installation, etc. The novel composite product adopts an integrated self-dyeing forming process and does not have problems such as paint and color loss. It is in a maintenance-free state. The polyester composite material meets the safety requirements of the country and is non-toxic and harmless. It can be recycled and reused. No waste water and waste gas is discharged in the production process, which responds to the national green and environmentally friendly sustainable development strategy. The service life can reach 20 years, the product replacement frequency is reduced, the use cost is reduced, the advanced production process reduces the carbon emission of the product and reduces environmental pollution, and helps the industrial upgrading.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A novel polyurethane composite protective fence and its molding process are disclosed. The novel polyurethane composite protective fence uses a modified basalt fiber-based reinforcing material, which is combined with polyurethane resin, and flame retardants and nano-inhibitors that inhibit the growth of weeds and vines are added. It is an environmentally friendly protective fence that is integrally formed by impregnation, pultrusion, winding, weaving and cutting. The structure of the novel polyurethane composite protective fence includes a foundation, posts, mesh panels, connectors and a top cover. The novel polyurethane composite protective fence comprises two parts: a composite material column and a reinforced concrete column. The reinforced concrete column is located inside the foundation and connected to the composite material column at the top. The foundation is a column made of C25 concrete. The composite material column is connected to the mesh panel via connectors, which include clips and anti-theft bolts. The clips are fixedly connected to the composite material column and the mesh panel by bolts, connecting the mesh panel and the composite material column as a whole. Each column is provided with a top cover. The mesh panel is provided with a composite material frame around its perimeter. Both sides of the composite material frame of the mesh panel are fixedly connected to the composite material column via the clips of the connectors.

[0006] Furthermore, the novel polyurethane composite protective fence uses modified basalt fiber as the base material, and the composite raw materials include polyurethane resin, reinforcing fiber, 300-450 knitted felt, BPO, tert-butyl ester, release agent, UV absorber, antioxidant, polyethylene powder, calcium powder, compound flame retardant, inhibitor and color paste.

[0007] Furthermore, the overall process flow of the novel polyurethane composite protective fence is as follows: multiple basalt fiber yarns → polyurethane resin extrusion and impregnation → twisting and winding → drying and shaping → weft length cutting → warp and weft weaving into a net → secondary impregnation with polyurethane resin → entering a tunnel-type drying oven for drying and shaping → cutting into a net.

[0008] Furthermore, the detailed process flow steps of the overall composite material manufacturing process are as follows: Step 1: The composite material mesh first extracts basalt fibers from the grouped yarn frames, and then fully combines them with polyurethane resin raw materials through an impregnation and bundling winding device; Step 2: The product is shaped through heating and cooling, and finally wound up to form the finished mesh. Step 3: Basalt fibers are extracted from the grouped yarn racks, fully squeezed and soaked with polyurethane resin raw materials, then twisted and wound together by a loom, and then woven into a net with composite material reinforcement. Step 4: The woven mesh is dried and cooled by spraying to meet the specified performance requirements. Finally, it is pulled and cut to produce the finished product. Step 5: the column is formed by a pultrusion process.

[0009] Further, the new polyurethane composite protective fence 1.8 m, 1.8+0.5 m, 2.2 m, 2.2+0.5 m four kinds of size, the protection height 0.5 m is installed in the top of the protective fence.

[0010] Further, the cross-sectional size of the new polyurethane composite protective fence is 60 mm in outer diameter and 52 mm in inner diameter, the length is determined according to the protection height and the slope of the ground, and the column spacing is generally 3000 mm.

[0011] Further, the base of the new polyurethane composite protective fence is generally 400 mm (long) x 400 mm (wide) x 500 mm (deep), and when the height difference of the mesh from the ground is greater than 50 mm, the height difference is greater than 50 mm, and the mesh is buried in the ground not less than 100 mm.

[0012] Further, the mesh of the new polyurethane composite protective fence is woven from woven steel and threaded steel, and the mesh size is 50 mm x 100 mm and 75 mm x 150 mm, and the mesh size is generally 1800 mm (high) x 2940 mm (wide) / 2200 mm (high) x 2940 mm (wide) in general section, and the mesh size is adjusted according to the column spacing in the slope section.

[0013] Further, the top cover of the new polyurethane composite protective fence is 66 mm in outer diameter and 3 mm in wall thickness, and is connected and installed at the top of the composite column.

[0014] The application provides a new polyurethane composite protective fence and a forming process thereof. 1. The application provides a new polyurethane composite protective fence and a forming process thereof, the polyurethane composite material has the advantages of light weight, high strength and maintenance-free in later period, the strength is twice that of the same diameter threaded steel bar, but the weight is only 1 / 4 of the steel bar, the light weight characteristic reduces the labor intensity of the site workers, reduces the occupational hazards in the construction process, simplifies the equipment and process from transportation, installation and other aspects, the new composite material product adopts an integrated self-dyeing forming process, and problems such as paint and color loss do not occur, and belongs to a maintenance-free state.

[0015] 2, The application provides a novel polyurethane composite protective fence and a forming process thereof, the polyester composite material of which meets the safety requirements of the country and is non-toxic and harmless, can be recycled and reused, does not discharge waste water and waste gas in the production process, responds to the green environmental protection sustainable development strategy of the country, has a service life of 20 years, reduces the replacement frequency of products, reduces the use cost, has an advanced production process, reduces the carbon emission of products, reduces environmental pollution, and helps industrial upgrading. BRIEF DESCRIPTION OF DRAWINGS

[0016] Figure 1 It is a front effect schematic view of the barbed wire cage of the novel polyurethane composite protective fence of the application. Figure 2 It is a front effect schematic view of the single-mesh grid of the novel polyurethane composite protective fence of the application. Figure 3 It is a three-dimensional effect schematic view of the barbed wire cage of the novel polyurethane composite protective fence of the application. Figure 4 It is an effect schematic view of the connecting piece of the novel polyurethane composite protective fence of the application. Figure 5 It is an effect schematic view of the novel polyurethane composite protective fence of the application for a culvert. Figure 6 It is an effect schematic view of the novel polyurethane composite protective fence of the application for a trapezoidal ditch. Figure 7 It is a process flow chart of the novel polyurethane composite protective fence of the application. Figure 8 It is a process flow chart of the novel polyurethane composite protective fence of the application. DETAILED DESCRIPTION

[0017] The technical solutions in the embodiments of the application will be described clearly and completely below with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative labor fall within the protection scope of the application.

[0018] Embodiment 1: As Figures 1-8As shown, this invention provides a novel polyurethane composite protective fence and its molding process. The polyurethane composite protective fence uses a modified basalt fiber-based reinforcing material, which is combined with a novel polyurethane resin, and flame retardants and nano-inhibitors that inhibit the growth of weeds and vines are added. It is an environmentally friendly protective fence that is integrally formed by impregnation, pultrusion, winding, weaving and cutting. The structure of the novel polyurethane composite protective fence includes a base, posts, mesh panels, connectors and a top cover. The new polyurethane composite protective fence consists of two parts: a composite material column and a reinforced concrete column. The reinforced concrete column is located inside the foundation and connected to the composite material column at the top. The foundation is a column made of C25 concrete. The composite material column is connected to the mesh panel via connectors. The connectors include clips and anti-theft bolts. The clips are fixedly connected to the composite material column and the mesh panel by bolts, connecting the mesh panel and the composite material column as one unit. Each column is provided with a top cover. The mesh panel is provided with a composite material frame around its perimeter. Both sides of the composite material frame of the mesh panel are fixedly connected to the composite material column via the clips of the connectors. The novel polyurethane composite protective fence uses modified basalt fiber as the base material. The composite raw materials include polyurethane resin, reinforcing fiber, 300-450 knitted felt, BPO, tert-butyl ester, release agent, UV absorber, antioxidant, polyethylene powder, calcium powder, compound flame retardant, inhibitor, and color paste. Polyurethane resin has the advantages of high strength and corrosion resistance. The reinforcing fiber is modified basalt fiber. The 300-450 knitted felt increases or decreases transverse and longitudinal strength. BPO and tert-butyl ester are both fixing agents. The release agent is used for demolding. The UV absorber and antioxidant both increase weather resistance. Polyethylene powder increases smoothness and prevents product cracking. Calcium powder is used as a strength filler. The compound flame retardant enhances flame retardant properties. The inhibitor is used to suppress vine climbing growth. The color paste is a colorant used for color filling.

[0019] Example 2: like Figures 1-7 As shown, this invention provides a novel polyurethane composite protective fence and its molding process. The overall process flow of the novel polyurethane composite protective fence is as follows: multiple basalt fiber yarns → polyurethane resin extrusion and impregnation → twisting and winding → drying and shaping → weft length cutting → warp and weft weaving into a net → secondary impregnation with polyurethane resin → entering a tunnel drying oven for drying and shaping → cutting into a net. The detailed process flow steps for the overall process are as follows: Step 1: The composite material mesh first extracts basalt fibers from the grouped yarn frames, and then fully combines them with polyurethane resin raw materials through an impregnation and bundling winding device; Step 2: Shape setting through heating, cooling, etc., and finally winding into finished mesh by traction; Step 3: Extract basalt fibers from the grouped creel, and fully extrude and soak the polyurethane resin raw material, then twist and wind through the braiding machine, and then weave into a mesh with the composite material; Step 4: Through fast drying, spray cooling, etc. to make the woven mesh meet the specified performance requirements, and finally cut off by traction to make finished products; Step 5: The column is shaped by pultrusion process; The advantages of the new polyurethane composite protective fence compared with the traditional metal mesh protective fence after the above process are as follows: 1) Service life Traditional material: The traditional metal mesh protective fence is a metal mesh, which is prone to rust and corrosion, and has a short service life, with an average of 8-10 years. The theoretical service life of the reinforced concrete protective fence is 20 years, but problems such as imperfect formwork joints and insufficient vibration during production, or lack of timely maintenance, can greatly reduce the service life.

[0020] New polyurethane composite material: The new polyurethane composite modified basalt fiber is light and high-strength; it contains ultraviolet-resistant absorbent and antioxidant, and does not rust and corrode, with a service life ≥20 years, far exceeding that of traditional materials.

[0021] 2) Resistance to extreme environment Traditional material: Coastal and windy areas have a strong corrosive effect on concrete and metal, which can easily lead to failure of the protective fence.

[0022] New polyurethane composite material: It is more resistant to corrosion and acid and alkali than traditional materials, and has a wider range of applications and better weather resistance in extreme environments.

[0023] 3) Strength Traditional material: The tensile strength of traditional metal protective fence is only 335Mpa.

[0024] New polyurethane composite material: The tensile strength is 696Mpa, and the compressive strength is 823Mpa.

[0025] 4) Lightweight Traditional material: The weight of the hot-dipped galvanized protective fence is more than 40Kg, and the weight of the reinforced concrete protective fence is even more than 1.2t, making transportation extremely difficult, time-consuming and labor-intensive, and increasing costs.

[0026] New polyurethane composite material: The weight of the new polyurethane composite mesh is about 6.5Kg, which is much lower than that of the metal mesh, making it easy to transport and install.

[0027] 5) Environmental protection Traditional material: the existing protective fence production process is more polluted, high energy consumption, will produce heavy metal wastewater, pollution gas and waste, poor environmental performance.

[0028] New polyurethane composite material: using modified basalt fiber as the basis of reinforced material, and new polyurethane resin composite. Low energy consumption, no wastewater, waste gas emission, material recycling, good environmental performance.

[0029] 6) cost comparison The cost of new composite material protective fence is about 5~10% lower than that of metal protective fence, and about 60% lower than that of reinforced concrete protective fence. The price of traditional protective fence is greatly affected by the fluctuation of steel price. The installation and maintenance cost of composite material protective fence is also lower than that of traditional protective fence. The comprehensive cost has a great advantage.

[0030] The comprehensive parameters of new polyurethane composite material protective fence and existing protective fence are as follows:

[0031] After comprehensive comparison: new polyurethane composite material protective fence has longer service life, better extreme environment resistance, better mechanical properties, lighter weight, better environmental performance and lower comprehensive cost than existing protective fence. The comprehensive advantage is obvious.

[0032] The new polyurethane composite material is a new, excellent high-strength, corrosion-resistant, high-temperature-resistant composite fiber material after mixing. Its environmental adaptability is very strong, and the cost performance is very high. When using traditional resin pultrusion, up to 4 or 5 different special fiber mats may be required. Using polyurethane pultrusion, special fiber roving can often be used instead of special fiber mat. The mat is easy to break, and the fragments may block the machine, affecting production. After canceling the special fiber mat, the raw material cost and the labor cost of operating the mat are reduced. After canceling the mat, the production line speed can be improved to some extent, thereby improving the cost efficiency. On the other hand, after using roving instead of mat, the fiber volume content can be increased to about 80%, while the fiber content of most non-polyurethane pultrusion products is 60%. Higher special content and better resin performance can create stronger and stiffer polyurethane pultrusion profiles. Polyurethane pultrusion products also have assembly advantages, especially convenient fastening. When screwing into polyurethane pultrusion products, there is no need to drill holes in advance, which can save time and labor. On the contrary, the force required to pull out the screw in polyurethane pultrusion products is more than twice that required to pull out the screw in polyester pultrusion products. Polyurethane pultrusion products have high strength, high hardness and other characteristics, and are widely used in construction, infrastructure and transportation, etc. Instead of steel and aluminum.

[0033] Polyurethane pultrusion process also has the following advantages: 1) The production process is continuous, the degree of automation is high, the product quality is stable, and the repeatability is good; 2) The product has good integrity, and the utilization rate of raw materials is high; 3) Adjusting the chemical ratio can meet the requirements of special occasions; 4) High fiber content, impregnation under tension, can fully develop the mechanical properties of continuous fibers, and the product has high strength.

[0034] The material strength ratio is as follows:

[0035] Example 3: As Figures 1-8 shown, the embodiment of the application provides a new type of polyurethane composite material protective fence and a forming process thereof. The new type of polyurethane composite material protective fence has four specifications of 1.8 m, 1.8+0.5 m, 2.2 m and 2.2+0.5 m, and the protective height of 0.5 m is achieved by installing a barbed cage at the top of the protective fence; The composite material column of the new type of polyurethane composite material protective fence has an outer diameter of 60 mm and an inner diameter of 52 mm, and the length is determined according to the protective height and the slope of the ground. The column spacing is generally 3000 mm, the reinforced concrete column is prefabricated, the concrete grade is not less than C30, and the cross-sectional size is 120 mm x 120 mm; The base of the new type of polyurethane composite material protective fence generally has a size of 400 mm (long) x 400 mm (wide) x 500 mm (deep). When the height difference of the mesh from the ground is greater than 50 mm, the height difference is greater than 50 mm, and the mesh is buried in the ground not less than 100 mm; The mesh of the new type of polyurethane composite material protective fence is woven from woven steel and threaded steel, and has two sizes of 50 mm x 100 mm and 75 mm x 150 mm. The mesh size is generally 1800 mm (high) x 2940 mm (wide) / 2200 mm (high) x 2940 mm (wide) in general sections, and is adjusted accordingly according to the column spacing in sloping sections; The top cover of the new type of polyurethane composite material protective fence has an outer diameter of 66 mm and a wall thickness of 3 mm, and is connected and installed at the top of the composite material column.

[0036] In this paper, the following points need attention: 1. The drawings of the embodiments of the present disclosure only relate to the structures involved in the embodiments of the present disclosure, and other structures can be referred to the general design.

[0037] 2. In the case of no conflict, the embodiments of the present disclosure and the features in the embodiments can be combined to obtain new embodiments.

[0038] While embodiments of the application have been shown and described, it is to be understood that the application is not limited to the details of the embodiments described, since various modifications can be made by those skilled in the art, without departing from the spirit and scope of the application, which are defined by the appended claims and their equivalents. All other embodiments obtained by persons of ordinary skill in the art based on the embodiments of the present application, without creative work, are within the scope of the present application.

Claims

1. A novel polyurethane composite material protective fence, characterized in that: The novel polyurethane composite protective fence uses modified basalt fiber as a reinforcing material, which is combined with polyurethane resin, and flame retardants and nano-inhibitors that inhibit the growth of weeds and vines are added. It is an environmentally friendly protective fence formed by impregnation, pultrusion, winding, weaving and cutting. The structure of the novel polyurethane composite protective fence includes a foundation, posts, mesh, connectors and top cover. The novel polyurethane composite protective fence comprises two parts: a composite material column and a reinforced concrete column. The reinforced concrete column is located inside the foundation and connected to the composite material column at the top. The foundation is a column made of C25 concrete. The composite material column is connected to the mesh panel via connectors, which include clips and anti-theft bolts. The clips are fixedly connected to the composite material column and the mesh panel by bolts, connecting the mesh panel and the composite material column as a whole. Each column is provided with a top cover. The mesh panel is provided with a composite material frame around its perimeter. Both sides of the composite material frame of the mesh panel are fixedly connected to the composite material column via the clips of the connectors.

2. The novel polyurethane composite protective fence according to claim 1, characterized in that: The novel polyurethane composite protective fence uses modified basalt fiber as the base material. The composite raw materials include polyurethane resin, reinforcing fiber, 300-450 knitted felt, BPO, tert-butyl ester, release agent, UV absorber, antioxidant, polyethylene powder, calcium powder, compound flame retardant, inhibitor and color paste.

3. The novel polyurethane composite protective fence according to claim 1, characterized in that: The overall process flow of the novel polyurethane composite protective fence is as follows: multiple basalt fiber yarns → polyurethane resin extrusion and impregnation → twisting and winding → drying and shaping → weft length cutting → warp and weft weaving into a net → secondary impregnation with polyurethane resin → entering a tunnel drying oven for drying and shaping → cutting into a net.

4. A novel polyurethane composite protective fence according to claim 3, characterized in that: The detailed process steps of the overall composite material manufacturing process are as follows: Step 1: The composite material mesh first extracts basalt fibers from the grouped yarn frames, and then fully combines them with polyurethane resin raw materials through an impregnation and bundling winding device; Step 2: The product is shaped through heating and cooling, and finally wound up to form the finished mesh. Step 3: Basalt fibers are extracted from the grouped yarn racks and fully squeezed and soaked with polyurethane resin raw materials. They are then twisted and wound together by a loom and woven into a net with composite material reinforcement. Step 4: The woven mesh is dried and cooled by spraying to meet the specified performance requirements. Finally, it is pulled and cut to produce the finished product. Step 5: The column is formed by pultrusion.

5. A novel polyurethane composite protective fence according to claim 1, characterized in that: The new polyurethane composite protective fence comes in four sizes: 1.8m, 1.8+0.5m, 2.2m, and 2.2+0.5m. The 0.5m protective height is achieved by installing barbed wire coils on the top of the protective fence.

6. A novel polyurethane composite protective fence according to claim 1, characterized in that: The composite material columns of the new polyurethane composite protective fence have an outer diameter of 60mm and an inner diameter of 52mm. The length is determined according to the protection height and the slope of the ground. The column spacing is generally 3000mm. The reinforced concrete columns are precast reinforced concrete with a concrete grade of not less than C30 and a cross-sectional size of 120mm x 120mm.

7. A novel polyurethane composite protective fence according to claim 1, characterized in that: The foundation of the new polyurethane composite protective fence generally has a bottom dimension of 400mm (length) x 400mm (width) x 500mm (depth). When the height difference between the mesh and the ground is greater than 50mm, the mesh should be buried at least 100mm below the ground.

8. A novel polyurethane composite material protective fence according to claim 1, characterized in that: The mesh of the new polyurethane composite protective fence is woven from braided and threaded ribs, with two mesh sizes: 50mm x 100mm and 75mm x 150mm. The mesh size is generally 1800mm (height) x 2940mm (width) / 2200mm (height) x 2940mm (width) in general areas, and adjusted accordingly for sloping areas based on the spacing between the posts.

9. A novel polyurethane composite protective fence according to claim 1, characterized in that: The top cover of the new polyurethane composite protective fence has an outer diameter of 66mm and a wall thickness of 3mm, and is snap-fitted onto the top of the composite material column.

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