A resin concrete monolithic drainage ditch and its manufacturing process

Abstract

This invention discloses a resin concrete monolithic drainage ditch and its production process, belonging to the field of drainage facility technology. The drainage ditch is made of modified resin concrete, its components including cashew nutshell oil-modified phenolic resin, hexahydrophthalic anhydride curing agent, nano-grade zinc oxide powder, composite aggregate, aluminate coupling agent, and expanded vermiculite powder. The composite aggregate contains fused silica sand, corundum sand, and pretreated continuous basalt fibers. The production process includes raw material pretreatment, batching, mixing, vacuum vibration molding, and stepped curing. This invention, through material formulation optimization and process improvement, enhances the mechanical properties, weather resistance, impermeability, and antibacterial properties of the drainage ditch, reduces weight, and facilitates construction, solving the performance deficiencies of existing products and making it suitable for various drainage scenarios.

Description

Technical Field

[0001] This invention relates to the field of drainage facilities technology, specifically to a resin concrete monolithic drainage ditch and its manufacturing process. Background Technology

[0002] Drainage ditches, as important drainage facilities, are widely used in municipal engineering, highways, residential communities, industrial parks, and other scenarios. Their performance directly affects the stability and service life of the drainage system. Traditional drainage ditches are mostly made of ordinary concrete, which has many inherent defects:

[0003] First, ordinary concrete has a high porosity and poor impermeability. Long-term contact with sewage can easily cause steel corrosion and matrix carbonization, leading to a decrease in structural strength. Its service life is generally only 5-8 years.

[0004] Secondly, its large weight requires large hoisting equipment for transportation and construction, which increases construction costs and difficulty.

[0005] Furthermore, it lacks frost resistance and is prone to cracking and peeling after repeated freeze-thaw cycles in cold regions, resulting in high maintenance costs.

[0006] With the development of materials technology, resin concrete, with its excellent corrosion resistance, high strength, and low permeability, is gradually replacing traditional concrete in the preparation of drainage ditches. However, existing resin concrete drainage ditches still have significant shortcomings in material formulation and production processes:

[0007] Limited choice of resin matrix: Most use epoxy resin or ordinary phenolic resin. Although epoxy resin has high strength, it has poor weather resistance and is prone to aging and yellowing when exposed to ultraviolet light for a long time. Ordinary phenolic resin is brittle, has insufficient impact resistance, and has a high free phenol content, which does not meet environmental protection requirements.

[0008] Limited functionality: It does not take into account the common problem of microbial growth in drainage scenarios, especially the easy growth of algae and bacteria in humid environments, which can lead to blockage of drainage channels and the generation of odors.

[0009] The production process is crude: fibers are prone to agglomeration during the mixing process, and improper control of vacuum vibration parameters leads to insufficient density of the mixture; the curing stage mostly adopts natural curing, which takes as long as 20-30 days, and fluctuations in environmental temperature and humidity can easily cause unstable product performance.

[0010] Therefore, in order to solve the above problems, a resin concrete monolithic drainage ditch and its production process are proposed. The material has an excellent formula, an optimized production process, and combines mechanical properties and functional characteristics. Summary of the Invention

[0011] The present invention aims to solve the problems of poor weather resistance, insufficient strength and toughness, lack of antibacterial function, unstable quality due to unreasonable production process, and poor construction adaptability of existing resin concrete drainage ditches.

[0012] To achieve the above objectives, the present invention provides the following technical solution:

[0013] The technical solution provided by this invention is: a resin concrete monolithic drainage ditch, characterized in that it includes a monolithic drainage ditch body made of modified resin concrete;

[0014] The modified resin concrete is composed of the following components by weight: 18-22 parts cashew nut shell oil modified phenolic resin, 5-7 parts hexahydrophthalic anhydride curing agent, 2-4 parts nano-grade zinc oxide powder, 105-115 parts composite aggregate, 1.5-2 parts aluminate coupling agent, and 3-5 parts expanded vermiculite powder.

[0015] The composite aggregate is composed of fused silica sand with a particle size of 0.1-0.5 mm, corundum sand with a particle size of 3-5 mm, and continuous basalt fibers with a length of 5-9 mm in a weight ratio of 1:2.5:0.2.

[0016] The continuous basalt fiber was pretreated with silane coupling agent KH-550: it was soaked in a 1% ethanol solution for 30 minutes and then dried.

[0017] The drainage ditch body has a trapezoidal cross section, with 3-5 reinforcing ribs extending along the length of the inner wall, and hemispherical anti-slip protrusions distributed in a matrix at the bottom. Both ends are provided with a boss with a sealing groove and a groove with a sealing rib. The boss and the groove are interference fit, and the sealing groove is provided with a water-swellable sealing strip.

[0018] Furthermore, the preparation method of the cashew nut shell oil modified phenolic resin is as follows: 30-40 parts by weight of cashew nut shell oil and 60-70 parts by weight of phenol are mixed, 2-3 parts by weight of 30% sodium hydroxide solution are added as a catalyst, the temperature is raised to 70-75℃ and stirred for 30 minutes, then 50-60 parts by weight of 37% formaldehyde solution are added, the temperature is controlled at 80-90℃ and reacted for 2-3 hours, and the temperature is lowered to below 40℃ to obtain the resin. The free phenol content is ≤3%, the solid content is ≥85%, and the viscosity (25℃) is 800-1200 mPa·s.

[0019] Furthermore, the expanded vermiculite powder has a particle size of 0.3-1 mm and a bulk density of 80-120 kg / m³. 3 Thermal conductivity ≤0.06W / (m·K).

[0020] A manufacturing process for a resin concrete monolithic drainage ditch includes the following steps:

[0021] S1: Raw material pretreatment: Continuous basalt fibers are cut into lengths of 5-9 mm, soaked in 1% KH-550 ethanol solution of silane coupling agent for 30 minutes, and dried at 80°C for later use; expanded vermiculite powder is dried at 105°C for 2 hours to remove moisture.

[0022] S2: Weigh the raw materials by weight: 18-22 parts cashew nut shell oil modified phenolic resin, 5-7 parts hexahydrophthalic anhydride curing agent, 2-4 parts nano-grade zinc oxide powder, 105-115 parts composite aggregate (fused silica sand, corundum sand, and pretreated basalt fiber mixed at a ratio of 1:2.5:0.2), 1.5-2 parts aluminate coupling agent, and 3-5 parts expanded vermiculite powder;

[0023] S3: Mixing and stirring: Add cashew nut shell oil modified phenolic resin and aluminate coupling agent to a planetary mixer and stir at 500 r / min for 2 minutes. Add nano-grade zinc oxide powder and adjust the speed to 1000 r / min and stir for 3 minutes. Then add composite aggregate and stir at 800 r / min for 6 minutes. Finally, add hexahydrophthalic anhydride curing agent and expanded vermiculite powder and stir at 400 r / min for 2 minutes.

[0024] S4: Molding: Pour the mixture into a steel mold with a temperature-controlled jacket, and use a vacuum vibration molding machine: first, evacuate to -0.09MPa and hold for 2 minutes, then turn on the vibration device (amplitude 0.5mm, frequency 55Hz) and vibrate for 10 minutes, while simultaneously introducing 30℃ hot water through the jacket for heat preservation.

[0025] S5: Curing: Place the molded part into a constant temperature and humidity curing chamber, first cure it at 23℃ and 65% relative humidity for 5 hours, then raise the temperature to 55℃ and 85% relative humidity at a rate of 5℃ / hour for 7 hours, then lower the temperature to 32℃ at a rate of 3℃ / hour and maintain it for 12 hours, and finally take it out and cure it naturally for 12 days to obtain a resin concrete monolithic drainage ditch.

[0026] Furthermore, the planetary mixer in S3 has a double-ribbon structure for its impeller, with a gap of ≤5mm between the impeller blade and the barrel wall.

[0027] Furthermore, the temperature control interlayer of the steel mold in S4 uses circulating water heating, with a water temperature fluctuation range of ≤±1℃.

[0028] Furthermore, the humidity control accuracy of the S5 constant temperature and humidity curing chamber is ±3%RH, and the temperature control accuracy is ±0.5℃.

[0029] The beneficial effects of this technical solution are:

[0030] (1) The cashew shell oil modified phenolic resin is used as the matrix. The cashew shell oil improves the brittleness of the phenolic resin and enhances its impact resistance. The free phenol content is low and meets environmental protection standards. It has good weather resistance and its performance is stable when exposed to ultraviolet light for a long time.

[0031] (2) Continuous basalt fibers pretreated with silane coupling agent form a three-level reinforcement structure with fused silica sand and corundum sand, which improves the compressive strength and flexural strength of the material and meets the requirements of heavy-duty traffic scenarios; the fiber and matrix interface are tightly bonded, which improves the elongation at break and toughness of the material.

[0032] (3) After the nano-sized zinc oxide powder is evenly dispersed, it forms an antibacterial interface, which can inhibit the growth of common microorganisms such as Escherichia coli and Staphylococcus aureus, and solve the problem of microbial growth in humid environments; its micro-filling effect reduces the water absorption rate of the material and improves its impermeability.

[0033] (4) The addition of expanded vermiculite powder reduces the dry density of the material, reduces the weight of a single section, and facilitates manual handling; the interference fit of the boss and the groove, combined with the water-swellable sealing strip, forms a double sealing structure, which improves the connection sealing performance and reduces the risk of leakage.

[0034] (5) The stepped curing process shortens the curing cycle, reduces the impact of environmental temperature and humidity fluctuations on product performance, and improves the product qualification rate; the optimization of vacuum vibration parameters ensures the compactness of the mixture and avoids strength fluctuations caused by bubble defects.

[0035] (6) Cashew shell oil is a natural renewable resource, which reduces raw material costs; local procurement of composite aggregates combined with improved process qualification rate reduces overall production costs. Attached Figure Description

[0036] Figure 1 This is a flowchart of a resin concrete monolithic drainage ditch and its production process proposed in this invention.

[0037] Figure 2 A parameter comparison table of a resin concrete monolithic drainage ditch and its production process proposed in this invention. Detailed Implementation

[0038] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] The specific implementation process is as follows:

[0040] Raw material preparation

[0041] Hexahydrophthalic anhydride curing agent: commercially available, 99% purity;

[0042] Nano-grade zinc oxide powder: average particle size 50nm, commercially available;

[0043] Fused silica sand: particle size 0.1-0.5mm, commercially available;

[0044] Corundum sand: 3-5mm particle size, commercially available;

[0045] Continuous basalt fiber: 5-9 mm in length, pretreated with silane coupling agent KH-550 (soaked in 1% ethanol solution for 30 minutes and then dried).

[0046] Aluminate coupling agent: commercially available, model DL-411;

[0047] Expanded vermiculite powder: particle size 0.3-1mm, bulk density 100kg / m³ 3 Thermal conductivity 0.05 W / (m·K), commercially available;

[0048] Silane coupling agent KH-550: Commercially available;

[0049] Common phenolic resin: commercially available, free phenol content 6.8%, solid content 82%;

[0050] Example 1:

[0051] Please see Figure 1-2 The present invention provides a technical solution: a resin concrete monolithic drainage ditch and its production process, comprising the following steps:

[0052] Preparation of cashew nut shell oil modified phenolic resin: Weigh 35 kg of cashew nut shell oil and 65 kg of phenol into a reaction vessel, stir and mix evenly, then add 2.5 kg of 30% sodium hydroxide solution, turn on the heating device to raise the temperature to 72°C, and maintain this temperature while stirring for 30 minutes; then slowly add 55 kg of 37% formaldehyde solution through a dropping funnel (dropping rate controlled at 10 kg / min), after the addition is complete, raise the temperature to 85°C, and keep the temperature constant for 2.5 hours; after the reaction is complete, turn off the heating, let it cool naturally to 35°C, and discharge for later use.

[0053] S1: Raw material pretreatment: Continuous basalt fibers are cut into 7mm lengths, soaked in 1% KH-550 ethanol solution of silane coupling agent for 30 minutes, and dried at 80℃ for later use; expanded vermiculite powder is dried at 105℃ for 2 hours to remove moisture;

[0054] S2: Weigh the raw materials (kg): 20kg cashew nut shell oil modified phenolic resin, 6kg hexahydrophthalic anhydride curing agent, 3kg nano-grade zinc oxide powder, 110kg composite aggregate (26.25kg fused silica sand, 65.625kg corundum sand, 2.125kg pretreated basalt fiber), 1.7kg aluminate coupling agent, and 4kg expanded vermiculite powder;

[0055] S3: Mixing and stirring: Add cashew shell oil modified phenolic resin and aluminate coupling agent to a planetary mixer (the mixing paddle has a double-ribbon structure with a 3mm gap between the paddle and the barrel wall), stir at 500r / min for 2 minutes, add nano-grade zinc oxide powder, adjust the speed to 1000r / min and stir for 3 minutes, then add composite aggregate, stir at 800r / min for 6 minutes, and finally add hexahydrophthalic anhydride curing agent and expanded vermiculite powder, stir at 400r / min for 2 minutes;

[0056] S4: Molding: Pour the mixture into a steel mold with a temperature-controlled jacket, and use a vacuum vibration molding machine: first, evacuate to -0.09MPa and maintain for 2 minutes, then turn on the vibration device (amplitude 0.5mm, frequency 55Hz) and vibrate for 10 minutes. At the same time, 30℃ hot water is introduced through the jacket for heat preservation (the temperature-controlled jacket of the steel mold is heated by circulating water, and the water temperature fluctuation range is ±0.5℃).

[0057] S5: Curing: Place the molded part into a constant temperature and humidity curing chamber (humidity control accuracy ±3%RH, temperature control accuracy ±0.5℃), first cure it at 23℃ and 65% relative humidity for 5 hours, then raise the temperature to 55℃ and 85% relative humidity at a rate of 5℃ / hour and cure it for 7 hours, then lower the temperature to 32℃ at a rate of 3℃ / hour and maintain it for 12 hours, and finally take it out and cure it naturally for 12 days to obtain a resin concrete monolithic drainage ditch.

[0058] In this embodiment, the proportions of each raw material conform to the scope of the claims, and the process parameters are strictly set in accordance with the production process limitations. The resulting drainage ditch has a compressive strength of 85 MPa, a flexural strength of 18 MPa, and a water absorption rate of 0.3%, meeting the mechanical performance requirements for heavy-duty scenarios. After pretreatment, the continuous basalt fiber is tightly bonded to the resin matrix, and no obvious cracks were observed in the impact test, demonstrating excellent toughness. The use of cashew nut shell oil-modified phenolic resin ensures that the material maintains stable performance and good weather resistance after artificial accelerated aging tests. The uniform dispersion of nano-sized zinc oxide powder has a significant antibacterial effect against Escherichia coli and Staphylococcus aureus, solving the problem of microbial growth in humid environments.

[0059]

[0060] Example 1 Parameter Data Table

[0061] Example 2:

[0062] Please see Figure 1-2 The present invention provides a technical solution: a resin concrete monolithic drainage ditch and its production process, comprising the following steps:

[0063] Preparation of cashew nut shell oil modified phenolic resin: Weigh 30 kg of cashew nut shell oil and 70 kg of phenol into a reaction vessel, stir and mix evenly, then add 2 kg of 30% sodium hydroxide solution, turn on the heating device to raise the temperature to 70°C, and maintain this temperature while stirring for 30 minutes; then slowly add 50 kg of 37% formaldehyde solution through a dropping funnel (dropping rate controlled at 10 kg / min), after the addition is complete, raise the temperature to 80°C and react at a constant temperature for 2 hours; after the reaction is complete, turn off the heating and allow it to cool naturally to 38°C, then discharge for later use.

[0064] S1: Raw material pretreatment: Continuous basalt fibers are cut into 5mm lengths, soaked in 1% KH-550 ethanol solution of silane coupling agent for 30 minutes, and dried at 80℃ for later use; expanded vermiculite powder is dried at 105℃ for 2 hours to remove moisture;

[0065] S2: Weigh the raw materials (kg): 18kg cashew nut shell oil modified phenolic resin, 5kg hexahydrophthalic anhydride curing agent, 2kg nano-grade zinc oxide powder, 105kg composite aggregate (25kg fused silica sand, 62.5kg corundum sand, 2kg pretreated basalt fiber), 1.5kg aluminate coupling agent, and 3kg expanded vermiculite powder;

[0066] S3: Mixing and stirring: Add cashew nut shell oil modified phenolic resin and aluminate coupling agent to a planetary mixer (the mixing paddle has a double helical ribbon structure with a 4mm gap between the paddle and the barrel wall), stir at 500r / min for 2 minutes, add nano-grade zinc oxide powder, adjust the speed to 1000r / min and stir for 3 minutes, then add composite aggregate, stir at 800r / min for 6 minutes, and finally add hexahydrophthalic anhydride curing agent and expanded vermiculite powder, stir at 400r / min for 2 minutes;

[0067] S4: Molding: Pour the mixture into a steel mold with a temperature-controlled jacket, and use a vacuum vibration molding machine: first, evacuate to -0.09MPa and hold for 2 minutes, then turn on the vibration device (amplitude 0.5mm, frequency 55Hz) and vibrate for 10 minutes. At the same time, 30℃ hot water is introduced through the jacket for heat preservation (the temperature-controlled jacket of the steel mold is heated by circulating water, and the water temperature fluctuation range is ±0.8℃).

[0068] S5: Curing: Place the molded part into a constant temperature and humidity curing chamber (humidity control accuracy ±3%RH, temperature control accuracy ±0.5℃), first cure it at 23℃ and 65% relative humidity for 5 hours, then raise the temperature to 55℃ and 85% relative humidity at a rate of 5℃ / hour and cure it for 7 hours, then lower the temperature to 32℃ at a rate of 3℃ / hour and maintain it for 12 hours, and finally take it out and cure it naturally for 12 days to obtain a resin concrete monolithic drainage ditch.

[0069] The amount of raw materials used in this embodiment is within the lower limit of the scope defined in the claims. The resulting drainage ditch has a compressive strength of 80 MPa, a flexural strength of 16 MPa, and a water absorption rate of 0.4%, all of which meet the basic usage requirements. The shorter basalt fibers are more evenly dispersed in the mixture, resulting in good material cross-sectional uniformity. The addition of expanded vermiculite powder reduces the material's dry density to 1850 kg / m³. 3 The weight of each section is reduced, making manual handling easier; antibacterial tests show good antibacterial effect against Escherichia coli, and the sealed structure shows no leakage after temperature difference cycling test, meeting the design goals for construction adaptability in the claims.

[0070]

[0071] Example 2 Parameter Data Table

[0072] Example 3:

[0073] Please see Figure 1-2 The present invention provides a technical solution: a resin concrete monolithic drainage ditch and its production process, comprising the following steps:

[0074] Preparation of cashew nut shell oil modified phenolic resin: Weigh 40 kg of cashew nut shell oil and 60 kg of phenol into a reaction vessel, stir and mix evenly, then add 3 kg of 30% sodium hydroxide solution, turn on the heating device to raise the temperature to 75°C, and maintain this temperature while stirring for 30 minutes; then slowly add 60 kg of 37% formaldehyde solution through a dropping funnel (dropping rate controlled at 10 kg / min), after the addition is complete, raise the temperature to 90°C, and react at a constant temperature for 3 hours; after the reaction is complete, turn off the heating, allow it to cool naturally to 36°C, and discharge for later use.

[0075] S1: Raw material pretreatment: Continuous basalt fibers are cut into 9mm lengths, soaked in 1% KH-550 ethanol solution of silane coupling agent for 30 minutes, and dried at 80℃ for later use; expanded vermiculite powder is dried at 105℃ for 2 hours to remove moisture;

[0076] S2: Weigh the raw materials (kg): 22kg cashew nut shell oil modified phenolic resin, 7kg hexahydrophthalic anhydride curing agent, 4kg nano-grade zinc oxide powder, 115kg composite aggregate (27.5kg fused silica sand, 68.75kg corundum sand, 2.25kg pretreated basalt fiber), 2kg aluminate coupling agent, and 5kg expanded vermiculite powder;

[0077] S3: Mixing and stirring: Add cashew nut shell oil modified phenolic resin and aluminate coupling agent to a planetary mixer (the mixing paddle has a double helical ribbon structure with a 5mm gap between the paddle and the barrel wall), stir at 500r / min for 2 minutes, add nano-grade zinc oxide powder, adjust the speed to 1000r / min and stir for 3 minutes, then add composite aggregate, stir at 800r / min for 6 minutes, and finally add hexahydrophthalic anhydride curing agent and expanded vermiculite powder, stir at 400r / min for 2 minutes;

[0078] S4: Molding: Pour the mixture into a steel mold with a temperature-controlled jacket and use a vacuum vibration molding machine: first, evacuate to -0.09MPa and hold for 2 minutes, then turn on the vibration device (amplitude 0.5mm, frequency 55Hz) and vibrate for 10 minutes. At the same time, 30℃ hot water is introduced through the jacket for heat preservation (the temperature-controlled jacket of the steel mold is heated by circulating water, and the water temperature fluctuation range is ±1℃).

[0079] S5: Curing: Place the molded part into a constant temperature and humidity curing chamber (humidity control accuracy ±3%RH, temperature control accuracy ±0.5℃), first cure it at 23℃ and 65% relative humidity for 5 hours, then raise the temperature to 55℃ and 85% relative humidity at a rate of 5℃ / hour and cure it for 7 hours, then lower the temperature to 32℃ at a rate of 3℃ / hour and maintain it for 12 hours, and finally take it out and cure it naturally for 12 days to obtain a resin concrete monolithic drainage ditch.

[0080] The amount of raw materials used in this embodiment is at the upper limit of the scope defined in the claims. The resulting drainage ditch has a compressive strength of 90 MPa, a flexural strength of 20 MPa, and a water absorption rate of 0.2%, exhibiting optimal mechanical properties and impermeability. The long basalt fibers form a continuous network structure in the material, resulting in significant reinforcement. After 200 freeze-thaw cycles, the strength remains good, making it suitable for applications in cold regions. The high content of nano-sized zinc oxide powder provides excellent antibacterial effect against Staphylococcus aureus. The increased amount of cashew nut shell oil-modified phenolic resin further enhances the material's toughness, increasing the impact absorption energy by 10% compared to Example 1.

[0081]

[0082] Example 3 Parameter Data Table

[0083] Example 4:

[0084] Please see Figure 1-2The present invention provides a technical solution: a resin concrete monolithic drainage ditch and its production process, comprising the following steps:

[0085] Preparation of cashew nut shell oil modified phenolic resin: Weigh 32 kg of cashew nut shell oil and 68 kg of phenol into a reaction vessel, stir and mix evenly, then add 2.2 kg of 30% sodium hydroxide solution, turn on the heating device to raise the temperature to 73°C, and maintain this temperature while stirring for 30 minutes; then slowly add 52 kg of 37% formaldehyde solution through a dropping funnel (dropping rate controlled at 10 kg / min), after the addition is complete, raise the temperature to 82°C, and keep the reaction at a constant temperature for 2.2 hours; after the reaction is complete, turn off the heating, let it cool naturally to 37°C, and discharge for later use.

[0086] S1: Raw material pretreatment: Continuous basalt fibers are cut into 6mm lengths, soaked in 1% KH-550 ethanol solution of silane coupling agent for 30 minutes, and dried at 80℃ for later use; expanded vermiculite powder is dried at 105℃ for 2 hours to remove moisture;

[0087] S2: Weigh the raw materials (kg): 19kg cashew nut shell oil modified phenolic resin, 5.5kg hexahydrophthalic anhydride curing agent, 2.5kg nano-grade zinc oxide powder, 108kg composite aggregate (25.75kg fused silica sand, 64.375kg corundum sand, 2.0625kg pretreated basalt fiber), 1.6kg aluminate coupling agent, and 3.5kg expanded vermiculite powder;

[0088] S3: Mixing and stirring: Add cashew nut shell oil modified phenolic resin and aluminate coupling agent to a planetary mixer (the mixing paddle has a double helical ribbon structure with a 3.5mm gap between the paddle and the barrel wall), stir at 500r / min for 2 minutes, add nano-grade zinc oxide powder, adjust the speed to 1000r / min and stir for 3 minutes, then add composite aggregate, stir at 800r / min for 6 minutes, and finally add hexahydrophthalic anhydride curing agent and expanded vermiculite powder, stir at 400r / min for 2 minutes;

[0089] S4: Molding: Pour the mixture into a steel mold with a temperature-controlled jacket, and use a vacuum vibration molding machine: first, evacuate to -0.09MPa and maintain for 2 minutes, then turn on the vibration device (amplitude 0.5mm, frequency 55Hz) and vibrate for 10 minutes. At the same time, 30℃ hot water is introduced through the jacket for heat preservation (the temperature-controlled jacket of the steel mold is heated by circulating water, and the water temperature fluctuation range is ±0.6℃).

[0090] S5: Curing: Place the molded part into a constant temperature and humidity curing chamber (humidity control accuracy ±3%RH, temperature control accuracy ±0.5℃), first cure it at 23℃ and 65% relative humidity for 5 hours, then raise the temperature to 55℃ and 85% relative humidity at a rate of 5℃ / hour and cure it for 7 hours, then lower the temperature to 32℃ at a rate of 3℃ / hour and maintain it for 12 hours, and finally take it out and cure it naturally for 12 days to obtain a resin concrete monolithic drainage ditch.

[0091] In this embodiment, the raw material ratio and process parameters are all within the middle values ​​of the claims. The resulting drainage ditch has a compressive strength of 83 MPa, a flexural strength of 17 MPa, and a water absorption rate of 0.35%, exhibiting balanced overall performance. The ratio of each component in the composite aggregate strictly follows 1:2.5:0.2, with uniform fiber dispersion and no agglomeration, achieving an optimal balance between material density and strength. Antibacterial tests show a significant inhibitory effect on mixed bacterial communities, adapting to complex drainage environments. The connecting structure maintains stable sealing performance after ±30℃ temperature difference cycling, with no leakage. This embodiment verifies the practicality of the intermediate ratio and is suitable for large-scale industrial production.

[0092]

[0093] Example 4 Parameter Data Table

[0094] Comparative Example 1:

[0095] Please see Figure 1-2 The present invention provides a comparative solution, which includes the following steps:

[0096] S1: Raw material pretreatment: Same as in Example 1;

[0097] S2: Weigh the raw materials (kg): 20kg of ordinary phenolic resin, 6kg of hexahydrophthalic anhydride curing agent, 3kg of nano-grade zinc oxide powder, 110kg of composite aggregate (26.25kg of fused silica sand, 65.625kg of corundum sand, 2.125kg of pretreated basalt fiber), 1.7kg of aluminate coupling agent, and 4kg of expanded vermiculite powder;

[0098] S3: Mixing and stirring: Same as in Example 1;

[0099] S4: Molding: Same as in Example 1;

[0100] S5: Maintenance: Same as in Example 1;

[0101] In this comparative example, ordinary phenolic resin was used instead of the cashew nut shell oil-modified phenolic resin in the claims. The resulting drainage ditch had a compressive strength of 70 MPa and a flexural strength of 12 MPa, which were significantly lower than those in Example 1. Ordinary phenolic resin is brittle and showed through cracks in the impact test. The free phenol content reached 6.8%, which does not meet environmental protection standards. After artificial accelerated aging test, the tensile strength decreased by 42%, and the weather resistance was poor.

[0102]

[0103] Comparative Example 1 Parameter Data Table

[0104] Comparative Example 2:

[0105] Please see Figure 1-2 The present invention provides a comparative solution, which includes the following steps:

[0106] S1: Raw material pretreatment: Continuous basalt fiber is not pretreated with silane coupling agent KH-550, and other procedures are the same as in Example 1;

[0107] S2: Weigh the raw materials (kg): Same as in Example 1;

[0108] S3: Mixing and stirring: Same as in Example 1;

[0109] S4: Molding: Same as in Example 1;

[0110] S5: Maintenance: Same as in Example 1;

[0111] This comparative example did not pretreat the basalt fiber, and the resulting drainage ditch had a compressive strength of 75 MPa and a flexural strength of 14 MPa, which was about 12%-15% lower than that of Example 1. Due to the poor bonding force between the fiber and the resin matrix, fiber pull-out was visible on the cross-section of the material, the water absorption rate increased to 0.5%, and the impermeability decreased. In the impact test, the fiber could not effectively transfer stress, and obvious cracks appeared.

[0112]

[0113] Comparative Example 2 Parameter Data Table

[0114] Comparative Example 3:

[0115] Please see Figure 1-2 The present invention provides a comparative solution, which includes the following steps:

[0116] S1: Raw material pretreatment: Same as in Example 1;

[0117] S2: Weigh the raw materials (kg): 20kg cashew nut shell oil modified phenolic resin, 6kg hexahydrophthalic anhydride curing agent, 3kg nano-grade zinc oxide powder, 110kg aggregate (26.25kg fused silica sand, 67.75kg corundum sand, excluding basalt fiber), 1.7kg aluminate coupling agent, and 4kg expanded vermiculite powder;

[0118] S3: Mixing and stirring: Same as in Example 1;

[0119] S4: Molding: Same as in Example 1;

[0120] S5: Maintenance: Same as in Example 1;

[0121] The comparative example, without the addition of basalt fiber, produced a drainage ditch with a compressive strength of 65 MPa and a flexural strength of 10 MPa, which is only 76%-55% of that in Example 1. The toughness is significantly insufficient (elongation at break 0.7%). The material is brittle and exhibits microcracks in simulated vehicle load tests. The impact resistance is poor and cannot meet the requirements of heavy-load scenarios. This comparison verifies the reinforcing effect of basalt fiber in composite aggregates.

[0122]

[0123] Comparative Example 3 Parameter Data Table

[0124] Please see Figure 1-2 :

[0125] Through a systematic comparative analysis of Examples 1-4 and Comparative Examples 1-3, it can be clearly seen that the present technical solution has achieved superior results in terms of material formulation, production process and comprehensive performance of resin concrete monolithic drainage ditches.

[0126] From the perspective of the material system, Examples 1-4 all use cashew nut shell oil-modified phenolic resin as the matrix, combined with continuous basalt fibers pretreated with silane coupling agent KH-550, nano-sized zinc oxide powder, expanded vermiculite powder, and composite aggregates to form a synergistic reinforcing system. Comparative Examples 1-3, by changing the resin type, omitting fiber pretreatment, and removing basalt fibers, respectively, exposed the performance shortcomings of the traditional solution. In Example 1, the drainage ditch using cashew nut shell oil-modified phenolic resin achieved a compressive strength of 85 MPa and a flexural strength of 18 MPa, with low water absorption... The free phenol content was only 0.3%, which is a significant improvement compared to 70MPa, 12MPa and 0.6% of Comparative Example 1 (ordinary phenolic resin). Especially in the weather resistance test, the performance decline after artificial accelerated aging was significantly less than that of Comparative Example 1, which confirms the advantages of modified resin in toughness and anti-aging properties. This is due to the fact that the long-chain alkyl groups in cashew nut shell oil effectively improve the brittleness of phenolic resin. At the same time, the free phenol content is controlled at 2.5% (≤3%), which meets environmental protection standards and solves the problem of excessive free phenol in traditional phenolic resin (6.8% in Comparative Example 1).

[0127] The synergistic design of composite aggregates is another core innovation of this scheme. In Examples 1-4, fused silica sand (0.1-0.5mm), corundum sand (3-5mm), and continuous basalt fiber (5-9mm) form a three-level reinforcement structure in a weight ratio of 1:2.5:0.2. The bonding force between the fiber and the resin matrix is ​​significantly improved after pretreatment. In Example 3, the network structure formed by 9mm long fibers achieves a compressive strength of 90MPa and a flexural strength of 20MPa, which is significantly higher than the 75MPa and 14MPa of Comparative Example 2 (without pretreated fibers). No cracks were generated in the impact test, while Comparative Example 2 showed obvious fracture due to poor bonding between the fiber and the matrix. Comparative Example 3, without the addition of basalt fiber, has a compressive strength of only 65MPa and a flexural strength of 10MPa, highlighting the defect of insufficient toughness. This further proves the irreplaceable role of basalt fiber in reinforcement and toughening.

[0128] In terms of functional properties, the introduction of nano-sized zinc oxide powder endows Examples 1-4 with excellent antibacterial properties, showing significant inhibitory effects against Escherichia coli and Staphylococcus aureus, thus solving the problem of microbial growth in the damp environment of traditional drainage ditches. Although the comparative examples do not directly compare antibacterial properties, they cannot achieve the same function due to the lack of this component. The application of expanded vermiculite powder achieves material lightweighting, reducing the dry density of Example 2 to 1850 kg / m³. 3 Compared to traditional resin concrete (approximately 2400 kg / m³), 3 The weight is reduced by more than 20%, and the reduced weight of a single section makes it easier to handle manually and greatly improves the adaptability of construction. This advantage cannot be reflected in the comparative sample because this component was not used.

[0129] Optimization of the production process is the key guarantee for stable performance. Examples 1-4 adopt a full-process control of "pretreatment-graded mixing-vacuum vibration molding-stepped curing": fiber pretreatment ensures uniform dispersion, and the double-ribbon structure of the planetary mixer (blade-to-barrel gap ≤5mm) avoids agglomeration; vacuum vibration molding (-0.09MPa vacuum, 55Hz frequency) ensures that the density of the mixture reaches more than 98%, reducing air bubble defects compared with traditional processes; stepped curing (23℃→55℃→32℃) shortens the cycle to 15-20 days, which is more efficient than natural curing (20-30 days), and the product qualification rate reaches more than 95%, far exceeding the 70%-80% of traditional processes. Comparative Examples 1-3 use extensive processes. Although the molding steps are the same, the parameters are not optimized, resulting in large performance fluctuations. For example, the water absorption rate fluctuation range of Comparative Example 1 is 0.2 percentage points larger than that of Example 1.

[0130] From the perspective of application scenario adaptability, the structural design and performance indicators of Examples 1-4 achieve multi-scenario coverage: the balanced performance of Example 1 is suitable for municipal roads, the high compressive strength of Example 3 meets the needs of heavy-duty industrial parks, the lightweight characteristics of Example 2 are suitable for manual construction scenarios, and the comprehensive cost-effectiveness of Example 4 is suitable for large-scale promotion. In terms of connection structure, the interference fit between the boss and the groove + the water-swellable sealing strip forms a double seal, which has no leakage in the ±30℃ temperature difference cycle test and is more reliable than the traditional rubber seal (leakage rate 15%-20%). The comparative example did not adopt this structural design and no relevant tests were conducted, but according to industry data, there is a risk of leakage.

[0131] Economic analysis shows that this solution achieves cost control through localized material procurement and process optimization. Cashew nut shell oil, as a natural and renewable resource, reduces costs by 15%-20% compared to epoxy resin. Expanded vermiculite powder replaces part of the aggregate, reducing density without sacrificing strength, and reducing material usage per segment by about 8%. Stepped curing shortens the production cycle and increases equipment utilization by 30%. Overall, the production costs of Examples 1-4 are reduced by about 12% compared to Comparative Example 1, balancing performance and economy.

[0132] In summary, this technical solution solves the problems of poor weather resistance, insufficient strength, single function, and inconvenient construction of existing technologies by innovative material combination (cashew shell oil modified phenolic resin, pretreated basalt fiber, and nano zinc oxide), synergistic structural design (three-level aggregate reinforcement and double sealing) and refined process control.

[0133] The test method is as follows:

[0134] Compressive strength test: Referring to GB / T50081-2019 "Standard for Test Methods of Physical and Mechanical Properties of Concrete", the drainage ditch bodies prepared in each embodiment and comparative example were cut into 100mm×100mm×100mm cubic specimens and tested using a universal testing machine. The test loading rate was 0.5MPa / s. The maximum load at specimen failure was recorded, and the compressive strength was calculated (compressive strength = maximum load / compressive area). Three parallel specimens were tested in each group, and the arithmetic mean was taken as the result.

[0135] Flexural strength test: Following GB / T50081-2019 "Standard for Test Methods of Physical and Mechanical Properties of Concrete", the specimen was processed into a 100mm×100mm×400mm prism and tested using the three-point bending method. The support span was 300mm, the loading rate was 0.05MPa / s, and the maximum load at fracture was recorded. The flexural strength was calculated using the formula: Flexural strength = 3 × Load × Span / (2 × Section width × Section height). 2 The calculation results are obtained by testing 3 samples in each group and taking the average value.

[0136] Impact toughness test: A simply supported beam impact testing machine was used. The specimen size was 100mm×100mm×500mm with a span of 400mm. A 2kg hammer was dropped freely from a height of 500mm to impact the midpoint of the specimen. The failure mode of the specimen (such as whether cracks appeared and the degree of fracture) was recorded, and the impact absorption energy was calculated (impact toughness = absorbed energy / cross-sectional area of ​​the specimen).

[0137] Permeability testing: Following GB / T50082-2009 "Standard for Test Methods of Long-Term Performance and Durability of Ordinary Concrete", a permeability tester was used. The test blocks were machined into cylinders with a diameter of 175mm × 185mm. After applying sealant to the sides of the specimens, they were placed into the permeability tester mold. Pressure was applied starting from 0.1MPa, increasing by 0.1MPa every 8 hours until 3 out of 6 specimens showed signs of seepage. The pressure value at this point was recorded as the permeability grade (e.g., P6, P8, etc.). Simultaneously, the 24-hour water absorption rate was tested: the dried test blocks were weighed and immersed in distilled water. After 24 hours, they were removed, the surface moisture was wiped off, and the weight was calculated (water absorption rate = (mass after water absorption - dry mass) / dry mass × 100%).

[0138] Ultraviolet aging test: Referring to GB / T16422.3-2022 "Laboratory Light Source Exposure Test Methods for Plastics - Part 3: Fluorescent Ultraviolet Lamps", an ultraviolet aging test chamber was used. The sample (100mm×100mm×50mm) was placed inside the chamber, and the temperature was set to 60℃, relative humidity to 50%, ultraviolet wavelength to 340nm, and irradiance to 0.71W / (m²). 2 •nm) and conduct a 1000-hour aging test. After the test, test the compressive strength and flexural strength retention rate of the sample, and observe whether cracking, discoloration or other phenomena appear on the surface.

[0139] Freeze-thaw cycle test: According to GB / T50082-2009 "Standard for Test Methods of Long-Term Performance and Durability of Ordinary Concrete", the specimen (100mm×100mm×100mm) was placed in a freeze-thaw chamber, first frozen at -20℃ for 4 hours, and then thawed in water at 20℃ for 4 hours, which constitutes one cycle. A total of 200 cycles were performed. After the test, the compressive strength loss rate was measured (loss rate = (strength before freeze-thaw - strength after freeze-thaw) / strength before freeze-thaw × 100%), and the surface spalling and cracking of the specimen were observed.

[0140] Antibacterial performance test: Refer to GB / T21510-2008 "Test Method for Antibacterial Performance of Nano-Inorganic Materials", and use the inhibition ring method and the shaking flask method.

[0141] Inhibition ring test: Escherichia coli and Staphylococcus aureus bacterial suspensions were evenly spread on nutrient agar medium. The sample (a 10 mm diameter disc) was placed in the center of the medium and incubated at 37°C for 24 hours. The diameter of the inhibition ring was measured (inhibition ring diameter = outer ring diameter - sample diameter).

[0142] Antibacterial rate test: Place 10g of sample into 100mL of bacterial solution (concentration 10). 5 Erlenmeyer flasks containing CFU / mL were incubated at 37°C with shaking for 24 hours. The viable count was calculated using the plate count method, and the inhibition rate was calculated using the formula (inhibition rate = (viable count of control group - viable count of experimental group) / viable count of control group × 100%).

[0143] The above descriptions are merely embodiments of the present invention, and common knowledge regarding specific technical solutions or characteristics is not elaborated upon here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solutions of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A resin concrete monolithic drainage ditch, characterized in that, Includes a monolithic drainage ditch body made of modified resin concrete; The modified resin concrete is composed of the following components by weight: 18-22 parts cashew nut shell oil modified phenolic resin, 5-7 parts hexahydrophthalic anhydride curing agent, 2-4 parts nano-grade zinc oxide powder, 105-115 parts composite aggregate, 1.5-2 parts aluminate coupling agent, and 3-5 parts expanded vermiculite powder. The composite aggregate is composed of fused silica sand with a particle size of 0.1-0.5 mm, corundum sand with a particle size of 3-5 mm, and continuous basalt fibers with a length of 5-9 mm in a weight ratio of 1:2.5:0.

2. The continuous basalt fiber was pretreated with silane coupling agent KH-550: specifically, it was soaked in a 1% KH-550 ethanol solution for 30 minutes and then dried. The drainage ditch body has a trapezoidal cross section, with 3-5 reinforcing ribs extending along the length of the inner wall, and hemispherical anti-slip protrusions distributed in a matrix at the bottom. Both ends are provided with a boss with a sealing groove and a groove with a sealing rib. The boss and the groove are interference fit, and the sealing groove is provided with a water-swellable sealing strip.

2. The resin concrete monolithic drainage ditch according to claim 1, characterized in that, The preparation method of the cashew nut shell oil modified phenolic resin is as follows: 30-40 parts by weight of cashew nut shell oil and 60-70 parts by weight of phenol are mixed, and 2-3 parts by weight of 30% sodium hydroxide solution are added as a catalyst. The mixture is heated to 70-75℃ and stirred for 30 minutes. Then, 50-60 parts by weight of 37% formaldehyde solution are added, and the temperature is controlled at 80-90℃ for 2-3 hours. The mixture is then cooled to below 40℃ to obtain the resin. The free phenol content is ≤3%, the solid content is ≥85%, and the viscosity at 25℃ is 800-1200 mPa·s.

3. The resin concrete monolithic drainage ditch according to claim 1, characterized in that, The expanded vermiculite powder has a particle size of 0.3-1 mm and a bulk density of 80-120 kg / m³. 3 Thermal conductivity ≤0.06W / (m・K).

4. A manufacturing process for a resin concrete monolithic drainage ditch as described in any one of claims 1-3, characterized in that, Includes the following steps: S1: Raw material pretreatment: Continuous basalt fibers are cut into lengths of 5-9 mm, soaked in 1% KH-550 ethanol solution of silane coupling agent for 30 minutes, and dried at 80°C for later use; expanded vermiculite powder is dried at 105°C for 2 hours to remove moisture. S2: Weigh the raw materials by weight: 18-22 parts cashew nut shell oil modified phenolic resin, 5-7 parts hexahydrophthalic anhydride curing agent, 2-4 parts nano-grade zinc oxide powder, 105-115 parts composite aggregate, 1.5-2 parts aluminate coupling agent, and 3-5 parts expanded vermiculite powder. S3: Mixing and stirring: Add cashew nut shell oil modified phenolic resin and aluminate coupling agent to a planetary mixer and stir at 500 r / min for 2 minutes. Add nano-grade zinc oxide powder and adjust the speed to 1000 r / min and stir for 3 minutes. Then add composite aggregate and stir at 800 r / min for 6 minutes. Finally, add hexahydrophthalic anhydride curing agent and expanded vermiculite powder and stir at 400 r / min for 2 minutes. S4: Molding: Pour the mixture into a steel mold with a temperature-controlled jacket, and use a vacuum vibration molding machine: first, evacuate to -0.09MPa and maintain for 2 minutes, then turn on the vibration device and vibrate for 10 minutes, while simultaneously introducing 30℃ hot water through the jacket for heat preservation; the amplitude of the vibration device is 0.5mm and the frequency is 55Hz. S5: Curing: Place the molded part into a constant temperature and humidity curing chamber, first cure it at 23℃ and 65% relative humidity for 5 hours, then raise the temperature to 55℃ and 85% relative humidity at a rate of 5℃ / hour for 7 hours, then lower the temperature to 32℃ at a rate of 3℃ / hour and maintain it for 12 hours, and finally take it out and cure it naturally for 12 days to obtain a resin concrete monolithic drainage ditch.

5. The production process according to claim 4, characterized in that, The planetary mixer in S3 has a double-ribbon structure for its impeller, with a gap of ≤5mm between the impeller blade and the barrel wall.

6. The production process according to claim 4, characterized in that, In S4, the temperature control interlayer of the steel mold uses circulating water heating, with a water temperature fluctuation range of ≤±1℃.

7. The production process according to claim 4, characterized in that, The humidity control accuracy of the S5 constant temperature and humidity curing chamber is ±3%RH, and the temperature control accuracy is ±0.5℃.

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