Thin-wall electric pole and preparation process thereof

Abstract

The invention discloses a thin-wall electric pole and a preparation technology thereof, and belongs to the technical field of electric power engineering component preparation. The preparation process comprises five steps of raw material pretreatment, precise preforming, gradient curing and strengthening, thin-wall forming and precision calibration, and post-treatment and performance detection. The core innovation of the invention lies in transboundary fusion of advanced technologies in the fields of aerospace and chemical industry, adopts core technologies of dopamine bionic interface modification, three-dimensional weaving molding, supercritical CO2 assisted gradient curing, microcapsule self-repairing and the like, and is matched with green high-performance raw materials such as bio-based epoxy resin and the like, and through compound system optimization and process collaboration, the preparation method is simple, and the cost is low. And high-quality preparation of the thin-wall electric pole is achieved. The prepared thin-wall electric pole is excellent in structural integrity, excellent in mechanical property and high in weather resistance and has a self-repairing function.

Description

Technical Field

[0001] This invention belongs to the field of power engineering component preparation technology, specifically relating to a thin-walled electric pole and its preparation process. Background Technology

[0002] Thin-walled poles are widely used in power transmission network construction due to their advantages such as light weight, convenient transportation and installation, and high material utilization. Traditional manufacturing processes for thin-walled poles often employ centrifugal casting, using reinforced concrete as the main raw material. This process has several drawbacks: First, uneven material distribution during centrifugal casting leads to large deviations in pole wall thickness and unstable mechanical properties. Second, the concrete curing period is long, typically requiring more than 28 days, resulting in low production efficiency. Third, thin-walled poles made of reinforced concrete have poor corrosion resistance, easily cracking and rusting in harsh environments such as humidity and salinity, resulting in a short service life. Fourth, traditional processes are highly dependent on molds; different molds need to be customized for different pole specifications, leading to high production costs and difficulty in fabricating complex structures.

[0003] Traditional thin-walled pole materials suffer from defects such as weak interfacial bonding, susceptibility to cracking that cannot be repaired after cracking, and insufficient weather resistance. Meanwhile, traditional manufacturing processes, such as centrifugal casting and conventional thermosetting, suffer from unstable molding quality, poor curing uniformity, and low production efficiency. Therefore, integrating these advanced technologies across disciplines to develop novel thin-walled pole manufacturing processes through material innovation and process optimization, breaking through traditional technological bottlenecks, has significant practical implications and application value. Summary of the Invention

[0004] In view of the above-mentioned shortcomings in the prior art, the present invention provides a thin-walled electric pole and its manufacturing process to solve the problems in the background art.

[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0006] A fabrication process for a thin-walled electric pole includes the following steps:

[0007] S1. Raw material pretreatment

[0008] S11. Basalt fiber felt is modified by dopamine biomimetic modification to obtain modified basalt fiber felt;

[0009] S12. Bio-based epoxy resin and nano-montmorillonite modified filler are solution intercalated and composited. After solvent removal by rotary evaporation, glass microsphere lightweight filler, microcapsule self-healing agent and curing accelerator are added to obtain a mixed system.

[0010] S13. The modified basalt fiber felt is pre-impregnated in the above-mentioned mixture for 1-2 hours to obtain a composite slurry;

[0011] S2. The modified basalt fiber felt of preimpregnated composite slurry is three-dimensionally interwoven to form the initial skeleton of the pole. Then the skeleton is placed in a mold and a segmented vacuum bag pressing process is adopted. First, it is pre-pressed at 0.03-0.05MPa for 1 hour, and then the pressure is increased to 0.06-0.08MPa and held for 2-3 hours to form the initial skeleton.

[0012] S3. Place the preformed embryo in a supercritical curing autoclave, first introduce CO2 to establish a supercritical environment, and keep it at the temperature for 1-2 hours to achieve CO2 penetration; then carry out gradient temperature curing, raising the temperature to 90-110℃ at a rate of 3-5℃ / h, maintaining the pressure at 8-12MPa, and keeping it at the temperature for 3-5 hours, then slowly depressurizing to atmospheric pressure and naturally cooling to room temperature to complete curing;

[0013] S4. Place the cured preform on a CNC winding machine and use high-performance glass fiber yarn for bidirectional cross-winding to form a reinforcing layer. During the winding process, ultrasonic-assisted compaction is applied simultaneously to obtain the shaped pole.

[0014] S5. Surface modification and functional coating treatment are carried out on the formed pole. First, the surface is modified by using a composite solution of silane coupling agent KH-550 and titanate coupling agent. After drying, a fluorocarbon-nano zirconium oxide composite anti-corrosion coating is prepared by electrostatic spraying process to obtain the finished thin-walled pole.

[0015] Furthermore, the dopamine biomimetic modification of the basalt fiber felt includes immersing the fiber felt in a dopamine solution with a mass fraction of 2-3%, adjusting the pH value to 8.0-8.5, stirring at a constant temperature of 25-30℃ for 6-12 hours, and then vacuum drying it.

[0016] Further, the mass fraction of each raw material in step S1 is as follows: 25%-35% modified basalt fiber felt, 40%-50% bio-based epoxy resin, 5%-10% nano-montmorillonite modified filler, 5%-10% glass microsphere lightweight filler, 3%-5% microcapsule self-healing agent, and 0.5%-1.0% curing accelerator.

[0017] Furthermore, the microcapsule self-healing agent is a urea-formaldehyde resin coated with epoxy resin type.

[0018] Furthermore, the weaving density of the three-dimensional weaving is 20-30 threads / cm. 2 The weaving angle is ±30°-±60°.

[0019] Further, in step S4, the angle of the bidirectional cross-winding is ±45°, the winding tension is 40-60N, and the thickness of the reinforcing layer is 1.0-2.0mm; the power of the ultrasonic-assisted compaction is 100-200W, the frequency is 20-40kHz, and a compaction treatment is performed every 2 layers of winding, with a compaction pressure of 0.1-0.15MPa.

[0020] Further, in step S5, the composite coupling agent solution is a mixed solution of KH-550 with a mass fraction of 2%-5% and titanate coupling agent with a mass fraction of 1%-2%, and the solvent is a mixture of ethanol and water with a volume ratio of 3:1-5:1.

[0021] Further, in step S5, the fluorocarbon-nanozirconia composite coating has a nanozirconia mass fraction of 5%-8%, a coating thickness of 80-120μm, and is dried and cured by hot air circulation at 80-90℃ for 1-2 hours after spraying.

[0022] Further, in step S1, the solvent of the dopamine solution is a Tris-HCl buffer solution with a concentration of 50 mmol / L;

[0023] The areal density of the modified basalt fiber felt is 300-500 g / m³. 2 The fiber diameter is 10-15μm, and the contact angle of the modified fiber surface is ≤60°.

[0024] The bio-based epoxy resin is prepared by modifying castor oil with epichlorohydrin, and has an epoxy value of 0.4-0.6 eq / 100g;

[0025] The nano-montmorillonite modified filler is modified by hexadecyltrimethylammonium bromide intercalation;

[0026] The glass microsphere lightweight filler has a particle size of 50-100 μm and a density of 0.3-0.5 g / cm³. 3 ;

[0027] The curing accelerator is 2-methylimidazole.

[0028] Further, in step S5, the titanate coupling agent is isopropyltristearate titanate;

[0029] The fluorocarbon-nanozirconia composite coating is made by mixing fluorocarbon resin, nanozirconia, curing agent and diluent in a mass ratio of 5:0.3:1:2.

[0030] Compared with the prior art, the present invention has the following beneficial effects:

[0031] This invention innovatively employs a three-dimensional weaving process to prepare the initial skeleton, combined with segmented vacuum bag pressing, completely solving the defects of traditional layup processes such as easy delamination and numerous pores; supercritical CO2-assisted curing ensures uniform curing and eliminates internal stress; subsequent ultrasonic-assisted winding and compaction, along with CNC precision machining, ensure that the pole end face perpendicularity is ≤0.02mm / m and the outer diameter tolerance is within ±0.2mm, resulting in structural integrity and dimensional accuracy significantly superior to traditional processes.

[0032] Dopamine biomimetic modification technology significantly improves the interfacial bonding force between fibers and resins. The three-dimensional braided structure and glass fiber reinforcement layer form a synergistic reinforcement effect, making the bending strength of the pole no less than 85MPa and the compressive strength no less than 120MPa. The microcapsule self-healing agent doped in the composite slurry can automatically release the repair agent when microcracks occur in the pole, realizing crack self-repair (healing rate ≥80%), significantly improving the service life and reliability of the pole.

[0033] The fluorocarbon-nanozirconia composite coating, combined with composite coupling agent modification treatment, ensures that the corrosion area of ​​the pole does not exceed 2% after 720 hours of salt spray corrosion and that the mechanical property retention rate is not less than 85% after 1000 hours of damp heat aging, significantly improving weather resistance. The use of bio-based epoxy resin to replace traditional petroleum-based resin, combined with supercritical CO2-assisted curing, shortens the curing cycle by more than 60% compared to traditional processes. The production process has no harmful gas emissions and generates little solid waste, meeting the requirements of green manufacturing and carbon neutrality.

[0034] This solution is the first to integrate cross-disciplinary technologies such as dopamine biomimetic modification, three-dimensional weaving, supercritical CO2 curing, and microcapsule self-healing into the preparation of thin-walled poles, demonstrating outstanding technological innovation. The raw materials used are widely available and reasonably priced, and the production equipment can be modified from traditional equipment, making the cost controllable. The prepared poles are lightweight, easy to transport and install, and suitable for power transmission network construction in different terrains and environments such as plains, mountains, and coastal saline-alkali lands, making them highly adaptable. Attached Figure Description

[0035] Figure 1 This is a process flow diagram of the fabrication process of a thin-walled electric pole according to the present invention. Detailed Implementation

[0036] To enable those skilled in the art to better understand the present invention, the technical solution of the present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0037] A fabrication process for a thin-walled electric pole includes five steps: raw material pretreatment, precision preforming, gradient curing and strengthening, thin-wall forming and precision calibration, and post-processing and performance testing, as detailed below:

[0038] S1. Raw material pretreatment: The core lies in fiber interface modification and functional composite slurry preparation, specifically divided into three steps: First, fiber biomimetic modification, drawing on dopamine self-polymerization modification technology in the field of biomaterials, basalt fiber felt is immersed in a 2-3% dopamine solution prepared with 50 mmol / L Tris-HCl buffer solution, the pH value is adjusted to 8.0-8.5 with hydrochloric acid, and stirred at 200-300 r / min for 6-12 h at a constant temperature of 25-30℃, so that dopamine self-polymerizes on the fiber surface to form a polydopamine coating. After removal, it is dried in a vacuum drying oven at 60-80℃ for 4-6 h to obtain modified basalt fiber felt. The polydopamine coating can significantly improve the interfacial bonding force between the fiber and the resin; Second, The first step involves the composite system, where bio-based epoxy resin (modified with castor oil and epichlorohydrin, epoxy value 0.4-0.6 eq / 100g) and nano-montmorillonite-modified filler (hexadecyltrimethylammonium bromide intercalation, interlayer spacing ≥3.5nm) are added to acetone solvent for solution intercalation composite at a solid-liquid ratio of 1:5-1:8, a stirring rate of 500-800 r / min, and a stirring time of 30-60 min. The solvent is then removed by rotary evaporation at 50-60℃ and a vacuum of -0.06 to -0.08 MPa to obtain the epoxy resin-nano-montmorillonite composite system. The third step involves the functional system doping, where lightweight glass microsphere filler (particle size 50-100 μm, density 0.3-0.5 g / cm³) is added to the above composite system. 3 The following ingredients are added: microcapsule self-healing agent (urea-formaldehyde resin coated with epoxy resin, particle size 50-100μm, encapsulation rate ≥85%) and curing accelerator 2-methylimidazole. These are then mixed in a high-speed mixer at 1000-1500r / min for 20-30min to disperse evenly. Modified basalt fiber felt is then immersed in this mixture for 1-2 hours to allow the slurry to fully penetrate the fibers, resulting in a composite slurry. The mass fractions of each raw material are: modified basalt fiber felt 25%-35%, bio-based epoxy resin 40%-50%, nano-montmorillonite modified filler 5%-10%, glass microsphere lightweight filler 5%-10%, microcapsule self-healing agent 3%-5%, and curing accelerator 0.5%-1.0%.

[0039] S2. Precision Pre-forming: An innovative combination of aerospace-grade 3D weaving technology and vacuum bagging process enhances the structural integrity of the initial preform. First, a custom steel mold is prepared according to the pole specifications (length 8-15m, outer diameter 150-300mm). The inner wall of the mold is uniformly coated with a 5-10μm thick layer of PTFE-modified release agent to reduce demolding resistance and improve surface smoothness. Then, based on the pole's 3D model, a four-step 3D weaving process is used to interweave modified basalt fiber monofilaments (linear density 100-200tex) with pre-impregnated composite slurry, forming the initial pole skeleton. The weaving density is controlled at 20-30 strands / cm². 2The weaving angle is ±30°-±60°, which significantly improves the anti-delamination ability and mechanical properties of the preform. The woven preform skeleton is placed in a custom mold, and then breathable felt, a release film, and a vacuum bag are laid in sequence. After sealing, a segmented vacuum bag pressing process is used. First, pre-press at 0.03-0.05 MPa for 1 hour to expel residual air from the skeleton, then increase the pressure to 0.06-0.08 MPa and hold for 2-3 hours to ensure the preform is tightly formed. The entire process is carried out in an environment of 20-25℃ and relative humidity ≤60% to prevent premature curing of the slurry.

[0040] S3. Gradient Curing and Strengthening: Utilizing supercritical CO2-assisted gradient curing technology from the chemical industry, this method solves the problems of uneven curing and long cycles in traditional curing processes. The preform, along with the mold, is placed in a supercritical curing autoclave. First, CO2 with a purity ≥99.9% is introduced, the temperature is raised to 40-50℃, and the pressure is increased to 8-12MPa. This supercritical state is maintained for 1-2 hours. Utilizing the high permeability of supercritical CO2, CO2 fully penetrates into the preform, reducing the viscosity of the slurry and promoting the diffusion of the curing agent. Subsequently, gradient curing is performed, slowly raising the temperature to 90-110℃ at a rate of 3-5℃ / h, maintaining the pressure at 8-12MPa, and holding for 3-5 hours to fully cure the bio-based epoxy resin. After curing, the pressure is slowly released to atmospheric pressure at a rate ≤0.5MPa / min, and the heating device is turned off, allowing the preform to cool naturally to room temperature with the autoclave (cooling rate ≤10℃ / h) to avoid internal stress caused by sudden temperature and pressure changes. Pressure sensors (accuracy ±0.1MPa) and temperature sensors (accuracy ±1℃) inside the curing autoclave monitor environmental parameters in real time to ensure a stable curing process. After curing, the substrate is demolded and then circularly sanded using 80-120 grit sandpaper at a speed of 15-20 r / min to remove surface burrs and adjust the surface roughness to Ra2.0-3.5μm, further improving the interfacial bonding between the subsequent reinforcing layer and the preform.

[0041] S4. Thin-wall forming and precision calibration: The polished preform is fixed on a CNC winding machine. A reinforcing layer is prepared by bidirectional cross-winding using high-performance glass fiber yarn (tensile strength ≥3500MPa, linear density 200-300tex, surface pretreated with silane coupling agent). The winding angle is set to ±45°, the winding tension is controlled at 40-60N, the yarn spacing is 2-5mm, 3-5 layers are wound, and the reinforcing layer thickness is controlled at 1.0-2.0mm. During the winding process, an ultrasonic-assisted compaction device is set next to the winding head, with a power of 100-200W and a frequency of 20-40kHz. The ultrasonic probe is 5-10mm away from the winding surface. Ultrasonic vibration helps to expel air between the winding layers, improving the density of the reinforcing layer. Mechanical compaction is performed every two layers using a pressure of 0.1-0.15MPa to ensure a tight bond between the reinforcing layer and the preform. After the winding is completed, the pole is transferred to a CNC turning machine and the two ends of the pole are precision machined at a cutting speed of 100-150m / min and a feed rate of 0.1-0.2mm / r to ensure that the perpendicularity of the end face is ≤0.02mm / m and the outer diameter tolerance is controlled within ±0.2mm, thus completing the initial forming of the thin-walled pole.

[0042] S5. Post-treatment and Performance Testing: Surface modification and functional coating treatment are applied to the initially formed thin-walled poles to improve weather resistance and service life. Step 1: Surface modification with composite coupling agent. A composite coupling agent solution is prepared: using a mixture of ethanol and water (volume ratio 3:1-5:1) as the solvent, 2%-5% (by mass) of silane coupling agent KH-550 and 1%-2% (by mass) of titanate coupling agent (isopropyltristearate titanate) are added. After stirring and dissolving evenly, the pole is immersed in the solution for 10-20 minutes, then removed and air-dried naturally. Through the synergistic effect of the two coupling agents, the adhesion between the coating and the pole surface is significantly improved. Step 2: Functional coating preparation. Preparation of fluorocarbon-nanozirconia composite anti-corrosion coating: Fluorocarbon resin, silane coupling agent-modified nanozirconia (particle size 20-50nm), curing agent and diluent are mixed evenly at a mass ratio of 5:0.3:1:2. The coating is prepared by electrostatic spraying, and the coating thickness is controlled at 80-120μm. After spraying, the pole is placed in a hot air circulating oven and dried and cured for 1-2 hours at 80-90℃ and wind speed of 1-2m / s. Nanozirconia can significantly improve the hardness and corrosion resistance of the coating. After the coating cures, the pole undergoes comprehensive performance testing: Bending strength and compressive strength are tested using a universal testing machine, requiring a bending strength of no less than 85 MPa and a compressive strength of no less than 120 MPa; durability is tested using a salt spray test chamber for 720 hours, requiring surface corrosion area to not exceed 2%; aging resistance is tested using a damp heat aging test chamber at 40℃ and 90% relative humidity for 1000 hours, requiring mechanical property retention of no less than 85%; the healing of artificially pre-fabricated microcracks (0.1-0.2 mm wide) is observed under a microscope to test self-healing performance, with a crack healing rate ≥80% after 48 hours of placement at room temperature and humidity. After all tests are passed, the finished thin-walled pole is obtained.

[0043] This invention also provides a thin-walled pole prepared using the above-described process. The thin-walled pole comprises, from the inside out, a three-dimensional woven basalt fiber composite preform layer, a glass fiber reinforcement layer, and a fluorocarbon-nanozirconia composite coating. The overall wall thickness of the pole is 6-12 mm, the length is 8-15 m, and the outer diameter is 150-300 mm. To facilitate installation and connection, metal connecting flanges are provided at both ends of the pole. The flanges are fixed to the pole body by pre-embedded fiber-reinforced resin anchors. The anchors are made of the same fiber-reinforced resin material as the pole body, and the surface of the anchors undergoes dopamine biomimetic modification treatment to improve the interfacial bonding strength between the anchors and the pole body. The anchors are embedded in the pole body to a depth of 150-200 mm to ensure a secure connection.

[0044] The complete technical solution of the present invention will be described in detail below with reference to specific embodiments and comparative examples. All embodiments employ a combination of the core technologies of the present invention. The advancement and necessity of the complete technical solution of the present invention are verified by testing core indicators such as molding accuracy, mechanical properties, durability, self-healing performance, and production efficiency.

[0045] Example 1 (Baseline Group: Standard Specifications)

[0046] 1. Raw material pretreatment: Select 30% modified basalt fiber felt (area density 400g / m³) by mass fraction. 2 The composition includes: 12 μm fiber diameter, 45% bio-based epoxy resin (castor oil modified, epoxy value 0.5 eq / 100g), 8% nano-montmorillonite (hexadecyltrimethylammonium bromide intercalated, interlayer spacing 4.0 nm), and 10% glass microspheres (particle size 80 μm, density 0.4 g / cm³). 3 The mixture consisted of 6% microcapsule self-healing agent (urea-formaldehyde resin coated with epoxy resin, particle size 80μm, encapsulation rate 88%) and 1% curing accelerator 2-methylimidazole (total 100%). Basalt fiber felt was first immersed in a 2.5% dopamine solution (50mmol / L Tris-HCl buffer, pH=8.2), stirred at 28℃ for 8h, and then vacuum dried at 60℃ for 5h to obtain modified fiber felt. Next, bio-based epoxy resin and nano-montmorillonite were intercalated and composited using acetone solution (solid-liquid ratio 1:6, stirred at 600r / min for 45min). After solvent removal by rotary evaporation at 55℃, the remaining components were added and stirred at 1200r / min for 25min. The modified fiber felt was then immersed in the pre-impregnation solution for 1.5h to obtain the composite slurry.

[0047] 2. Precision Pre-forming: A 10m long, 200mm outer diameter steel mold is prepared, with an 8μm layer of polytetrafluoroethylene (PTFE) release agent applied to the inner wall. A four-step three-dimensional weaving method is employed (weaving density 25 strands / cm). 2 The initial embryo skeleton is formed at an angle of ±45°. After being placed in the mold, it is vacuum-packed in sections (first pre-pressed at 0.04MPa for 1 hour, then held at 0.07MPa for 2.5 hours) at an ambient temperature of 22℃ and a humidity of 55%.

[0048] 3. Gradient curing and strengthening: The preform is placed in a supercritical curing autoclave, 99.95% CO2 is introduced, and it is held at 45℃ and 10MPa for 1.5h; the temperature is then increased to 100℃ at a rate of 4℃ / h, and held at 10MPa for 4h; the pressure is then released to atmospheric pressure at 0.3MPa / min, and the temperature is allowed to drop naturally at 8℃ / h. After demolding, the surface is polished in a ring with 100-grit sandpaper at 18r / min, achieving a surface roughness Ra = 2.8μm.

[0049] 4. Thin-wall forming and precision calibration: CNC winding of high-performance glass fiber yarn (tensile strength 3800MPa, linear density 250tex), winding angle ±45°, tension 50N, yarn spacing 3mm, 4 layers; synchronous ultrasonic-assisted compaction (power 150W, frequency 30kHz, probe distance 8mm), compaction at 0.12MPa for every 2 layers. CNC turning of both ends (cutting speed 120m / min, feed rate 0.15mm / r) to ensure end face perpendicularity of 0.015mm / m and outer diameter tolerance ±0.15mm.

[0050] 5. Post-treatment and performance testing: The pole was treated with a composite coupling agent solution (ethanol:water = 4:1, 2.5% KH-550 + 1.5% isopropyl tristearate titanate) for 15 min, then air-dried. A fluorocarbon-nanozirconia coating (100 μm thickness, fluorocarbon resin:nanozirconia:curing agent:diluent = 5:0.3:1:2) was then electrostatically sprayed and dried with hot air circulation at 85℃ for 1.5 h (wind speed 1.5 m / s). Testing results: flexural strength 89 MPa, compressive strength 126 MPa; salt spray corrosion area 1.5% after 720 h; mechanical property retention rate 88% after 1000 h of damp heat aging; 0.15 mm microcrack healing rate 85% after 48 h; production cycle (including curing) 48 h.

[0051] Example 2 (Large-size group: adapted for long-distance power transmission)

[0052] 1. Raw material pretreatment: Same as in Example 1 (components and proportions remain unchanged).

[0053] 2. Precision Pre-forming: A 15m long, 300mm outer diameter steel mold is prepared, with a 10μm layer of polytetrafluoroethylene (PTFE) release agent applied to the inner wall. The three-dimensional weaving density is 22 threads / cm². 2 The weaving angle is ±30°; the vacuum bag is compressed in sections (pre-compressed at 0.03MPa for 1 hour, then held at 0.06MPa for 3 hours), with an ambient temperature of 23℃ and a humidity of 58%.

[0054] 3. Gradient curing and strengthening: The product is cured in a supercritical CO2 environment at 40℃ and 8MPa for 2 hours; then heated to 90℃ at a rate of 3℃ / h and held at 8MPa for 5 hours; pressure is released at 0.2MPa / min, and the product is allowed to cool naturally at 6℃ / h. After demolding, it is sanded in a circular motion with 80-grit sandpaper at 15r / min, achieving a Ra = 3.2μm.

[0055] 4. Thin-wall forming and precision calibration: CNC winding of glass fiber yarn (linear density 300tex), winding angle ±45°, tension 60N, yarn spacing 5mm, 5 layers; ultrasonic-assisted compaction (power 200W, frequency 20kHz), compaction at 0.15MPa for every 2 layers. CNC turning (cutting speed 100m / min, feed rate 0.2mm / r), end face perpendicularity 0.018mm / m, outer diameter tolerance ±0.2mm.

[0056] 5. Post-treatment and performance testing: Same as the post-treatment process in Example 1. Testing results: flexural strength 86 MPa, compressive strength 122 MPa; salt spray corrosion area 1.8% after 720 h; mechanical property retention rate 86% after 1000 h of damp heat aging; healing rate of 0.2 mm microcracks 82% after 48 h; production cycle 52 h.

[0057] Example 3 (Lightweight Group)

[0058] 1. Raw material pretreatment: The raw materials are selected by mass fraction as follows: 28% modified basalt fiber felt, 42% bio-based epoxy resin, 6% nano-montmorillonite, and 15% glass microspheres (particle size 100μm, density 0.3g / cm³). 3 The mixture contains 8% microcapsule self-healing agent and 1% curing accelerator (total 100%). The dopamine modification and slurry preparation process are the same as in Example 1.

[0059] 2. Precise preforming: Same as Example 1 (10m×200mm specification), three-dimensional weaving density 28 threads / cm2, weaving angle ±60°; segmented vacuum bag pressing (first 0.05MPa pre-press for 1h, then 0.08MPa pressure for 2h).

[0060] 3. Gradient curing and strengthening: The product is held at 50℃ and 12MPa for 1 hour in a supercritical CO2 environment; then heated to 110℃ at a rate of 5℃ / h and held at 12MPa for 3 hours; pressure is released at 0.5MPa / min, and the product is allowed to cool naturally at 10℃ / h. After demolding, it is sanded with 120-grit sandpaper at 20r / min, achieving a Ra = 2.2μm.

[0061] 4. Thin-wall forming and precision calibration: Same as the winding and turning process in Example 1, with a reinforcing layer thickness of 1.5 mm.

[0062] 5. Post-processing and performance testing: Same as Example 1. Testing results: Bending strength 85 MPa, compressive strength 120 MPa; salt spray corrosion area 1.6% after 720 h; mechanical property retention rate 85% after 1000 h of damp heat aging; healing rate of 0.1 mm microcracks 87% after 48 h; production cycle 46 h; pole weight reduced by 12% compared to Example 1.

[0063] Comparative Example 1 (lacking 3D weaving, using traditional wet layup)

[0064] 1. Raw material pretreatment: Same as in Example 1 (components and proportions remain unchanged, and dopamine modification proceeds normally).

[0065] 2. Preforming: The traditional wet lay-up process is adopted, in which the fiber felt of preimpregnated slurry is laid layer by layer in the mold, and the material is manually compacted and degassed. There is no three-dimensional weaving step. The subsequent vacuum bag pressing parameters are the same as in Example 1.

[0066] 3. Gradient curing and strengthening: Same as the supercritical CO2 curing process in Example 1.

[0067] 4. Thin-wall forming and precision calibration: Same as the winding and turning process in Example 1.

[0068] 5. Post-processing and performance testing: Same as Example 1. Testing: Bending strength 68MPa, compressive strength 95MPa; pole delamination defect rate 35%; end face perpendicularity 0.035mm / m, outer diameter tolerance ±0.35mm; salt spray corrosion area 3.2% after 720h; mechanical property retention rate 75% after 1000h of damp heat aging; self-repair rate 84%; production cycle 50h.

[0069] Comparative Example 2 (using conventional thermosetting)

[0070] 1. Raw material pretreatment: Same as in Example 1.

[0071] 2. Precision preforming: Same as the three-dimensional weaving and vacuum bag pressing process in Example 1.

[0072] 3. Curing: Traditional oven heat curing is used, with preheating at 80℃ for 2 hours, constant temperature curing at 100℃ for 6 hours, and natural cooling to room temperature.

[0073] 4. Thin-wall forming and precision calibration: Same as in Example 1.

[0074] 5. Post-processing and performance testing: Same as Example 1. Testing results: Flexural strength 75MPa, compressive strength 108MPa; uneven curing, internal porosity 12%; end face perpendicularity 0.028mm / m, outer diameter tolerance ±0.25mm; salt spray corrosion area 2.5% after 720h; mechanical property retention rate 78% after 1000h of damp heat aging; self-healing rate 83%; production cycle 72h (curing time extended).

[0075] Comparative Example 3 (Traditional Resin)

[0076] 1. Raw material pretreatment: Ordinary basalt fiber felt (without dopamine modification) is used, and ordinary petroleum-based epoxy resin is used instead of bio-based epoxy resin; the microcapsule self-healing agent is removed, and the component ratio is adjusted to 30% ordinary fiber felt, 51% petroleum-based epoxy resin, 8% nano montmorillonite, 10% glass microspheres, and 1% curing accelerator (total 100%); there is no dopamine modification step, and the slurry preparation is only conventional mixing.

[0077] 2. Precision preforming: Same as Example 1.

[0078] 3. Gradient curing and strengthening: Same as in Example 1.

[0079] 4. Thin-wall forming and precision calibration: Same as in Example 1.

[0080] 5. Post-processing and performance testing: Same as Example 1. Testing results: Flexural strength 70 MPa, compressive strength 102 MPa; fiber-resin interface bonding strength 15.8 MPa (26.8 MPa in Example 1); no self-healing function, 0.15 mm microcrack healing rate 10% after 48 hours; salt spray corrosion area 4.5% after 720 hours; mechanical property retention rate 70% after 1000 hours of damp heat aging; production cycle 48 hours; poor environmental performance, VOC emissions exceed standards.

[0081] Comparative Example 4 (Traditional process control group: centrifugal casting + reinforced concrete)

[0082] 1. Raw materials: cement, sand and gravel, steel bars, water-reducing agent (traditional reinforced concrete raw materials).

[0083] 2. Preparation process: The traditional centrifugal casting method is adopted. The concrete slurry is injected into the steel mold, the centrifuge speed is 300r / min, and the centrifugation time is 20min; then it is naturally cured for 28 days.

[0084] 3. Post-processing: Simple surface polishing, no functional coating treatment.

[0085] 4. Performance Testing: Same testing standards as Example 1. Testing: Bending strength 55MPa, compressive strength 110MPa; pole wall thickness deviation ±2mm; 15% corrosion area (steel reinforcement corrosion) after 720h salt spray; no self-healing function; production cycle 29 days; weight 65% heavier than Example 1; difficult to transport and install.

[0086] The core performance indicators of Examples 1-3 and Comparative Examples 1-4 are summarized in the table below, which intuitively demonstrates the advantages of the complete technical solution of the present invention:

[0087] Table 1 Summary of Core Performance Indicators

[0088]

[0089]

[0090] Results analysis:

[0091] 1. Examples 1-3 (which utilize a complete combination of core technologies including three-dimensional weaving, supercritical CO2 curing, dopamine modification, microcapsule self-healing, and bio-based resin) all exhibit excellent performance. The molding accuracy (end face perpendicularity ≤ 0.018 mm / m, outer diameter tolerance ≤ ±0.20 mm), mechanical properties (flexural strength ≥ 85 MPa, compressive strength ≥ 120 MPa), weather resistance (salt spray corrosion area ≤ 1.8%, damp heat aging retention rate ≥ 85%) and self-healing rate (≥ 82%) all meet the design requirements. Furthermore, the production cycle is short (46-52 h) and the weight is controllable.

[0092] 2. Comparative Example 1, lacking three-dimensional weaving, exhibited obvious delamination defects, resulting in a significant decrease in mechanical properties and molding precision; Comparative Example 2, lacking supercritical CO2 curing, suffered from uneven curing, high porosity, decreased mechanical properties, and a 46% extension in production cycle; Comparative Example 3, lacking dopamine modification and microcapsules, had insufficient interfacial bonding, lost its self-healing function, and significantly deteriorated weather resistance; these findings fully demonstrate the synergistic effect of the core technologies of this invention, and that none of them can be omitted.

[0093] 3. Comparative Example 4 (traditional reinforced concrete centrifugal casting) has extremely poor molding accuracy, insufficient mechanical properties, poor corrosion resistance, no self-healing function, and a production cycle of up to 29 days and a weight increase of 65%, highlighting the comprehensive advantages of the technical solution of this invention in terms of performance, efficiency, and lightweight.

[0094] The above are merely embodiments of the present invention. The circuits, electronic components, and modules involved are all prior art, fully achievable by those skilled in the art, and require no further explanation. The scope of protection in this application does not involve improvements to the software and methods. Commonly known structures and characteristics in the solutions are not described in detail here. Those skilled in the art are aware of all common technical knowledge in the field prior to the application date or priority date, are aware of all prior art in that field, and have the ability to apply conventional experimental methods prior to that date. Those skilled in the art can, under the guidance of this application, improve and implement this solution in combination with their own capabilities. Some typical known structures or methods should not be obstacles for those skilled in the art to implement this application. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention. These should also be considered within the scope of protection of the present invention, and will not affect the effectiveness of the implementation of the present invention or the practicality of the application.

Claims

1. A manufacturing process for a thin-walled electric pole, characterized in that: Includes the following steps: S1. Basalt fiber felt is modified with dopamine biomimetic technology to obtain modified basalt fiber felt; bio-based epoxy resin and nano-montmorillonite modified filler are solution intercalated and composited, and after solvent removal by rotary evaporation, glass microsphere lightweight filler, microcapsule self-healing agent and curing accelerator are added to obtain a mixed system; the modified basalt fiber felt is pre-impregnated in the above mixed system for 1-2 hours to obtain composite slurry; S2. The modified basalt fiber felt of preimpregnated composite slurry is three-dimensionally interwoven to form the initial skeleton of the pole. Then the skeleton is placed in a mold and a segmented vacuum bag pressing process is adopted. First, it is pre-pressed at 0.03-0.05MPa for 1 hour, and then the pressure is increased to 0.06-0.08MPa and held for 2-3 hours to form the initial skeleton. S3. Place the preformed embryo in a supercritical curing autoclave, first introduce CO2 to establish a supercritical environment, and keep it at the temperature for 1-2 hours to achieve CO2 penetration; then carry out gradient temperature curing, raising the temperature to 90-110℃ at a rate of 3-5℃ / h, maintaining the pressure at 8-12MPa, and keeping it at the temperature for 3-5 hours, then slowly depressurizing to atmospheric pressure and naturally cooling to room temperature to complete curing; S4. Place the cured preform on a CNC winding machine and use high-performance glass fiber yarn for bidirectional cross-winding to form a reinforcing layer. During the winding process, ultrasonic-assisted compaction is applied simultaneously to obtain the shaped pole. S5. Surface modification and functional coating treatment are carried out on the formed pole. First, the surface is modified by using a composite solution of silane coupling agent KH-550 and titanate coupling agent. After drying, a fluorocarbon-nano zirconium oxide composite anti-corrosion coating is prepared by electrostatic spraying process to obtain the finished thin-walled pole.

2. The manufacturing process of a thin-walled electric pole as described in claim 1, characterized in that: The dopamine biomimetic modification of basalt fiber felt involves immersing the fiber felt in a 2-3% (w / w) dopamine solution, adjusting the pH to 8.0-8.5, stirring at a constant temperature of 25-30°C for 6-12 hours, and then vacuum drying it.

3. The manufacturing process of a thin-walled electric pole as described in claim 1, characterized in that: The mass fraction of each raw material in step S1 is as follows: 25%-35% modified basalt fiber felt, 40%-50% bio-based epoxy resin, 5%-10% nano-montmorillonite modified filler, 5%-10% glass microsphere lightweight filler, 3%-5% microcapsule self-healing agent, and 0.5%-1.0% curing accelerator.

4. The manufacturing process of a thin-walled electric pole as described in claim 3, characterized in that: The microcapsule self-healing agent is a urea-formaldehyde resin coated epoxy resin type.

5. The manufacturing process of a thin-walled electric pole as described in claim 1, characterized in that: The weaving density of the three-dimensional weaving is 20-30 threads / cm. 2 The weaving angle is ±30°-±60°.

6. The manufacturing process of a thin-walled electric pole as described in claim 1, characterized in that: In step S4, the bidirectional cross-winding angle is ±45°, the winding tension is 40-60N, and the thickness of the reinforcing layer is 1.0-2.0mm; the ultrasonic-assisted compaction power is 100-200W, the frequency is 20-40kHz, and compaction is performed once every two windings, with a compaction pressure of 0.1-0.15MPa.

7. The manufacturing process of a thin-walled electric pole as described in claim 1, characterized in that: In step S5, the composite coupling agent solution is a mixed solution of KH-550 with a mass fraction of 2%-5% and titanate coupling agent with a mass fraction of 1%-2%, and the solvent is a mixture of ethanol and water with a volume ratio of 3:1-5:

1.

8. The manufacturing process of a thin-walled electric pole as described in claim 1, characterized in that: In step S5, the fluorocarbon-nanozirconia composite coating has a nanozirconia mass fraction of 5%-8% and a coating thickness of 80-120μm. After spraying, it is dried and cured by hot air circulation at 80-90℃ for 1-2 hours.

9. The manufacturing process of a thin-walled electric pole as described in claim 1, characterized in that: In step S1, the solvent for the dopamine solution is a Tris-HCl buffer solution with a concentration of 50 mmol / L; The areal density of the modified basalt fiber felt is 300-500 g / m³. 2 The fiber diameter is 10-15μm, and the contact angle of the modified fiber surface is ≤60°. The bio-based epoxy resin is prepared by modifying castor oil with epichlorohydrin, and has an epoxy value of 0.4-0.6 eq / 100g; The nano-montmorillonite modified filler is modified by hexadecyltrimethylammonium bromide intercalation; The glass microsphere lightweight filler has a particle size of 50-100 μm and a density of 0.3-0.5 g / cm³. 3 ; The curing accelerator is 2-methylimidazole.

10. The manufacturing process of a thin-walled electric pole as described in claim 1, characterized in that: In step S5, the titanate coupling agent is isopropyl tristearate titanate; The fluorocarbon-nanozirconia composite coating is made by mixing fluorocarbon resin, nanozirconia, curing agent and diluent in a mass ratio of 5:0.3:1:2.

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