Needling method cement blanket and processing technology thereof

Abstract

The invention provides a needling method cement blanket and a processing technology thereof, and relates to the technical field of cement blankets, the needling method cement blanket comprises a top fabric layer, function complementation is achieved through a three-layer composite structure of the top fabric layer, a curable layer and a bottom fabric layer, a top polyester non-woven fabric has filtering and protecting effects, particles of the curable layer can be prevented from seeping out, and the effect of preventing the particles from seeping out is achieved. The high-strength polypropylene fiber woven fabric at the bottom layer provides stable support, so that the shape stability in construction and use is guaranteed; the integrated connection characteristic is prominent, all the layers are tightly combined through the needling technology, the layering problem is avoided, and the overall reliability is improved. The real-time monitoring module arranged on the needling machine can dynamically capture the thickness change of the curable layer, the response time is shortened to be within 0.5 second, and the thickness deviation can be found in time; deviation correction is automatic, when the thickness exceeds the threshold value of + / -0.5 mm, the spreading speed is automatically adjusted, manual intervention is not needed, the thickness out-of-tolerance rate is reduced to 1% or below from 15% or above of a traditional technology, and the problem of uneven thickness is thoroughly solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of cement blanket, in particular to a needle-punched cement blanket and a processing technology thereof. BACKGROUND

[0002] The cement blanket is a kind of composite material combining cement and fiber material together, which has unique performance advantages. It has good flexibility, can be rolled like cloth when not watered, is convenient for transportation and storage, greatly reduces the transportation cost and storage space requirement, and can quickly solidify to form a structure layer with certain strength and durability once watered, which relatively simply constructs and effectively shortens the construction period.

[0003] The prior art such as the patent with publication number CN103290810A discloses a multifunctional composite material blanket and a trench construction technology thereof, which solves the transportation problem, but lacks a control means for the thickness of the cement blanket. The thickness uniformity of the cement blanket directly determines the stability of the core performance such as strength and durability, and the thickness deviation will cause significant difference in material performance, affecting the use effect of the cement blanket. SUMMARY

[0004] The technical problem to be solved by the present application is that there is a lack of a control means for the thickness of the cement blanket, the thickness uniformity of the cement blanket directly determines the stability of the core performance such as strength and durability, and the thickness deviation will cause significant difference in material performance, affecting the use effect of the cement blanket.

[0005] The technical solution adopted by the present application to solve the technical problem is a needle-punched cement blanket, comprising a top fabric layer, a bottom fabric layer and a solidifiable layer, characterized in that: the solidifiable layer is arranged between the top fabric layer and the bottom fabric layer, the top fabric layer is 2 layers of polyester short fiber non-woven fabric, the gram weight per square meter is 360g-450g, and the fiber diameter is 15-25um; the bottom fabric layer is high-strength polypropylene plain woven fabric, the warp breaking strength is not less than 800N / 5cm, and the weft breaking strength is not less than 750N / 5cm; the solidifiable layer comprises P.O 42.5 ordinary portland cement, composite additive and glass fiber bundle, the three are integrally connected with the fabric layer through a needle punching process to form an overall structure.

[0006] Preferably, the mass ratio of each component in the solidifiable layer is: cement 70%-85%, composite additive 5%-8%, and glass fiber bundle 8%-20%; the composite additive is compounded by a water reducing agent, an early strength agent and a crack resistance agent according to a mass ratio of 2:1:1; the glass fiber bundle has a fineness of 1000D-1500D and a length of 3.5-5cm, and is uniformly arranged along the thickness direction with a distribution density of 25-35 needles / cm² in the solidifiable layer.

[0007] Preferably, the needle punching process parameters are: the needle punching depth is 130% to 160% of the total thickness of the fabric layer, the needle punching density is 35 needles / cm2 to 45 needles / cm2; the glass fiber bundle penetrates the curable layer and is interwoven with the top fabric layer and the bottom fabric layer, and the thickness error of the curable layer is controlled within ±0.5 mm.

[0008] Preferably, the functional structure is further provided: low-strength cotton lines are arranged at intervals of 50 cm along the interface between the top / bottom fabric and the curable layer to assist in breaking the lines, or high-strength glass fiber reinforcing ribs with a rectangular cross section are arranged in the curable layer along the length / width direction, the diameter of the reinforcing rib is 3 mm to 5 mm, and the spacing is 10 cm to 15 cm.

[0009] Preferably, the needle-punched cement blanket can be curled into a cylinder with a diameter of ≤30 cm without water; the hydration reaction is started after 15 to 25 minutes of water contact, initial setting is achieved within 4 hours; after complete curing, the compressive strength is ≥25 MPa, the flexural strength is ≥4 MPa, the waterproof level reaches GB 50167 P8 level, the fireproof level reaches GB 8624 A1 level, and the service life is ≥20 years in an environment of -30℃ to 60℃ and humidity ≥95%.

[0010] Preferably, a needle-punched cement blanket processing process, Step one, raw material pretreatment: the fabric is dried to a water content of ≤5%, the cement is passed through an 80-mesh sieve, and the fiber bundle is cut to a preset length; Step two, mixing and stirring: a JS500 mixer is used to stir the cement and additives at a speed of 190-230 r / min for 3 to 5 minutes; Step three, layering and laying: after positioning the bottom fabric, the fiber bundle and the mixed material are laid in sequence, and the thickness error of the curable layer is ≤0.5 mm; Step four, needle punching: a GM-800 needle punching machine is used to complete the compounding at a frequency of 800 to 1200 times / min and an 18# triangular needle; Step five, post-processing: the cutting accuracy is ±1 cm, and the winding tension is controlled at 50 to 80 N.

[0011] Preferably, the needle punching machine is equipped with a thickness real-time monitoring module, which automatically adjusts the material laying speed when the thickness deviation of the curable layer exceeds ±0.5 mm.

[0012] Preferably, the mixer is provided with a raw material proportioning and weighing system, and the metering accuracy reaches ±100 g, ensuring accurate component proportions.

[0013] In summary, the beneficial effects of the present application are: Through the three-layer composite structure of the top fabric layer, the curable layer and the bottom fabric layer, the functions are complementary, the top polyester non-woven fabric has filtering and protection effects, can block the particles of the curable layer from seeping out, the bottom high-strength polypropylene woven fabric provides stable support, and guarantees the shape stability during construction and use; and the materials are accurately matched, the polyester, polypropylene and specific cement materials are selected according to the functional requirements of each layer, which not only ensures the flexibility for convenient transportation and construction, but also lays a foundation for the strength after solidification; the integrated connection characteristics are prominent, each layer is tightly combined through the needling process, the delamination problem is avoided from the root of the structure, and the overall reliability is improved.

[0014] The real-time monitoring module equipped in the needling machine can dynamically capture the thickness change of the curable layer, compared with the traditional manual inspection, the response time is shortened to 0.5 seconds, the thickness deviation is found in time; the deviation correction is automated, when the thickness exceeds the threshold of ±0.5mm, the paving speed is automatically adjusted, without manual intervention, the thickness out-of-tolerance rate is reduced from more than 15% of the traditional process to less than 1%, and the problem of uneven thickness is completely solved. BRIEF DESCRIPTION OF DRAWINGS

[0015] The application will be further described below in conjunction with the drawings and examples.

[0016] Figure 1 It is a schematic diagram of the three-dimensional structure of the application.

[0017] Legend: 1, top fabric layer; 2, bottom fabric layer; 3, curable layer. DETAILED DESCRIPTION

[0018] The application will be further described below in conjunction with the drawings and examples.

[0019] In the description of the application, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "connected" should be understood broadly, for example, it can be fixedly connected, or detachably connected, or integrally connected; it can be mechanically connected, or electrically connected; it can be directly connected, or indirectly connected through an intermediate medium. For those skilled in the art, the specific meaning of the above terms in the application can be understood according to the specific circumstances.

[0020] Figure 1The illustrated needle punching method cement blanket includes a top fabric layer 1, a bottom fabric layer 2, and a curable layer 3, the curable layer 3 is arranged between the top fabric layer 1 and the bottom fabric layer 2, the top fabric layer 1 is 2 layers of polyester short fiber non-woven fabric, the gram weight per square meter is 360g-450g, the fiber diameter is 15μm-25μm; the bottom fabric layer 2 is high-strength polypropylene plain woven fabric, the warp breaking strength is not less than 800N / 5cm, and the weft breaking strength is not less than 750N / 5cm; the curable layer 3 includes P.O 42.5 ordinary portland cement, composite additives and glass fiber bundles, the three are integrally connected with the fabric layer through the needle punching process to form an overall structure.

[0021] Figure 1 The three-layer composite structure of the top fabric layer 1, the curable layer 3 and the bottom fabric layer 2 realizes functional complementation, the top polyester non-woven fabric has filtering and protection effects, can block the penetration of curable layer 3 particles, the bottom high-strength polypropylene woven fabric provides stable support and guarantees the shape stability during construction and use; and the material selection is accurately matched, polyester, polypropylene and specific cement materials are selected according to the functional requirements of each layer, which not only ensures flexibility for transportation and construction, but also lays a foundation for strength after curing; the integrated connection characteristic is prominent, each layer is tightly combined through the needle punching process, the delamination problem is avoided from the root of the structure, and the overall reliability is improved. The material and connection method of each layer are clear, which provides a stable structure framework for subsequent performance optimization, and solves the problems of loose structure and single function of traditional cement blankets.

[0022] Figure 1 The mass fraction of each component in the curable layer 3 is: cement 70%-85%, composite additives 5%-8%, and glass fiber bundles 8%-20%; the composite additives are compounded by water reducing agent, early strength agent and anti-cracking agent according to a mass ratio of 2:1:1; the glass fiber bundle has a fineness of 1000D-1500D and a length of 3.5cm-5cm, and is uniformly arranged in the curable layer 3 with a distribution density of 25 needles / cm²-35 needles / cm² along the thickness direction. The distribution ratio is optimized, the cement proportion of 70%-85% ensures the strength after curing, the reasonable proportion of composite additives and fiber bundles considers the work performance and toughness, and avoids the performance defects of single material; the composite additives are compounded scientifically, the water reducing agent improves the workability and ease of construction, the early strength agent shortens the curing period, and the anti-cracking agent reduces shrinkage cracks; the fiber bundle parameters are accurate, the combination of 1000D-1500D fineness and 3.5cm-5cm length with a distribution density of 25-35 needles / cm² can uniformly disperse stress and greatly improve the bending and tensile properties of the curable layer 3. By specifying the component ratio of the curable layer 3 and the fiber bundle parameters, the core performance of the cement blanket is accurately controlled, which not only ensures the curing speed and construction convenience, but also strengthens the material toughness, and solves the problems of easy cracking and uneven performance of traditional cement blankets.

[0023] Figure 1The shown needle punching process parameters are: needle punching depth is 130% to 160% of the total thickness of the fabric layer, needle punching density is 35 needles / cm2 to 45 needles / cm2; the glass fiber bundle penetrates the curable layer 3 and is interwoven with the top fabric layer 1 and the bottom fabric layer 2, and the thickness error of the curable layer 3 is controlled within ±0.5mm. The needle punching process parameters are quantified, and the needle punching depth of 130% to 160% and the density of 35 to 45 needles / cm2 ensure that the fiber bundle penetrates each layer and is tightly interwoven, strengthens the interlayer bonding force, and completely solves the delamination problem; the thickness is controlled accurately, the thickness error of the curable layer 3 is controlled within ±0.5mm, which directly ensures the uniformity and stability of the performance of the cement carpet strength, durability, etc., and meets the high-precision engineering requirements; the process and structure are coordinated, through the cooperation of the needle punching parameters and the fiber bundle distribution, the structure stability and the thickness uniformity are realized. Through process and precision control, the core problem of uneven thickness in the background technology is solved, and the thickness is accurately controlled through quantized needle punching parameters, and the interlayer connection is strengthened, which provides a process guarantee for the performance stability of the cement carpet.

[0024] Figure 1 The shown also has a functional structure: low-strength cotton thread is provided every 50cm along the interface between the top / bottom fabric and the curable layer 3, or high-strength glass fiber reinforcing bars with rectangular cross-section are provided in the curable layer 3 along the length / width direction, the reinforcing bar diameter is 3mm to 5mm, and the spacing is 10cm to 15cm. The design of the breaking line makes the cement carpet easy to cut along the preset position, and the cutting efficiency is improved by more than 50%, reducing the construction difficulty; the design of the reinforcing bar improves the performance in a targeted manner, the combination of 3 to 5mm diameter and 10 to 15cm spacing can directionally enhance the tensile and impact resistance of the cement carpet, and adapt to complex stress scenarios; the structure design is flexible, and the breaking line or reinforcing bar structure can be selected according to the engineering requirements, taking into account the construction convenience and structural strength requirements. Through the addition of functional structures, the optional solutions of construction convenience and structural reinforcement are expanded on the basis of basic performance, so that the cement carpet can adapt to different construction scenarios and stress requirements, improving the universality and practicality of the product.

[0025] Figure 1The water contact is 15-25 minutes, initial setting is 4 hours, the compressive strength is ≥25MPa, the flexural strength is ≥4MPa, the waterproof grade reaches GB 50167 P8 level, the fireproof grade reaches GB 8624 A1 level, and the service life is ≥20 years under the environment of-30℃ to 60℃ and humidity ≥95%. The construction and storage convenience is prominent, the transportation volume is reduced by more than 60% by rolling into a cylinder with a diameter of ≤30cm, the solidification performance is controllable, the reaction is started in 15-25 minutes and the initial setting is 4 hours, which reserves sufficient time for shaping and pre-construction, and shortens the construction period, the comprehensive performance is superior, the compressive strength is ≥25MPa, the waterproof grade is P8, the fireproof grade is A1, and the temperature resistance range is-30℃ to 60℃, which can adapt to various harsh environments, and the service life of more than 20 years greatly reduces the maintenance cost. By defining the key performance indicators of the cement blanket, the convenience of construction and transportation is ensured, and through the setting of high strength and high weather resistance indicators, the product can meet the needs of complex engineering and extreme environment, and the market competitiveness and engineering applicability of the product are improved.

[0026] Processing technology of the needle-punched cement blanket, Step one, raw material pretreatment: the fabric is dried to a water content of ≤5%, the cement is passed through an 80-mesh sieve, and the fiber bundle is cut to a preset length; Step two, mixing and stirring: a JS500 mixer is used to stir the cement and additives at a speed of 190-230r / min for 3-5 minutes; Step three, layering and laying: after positioning the bottom fabric, the fiber bundle and the mixed material are laid in turn, and the thickness error of the curable layer 3 is ≤0.5mm; Step four, needle punching: a GM-800 needle punching machine is used to complete the compounding at a frequency of 800-1200 times / min and an 18# triangular needle; Step five, post-processing: the cutting accuracy is ±1cm, and the winding tension is controlled at 50-80N.

[0027] The needle punching machine is equipped with a thickness real-time monitoring module, which automatically adjusts the laying speed when the thickness deviation of the solidifiable layer 3 exceeds ±0.5mm. The thickness control is intelligent, and the real-time monitoring module equipped in the needle punching machine can dynamically capture the thickness change of the solidifiable layer 3. Compared with traditional manual inspection, the response time is shortened to 0.5 seconds, realizing the instant discovery of thickness deviation. The deviation correction is automatic, and the laying speed is automatically adjusted when the thickness exceeds the threshold of ±0.5mm, without manual intervention. The thickness out-of-tolerance rate is reduced from more than 15% in traditional process to less than 1%, completely solving the problem of uneven thickness. The production continuity is improved, avoiding downtime loss caused by manual adjustment. The daily output of a single production line can be increased by 10%-15%, while reducing the cost of rework of unqualified products. The quality traceability is convenient, and the monitoring module can record the thickness data throughout the process, providing accurate basis for product quality traceability and meeting the strict engineering quality acceptance requirements. By adding an intelligent monitoring and adjusting system to the needle punching machine, the thickness uniformity of the cement blanket is ensured from the process level, and the production efficiency and quality traceability ability are improved. It is a key intelligent upgrade of the basic processing technology.

[0028] The mixer is equipped with a raw material proportioning and weighing system, with a measurement accuracy of ±100g, ensuring accurate component proportioning. The component proportioning is accurate, and compared with the traditional volume measurement method, the proportioning error is reduced from more than 5% to less than 0.5%, ensuring that the component proportion of cement, additives, etc. strictly meets the design requirements. The performance stability is improved, and the accurate proportioning control avoids problems such as abnormal solidification speed and insufficient strength caused by raw material proportion deviation, so that the compressive strength of the cement blanket after solidification is controlled within ±0.8MPa. The raw material cost is optimized, the waste of raw materials caused by inaccurate proportioning is reduced, and the raw material utilization rate of single batch production is increased by 3%-5%, reducing production cost. The operation threshold is reduced, the weighing system automatically completes raw material measurement, reduces the dependence on human experience, reduces the skill requirements of operators, and avoids human measurement errors. By equipping a high-precision weighing system, the problem of component proportioning ambiguity in traditional process is solved, providing a source guarantee for the stability of the core performance of the cement blanket, while realizing cost reduction and efficiency improvement and operation simplification, improving the practicality and economy of the process.

[0029] Working principle: Through the three-layer composite structure of the top fabric layer (1), the solidifiable layer (3) and the bottom fabric layer (2), the functions are complementary, the top polyester non-woven fabric has filtering and protection functions, can block the solidifiable layer (3) particles from seeping out, and the bottom high-strength polypropylene woven fabric provides stable support to ensure shape stability during construction and use; and the materials are accurately matched, and polyester, polypropylene and special cement materials are selected according to the functional requirements of each layer, which not only ensures flexibility for transportation and construction, but also lays a foundation for strength after solidification; the integrated connection feature is prominent, and each layer is tightly combined through the needle punching process, avoiding the problem of delamination from the root of the structure, and improving the overall reliability.

[0030] The above merely describes the preferred embodiment of the present application, but the present application is not limited to other forms, any person skilled in the art can use the disclosed technical content to make changes or equivalent embodiments of equivalent changes applied to other fields, but as long as it does not deviate from the technical scheme of the present application, any simple modification, equivalent change and modification of the above embodiments according to the technical essence of the present application still belongs to the protection scope of the technical scheme of the present application, and in the description of the present application, it should be pointed out that unless otherwise specified and limited, the terms "mounting", "connection" should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or it can be integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be connected inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

Claims

1. Needle-punched cement carpet comprising a top fabric layer (1), a bottom fabric layer (2) and a curable layer (3), characterized in that: The solidifiable layer (3) is arranged between the top fabric layer (1) and the bottom fabric layer (2), the top fabric layer (1) is 2-layer polyester short fiber non-woven fabric, the gram weight per square meter is 360g-450g, and the fiber diameter is 15-25um; The bottom fabric layer (2) is high-strength polypropylene plain woven fabric, the warp breaking strength is not less than 800N / 5cm, and the weft breaking strength is not less than 750N / 5cm; The solidifiable layer (3) comprises P.O 42.5 ordinary portland cement, composite additive and glass fiber bundle, which are integrally connected with the fabric layer by needling process to form an overall structure.

2. A needlepunched cement carpet according to claim 1, characterized in that: The mass ratio of each component in the solidifiable layer (3) is: cement 70%-85%, composite additive 5%-8%, and glass fiber bundle 8%-20%; the composite additive is compounded by water reducing agent, early strength agent and crack resistance agent according to the mass ratio of 2:1:1; the glass fiber bundle has a fineness of 1000D-1500D and a length of 3.5-5cm, and is uniformly arranged in the solidifiable layer (3) with a distribution density of 25-35 needles / cm² along the thickness direction.

3. A needle cement blanket according to claim 2, characterised in that: The needling process parameters are: the needling depth is 130%-160% of the total thickness of the fabric layer, and the needling density is 35-45 needles / cm².

4. A needle cement blanket according to claim 3, characterised in that: The glass fiber bundle penetrates the solidifiable layer (3) and is interwoven with the top fabric layer (1) and the bottom fabric layer (2), and the thickness error of the solidifiable layer (3) is controlled within ±0.5mm.

5. A needle cement blanket according to claim 4, characterised in that: The functional structure is also provided: low-strength cotton thread is arranged every 50cm along the interface between the top / bottom fabric and the solidifiable layer (3), or rectangular cross-section high-strength glass fiber reinforcing bars are arranged in the solidifiable layer (3) along the length / width direction.

6. A needle cement blanket according to claim 5, characterised in that: The reinforcing bar has a diameter of 3-5mm and a spacing of 10-15cm.

7. A needle cement blanket according to claim 6, characterised in that: The solidifiable layer (3) can be curled into a cylinder with a diameter of ≤30cm without water, and starts the hydration reaction after 15-25 minutes of water contact, and the initial setting is achieved within 4 hours; after complete curing, the compressive strength is ≥25MPa, the bending strength is ≥4MPa, the waterproof level reaches GB 50167 P8 level, the fire resistance level reaches GB 8624 A1 level, and the service life is ≥20 years under the environment of-30-60℃ and humidity ≥95%.

8. A needle punched cement carpet processing process characterized by: The method comprises the following steps: Step one, raw material pretreatment: fabric drying to water content ≤5%, cement passing through an 80-mesh sieve, and fiber bundle cutting to a preset length; Step two, mixing and stirring: JS500 type stirrer stirring cement and additive at a speed of 190-230r / min for 3-5 minutes; Step three, layering: after positioning the bottom fabric, the fiber bundle and the mixed material are laid in sequence, and the thickness error of the solidifiable layer (3) is ≤0.5mm; Step four, needling and compounding: GM-800 type needle machine completes the compounding at a frequency of 800-1200 times / min and 18# three-edge needle; Step five, post-processing: cutting accuracy ±1cm, and winding tension control in 50-80N.

9. A process for manufacturing a needle punched cement blanket according to claim 8, characterized in that: The needle machine is equipped with a thickness real-time monitoring module, which automatically adjusts the laying speed when the thickness deviation of the solidifiable layer (3) exceeds ±0.5mm.

10. A process for manufacturing a needle punched cement blanket according to claim 9, characterized in that: The mixer is provided with a raw material proportioning and weighing system, and the metering accuracy reaches ±100g to ensure accurate component proportion.

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