Reinforcement cage and manufacturing method thereof

Abstract

The invention is suitable for the technical field of building structures, and provides a reinforcement cage and a manufacturing method thereof.The reinforcement cage comprises a main frame body and composite material stirrups, the main frame body comprises a plurality of composite material main reinforcements, and the multiple composite material main reinforcements are parallel to one another and arranged at intervals along a preset track; the composite material stirrups are arranged on the main frame body and connected with the multiple composite material main reinforcements, the composite material stirrups and the main frame body jointly form a reinforcement cage structure, and the composite material stirrups are formed by curing a composite material prepreg tape wound on the main frame body. Compared with a reinforcement cage assembled and manufactured by using a cured and shaped composite material reinforcement material in the prior art, the reinforcement cage provided by the invention does not need to be additionally demolded and bound, and the construction difficulty and cost are relatively low.

Description

Technical Field

[0001] This application belongs to the field of building structure technology, and more specifically, relates to a stiffening cage and its manufacturing method. Background Technology

[0002] Reinforced concrete, with its reliable performance and low cost, is a modern engineering structural material widely used in various fields of civil engineering. With economic development and the continuous advancement of global urbanization, the theory, design, and application of reinforced concrete in structural fields have seen tremendous progress over the past century. However, in contrast to the rapid development in theory, design, and construction technology, the problem of structural durability caused by steel corrosion has become a major concern. During normal use, reinforced concrete develops numerous microcracks. Moisture and other media in the air react with the steel reinforcement inside the concrete through these microcracks, causing corrosion, reducing the durability of the reinforced concrete member, and jeopardizing structural safety. The reduction in the durability of reinforced concrete structures caused by steel corrosion is particularly significant in corrosive environments. Maintaining reinforced concrete structures not only requires substantial financial, human, and material resources but can also pose safety hazards. Using composite material reinforcement to replace steel reinforcement can effectively solve the problem of steel corrosion. Therefore, composite materials have attracted significant attention and widespread application in civil engineering, and composite material reinforcement and stirrups are beginning to replace traditional steel reinforcement products in concrete.

[0003] However, existing composite reinforcement materials are difficult to bend into different shapes of stirrups after curing and shaping, and the reinforcement cage has great construction difficulties (especially when the longitudinal reinforcement is densely distributed, the stirrup diameter is large and the stiffness is high, and it is a closed stirrup). Summary of the Invention

[0004] The purpose of this application is to provide a reinforcing cage and its manufacturing method, which aims to solve the technical problem that the construction of reinforcing cages made of composite material reinforcing materials is difficult in the prior art.

[0005] To achieve the above objectives, according to one aspect of this application, a reinforcement cage is provided, comprising: a main frame body and composite material stirrups, wherein the main frame body includes a plurality of composite material main bars, which are parallel to each other and spaced apart along a preset trajectory; the composite material stirrups are disposed on the main frame body and connected to the plurality of composite material main bars, the composite material stirrups and the main frame body together form a reinforcement cage structure, and the composite material stirrups are formed by curing a composite material prepreg tape wound on the main frame body.

[0006] Optionally, the composite material stirrups are formed by curing composite prepreg tape continuously wound on the main frame, or the composite material stirrups are formed by curing multiple composite prepreg tapes that are spaced apart along the length of the main frame and wound on the main frame respectively.

[0007] Optionally, the main reinforcement of the composite material is a continuous fiber reinforced resin-based composite material; the resin in the continuous fiber reinforced resin-based composite material is at least one of epoxy resin, vinyl ester resin, unsaturated polyester resin, orthophthalic resin, and phenolic resin; or, the resin in the continuous fiber reinforced resin-based composite material is at least one of polyethylene resin, polypropylene resin, polyamide, and polycarbonate.

[0008] Optionally, the composite prepreg tape is a strip-shaped prepreg formed by impregnating continuous fibers, unidirectional tapes made of continuous fibers, and fabrics made of continuous fibers with resin.

[0009] Optionally, the continuous fiber is at least one of carbon fiber, glass fiber, basalt fiber, aramid fiber, and hybrid fiber.

[0010] Optionally, the resin in the composite prepreg tape is at least one of thermosetting resin or thermoplastic resin.

[0011] According to another aspect of this application, a method for manufacturing a reinforcing cage is provided. The method includes: arranging and fixing a plurality of parallel composite material main reinforcing bars at intervals along a preset trajectory to form a main frame; if the resin in the composite prepreg tape is a thermoplastic resin, heating the composite prepreg tape to soften it; if the resin in the composite prepreg tape is a thermosetting resin, not heating the composite prepreg tape; winding the composite prepreg tape in a taut state around the surface of the main frame to a preset number of layers to obtain a semi-finished product; placing the semi-finished product in a specified temperature for curing, and cutting the cured semi-finished product to obtain a reinforcing cage.

[0012] Optionally, the method of heating the composite prepreg tape includes at least one of hot air heating, conductive heating, dielectric heating, electromagnetic heating, electromagnetic radiation heating, and ultrasonic heating.

[0013] Optionally, the composite prepreg tape is wound continuously on the surface of the main frame at a fixed winding angle along the length of the main composite reinforcement in a taut state, and wound to a preset number of layers to obtain a semi-finished product; or, the composite prepreg tape is wound continuously on the surface of the main frame at a varying winding angle along the length of the main composite reinforcement in a taut state, and wound to a preset number of layers to obtain a semi-finished product; or, multiple composite prepreg tapes are wound on the surface of the main frame at preset distances along the length of the main composite reinforcement in a taut state, and wound to a preset number of layers to obtain a semi-finished product.

[0014] Optionally, the winding angle is a, -90°≤a<0°, or 0°<a≤+90°.

[0015] The beneficial effects of the reinforcing cage provided in this application are as follows: Compared with the prior art, the reinforcing cage provided in this application, by placing composite material stirrups on the main frame and connecting the composite material stirrups with multiple composite material main reinforcement bars, enables the reinforcing cage to form a reinforcing cage structure together with the main frame through the composite material stirrups. Compared with traditional reinforcing cages, the reinforcing cage provided in this application has the characteristics of high strength, light weight, and excellent corrosion resistance. Therefore, using the reinforcing cage provided in this application as a component to reinforce concrete structures can significantly improve the durability of reinforced concrete structures, thereby extending the structural life, reducing maintenance costs, and reducing carbon emissions. At the same time, the reinforcing cage provided in this application uses composite material prepreg tape to make composite material stirrups. Since the composite material prepreg tape has a certain degree of flexibility in the uncured state, it can be wound before manufacturing the reinforcing cage. The composite prepreg tape is cured on the main frame to form composite stirrups that are fully connected to the main frame. Compared with the existing technology of using cured composite reinforcement to assemble the reinforcement cage, the composite stirrups of the reinforcement cage provided in this application can be directly formed on the main frame without additional demolding and binding, and can be fully connected to the main frame. This effectively reduces the construction difficulty and cost, and allows the reinforcement cage provided in this application to be manufactured on the construction site. In addition, the reinforcement cage provided in this application can also achieve active control of the mechanical properties, durability and interfacial bonding performance with concrete by adjusting the shape, size and quantity of composite stirrups, and optimizing the winding layup design of the composite prepreg tape (such as winding angle, number of layers), winding tension, material type, heating temperature and pressure, thereby meeting the needs of various structural applications. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application, 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 of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the structure of the reinforcing cage provided in the embodiments of this application;

[0018] Figure 2 This is a schematic diagram of the structure of a reinforcing cage provided in another embodiment of this application;

[0019] Figure 3 A schematic diagram illustrating the manufacturing process of the reinforcing cage provided in this application embodiment;

[0020] Figure 4A schematic diagram of a fiberglass reinforced cage with spiral stirrups provided in an embodiment of this application;

[0021] Figure 5 A schematic diagram of a fiberglass cage with regular hexagonal stirrups provided for an embodiment of this application;

[0022] Figure 6 A schematic diagram of a multi-layer, multi-angle fiberglass reinforced cage with spiral stirrups provided for an embodiment of this application;

[0023] Figure 7 A schematic diagram of a fiberglass reinforced cage with regular hexagonal stirrups, manufactured on-site, provided for an embodiment of this application;

[0024] The details of the reference numerals used in the above figures are as follows:

[0025] 10. Composite material main reinforcement;

[0026] 20. Composite material stirrups;

[0027] 30. Composite material prepreg tape. Detailed Implementation

[0028] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of this application.

[0029] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly or indirectly on that other element. When an element is referred to as being "connected to" another element, it can be directly or indirectly connected to that other element. Unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0030] It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0031] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0032] As described in the background section, reinforced concrete possesses advantages such as reliable performance and low cost, making it a widely used modern engineering structural material in various fields of civil engineering. With economic development and the continuous advancement of global urbanization, the theory, design, and application of reinforced concrete in structural fields have seen tremendous progress over the past century. However, in contrast to the rapid development in theory, design, and construction technology, the problem of structural durability caused by steel corrosion has become a major concern. During normal use, reinforced concrete generates numerous microcracks. Moisture and other media in the air react with the steel reinforcement inside the concrete through these microcracks, causing corrosion, reducing the durability of the reinforced concrete member, and jeopardizing structural safety. The reduction in the durability of reinforced concrete structures caused by steel corrosion is particularly significant in corrosive environments. Maintaining reinforced concrete structures not only requires substantial financial, human, and material resources but can also pose safety hazards. Using composite material reinforcement to replace steel reinforcement can effectively solve the problem of steel corrosion. Therefore, composite materials have attracted significant attention and widespread application in civil engineering, and composite material reinforcement and stirrups are beginning to replace traditional steel reinforcement products in concrete. However, existing composite reinforcement materials are difficult to bend into different shapes of stirrups after curing and shaping, and the reinforcement cage has great construction difficulties (especially when the longitudinal reinforcement is densely distributed, the stirrup diameter is large and the stiffness is high, and it is a closed stirrup).

[0033] See Figures 1 to 7As shown, in order to solve the above problems, according to one aspect of this application, an embodiment of this application provides a reinforcing cage, which includes: a main frame body and composite material stirrups 20, wherein the main frame body includes a plurality of composite material main bars 10, the plurality of composite material main bars 10 are parallel to each other and are spaced apart along a preset trajectory; the composite material stirrups 20 are disposed on the main frame body and connected to the plurality of composite material main bars 10, the composite material stirrups 20 and the main frame body together form a reinforcing cage structure, and the composite material stirrups 20 are cured and formed by a composite material prepreg tape 30 wound on the main frame body. The reinforcing cage provided in this embodiment forms a reinforcing cage structure by placing composite material stirrups 20 on the main frame and connecting the composite material stirrups 20 with multiple composite material main reinforcement bars 10. Compared with traditional reinforcing cages, the reinforcing cage provided in this embodiment has the characteristics of high strength, light weight, and excellent corrosion resistance. Therefore, using the reinforcing cage provided in this embodiment as a component to reinforce concrete structures can significantly improve the durability of reinforced concrete structures, thereby extending structural life, reducing maintenance costs, and reducing carbon emissions. At the same time, the reinforcing cage provided in this embodiment uses composite material prepreg tape 30 to make composite material stirrups 20. Since the composite material prepreg tape 30 has a certain degree of flexibility in the uncured state, during the manufacturing of the reinforcing cage, the uncured composite material prepreg tape 30 can be first wrapped around the main frame, and then the composite material stirrups 20 can be added. The composite material prepreg tape 30 is cured to form composite material stirrups 20 that are fully connected to the main frame. Compared with the existing technology that uses cured composite material reinforcement to assemble the reinforcement cage, the composite material stirrups 20 of the reinforcement cage provided in this embodiment can be directly formed on the main frame without additional demolding and binding, and can be fully connected to the main frame. This effectively reduces the construction difficulty and cost, and allows the reinforcement cage provided in this embodiment to be manufactured on the construction site. In addition, the reinforcement cage provided in this embodiment can also achieve active control of the mechanical properties, durability and interfacial bonding performance with concrete by adjusting the shape, size and quantity of composite material stirrups 20, and optimizing the winding layup design of composite material prepreg tape 30 (such as winding angle, number of layers), winding tension, material type, heating temperature and pressure, thereby meeting the needs of various structural applications.

[0034] In one specific embodiment, the composite material stirrups are formed by curing composite material prepreg tape 30 continuously wound on the main frame, or the composite material stirrups are formed by curing multiple composite material prepreg tapes 30 that are spaced apart along the length of the main frame and respectively wound on the main frame.

[0035] In one specific embodiment, the preset trajectory provided in this embodiment is a circle. Of course, in other embodiments, the preset trajectory provided in this embodiment can also be a rectangle or other shapes.

[0036] In one optional embodiment, the composite material provided in this embodiment refers to a continuous fiber reinforced resin matrix composite material.

[0037] In one specific embodiment, because the composite material has the characteristics of high strength, light weight and excellent corrosion resistance, the reinforcing cage provided in this embodiment has the advantages of being easier to construct and having better durability compared with traditional reinforcing cages that are easily corroded by water, oxygen and chloride ions from the external environment.

[0038] In one specific embodiment, since the reinforcement cage provided in this embodiment adopts the process of directly winding the composite prepreg tape 30 as stirrups on the composite main reinforcement 10, it avoids the relatively time-consuming and laborious demolding and the problems of the position and quantity of stirrups not matching the original design due to improper construction.

[0039] In one specific embodiment, the composite material stirrup 20 is made by using a continuous fiber reinforced resin matrix composite prepreg tape 30, which has advantages such as high production efficiency and stable production quality compared with other continuous fiber reinforced thermosetting resin matrix composite material stirrups 20.

[0040] In one specific embodiment, the reinforcing cage provided in this embodiment is suitable for infrastructure construction in corrosive environments such as coastal areas and areas where snow-melting salt is used extensively. It can also be applied to concrete structures made by directly mixing seawater and sea sand, as well as the construction of offshore islands and reefs.

[0041] In one specific embodiment, the main composite reinforcement 10 in this embodiment is made of continuous fiber reinforced resin-based composite material; the resin in the continuous fiber reinforced resin-based composite material is at least one of epoxy resin, vinyl resin, unsaturated polyester resin, orthophthalic resin, and phenolic resin; or, the resin in the continuous fiber reinforced resin-based composite material is at least one of polyethylene resin, polypropylene resin, polyamide, and polycarbonate.

[0042] In one optional embodiment, the resin used to manufacture the composite main reinforcement 10 provided in this embodiment is at least one of thermoplastic resins such as epoxy resin, vinyl resin, unsaturated polyester resin, phthalic resin, and phenolic resin.

[0043] In another embodiment, the resin used to manufacture the composite main reinforcement 10 provided in this embodiment is a continuous fiber reinforced resin matrix composite material, and the resin is at least one of thermosetting resins such as polyethylene resin, polypropylene resin, polyamide, and polycarbonate.

[0044] In one optional embodiment, the composite main reinforcement 10 provided in this embodiment is an existing fiber-reinforced resin-based composite reinforcement. Of course, in other embodiments, the composite main reinforcement 10 provided in this embodiment can also be a composite reinforcement customized by methods such as winding, pultrusion, and additive manufacturing.

[0045] In one optional embodiment, the fiber-reinforced resin-based composite material reinforcement provided in this embodiment is at least one of plain reinforcement, threaded reinforcement, and sandblasted composite reinforcement.

[0046] In one optional embodiment, the composite material stirrup 20 provided in this embodiment can be a polygonal stirrup, a spiral stirrup, or a combination stirrup with various shapes.

[0047] In one specific embodiment, the composite prepreg tape 30 in this embodiment is a strip-shaped prepreg formed by impregnating continuous fibers, unidirectional tapes made of continuous fibers, and fabrics made of continuous fibers with resin.

[0048] In one specific embodiment, the continuous fiber is at least one selected from carbon fiber, glass fiber, basalt fiber, aramid fiber, and hybrid fiber. The aforementioned fiber materials have advantages such as good durability, high strength, and light weight, which can provide the necessary strength, stiffness, and durability for the composite stirrup 20. This ensures that the composite stirrup 20 meets the in-section shear strength requirements within the expected service life of the structure, while effectively connecting the reinforcing bars and the compression zone concrete so that they can jointly bear the load.

[0049] In one specific embodiment, the resin in the composite prepreg tape 30 is at least one of thermosetting resin or thermoplastic resin. The aforementioned thermosetting resin and thermoplastic resin materials have the characteristics of being plastic at a certain temperature and curing after cooling, as well as good compatibility with fiber materials. They can serve as the matrix of the composite material, providing the necessary toughness and stiffness for the composite stirrup 20, so that the composite stirrup 20 can be directly fixed to the composite main reinforcement 10.

[0050] In one optional embodiment, the glass transition temperature of the resin material used to manufacture the composite prepreg tape 30 is 60°C to 500°C. When the glass transition temperature of the resin material is higher than 500°C, the required heating temperature will be too high, resulting in insufficient softening of the composite prepreg tape 30. This leads to poor winding and bonding of the composite stirrups 20 and may cause safety hazards. Conversely, when the glass transition temperature of the resin material is lower than 60°C, the glass transition temperature is too low. In hot weather or under direct sunlight, the strength and stiffness of the composite stirrups 20 are easily affected, thus threatening structural safety.

[0051] In one optional embodiment, the curing temperature and curing pressure of the composite prepreg tape 30 provided in this embodiment should be selected according to the different resin materials used in the composite prepreg tape 30. If the resin material is a thermoplastic resin, the semi-finished product can be directly placed at room temperature for cooling.

[0052] In one alternative embodiment, the resin used to manufacture the composite prepreg tape 30 provided in this embodiment is a thermoplastic resin.

[0053] In one specific embodiment, the composite stirrup 20 made of composite prepreg tape 30 with thermoplastic resin has advantages over stirrups made of other continuous fiber reinforced thermosetting resin-based composite materials, such as high production efficiency, stable production quality, uniform resin content, weldability, recyclability, and long prepreg storage period.

[0054] In another embodiment, the resin used to manufacture the composite prepreg tape 30 provided in this embodiment is a thermosetting resin.

[0055] See Figure 3 As shown, according to another aspect of this application, a method for manufacturing a reinforcing cage is provided. The method includes: S101, arranging and fixing multiple parallel composite material main reinforcing bars 10 at intervals along a preset trajectory to form a main frame; S103, if the resin in the composite material prepreg tape 30 is a thermoplastic resin, heating the composite material prepreg tape 30 to soften it; if the resin in the composite material prepreg tape 30 is a thermosetting resin, not heating the composite material prepreg tape 30; S105, winding the composite material prepreg tape 30 in a taut state around the surface of the main frame to a preset number of layers to obtain a semi-finished product; S107, placing the semi-finished product in a specified temperature for curing, and cutting the cured semi-finished product to obtain a reinforcing cage. In a specific embodiment, the taut state of the composite material prepreg tape 30 refers to pulling and tightening the composite material prepreg tape 30 so that the composite material prepreg tape 30 can fully contact the surface of the main frame.

[0056] In one specific embodiment, the preset number of layers provided in this embodiment can be one or more layers.

[0057] In an optional embodiment, in step S107, while the semi-finished product is placed at a specified temperature for curing, pressure can be applied to the semi-finished product to improve the curing effect.

[0058] In one specific embodiment, the multiple composite material main ribs 10 provided in this embodiment are fixed by a rotatable support of an external winding device. The multiple composite material main ribs 10 fixed on the rotatable support can serve as a core mold for winding the composite material prepreg tape 30.

[0059] In an optional embodiment, after the multiple composite main ribs 10 form the main frame and before the composite prepreg tape 30 is wound, that is, between steps S101 and S103, the main frame can be supported by setting appropriate filler on the main frame, thereby preventing the main frame from deforming due to force during the winding of the composite prepreg tape 30.

[0060] In one specific embodiment, the composite prepreg tape 30 needs to have a certain tension during the winding process to ensure that after the composite prepreg tape 30 is cured and forms the composite stirrup 20, the composite stirrup 20 can be fully bonded to the composite main reinforcement 10 and have good mechanical properties. If the composite main reinforcement 10 has a large aspect ratio, a filler with a certain rigidity that does not change the original shape of the main frame and does not affect the winding process needs to be placed in the main frame to support the main frame and prevent the main frame from deforming under stress when the composite prepreg tape 30 is wound. At the same time, the filler needs to be removed after the semi-finished product cools down.

[0061] In one optional embodiment, the filler material provided in this embodiment can be at least one of metal materials (such as aluminum tubes, steel tubes, etc.) and organic materials (such as polystyrene foam, various polyethylene inflatable films, bubble bags, wood, paper materials, etc.).

[0062] In one specific embodiment, after the composite prepreg tape 30 provided in this embodiment is introduced to the top of the main frame through the external yarn frame, the composite prepreg tape 30, which is made of thermoplastic resin, can be appropriately heated to fully soften the composite prepreg tape 30.

[0063] In one specific embodiment, the method for heating the composite prepreg tape 30 includes at least one of hot air heating, conductive heating, dielectric heating, electromagnetic heating, electromagnetic radiation heating, and ultrasonic heating.

[0064] In one specific embodiment, after the composite prepreg tape 30 made of thermoplastic resin provided in this embodiment is softened, the softened composite prepreg tape 30 can be pulled out and wrapped around the main frame in a taut state.

[0065] In one specific embodiment, the winding angle provided in this embodiment refers to the angle between the composite prepreg tape 30 and the length direction of the composite main reinforcement 10.

[0066] In one specific embodiment, the composite prepreg tape 30 is wound continuously on the surface of the main frame at a fixed winding angle along the length direction of the composite main rib 10 in a taut state, and wound to a preset number of layers to obtain a semi-finished product; or, the composite prepreg tape 30 is wound continuously on the surface of the main frame at a varying winding angle along the length direction of the composite main rib 10 in a taut state, and wound to a preset number of layers to obtain a semi-finished product; or, multiple composite prepreg tapes 30 are wound on the surface of the main frame at a preset distance along the length direction of the composite main rib 10 in a taut state, and wound to a preset number of layers to obtain a semi-finished product.

[0067] In one specific embodiment, the manufacturing process of the composite material stirrup 20 includes continuously winding the composite material prepreg tape 30 directly onto the main frame to form a stirrup, and winding multiple composite material prepreg tapes 30 at a predetermined distance on the main frame to form a stirrup. The continuous winding process is mainly used to manufacture spiral stirrups, and the winding process at a predetermined distance is mainly used to manufacture polygonal stirrups. Both of the above processes can be used to manufacture composite stirrups.

[0068] In one specific embodiment, the composite prepreg tape 30 is wound along the length of the composite main reinforcement 10 at a fixed or varying winding angle until it covers the entire length of the main frame, thus completing one layer of winding of the composite prepreg tape 30.

[0069] In one specific embodiment, the composite prepreg tape 30 provided in this embodiment can be wound at a fixed winding angle or a variable winding angle throughout the continuous winding process. For example, it can be wound at a winding angle of +80° throughout the entire process, or at a winding angle of +80° for the first half and +60° for the second half. Therefore, the spacing of the composite stirrups 20 and the stirrup reinforcement ratio of the corresponding concrete component can be adjusted and controlled.

[0070] In one optional embodiment, the composite prepreg tape 30 provided in this embodiment may have one or more winding layers.

[0071] In one specific embodiment, the more layers of the composite prepreg tape 30 provided in this embodiment are wound, the greater the thickness of the composite stirrup 20, and the higher the corresponding bearing capacity. However, if the number of layers of the composite prepreg tape 30 is too large and the thickness of the composite stirrup 20 is too large, it will affect the bond between the composite main reinforcement 10 and the composite stirrup 20, weaken the performance of the reinforcement cage, and even cause the composite stirrup 20 to detach from the main frame in extreme cases. Therefore, in practical applications, the comprehensive impact of the number of winding layers on the reinforcement cage should be considered, and a suitable number of winding layers should be selected according to the requirements.

[0072] In one specific embodiment, the winding angle is a, -90°≤a<0°, or 0°<a≤+90°.

[0073] In one optional embodiment, the sign of the winding angle provided in this embodiment is related to the winding direction. When the absolute value of the winding angle is the same, the angle between the composite prepreg tape 30 and the composite main reinforcement 10 along their length is the same. Positive and negative angles represent opposite winding directions. For example, Figure 6 The two 'a's are +83° and -83° respectively.

[0074] In one specific embodiment, the combination of winding layers and winding angle provided in this embodiment includes at least one of single-layer single-angle, single-layer multi-angle, single-layer variable-angle, multi-layer single-angle, multi-layer multi-angle, and multi-layer variable-angle. For example, the composite prepreg tape 30 starts winding from one end of the main frame at a winding angle of +80° and stops winding at the other end of the main frame, winding the entire length to cover the entire length of the main frame, forming a single-layer single-angle spiral composite material stirrup 20; or the composite prepreg tape 30 starts winding from one end of the main frame at a winding angle of +80°, then changes to a winding angle of +60° at half the length of the main frame, stopping winding at the other end of the main frame, forming a single-layer multi-angle spiral composite material stirrup 20 with half lengths of +80° and +60°; or the composite prepreg tape 30 starts winding from one end of the main frame at a winding angle of +10°, linearly increasing the winding angle as the winding distance increases and continuously winding, until the other end of the main frame... When one end stops winding, the winding angle reaches +80°, forming a single-layer variable-angle spiral composite material stirrup 20; or the composite prepreg tape 30 is first wound at a +80° winding angle to cover the entire length of the main frame to form the first layer of composite material stirrup 20, and then wound in the opposite direction at a -80° winding angle to cover the entire length of the main frame again to form the second layer, finally forming a multi-layer multi-angle spiral composite material stirrup 20 with +80° and -80°; or the composite prepreg tape 30 is first wound at a +80° winding angle to cover the entire length of the main frame to form the first layer, and then the winding angle is linearly reduced and continuously wound in the opposite direction as the winding distance increases, until the winding angle reaches -80° at the beginning of the winding, forming a multi-layer variable-angle spiral composite material stirrup 20.

[0075] In one specific embodiment, the above conditions also apply to the polygonal composite material stirrups 20. For example, the composite prepreg tape 30 is wound once at a preset position on the main frame at a +90° winding angle, the composite prepreg tape 30 is cut and moved to the next preset position, and the above process is repeated from one end of the main frame to the other end, covering the entire length of the main frame to form a single-layer, single-angle polygonal composite material stirrup 20; or the composite prepreg tape 30 is wound five times at a preset position on the main frame at a +90° winding angle, the composite prepreg tape 30 is cut and moved to the next preset position, and the above process is repeated from one end of the main frame to the other end, covering the entire length of the main frame to form a multi-layer, single-angle polygonal composite material stirrup 20.

[0076] In one specific embodiment, in step S107, the semi-finished product is cured at a temperature corresponding to the type of resin used in the composite prepreg tape 30, or cured at a temperature and pressure corresponding to the type of resin used in the composite prepreg tape 30, and then cooled at room temperature. If the type of resin used in the composite prepreg tape 30 is a thermoplastic resin, the semi-finished product can be directly cured and cooled at room temperature.

[0077] In one specific embodiment, when the resin used in the composite prepreg tape 30 is a thermoplastic resin, since the composite stirrup 20 is made of the heated and softened composite prepreg tape 30, it needs to be cooled in a suitable environment until the composite prepreg tape 30 is re-cured, wherein the suitable environment includes temperature and pressure environments.

[0078] In one optional embodiment, the curing temperature and pressure environment of the composite prepreg tape 30 provided in this embodiment includes any one of room temperature and normal pressure, room temperature and high pressure, high temperature and normal pressure, and high temperature and high pressure. Room temperature refers to room temperature (about 25°C), normal pressure refers to 1 standard atmosphere (about 101 kPa), and pressure above normal pressure is high pressure. The selection of the curing environment is jointly determined by factors such as the type of resin material used in the composite prepreg tape 30 and the requirements for the bonding quality between the composite main reinforcement 10 and the composite stirrup 20.

[0079] In one specific embodiment, the semi-finished product provided in this embodiment can be cut according to the needs of specific engineering applications after cooling, thereby obtaining a rib cage of a predetermined length.

[0080] In one alternative embodiment, a roughened composite material stirrup 20 can be obtained by adding sand to the surface of the composite prepreg tape 30 using a sand-adding device and then using the sand-adding composite prepreg tape 30 to fabricate the composite stirrup 20.

[0081] In one specific embodiment, the cast-in-place or precast concrete components with reinforcing cages provided in this embodiment can be cured with high-temperature steam, thereby improving the production efficiency of concrete components and ensuring the quality of finished products.

[0082] In one alternative embodiment, the reinforcing cage provided in this embodiment may be prefabricated or manufactured on the construction site.

[0083] In one specific embodiment, if the winding process of the composite prepreg tape 30 is completed manually on the construction site, the winding quality needs to be checked and confirmed before pouring concrete to ensure that the quality of the final reinforcement cage meets the design requirements.

[0084] In one specific embodiment, the reinforcing cage provided in this embodiment can be applied to infrastructure construction in corrosive environments such as coastal areas and areas where snow-melting salt is used extensively, concrete structures made by directly mixing seawater and sea sand, and the construction of offshore islands and reefs.

[0085] In one specific embodiment, the manufacturing method of the reinforcing cage provided in this embodiment is simple to operate, has a short production cycle, and low cost, making it suitable for industrial promotion and large-scale application.

[0086] See Figure 4 As shown, in a specific embodiment, the reinforcing cage provided in this embodiment is a glass fiber reinforced resin-based reinforcing cage with spiral stirrups, that is, a glass fiber composite spiral reinforcing cage. The glass fiber composite spiral reinforcing cage provided in this embodiment consists of two parts: six composite main reinforcing bars 10 and composite stirrups 20 made by continuously winding composite prepreg tape 30. The composite main reinforcing bars 10 are sandblasted glass fiber reinforced composite bars with a total length of 1000mm, a nominal diameter of 25mm, a tensile strength of 597MPa, and an elastic modulus of 41.9GPa. The composite prepreg tape 30 is a continuous glass fiber reinforced thermoplastic polypropylene resin-based composite unidirectional prepreg tape with a fiber mass content of 40%, a width of 10mm, a thickness of 0.25mm, a tensile strength of not less than 500MPa, and a heat distortion temperature of not less than 150℃.

[0087] See Figure 4 As shown, in a specific embodiment, the fiberglass composite spiral reinforcement cage provided in this embodiment has a winding angle α of -83° for the composite prepreg tape 30 during manufacturing.

[0088] In one specific embodiment, when manufacturing the fiberglass composite spiral reinforcement cage provided in this embodiment, the main composite reinforcement 10 is first fixed by the rotatable clamp of the external winding device. The six main composite reinforcement 10 are evenly distributed and fixed on a circle with a diameter of 300mm to obtain the main frame as the mandrel for continuous winding of fixed length. Then, cylindrical polystyrene foam is placed on the main frame as filler to support the main frame and prevent the main frame from deforming under stress during winding. Then, the prepreg tape 30 of composite material is heated by a hot air gun fixed on the external winding device to soften it to semi-transparent. Then, the softened prepreg tape 30 of composite material is pulled out and wound on the main frame at a winding angle of -83° along the length direction of the main composite reinforcement 10 in a taut state. After completion, the winding is repeated twice, for a total of three layers, to obtain a semi-finished product. Then, the semi-finished product is cooled at room temperature and pressure for 5 minutes. Finally, the cooled semi-finished product is cut, and the clamped areas at both ends are removed, with 150mm removed from each end to obtain the reinforcement cage.

[0089] In one specific embodiment, the fiberglass composite spiral reinforcement cage provided in this embodiment is widely used in reinforced concrete structures in the field of civil engineering, especially in columns. Therefore, this embodiment has a relatively general representative significance. The fiberglass composite reinforcement and prepreg tape used in this embodiment have excellent durability and mechanical properties. The purpose of using thermoplastic resin-based composite prepreg tape 30 is to effectively shorten the production time, reduce the inconvenience caused by fixed stirrups during construction, promote the use of composite materials in the field of civil engineering to reduce the consumption of non-renewable resources such as steel, and reduce carbon emissions.

[0090] See Figure 5 As shown, in a specific embodiment, the reinforcing cage provided in this embodiment is a glass fiber reinforced resin-based reinforcing cage with regular hexagonal stirrups, that is, a glass fiber composite regular hexagonal reinforcing cage. The glass fiber composite regular hexagonal reinforcing cage provided in this embodiment consists of two parts: six composite main reinforcing bars 10 and composite stirrups 20 made by winding composite prepreg tape 30 at preset intervals. Among them, the composite main reinforcing bars 10 are sandblasted glass fiber reinforced composite bars with a total length of 1000mm, a nominal diameter of 25mm, a tensile strength of 597MPa, and an elastic modulus of 41.9GPa. The composite prepreg tape 30 is a continuous glass fiber reinforced thermoplastic polypropylene resin-based composite unidirectional prepreg tape with a fiber mass content of 40%, a width of 10mm, a thickness of 0.25mm, a tensile strength of not less than 500MPa, and a heat distortion temperature of not less than 150℃.

[0091] See Figure 5 As shown, in a specific embodiment, when the glass fiber composite hexagonal rib cage provided in this embodiment is manufactured, the winding angle α of the composite prepreg tape 30 is -90°.

[0092] In one specific embodiment, when manufacturing the glass fiber composite hexagonal reinforcement cage provided in this embodiment, the main composite reinforcement 10 is first fixed using a rotatable clamp of an external winding device. Six main composite reinforcement 10s are evenly distributed and fixed on a circle with a diameter of 300mm, forming a main frame that serves as the mandrel for continuous winding at a fixed length. Next, cylindrical polystyrene foam is placed on the main frame as filler to support it and prevent deformation during winding. Then, a hot air gun fixed to the winding device is used to heat the prepreg tape 30, softening it to half its original size. Transparent, then the softened composite prepreg tape 30 is pulled out and wound three times at a +90° winding angle along the length of the composite main rib 10 in a taut state at the starting position at one end of the main frame. The composite prepreg tape 30 is cut and moved 40mm to the other end to the next preset position. The above process is repeated, starting from one end of the main frame and ending at the other end, covering the entire length of the main frame, with a total of three layers, to obtain a semi-finished product. Then the semi-finished product is cooled at room temperature and pressure for 5 minutes. Finally, the cooled semi-finished product is cut, and the clamped areas at both ends are removed, with 150mm removed from each end to obtain the rib cage.

[0093] In one specific embodiment, the fiberglass composite hexagonal reinforcement cage provided in this embodiment has a wide range of applications in the field of civil engineering. By changing the number and position of the main reinforcement bars 10 of the composite material used, common reinforcement cages constrained by rectangular or near-circular stirrups can be fabricated. Furthermore, due to its simple operation and high tolerance for error, the winding method and angle selected in this example can be used for on-site fabrication of reinforcement cages.

[0094] See Figure 6 As shown, in a specific embodiment, the reinforcing cage provided in this embodiment is a multi-layer, multi-angle glass fiber reinforced resin-based reinforcing cage using spiral stirrups, namely, a multi-layer, multi-angle glass fiber composite spiral reinforcing cage. The multi-layer, multi-angle glass fiber composite spiral reinforcing cage provided in this embodiment consists of two parts: six composite main reinforcing bars 10 and composite stirrups 20 made by continuously winding composite prepreg tape 30. The composite main reinforcing bars 10 are sandblasted glass fiber reinforced composite bars with a total length of 1000mm, a nominal diameter of 25mm, a tensile strength of 597MPa, and an elastic modulus of 41.9GPa. The composite prepreg tape 30 is a continuous glass fiber reinforced thermoplastic polypropylene resin-based composite unidirectional prepreg tape with a fiber mass content of 40%, a width of 10mm, a thickness of 0.25mm, a tensile strength of not less than 500MPa, and a heat distortion temperature of not less than 150℃.

[0095] See Figure 6 As shown, in a specific embodiment, the winding angle α of the composite prepreg tape 30 is -83° and +83° respectively during the manufacturing of the multi-layer multi-angle glass fiber composite spiral reinforcement cage provided in this embodiment.

[0096] In one specific embodiment, when manufacturing the multi-layer, multi-angle fiberglass composite spiral reinforcement cage provided in this embodiment, the main composite reinforcement 10 is first fixed using a rotatable clamp of an external winding device. Six main composite reinforcement 10 are evenly distributed and fixed on a circle with a diameter of 300mm, forming a main frame that serves as the mandrel for continuous winding at a fixed length. Next, cylindrical polystyrene foam is placed on the main frame as filler to support it and prevent deformation during winding. Then, a hot air gun fixed to the winding device is used to... The prepreg tape 30 of composite material is heated to soften it to semi-transparent. Then, the softened prepreg tape 30 is pulled out and wound on the main frame at a winding angle of -83° along the length of the main rib 10 of composite material under tension. After completion, the winding angle is changed and another layer is wound on the main frame at a winding angle of +83°. The total number of layers is two, resulting in a semi-finished product. The semi-finished product is then cooled at room temperature and pressure for 5 minutes. Finally, the cooled semi-finished product is cut, and the clamped areas at both ends are removed, with 150mm removed from each end, to obtain the rib cage.

[0097] In one specific embodiment, the multi-layer, multi-angle fiberglass composite spiral reinforcement cage provided in this embodiment has a wider constraint area compared to the fiberglass composite spiral reinforcement cage and the fiberglass composite hexagonal reinforcement cage in the above embodiments. The composite material stirrups 20 of the reinforcement cage provided in this embodiment are wound one layer each at an angle of -83° and +83°, so that the total number of composite protective layers reaches two layers. Compared with the manufacturing method shown in the embodiment of the fiberglass composite spiral reinforcement cage, which produces double-layer fiberglass composite spiral stirrups, the composite material stirrups 20 in this embodiment have a larger contact bonding area with the main frame, a wider constraint area, and a thinner stirrup thickness. This ensures the bonding performance between the stirrups and the main frame and the performance of the reinforcement cage even when more layers of composite material stirrups 20 are required.

[0098] See Figure 7As shown, in a specific embodiment, the reinforcing cage provided in this embodiment is a glass fiber reinforced resin-based reinforcing cage using regular hexagonal stirrups, that is, a glass fiber composite regular hexagonal reinforcing cage. The glass fiber composite regular hexagonal reinforcing cage provided in this embodiment consists of two parts: six composite main reinforcing bars 10 and composite stirrups 20 made by winding composite prepreg tape 30 at preset intervals. The composite main reinforcing bars 10 are sandblasted glass fiber reinforced composite bars with a total length of 1000mm, a nominal diameter of 25mm, a tensile strength of 597MPa, and an elastic modulus of 41.9GPa. The composite prepreg tape 30 is a continuous glass fiber reinforced thermoplastic polypropylene resin-based composite unidirectional prepreg tape with a fiber mass content of 40%, a width of 10mm, a thickness of 0.25mm, a tensile strength of not less than 500MPa, and a heat distortion temperature of not less than 150℃.

[0099] See Figure 7 As shown, in a specific embodiment, when manufacturing the glass fiber composite hexagonal reinforcement cage provided in this embodiment, the main composite reinforcement 10 is first fixed at the construction site. Six main composite reinforcement 10s are evenly distributed and fixed on a circle with a diameter of 300mm to obtain the main frame as a mandrel for continuous winding at a fixed length. Then, the prepreg tape 30 of the composite material is heated by a heating device to soften it to semi-transparent. Then, the softened prepreg tape 30 of the composite material is pulled out and wound three times at a +90° winding angle along the length direction of the main composite reinforcement 10 in a taut state at the starting position at one end of the main frame. The prepreg tape 30 of the composite material is cut and moved 40mm to the other end to the next preset position. The above process is repeated from one end of the main frame to the other end, covering the entire length of the main frame, with a total of three layers, to obtain a semi-finished product. After the semi-finished product cools to room temperature, the composite material stirrups 20 are checked and confirmed to be in the designated position, and the reinforcement cage is obtained.

[0100] In one specific embodiment, the glass fiber composite hexagonal reinforcement cage provided in this embodiment can be manufactured on the construction site by manual or mechanical means, and has a wide range of applications in the field of civil engineering, improving the flexibility of construction.

[0101] In summary, implementing the reinforcing cage and its manufacturing method provided in this embodiment has at least the following beneficial technical effects: The reinforcing cage provided in this embodiment, by placing composite material stirrups 20 on the main frame and connecting the composite material stirrups 20 with multiple composite material main reinforcement bars 10, enables the reinforcing cage to form a reinforcing cage structure together with the main frame through the composite material stirrups 20 and the main frame. Compared with traditional reinforcing cages, the reinforcing cage provided in this embodiment has the characteristics of high strength, light weight, and excellent corrosion resistance. Therefore, using the reinforcing cage provided in this embodiment as a component to reinforce concrete structures can significantly improve the durability of reinforced concrete structures, thereby extending the structural life, reducing maintenance costs, and reducing carbon emissions. At the same time, the reinforcing cage provided in this embodiment uses composite material prepreg tape 30 to make composite material stirrups 20. Since the composite material prepreg tape 30 has a certain degree of flexibility in the uncured state, when manufacturing the reinforcing cage, it is possible to first place the uncured composite material... The prepreg tape 30 is wound around the main frame, and then the prepreg tape 30 is cured to form composite material stirrups 20 that are fully connected to the main frame. Compared with the existing technology of using cured composite material reinforcement to assemble the reinforcement cage, the composite material stirrups 20 of the reinforcement cage provided in this embodiment can be directly formed on the main frame without additional demolding and binding, and can be fully connected to the main frame. This effectively reduces the construction difficulty and cost, and allows the reinforcement cage provided in this embodiment to be manufactured on the construction site. In addition, the reinforcement cage provided in this embodiment can also achieve active control of the mechanical properties, durability and interfacial bonding performance with concrete by adjusting the shape, size and quantity of the composite material stirrups 20, and optimizing the winding layup design of the prepreg tape 30 (such as winding angle, number of layers), winding tension, material type, heating temperature and pressure, thereby meeting the needs of various structural applications.

[0102] The above are merely preferred embodiments of this application and are not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A reinforcement cage, characterized in that, The reinforcement cage comprises: a main frame body comprising a plurality of composite main reinforcement bars (10) arranged in parallel with each other and at intervals along a preset track; a composite stirrup (20) arranged on the main frame body and connected with the plurality of composite main reinforcement bars (10), the composite stirrup (20) and the main frame body together forming a reinforcement cage structure, the composite stirrup (20) being formed by curing a composite prepreg tape (30) wound on the main frame body.

2. The reinforcement cage of claim 1, wherein, The composite stirrup is formed by curing a composite prepreg tape (30) continuously wound on the main frame body, or the composite stirrup is formed by curing a plurality of composite prepreg tapes (30) arranged at intervals along the length direction of the main frame body and wound on the main frame body respectively.

3. The reinforcement cage of claim 1, wherein, The composite main reinforcement bar (10) is made of a continuous fiber reinforced resin-based composite material; The resin in the continuous fiber reinforced resin-based composite material is at least one of an epoxy resin, a vinyl resin, an unsaturated polyester resin, an ortho-phthalic resin, and a phenolic resin; Or, the resin in the continuous fiber reinforced resin-based composite material is at least one of a polyethylene resin, a polypropylene resin, a polyamide, and a polycarbonate.

4. A reinforcement cage according to claim 1 or 2, characterised in that, The composite prepreg tape (30) is one of a continuous fiber, a unidirectional tape made of continuous fibers, and a fabric made of continuous fibers, and is a strip-shaped prepreg formed after impregnation with resin.

5. The reinforcement cage of claim 4, wherein, The continuous fiber is at least one of a carbon fiber, a glass fiber, a basalt fiber, an aramid fiber, and a hybrid fiber.

6. The reinforcement cage of claim 4, wherein, The resin in the composite prepreg tape (30) is at least one of a thermosetting resin or a thermoplastic resin.

7. A method for manufacturing the reinforcement cage according to any one of claims 1 to 6, characterized in that, The method for manufacturing the reinforcement cage comprises: arranging a plurality of the composite main reinforcement bars (10) arranged in parallel with each other at intervals along a preset track and fixing the same to form the main frame body; if the resin in the composite prepreg tape (30) is a thermoplastic resin, heating the composite prepreg tape (30) to soften the same, and if the resin in the composite prepreg tape (30) is a thermosetting resin, not heating the composite prepreg tape (30); winding the composite prepreg tape (30) in a tensioned state on the surface of the main frame body and to a preset number of layers to obtain a semi-finished product; curing the semi-finished product in a specified temperature and cutting the cured semi-finished product to obtain the reinforcement cage.

8. The method of manufacturing a reinforcement cage according to claim 7, wherein The method for heating the composite prepreg tape (30) comprises at least one of hot air heating, conduction heating, dielectric heating, electromagnetic heating, electromagnetic radiation heating, and ultrasonic heating.

9. The method of manufacturing a reinforcement cage according to claim 7, wherein The composite prepreg tape (30) is wound in a tensioned state on the surface of the main frame body continuously along the length direction of the composite main reinforcement bar (10) at a fixed winding angle and to a preset number of layers to obtain a semi-finished product. Or, the composite material prepreg tape (30) is continuously wound on the surface of the main frame body along the length direction of the composite material main reinforcement (10) at a changing winding angle in a tensioned state, and wound to a preset number of layers to obtain the semi-finished product. Or, a plurality of the composite material prepreg tapes (30) are wound on the surface of the main frame body at a preset distance apart along the length direction of the composite material main reinforcement (10) in a tensioned state, and wound to a preset number of layers to obtain the semi-finished product.

10. The method of manufacturing a reinforcement cage according to claim 9, wherein The winding angle is a, -90°≤a<0°, or 0°<a≤+90°.

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