Process for manufacturing building combined template by using bi-component polyurethane

Abstract

The invention provides a process for manufacturing a building combined type template by using bi-component polyurethane, and relates to the field of building combined type template manufacturing, and the process comprises the following steps: step 1, neatly placing fiber yarn balls, felts and cloth on a creel according to process requirements; 2, the fibers, the felt and the cloth led out by the creel sequentially penetrate through a yarn penetrating plate, and through hole site design of the yarn penetrating plate, the fibers, the felt and the cloth are distributed to a pre-forming mold according to a preset proportion and a distribution mode; 3, performing through a performing mold to form a preformed body with the shape consistent with that of the designed cross section of the product; 4, a forming mold is preheated to the set temperature, the preformed body continuously enters a cavity of the forming mold, meanwhile, the two-component polyurethane mixture is injected into the mold cavity through a glue injection machine, and polyurethane, the glass fibers, the felt and the cloth are solidified in the forming mold and pulled out through a traction machine; and 5, cutting the finished product conveyed from the traction machine at a constant speed by a cutting machine at a fixed length. The defects that an aluminum alloy formwork is high in price and a plastic formwork is low in strength are overcome.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of building combined formwork manufacturing, in particular to a process for manufacturing building combined formwork by using two-component polyurethane. BACKGROUND

[0002] With China entering an aging society, personnel-intensive enterprises that need a large number of workers have successively experienced labor shortages, and among them, construction enterprises are undoubtedly the first to suffer, especially traditional craftsmen for formwork manufacturing and installation. In order to solve the above problems, the state vigorously promotes the prefabricated building mode to implement factory production, attracting some young people to this industry, and various places have successively developed combined aluminum alloy formwork and combined plastic formwork, but the effect is very small, because the aluminum alloy formwork is too expensive and the plastic formwork is too low in strength and is not widely accepted by the market. SUMMARY

[0003] The present application provides a process for manufacturing building combined formwork by using two-component polyurethane, to solve at least one of the technical problems raised in the background art.

[0004] To solve the above technical problems, the present application discloses a process for manufacturing building combined formwork by using two-component polyurethane, comprising: Step 1: Place the fiber yarn ball, felt and cloth on the yarn rack in an orderly manner according to the process requirements, and ensure that the fiber yarn ball, felt and cloth are smoothly drawn out; Step 2: The fiber, felt and cloth drawn out from the yarn rack are sequentially threaded through the yarn threading plate, and the fiber, felt and cloth are distributed to the preforming mold according to the preset proportion and distribution mode through the hole design of the yarn threading plate; Step 3: Form a preformed body consistent with the designed cross-sectional shape of the product by preforming through the preforming mold; Step 4: Preheat the forming mold to a set temperature, continuously feed the preformed body into the forming mold cavity, and simultaneously inject the two-component polyurethane mixture into the mold cavity through the glue injection machine. The polyurethane is cured with the glass fiber, felt and cloth in the forming mold, and is pulled out by the traction machine; Step 5: The finished product sent at a uniform speed from the traction machine is cut by the cutting machine according to the set length.

[0005] Preferably, the fiber is a long fiber, which includes but is not limited to glass fiber, carbon fiber and basalt fiber.

[0006] Preferably, the felt is a fiber processed felt, and the cloth is a cloth processed by fiber.

[0007] Preferably, the two-component polyurethane mixture is a mixture of two-component polyurethane and filler, the mixture is an inorganic filler, and the inorganic filler includes any one or more of calcium carbonate, calcium sulfate, talc, kaolin and glass beads.

[0008] Preferably, the finished product solidified in the mold is pulled out of the mold at a constant speed by two hydraulic clamps on the pultrusion machine.

[0009] Preferably, the step 4 comprises: The pre-production evaluation process comprises: Actual step 41: Obtain the theoretical pultrusion speed range and the theoretical wetting-drawing matching coefficient range in the pultrusion process of the current application preform and the current application two-component polyurethane mixture; Step 42: Detect the viscosity and surface tension of the current application two-component polyurethane mixture, and detect the areal density and thickness of the current application preform; Step 43: Determine the actual wetting characteristic parameters of the current application preform based on the areal density and thickness of the current application preform, and determine the actual penetration characteristic parameters of the current application two-component polyurethane mixture based on the viscosity and surface tension of the current application two-component polyurethane mixture; Step 44: From the theoretical pultrusion speed range, select multiple pre-pultrusion speeds according to a preset gradient, determine the wetting-drawing matching coefficient corresponding to each pre-pultrusion speed, determine the wetting-drawing matching coefficient that meets the theoretical wetting-drawing matching coefficient range and has an absolute deviation from 1 less than a preset deviation value as the first wetting-drawing matching coefficient, and the corresponding pre-pultrusion speed as the first pultrusion speed; when the first wetting-drawing matching coefficient cannot be determined, an alarm is given; The wetting-drawing matching coefficient is determined based on the actual wetting characteristic parameters of the preform, the actual penetration characteristic parameters of the two-component polyurethane mixture, and the pultrusion speed range; When step 44 does not alarm, the pultrusion speed is set based on the first pultrusion speed, and the actual pulling speed through the molding die is controlled to be the pultrusion speed when the current application preform and the current application two-component polyurethane mixture are actually produced in batches.

[0010] Preferably, it further comprises: Step 45: Control the mold temperature adjusting device corresponding to each sub-temperature zone of the molding die according to the theoretical temperature of each sub-temperature zone, and detect and determine the temperature uniformity of each sub-temperature zone; when the temperature uniformity of any sub-temperature zone is less than a preset uniformity, an alarm is given; Step 46: When step 45 does not alarm, based on the temperature uniformity of each glue injection sub-temperature zone, obtain the theoretical glue injection pressure range corresponding to the current application preform and the current application two-component polyurethane mixture and correct it to determine the corrected glue injection pressure range; The theoretical glue injection pressure range corresponding to the current application preform, the current application two-component polyurethane mixture corresponds to: the theoretical glue injection pressure range, the theoretical glue injection pressure-product out of the molding mold based on the ultrasonic detection of the ultrasonic velocity fitting curve; and intercept the target curve segment corresponding to the correction glue injection pressure range; The target curve segment is divided into a plurality of pressure segment curves, and the difference between the maximum ultrasonic velocity and the minimum ultrasonic velocity of each pressure segment curve is less than the ultrasonic velocity difference; Step 47: based on the setting of the pultrusion speed and the corresponding wetting-drawing matching coefficient, combined with the velocity characteristics of each pressure segment curve, the solidification evaluation value corresponding to each pressure segment curve is determined, and the target glue injection pressure is finally determined; For the actual batch production of the current application preform and the current application two-component polyurethane mixture, the actual glue injection pressure is controlled to be the target glue injection pressure.

[0011] Preferably, the two-component polyurethane mixture is a mixture of two-component polyurethane and filler, and the mixture is an inorganic filler, and the inorganic filler includes any one or more of calcium carbonate, calcium sulfate, talc, kaolin and glass beads.

[0012] Preferably, the step 4 further comprises a step 40 of preparing a two-component polyurethane mixture before the step 4. Step 40 includes: Step 401: obtaining the theoretical mixing temperature of each mixing stage of the current application two-component polyurethane mixture; Step 402: taking the current application two-component polyurethane sample and the current application inorganic filler sample and mixing uniformly to obtain the density of the mixed uniform material; and obtaining the viscosity of the mixed uniform material at the theoretical mixing temperature of each mixing stage obtained in step 401; Step 403: obtaining the viscosity of the two-component polyurethane at the theoretical mixing temperature of each mixing stage obtained in step 401; Step 404: determining the dispersion difficulty coefficient based on steps 402, 403 and the density and particle size of the inorganic filler; Step 405: determining the target stirring speed of each mixing stage based on the dispersion difficulty coefficient and the reference stirring speed of each mixing stage; The first mixing stage test target duration is carried out with the target stirring speed corresponding to the first mixing stage, and the first mixing stage viscosity before the first mixing stage and the mixing system viscosity at the end of the target duration are determined; Step 406: determining the viscosity sensitivity coefficient based on step 405, and determining the target duration of each mixing stage based on the viscosity sensitivity coefficient; In the current application of two-component polyurethane and the current application of inorganic filler batch mixing, the actual temperature control time length of each mixing stage is controlled as the corresponding target time length, and the actual stirring speed is controlled as the corresponding target stirring speed.

[0013] The technical solutions of the present application will be further described in detail below with the help of the accompanying drawings and examples.

[0014] Compared with the prior art, the present application has the following beneficial effects: The traditional template production and installation height depends on experienced craftsmen. The process of the present application realizes full-process mechanization and continuous production. From automatic extraction and distribution of fiber yarn balls, felt and cloth to automatic preparation of preformed bodies, to integrated operations of glue injection, curing, traction and cutting, the dependence on manual operation is greatly reduced, and production can be completed without a large number of traditional craftsmen.

[0015] Compared with the combined aluminum alloy template, the process of the present application uses two-component polyurethane and fiber composite materials, which significantly reduces the cost of raw materials, and the production process is continuous and efficient.

[0016] Compared with the combined plastic template, long fibers (glass fiber, carbon fiber, etc.), fiber felt and cloth are used as reinforcing materials in the process, and a two-component polyurethane matrix is used to increase the bending strength of the template. At the same time, through the addition of inorganic fillers (calcium carbonate, talc powder, etc.), the wear resistance, corrosion resistance and other properties are further improved, completely solving the defect of "low strength" of the plastic template. The cost performance of the template is outstanding, and it is more easily accepted by the market.

[0017] Glass fiber, carbon fiber, basalt fiber, etc. can be used, combined with felt and cloth processed from fibers, and the material combination can be flexibly adjusted according to the requirements of different building projects for strength, lightweight, weather resistance, etc. to adapt to various scenes such as residential, industrial building and municipal engineering.

[0018] The two-component polyurethane mixture can be adjusted by adjusting the types (calcium carbonate, calcium sulfate, etc.) and proportions of inorganic fillers to customize the surface wear resistance, thermal conductivity and other functions of the template. For example, adding glass beads can reduce the thermal conductivity of the template to meet the application requirements of thermal insulation templates; adding talc powder can improve the surface flatness to adapt to high-precision concrete pouring scenes. DETAILED DESCRIPTION

[0019] The accompanying drawings are used to provide a further understanding of the present application, and constitute a part of the specification, together with the embodiments of the present application, to explain the present application, and do not constitute a limitation on the present application. In the drawings: Figure 1 It is a flowchart of the present application; Figure 2 It is a schematic diagram of the yarn rack of the present application; Figure 3 A schematic view of a threading plate of the present application; Figure 4 A schematic view of a preforming mold of the present application; Figure 5 A schematic view of a forming mold of the present application; Figure 6 A schematic view of a pulling machine of the present application; Figure 7 A schematic view of a cutting machine of the present application. DETAILED DESCRIPTION

[0020] The preferred embodiments of the present application will be described herein below with reference to the drawings; it should be understood that the preferred embodiments described herein are intended to describe and explain the present application, and are not intended to limit the present application.

[0021] In addition, the description such as "first", "second" and the like in the present application is only for the purpose of description, and does not mean to particularly indicate the order or sequence, nor to limit the present application, which is merely to distinguish the components or operations described by the same technical terms, and cannot be understood as indicating or implying the relative importance of the indicated technical features or implying the number of the indicated technical features. Therefore, the features defined as "first", "second" can explicitly or implicitly include at least one of the features. In addition, the technical solutions and technical features of various embodiments can be combined with each other, but it must be based on the realization of a person skilled in the art, and when the combination of technical solutions appears to be contradictory or unachievable, it should be considered that the combination of technical solutions does not exist, nor within the scope of protection required by the present application.

[0022] The present application provides the following embodiments: Embodiment 1, the present application provides a process for making building combined formwork with two-component polyurethane, as shown in Figures 1-7 , comprising: Step 1: Place the fiber yarn, felt and cloth on the yarn rack according to the process requirements, and ensure smooth yarn drawing; Step 2: The fiber, felt and cloth drawn out of the yarn rack are sequentially threaded through the threading plate, and the fiber, felt and cloth are distributed to the preforming mold according to the preset proportion and distribution mode through the hole design of the threading plate; Step 3: Form a preformed body consistent with the product design cross-sectional shape by preforming the preforming mold; Step 4: Preheat the forming mold to the set temperature, continuously enter the preformed body into the forming mold cavity, and at the same time, inject the two-component polyurethane mixture into the mold cavity through the glue injection machine, and the polyurethane is cured with the glass fiber, felt and cloth in the forming mold, and is pulled out by the pulling machine; Step 5: The finished product sent at a constant speed from the pulling machine is cut by the cutting machine according to the set length.

[0023] The fiber is a long fiber, including but not limited to glass fiber, carbon fiber and basalt fiber.

[0024] Wherein, the felt is a fiber-processed felt, and the cloth is a fiber-processed cloth.

[0025] The two-component polyurethane mixture is a mixture of two-component polyurethane and filler. The mixture is an inorganic filler, which includes one or more of calcium carbonate, calcium sulfate, talc, kaolin, and glass microspheres.

[0026] In this process, the finished product, which has solidified in the mold, is pulled out of the mold at a constant speed by two hydraulic clamping devices on the pultrusion machine working alternately forward. Because the two hydraulic clamping devices work alternately, there is no need to stop and wait, which enables continuous pulling out of the finished product, effectively improving production efficiency. Compared with the traditional intermittent pultrusion method, the production efficiency can be improved to meet the needs of large-scale production.

[0027] In recent years, many companies have successively mass-produced thermosetting two-component polyurethane composites specifically for composite material pultrusion processes. These composites have excellent mechanical properties, good corrosion resistance, and good aging resistance. Our company uses this two-component polyurethane material, along with glass fiber yarn and glass fiber cloth, to produce composite building formwork using the pultrusion process. The price is only one-third that of aluminum alloy, and the mechanical properties are superior to those of aluminum alloy. This overcomes the shortcomings of high price of aluminum alloy formwork and low strength of plastic formwork, and will surely bring huge social and economic benefits.

[0028] The beneficial effects of the above technical solution are as follows: Traditional template fabrication and installation heavily rely on experienced technicians. This invention achieves fully mechanized and continuous production. From the automatic extraction and distribution of fiber yarns, felt, and cloth, to the automated preparation of preforms, and the integrated operation of glue injection, curing, traction, and cutting, it significantly reduces reliance on manual labor and can complete production without a large number of traditional technicians.

[0029] Compared to modular aluminum alloy templates, the process of this invention uses a two-component polyurethane and fiber composite material, which significantly reduces raw material costs and makes the production process continuous and efficient.

[0030] Compared to modular plastic formwork, this process uses long fibers (glass fiber, carbon fiber, etc.), fiber mat, and cloth as reinforcing materials, combined with a two-component polyurethane matrix, to improve the bending strength of the formwork. Furthermore, the addition of inorganic fillers (calcium carbonate, talc, etc.) further enhances its wear resistance and corrosion resistance, completely solving the problem of "too low strength" in plastic formwork. The formwork offers a significant cost-performance advantage and is more easily accepted by the market.

[0031] Long fibers such as glass fiber, carbon fiber, and basalt fiber can be used, combined with fiber-processed felts and cloths. The material combination can be flexibly adjusted according to the strength, lightweight, and weather resistance requirements of different construction projects, making it suitable for various scenarios such as residential, industrial buildings, and municipal engineering.

[0032] Two-component polyurethane mixtures can be customized to improve the surface wear resistance and thermal conductivity of templates by adjusting the type and proportion of inorganic fillers (calcium carbonate, calcium sulfate, etc.). For example, adding glass microspheres can reduce the thermal conductivity of the template to meet the application requirements of thermal insulation templates; adding talc can improve surface smoothness and adapt to high-precision concrete pouring scenarios.

[0033] Example 2, based on Example 1, step 4 includes: The actual pre-batch production evaluation process includes: Actual step 41: Obtain the theoretical pultrusion speed range and theoretical wetting-traction coefficient range during the pultrusion molding process of the current application preform and the current application two-component polyurethane mixture; Step 42: Detect the viscosity and surface tension of the currently applied two-component polyurethane mixture, and detect the areal density and thickness of the currently applied preform; Step 43: Determine the actual wetting characteristic parameters of the preform used in the current application based on its areal density and thickness; determine the actual permeation characteristic parameters of the two-component polyurethane mixture used in the current application based on its viscosity and surface tension. Step 44: From the theoretical pultrusion speed range, select multiple pre-selected pultrusion speeds according to a preset gradient, determine the wetting-traction matching coefficient corresponding to each pre-selected pultrusion speed, and determine the wetting-traction matching coefficient that meets the theoretical wetting-traction matching coefficient range and whose absolute deviation from 1 is less than a preset deviation value (the value is 0.05~0.2; by setting this deviation value, we can screen out the wetting-traction matching coefficients that are close to the ideal state (the deviation from 1 is small, indicating that the actual matching degree is small compared with the theoretical optimal value), and then determine the corresponding first pultrusion speed. If the absolute deviation of a matching coefficient from 1 exceeds this value, it is considered as not meeting the requirements, to avoid problems such as insufficient wetting of the preform and asynchronous traction during the pultrusion process due to poor matching effect, and to ensure the stability of the pultrusion process and product quality. The wetting-traction matching coefficient corresponding to this value is the first wetting-traction matching coefficient, and the corresponding pre-selected pultrusion speed is the first pultrusion speed; when the first wetting-traction matching coefficient cannot be determined, an alarm is triggered. The impregnation-traction ratio is determined based on the actual impregnation characteristics of the preform, the actual penetration characteristics of the two-component polyurethane mixture, and the pultrusion speed range. If no alarm is triggered in step 44, the pultrusion speed is determined based on the first pultrusion speed. In actual batch production, the actual traction speed through the forming die is controlled to be the pultrusion speed.

[0034] The wetting characteristic parameter of the preform is calculated as follows: (area density of the preform detected in step 42 ÷ thickness detected in step 42). The larger the wetting characteristic parameter of the preform, the more difficult the preform is to be wetted; The permeation characteristic parameter of a two-component polyurethane mixture = surface tension of the two-component polyurethane mixture ÷ viscosity of the two-component polyurethane mixture; The higher the permeation characteristic parameter of a two-component polyurethane mixture, the lower the viscosity and the higher the surface tension, indicating strong flow and permeation ability.

[0035] The wetting-traction compatibility factor K = (actual penetration characteristic parameter of the two-component polyurethane mixture ÷ actual wetting characteristic parameter of the preform ÷ pultrusion speed) ÷ (reference wetting characteristic parameter of the two-component polyurethane mixture ÷ reference wetting characteristic parameter of the preform ÷ reference pultrusion speed). The closer K is to 1, the higher the degree of matching between the "actual process parameters (resin penetration, preform impregnation, pultrusion speed)" and the "benchmark optimal parameters", and the more ideal the impregnation-traction effect. In this process, the benchmark / theoretical parameters refer to the optimal combination of process parameters determined through historical production verification for the current application preform and the current application two-component polyurethane mixture, both of the same type of application preform (all parameters meet the same design standard, and the parameters are completely identical or meet the same design standard range) and two-component polyurethane mixture (all parameters meet the same standard). (The actual optimal combination of process parameters from a benchmark batch can be selected as the benchmark / theoretical parameters). Specifically, it includes the following three types of benchmark parameters, which together constitute the "reference benchmark" for process matching: 1. Baseline permeation characteristics of two-component polyurethane blends Based on multiple process verifications of the same two-component polyurethane mixture in historical production, the optimal value of the penetration characteristic parameter (i.e., the historical best value of "surface tension ÷ viscosity") was selected as the one that "has the strongest resin penetration ability and best matches the wetting of the preforms used in the same application". This parameter reflects the optimal flow and penetration ability of the resin under baseline conditions and serves as a reference for judging whether the actual resin penetration performance meets the standards.

[0036] 2. Baseline wetting characteristics of the preform: For the same preform raw material, through historical production verification, the optimal value of the impregnation characteristic parameter (i.e., the historical optimum value of "areal density ÷ thickness") was determined to achieve the lowest resin impregnation difficulty and the most stable finished product quality. This parameter reflects the optimal structural porosity of the preform under the baseline condition and serves as a reference for judging whether the actual impregnation difficulty of the preform is reasonable.

[0037] 3. Reference pultrusion speed: By combining the aforementioned baseline penetration and wetting characteristics, and through gradient testing of pultrusion speeds in historical production, the historical optimal pultrusion speed was determined to achieve "sufficient resin wetting, highest production efficiency, and no defects such as insufficient or excessive resin in the finished product." This parameter serves as a benchmark for balancing "wetting time" and "production rhythm," used to determine whether the actual pultrusion speed matches the raw material characteristics.

[0038] Theoretical pultrusion speed range and theoretical impregnation-traction blending coefficient range: For the current application preform and the current application two-component polyurethane compound corresponding to the same application preform (all parameters meet the same standard, the parameters are completely the same or meet the same standard range) and two-component polyurethane compound (all parameters meet the same standard), the pultrusion speed range and impregnation-traction blending coefficient range that are qualified for production quality are determined through historical production verification.

[0039] The beneficial effects of the above technical solution are as follows: The wetting difficulty of the preform is accurately quantified by using the actual wetting characteristic parameters (areal density ÷ thickness) of the preform, and the resin penetration ability is quantified by combining the actual penetration characteristic parameters (surface tension ÷ viscosity) of the two-component polyurethane. This ensures that the matching analysis of "wetting difficulty" and "penetration ability" is based on the raw material characteristics.

[0040] By using the wetting-traction matching coefficient K (the ratio of actual parameters to reference parameters), the matching degree of "resin penetration, preform wetting, and pultrusion speed" is quantified. The pultrusion speed is determined only when K is close to 1, ensuring sufficient wetting from the process parameter level.

[0041] In actual production, the defect rate of finished products, such as insufficient glue, excessive glue, and dimensional deviation, can be controlled below 0.3%, which is lower than that of traditional experience-based production. The batch-to-batch fluctuation of the mechanical properties of finished products (such as bending strength) is ≤5%.

[0042] The clear definition of the theoretical pultrusion speed range defines the "theoretical feasible boundary" for the selection of pultrusion speed, avoiding repeated adjustments due to speed exceeding the limit; the method of pre-selecting pultrusion speed by setting a preset gradient significantly shortens the screening time for process parameters.

[0043] In actual mass production, the determination of pultrusion speed does not rely on the operator's experience and can be put into production quickly based on the evaluation results.

[0044] The baseline parameters are determined based on the historical best values ​​of the same raw materials, ensuring the reusability of process parameters. When producing new batches, there is no need to repeat a large number of trial production verifications, and the raw material trial production loss is reduced by more than 60%.

[0045] Due to the high matching of process parameters, the utilization rate of resin and preform is increased to over 98%, avoiding raw material scrap due to insufficient impregnation or resin waste due to excessive impregnation, thus reducing raw material costs.

[0046] Example 3, based on Example 2, further includes: Step 45: Control the operation of the mold temperature adjustment device corresponding to each sub-temperature zone according to the theoretical temperature of each sub-temperature zone of the molding die, and detect and determine the temperature uniformity of each sub-temperature zone; when the temperature uniformity of any sub-temperature zone is less than the preset uniformity (e.g., 0.85~0.95), an alarm is triggered; divide the molding die into multiple sub-temperature zones at intervals along the traction direction. Step 46: If no alarm is triggered in step 45, based on the temperature uniformity of each injection sub-temperature zone, obtain and correct the theoretical injection pressure range corresponding to the currently applied preform and the currently applied two-component polyurethane mixture, and determine the corrected injection pressure range. Obtain the theoretical injection pressure range corresponding to the current application preform and the current application two-component polyurethane mixture: within the theoretical injection pressure range, the fitting curve of the theoretical injection pressure - the ultrasonic velocity based on ultrasonic detection when the product exits the molding mold; and extract the target curve segment corresponding to the corrected injection pressure range. The target curve segment is divided into multiple pressure-partial curve segments. The difference between the maximum ultrasonic velocity and the minimum ultrasonic velocity of each pressure-partial curve segment is less than the ultrasonic velocity difference. Step 47: Based on the set extrusion speed and the corresponding wetting-traction fit coefficient By combining the sound velocity characteristics of each pressure segment curve, the curing evaluation value corresponding to each pressure segment curve is determined, and the target injection pressure is finally determined (the average injection pressure of the pressure segment curves whose curing evaluation values ​​meet the preset curing evaluation value requirements is the target injection pressure). ; The solidification evaluation value for the j-th curve segment; The average ultrasonic velocity of the j-th curve segment; The ideal ultrasonic velocity corresponding to the current product; The reference traction speed; To match the evaluation weight of the coefficient (by comparing the impact of different values ​​on product quality through process experiments, the greater the impact on quality, the larger the value, and the value is greater than 0 and less than 1); The weight for evaluating traction speed is determined by comparing the impact of different values ​​on product quality through process experiments. The greater the impact on quality, the larger the value, and the value is greater than 0 and less than 1. The sum is 1; When producing preforms and two-component polyurethane mixtures for current applications in actual batch production, the target injection pressure is controlled by the actual injection pressure.

[0047] Sub-temperature zone and temperature uniformity: Sub-temperature zones: For the same type of mold (forming mold), multiple temperature control zones are divided at intervals along the traction direction. They are the basic units for achieving precise control of the mold temperature gradient.

[0048] Acquisition method: Based on the structural design of the same mold, the traction direction is divided according to the optimal interval verified by the process (such as every 0.8m), to ensure that the temperature of each section can be independently controlled to adapt to the resin curing rhythm.

[0049] Temperature uniformity: The degree of uniformity of temperature distribution within each sub-temperature zone of the same mold. Temperature uniformity of sub-temperature zone = 1 - (standard deviation of sub-temperature zone temperature ÷ average temperature of sub-temperature zone); It is a key indicator to ensure uniform curing of resin.

[0050] Acquisition method: Arrange several high-precision temperature sensors in each sub-temperature zone of the same mold.

[0051] In this embodiment, theoretical parameters refer to the combination of process parameters that meet production quality requirements, determined through historical production verification, for the current application preform and the current application two-component polyurethane compound corresponding to the same application preform (all parameters meet the same design standard, the parameters are completely identical or meet the same design standard range) and the two-component polyurethane compound (all parameters meet the same standard). (The optimal combination of actual process parameters from a benchmark batch can be selected as the theoretical parameters). The combination of process parameters includes: theoretical injection pressure range. Theoretical injection pressure range: Definition: For the same molded body (historically verified baseline wetting characteristic parameters), the same adhesive compound (historically verified baseline penetration characteristic parameters), and the same mold (injection structure historically verified and fixed), the theoretical range of injection pressure that meets quality requirements, precisely derived through fluid mechanics and verified in actual practice, is defined as the range that satisfies quality requirements. The corresponding uniformity is the theoretical uniformity. (Can be 1); 3. Theoretical injection pressure - ultrasonic velocity fitting curve: Definition: The historical verification curve of injection pressure and ultrasonic velocity of product ejection (directly reflecting curing quality and internal structure) under the same molded body, the same rubber compound, and the same mold.

[0052] Acquisition method: Under the same conditions, conduct multiple sets of injection pressure experiments (covering the theoretical injection pressure range), detect the ultrasonic velocity of the samples, fit and form a curve, and quantify the correspondence between "injection pressure and curing quality".

[0053] Theoretical injection pressure range Correct the injection pressure range ; ; This is the pressure correction ratio; This is the average temperature uniformity of all sub-temperature zones in step 45; This is the correction factor corresponding to temperature uniformity; The above refers to the theoretical uniformity.

[0054] The determination was made through comparative experiments. Typical mold sub-temperature uniformity (e.g., 0.8, 0.85, 0.9, 0.95) was selected. Under each uniformity, the actual injection pressure that achieved the desired injection effect (e.g., wetting integrity, no overflow / shortage) was tested. The ratio of the actual pressure to the theoretical pressure (i.e., the pressure correction ratio s) was calculated, and then a linear fit was performed with "uniformity U" as the horizontal axis and "correction ratio s" as the vertical axis to determine the correctness.

[0055] The beneficial effects of the above technical solution are as follows: Step 45 controls the theoretical temperature of each sub-temperature zone of the molding die and detects the temperature uniformity. An alarm is triggered when the uniformity fails to meet the standard, ensuring that the temperature uniformity of each sub-temperature zone of the die meets the requirements. Uniform die temperature is the foundation for the molding of preforms and two-component polyurethane mixtures. Uniform temperature can avoid product molding defects caused by local temperature differences (such as local curing being too fast or too slow, uneven stress, etc.), and provides a stable temperature environment for subsequent glue injection and product quality.

[0056] Step 46 corrects the theoretical injection pressure range based on the temperature uniformity of the sub-temperature zone. It then combines the fitted curve of the theoretical injection pressure and ultrasonic velocity to extract the target curve segment and divide it into pressure-dividing sections. This method fully considers the influence of the preform, the two-component polyurethane mixture, and the mold temperature uniformity on the injection pressure. This ensures that the injection pressure correction is based on multi-factor synergistic analysis, better reflecting the complex working conditions in actual production. It avoids pressure mismatch problems caused by relying solely on theoretical injection pressure (such as excessive pressure leading to preform damage, or insufficient pressure leading to incomplete injection).

[0057] Step 47 combines the pultrusion speed, wetting-traction coefficient, and acoustic velocity characteristics of each pressure segment curve to determine the curing assessment value, ultimately determining the target injection pressure. Ultrasonic velocity effectively reflects the degree of material curing. By analyzing the curing assessment value using acoustic velocity characteristics, it can be ensured that the two-component polyurethane mixture can fully cure after injection, resulting in stable mechanical and chemical properties, and improving the overall quality and service life of the product.

[0058] Mass production ensures controllable quality and strong consistency.

[0059] Example 4, based on any one of Examples 1-3, further includes step 40 before step 4: preparing a two-component polyurethane mixture; Step 40 includes: Step 401: Obtain the reference mixing temperature for each mixing stage of the currently applied two-component polyurethane mixture; Step 402: Take the currently applied two-component polyurethane sample and the currently applied inorganic filler sample, mix them evenly, and obtain the density of the evenly mixed material; and obtain the viscosity of the evenly mixed material at the reference mixing temperature of each mixing stage obtained in step 401. Step 403: Obtain the viscosity of the two-component polyurethane at the reference mixing temperature for each mixing stage obtained in step 401; Step 404: Determine the dispersion difficulty coefficient based on steps 402 and 403, as well as the density and particle size of the inorganic filler; Step 405: Determine the target stirring speed for each mixing stage based on the dispersion difficulty coefficient and the baseline stirring speed for each mixing stage; The target mixing time for the first mixing stage is determined by the target stirring speed corresponding to the first mixing stage, and the viscosity of the mixing system before the start of the first mixing stage and the viscosity of the mixing system at the end of the target time are determined. Step 406; Based on step 405, determine the viscosity sensitivity coefficient, and based on the viscosity sensitivity coefficient, determine the target duration of each mixing stage; When batch mixing the currently used two-component polyurethane and the currently used inorganic filler, the actual temperature control time of each mixing stage is controlled to be the corresponding target time and the actual stirring speed is controlled to be the corresponding target stirring speed.

[0060] Difficulty level C = ; in, This refers to the density of the currently used two-component polyurethane. The density of the currently used two-component polyurethane sample and the currently used inorganic filler sample after uniform mixing; The particle size of the inorganic filler sample currently in use (sample testing); The arithmetic mean of the viscosity at the reference mixing temperature of each mixing stage obtained in step 401 for the current application of the two-component polyurethane sample. The arithmetic mean of the viscosity of the material after uniformly mixing the two-component polyurethane sample and the inorganic filler sample is obtained in step 401 at the reference mixing temperature of each mixing stage; D is the unit particle size in micrometers.

[0061] Viscosity sensitivity coefficient W = |Viscosity of the mixed system before the start of the first mixing stage - Viscosity of the mixed system at the end of the target duration| ÷ Difference in reference viscosity; The baseline viscosity difference is the baseline value corresponding to |viscosity of the mixed system before the start of the first mixing stage - viscosity of the mixed system at the end of the target duration|.

[0062] ; The target duration for the i-th mixing stage; This is the baseline duration for the i-th mixing phase; The viscosity sensitivity coefficient minus the duration compensation coefficient corresponds to the i-th mixing stage; Experimental determination was conducted. First, samples of the same two-component polyurethane and inorganic filler were taken, and the corresponding viscosity sensitivity coefficients were obtained. Then, with a fixed reference stirring speed, the duration of each mixing stage was varied, and the corresponding dispersion effects (such as agglomeration rate, viscosity uniformity, etc.) were tested. A fitting (linear fitting) method was used to obtain the duration compensation coefficient that optimizes each dispersion effect. This coefficient needs to be measured separately for each mixing stage, and its value is related to the difficulty of filler dispersion and the sensitivity of the system viscosity to mixing time—the coefficient is larger when the dispersion difficulty is high and the viscosity sensitivity is high; conversely, it is smaller when the dispersion difficulty is high and the viscosity sensitivity is low.

[0063] The above-mentioned baseline parameters are the optimal combination of process parameters determined through historical production verification for the current application of two-component polyurethane and the current application of inorganic filler (but the actual production batches may be different, and the raw material parameters meet the corresponding standard requirements). (The actual optimal combination of process parameters of a baseline batch can be selected as the baseline / theoretical parameters.) Reference mixing temperature: The temperature at which the material dispersion efficiency and activity are optimally balanced for the same two-component polyurethane and inorganic filler in each mixing stage, based on historical verification. At this temperature, the synergy between raw material viscosity, filler dispersibility, and mixing rate is best, preventing premature curing of the material due to excessively high temperatures, and avoiding reduced dispersion due to excessively low temperatures.

[0064] Reference stirring speed: The stirring speed at which the same two-component polyurethane and inorganic filler achieve "uniform dispersion and optimal energy consumption" in each mixing stage. This speed must ensure that the shear force is sufficient to break up filler agglomerates (if filler is present) and achieve molecular-level mixing of the two components, while avoiding excessive heat generation or equipment overload due to excessive speed.

[0065] Target duration of the mixing stage: The time required for each mixing stage to achieve the goal of "uniform dispersion and sufficient reaction". Its duration is determined by the viscosity change of the raw materials, the difficulty of dispersion and the reaction process in this stage. It is necessary to ensure that the material completes the transformation from "preliminary mixing" to "uniform dispersion" within this time limit, and there are no dispersion defects caused by insufficient time or performance degradation caused by excessive time.

[0066] Reference viscosity difference: It reflects the reasonable range of material viscosity variation during the mixing process in this stage (the reference value of |viscosity of the mixing system before the start of the first mixing stage - viscosity of the mixing system at the end of the target time|), which is tied to the stirring intensity and time depth. If the viscosity difference is too large, it means that the stirring parameters cannot effectively change the state of the material, and if it is too small, it may cause energy waste due to excessive stirring.

[0067] The beneficial effects of the above technical solution are as follows: The theoretical mixing temperature is obtained in step 401, providing a unified temperature benchmark for subsequent viscosity testing, ensuring the comparability of viscosity data, avoiding viscosity measurement errors caused by temperature differences, and thus making the calculation of the dispersion difficulty coefficient more accurate.

[0068] Steps 402-404 determine the dispersion difficulty coefficient by considering multiple factors such as density, particle size, and viscosity. This comprehensively takes into account the influence of the physical properties of the two-component polyurethane and inorganic fillers on the mixing difficulty, so that the dispersion difficulty coefficient can accurately reflect the complexity of the actual mixing. This provides a scientific basis for determining the target stirring speed, ensures the uniformity of the material dispersion after mixing, and reduces defects such as agglomeration.

[0069] Step 405 determines the target stirring speed for each mixing stage based on the dispersion difficulty coefficient and the benchmark stirring speed. The material state is different in different mixing stages (e.g., the initial stage may have severe agglomeration, and subsequent stages need to be homogenized). Targeted speed design can achieve the optimal shearing effect in each stage, which can effectively break up agglomerates and avoid energy waste or material performance degradation caused by over-stirring.

[0070] Step 406 determines the target duration by using a viscosity sensitivity coefficient, which takes into account the viscosity change characteristics of the material during the mixing process. This ensures that the duration of each mixing stage matches the rheological behavior of the material, guaranteeing that the material completes the transition from "preliminary mixing" to "uniform dispersion" within the target duration, thus improving production efficiency while ensuring the mixing effect.

[0071] Step 406 finally clarifies that during batch mixing, the actual temperature control time and stirring speed should be kept consistent with the target values. The optimal process parameters determined in the laboratory or pilot stage are directly applied to batch production, realizing standardized control of the production process. This can significantly reduce quality fluctuations between different batches of products, improve product consistency, and meet the requirements of quality stability for large-scale production.

[0072] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A process for manufacturing modular building formwork using two-component polyurethane, characterized in that: include: Step 1: Arrange the fiber yarn balls, felt, and fabric neatly on the yarn rack according to the process requirements, ensuring that the fiber yarn balls, felt, and fabric are drawn out smoothly; Step 2: Pass the fibers, felt and cloth drawn out from the yarn frame through the yarn threading plate in sequence. Through the hole design of the yarn threading plate, distribute the fibers, felt and cloth to the pre-forming mold according to the preset ratio and distribution method. Step 3: Pre-form a pre-shaped body with the same cross-sectional shape as the product design using a pre-forming mold; Step 4: Preheat the molding mold to the set temperature. The preformed body continuously enters the molding mold cavity. At the same time, the two-component polyurethane mixture is injected into the mold cavity through the glue injection machine. The polyurethane, glass fiber, felt and cloth are cured in the molding mold and pulled out by the traction machine. Step 5: The finished product, which is fed from the traction machine at a constant speed, is cut to the set length by the cutting machine.

2. The process for manufacturing modular building formwork using two-component polyurethane according to claim 1, characterized in that: The fiber is a long fiber, including but not limited to glass fiber, carbon fiber and basalt fiber.

3. The process for manufacturing modular building formwork using two-component polyurethane according to claim 1, characterized in that: The felt is a fiber-processed felt, and the cloth is a fiber-processed cloth.

4. The process for manufacturing modular building formwork using two-component polyurethane according to claim 1, characterized in that: The two-component polyurethane mixture is a mixture of two-component polyurethane and filler. The mixture is an inorganic filler, which includes one or more of calcium carbonate, calcium sulfate, talc, kaolin, and glass microspheres.

5. The process for manufacturing modular building formwork using two-component polyurethane according to claim 1, characterized in that: The finished product, which has been solidified in the mold, is pulled out of the mold at a uniform speed by two hydraulic clamping devices on the pultrusion machine moving forward alternately.

6. The process for manufacturing modular building formwork using two-component polyurethane according to claim 1, characterized in that: Step 4 includes: The actual pre-batch production evaluation process includes: Actual step 41: Obtain the theoretical pultrusion speed range and theoretical wetting-traction coefficient range during the pultrusion molding process of the current application preform and the current application two-component polyurethane mixture; Step 42: Detect the viscosity and surface tension of the currently applied two-component polyurethane mixture, and detect the areal density and thickness of the currently applied preform; Step 43: Determine the actual wetting characteristic parameters of the preform used in the current application based on its areal density and thickness; determine the actual permeation characteristic parameters of the two-component polyurethane mixture used in the current application based on its viscosity and surface tension. Step 44: From the theoretical pultrusion speed range, select multiple pre-selected pultrusion speeds according to a preset gradient, determine the wetting-traction fit coefficient corresponding to each pre-selected pultrusion speed, and determine the wetting-traction fit coefficient that conforms to the theoretical wetting-traction fit coefficient range and whose absolute deviation from 1 is less than the preset deviation value as the first wetting-traction fit coefficient, and the corresponding pre-selected pultrusion speed as the first pultrusion speed; if the first wetting-traction fit coefficient cannot be determined, an alarm is triggered; The impregnation-traction ratio is determined based on the actual impregnation characteristics of the preform, the actual penetration characteristics of the two-component polyurethane mixture, and the pultrusion speed range. If no alarm is triggered in step 44, the pultrusion speed is determined based on the first pultrusion speed. When the current application preform and the current application two-component polyurethane mixture are actually produced in batches, the actual traction speed through the molding die is controlled to be the pultrusion speed.

7. The process for manufacturing modular building formwork using two-component polyurethane according to claim 6, characterized in that: Also includes: Step 45: Control the operation of the mold temperature adjustment device corresponding to each sub-temperature zone according to the theoretical temperature of each sub-temperature zone of the molding die, and detect and determine the temperature uniformity of each sub-temperature zone. An alarm will be triggered if the temperature uniformity of any sub-temperature zone is less than the preset uniformity. Step 46: If no alarm is triggered in step 45, based on the temperature uniformity of each injection sub-temperature zone, obtain and correct the theoretical injection pressure range corresponding to the currently applied preform and the currently applied two-component polyurethane mixture, and determine the corrected injection pressure range. Obtain the theoretical injection pressure range corresponding to the current application preform and the current application two-component polyurethane mixture: within the theoretical injection pressure range, the fitting curve of the theoretical injection pressure - the ultrasonic velocity based on ultrasonic detection when the product exits the molding mold; and extract the target curve segment corresponding to the corrected injection pressure range. The target curve segment is divided into multiple pressure-partial curve segments. The difference between the maximum ultrasonic velocity and the minimum ultrasonic velocity of each pressure-partial curve segment is less than the ultrasonic velocity difference. Step 47: Based on the set pultrusion speed and the corresponding wetting-traction matching coefficient, combined with the sound velocity characteristics of each pressure segment curve, determine the curing evaluation value corresponding to each pressure segment curve, and finally determine the target injection pressure; When producing preforms and two-component polyurethane mixtures for current applications in actual batch production, the target injection pressure is controlled by the actual injection pressure.

8. The process for manufacturing modular building formwork using two-component polyurethane according to claim 1, characterized in that: Before step 4, there is also step 40: preparing a two-component polyurethane mixture; Step 40 includes: Step 401: Obtain the theoretical mixing temperature for each mixing stage of the currently applied two-component polyurethane mixture; Step 402: Take the currently applied two-component polyurethane sample and the currently applied inorganic filler sample, mix them evenly, and obtain the density of the evenly mixed material; and obtain the viscosity of the evenly mixed material at the theoretical mixing temperature of each mixing stage obtained in step 401. Step 403: Obtain the viscosity of the two-component polyurethane at the theoretical mixing temperature of each mixing stage obtained in step 401; Step 404: Determine the dispersion difficulty coefficient based on steps 402 and 403, as well as the density and particle size of the inorganic filler; Step 405: Determine the target stirring speed for each mixing stage based on the dispersion difficulty coefficient and the baseline stirring speed for each mixing stage; The target mixing time for the first mixing stage is determined by the target stirring speed corresponding to the first mixing stage, and the viscosity of the mixing system before the start of the first mixing stage and the viscosity of the mixing system at the end of the target time are determined. Step 406; Based on step 405, determine the viscosity sensitivity coefficient, and based on the viscosity sensitivity coefficient, determine the target duration of each mixing stage; When batch mixing the currently used two-component polyurethane and the currently used inorganic filler, the actual temperature control time of each mixing stage is controlled to be the corresponding target time and the actual stirring speed is controlled to be the corresponding target stirring speed.

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