Polymer composite guardrail and method for manufacturing the same

Abstract

The application belongs to the technical field of high polymer materials, and particularly relates to a high polymer composite guardrail and a preparation method thereof, which comprises the following steps: S1, uniformly blending modified PVC raw materials, glass fibers and additives to prepare molten composite materials; S2, taking a steel lining to perform surface punching processing, embedding the steel lining into the center of a mold, then feeding the molten composite materials into the mold, and performing an extrusion process on the outside to combine an ASA weather-resistant surface layer, so as to obtain a vertical column and a horizontal pipe after cooling and shaping; S3, high-temperature mold pressing of SMC sheet-shaped molding compound to obtain an SMC mold pressing sleeve; and S4, pre-installing the SMC mold pressing sleeve in a to-be-constructed area, inserting the bottom of the vertical column into the SMC mold pressing sleeve, and connecting adjacent vertical columns through the horizontal pipe to obtain the high polymer composite guardrail.

Description

Technical Field

[0001] This invention belongs to the field of polymer materials technology, specifically relating to a polymer composite guardrail and its preparation method. Background Technology

[0002] Currently used outdoor guardrails, especially those in rainy and mountainous areas of southwest China such as Yunnan and Guizhou, generally adopt the traditional structure of welded small square iron tubes with rust-proof paint applied to the surface. This type of guardrail has been in use for over 20 years and is the mainstream outdated product for outdoor protection.

[0003] Traditional iron square tube railings have been in use for over twenty years, far exceeding their normal service life, and rely solely on periodic manual painting for corrosion prevention. In actual maintenance, workers can only paint the surface of the railings; the base where the railings connect to the foundation and other hidden areas are left unpainted. Furthermore, the rainy and humid climate of Yunnan and Guizhou makes the base of the railings prone to water accumulation, rust, and rot, ultimately leading to railing breakage and seriously threatening safety.

[0004] Meanwhile, the southwest region has strong ultraviolet radiation and abundant rainfall, which makes the paint on the iron guardrail surface extremely easy to peel off and flake, and the steel corrodes rapidly. Even with normal maintenance, it cannot meet the needs of long-term use.

[0005] More importantly, the construction of guardrails is extremely large. Traditional iron guardrails require on-site cutting, welding, and painting, which involves many procedures and takes a long time. Installation cannot be completed in a short period of time, and large-scale replacement is extremely costly.

[0006] Therefore, how to overcome the drawback of frequent maintenance of guardrails in the southwest region at low cost is a technical problem that urgently needs to be solved in this field.

[0007] It should be noted that the information disclosed in this background section is only for understanding the background technology of the present application concept, and therefore, the above description is not considered to constitute prior art information. Summary of the Invention

[0008] This disclosure provides at least one example of a polymer composite guardrail and its preparation method.

[0009] In a first aspect, the present disclosure provides a method for preparing a polymer composite guardrail, comprising the following steps: S1, uniformly mixing modified PVC raw materials, glass fiber and additives to prepare a molten composite material; S2, drilling holes in the surface of a steel liner, embedding it into the center of a mold, then feeding the molten composite material in, and applying an ASA weather-resistant surface layer to the outside through an extrusion process, and obtaining a post and a horizontal tube after cooling and shaping; S3, high-temperature molding SMC sheet molding compound to obtain an SMC die-cast sleeve; S4, pre-installing the SMC die-cast sleeve in the area to be constructed, inserting the bottom of the post into the SMC die-cast sleeve, and connecting adjacent posts laterally through the horizontal tube to obtain a polymer composite guardrail.

[0010] In one optional embodiment, the molten composite material comprises the following components by weight: 70-80 parts modified PVC resin; 15-20 parts alkali-free chopped glass fiber; and 2-4 parts composite stabilizer. 4-6 parts chlorinated polyethylene; 2-4 parts acrylate processing aid; 3-5 parts titanium dioxide; 0.1-0.5 parts UV stabilizer; 0.1-0.3 parts antioxidant; 1-3 parts lubricant; 3-5 parts color masterbatch.

[0011] In one alternative embodiment, the length of the alkali-free chopped glass fiber ranges from 6 to 12 mm.

[0012] In one alternative embodiment, the composite stabilizer comprises any one or more combinations of calcium stearate, zinc stearate, and hydrotalcite.

[0013] In one optional embodiment, the ASA weather-resistant surface layer comprises the following components by weight: 80-90 parts ASA resin; 5-15 parts titanium dioxide; 0.5-1 part UV stabilizer; 0.3-0.5 parts antioxidant; 2-4 parts compatibilizer; 0.5-1 part lubricant; and 1-3 parts color masterbatch.

[0014] Secondly, this disclosure also provides a polymer composite material guardrail made by the method described above, comprising: a post, the bottom of which is inserted into the SMC die-cast sleeve; a horizontal tube that connects adjacent posts laterally; and the SMC die-cast sleeve, the post, and the horizontal tube are fixed together by nylon quick-release plugs and expansion screws.

[0015] In one alternative embodiment, the inner wall of the column comprises, from the inside out, a steel lining, a molten composite material, and an ASA weather-resistant surface layer.

[0016] In one alternative embodiment, the thickness of the inner wall ranges from 8 to 10 mm.

[0017] In one alternative embodiment, a handrail is also included, which is disposed on the top of an adjacent column; and the handrail is provided with anti-slip texture.

[0018] Thirdly, this disclosure also provides an installation method for the polymer composite material guardrail as described above, including the following steps: fixing the SMC die-cast sleeve in the pre-installed area to be constructed, inserting the post into the SMC die-cast sleeve, inserting the nylon quick-release plug, and screwing in the expansion screw to achieve rapid expansion and locking; connecting the horizontal tube and the handrail to the post through the nylon quick-release plug, and screwing in the expansion screw to complete the lateral connection.

[0019] The beneficial effects of this invention are that the polymer composite material guardrail and its preparation method embed a steel lining within the PVC material. During the one-piece molding process of the guardrail, the molten composite material fully penetrates the steel lining, and after cooling, a seamless, integrated structure is formed without delamination or loosening. Furthermore, the steel lining is completely sealed by the polymer material, eliminating the risk of rust. At the same time, the ASA weather-resistant surface layer can further improve the guardrail's resistance to ultraviolet aging and rainwater erosion. The quick-install fixing components of the guardrail are made of nylon material, enabling rapid construction and installation without welding or complex tools.

[0020] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention are realized and obtained through the structures particularly pointed out in the description.

[0021] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described in detail below. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, 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.

[0023] As used herein, the phrases “in one embodiment,” “according to one embodiment,” “in some embodiments,” etc., generally refer to the fact that a particular feature, structure, or characteristic following the phrase can be included in at least one embodiment of this disclosure. Therefore, a particular feature, structure, or characteristic can be included in more than one embodiment of this disclosure, such that these phrases do not necessarily refer to the same embodiment. As used herein, the terms “example,” “exemplary,” etc., are used to “serve as an example, instance, or illustration.” Any implementation, aspect, or design described herein as “example” or “exemplary” is not necessarily to be construed as preferred or superior to other implementations, aspects, or designs. Rather, the use of the terms “example,” “exemplary,” etc., is intended to present concepts in a specific manner.

[0024] The terminology used herein is for the purpose of describing specific exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may also be intended to include plural forms unless otherwise clearly stated herein. The terms “comprising,” “including,” and “having” are inclusive and thus specify the presence of features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or combinations thereof. The method steps, processes, and operations described herein should not be construed as requiring them to be performed in the specific order discussed or shown, unless specifically identified as such. Additional or alternative steps may be employed.

[0025] In this paper, the modified PVC raw material (modified PVC resin) is SG-5 type; the acrylate processing aid is ACR-401; the UV stabilizer is any one of UV-531, UV-P and UV-327; the antioxidant is any one of antioxidant 1010 and antioxidant 168; and the compatibilizer is maleic anhydride grafted ASA.

[0026] In this article, PVC refers to polyvinyl chloride, and ASA refers to a synthetic resin made by graft copolymerization of styrene, acrylonitrile, and acrylate rubbers.

[0027] The following describes some embodiments of the present invention in detail. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0028] This disclosure provides a method for preparing a polymer composite guardrail, comprising the following steps: S1, uniformly mixing modified PVC raw materials, glass fiber, and additives to prepare a molten composite material; S2, drilling holes in the surface of a steel liner, embedding it into the center of a mold, then feeding the molten composite material in, and applying an ASA weather-resistant surface layer to the outside through an extrusion process, followed by cooling and shaping to obtain posts and horizontal tubes; S3, high-temperature molding SMC sheet molding compound to obtain an SMC die-cast sleeve; S4, pre-installing the SMC die-cast sleeve in the area to be constructed, inserting the bottom of the posts into the SMC die-cast sleeve, and connecting adjacent posts laterally through horizontal tubes to obtain a polymer composite guardrail.

[0029] In some embodiments, specifically, the molten composite material comprises the following components by weight: 70-80 parts modified PVC resin; 15-20 parts alkali-free chopped glass fiber; 2-4 parts composite stabilizer; 4-6 parts chlorinated polyethylene; 2-4 parts acrylate processing aid; 3-5 parts titanium dioxide; 0.1-0.5 parts UV stabilizer; 0.1-0.3 parts antioxidant; 1-3 parts lubricant; and 3-5 parts color masterbatch.

[0030] In some embodiments, specifically, the length of the alkali-free chopped glass fiber ranges from 6 to 12 mm.

[0031] In some embodiments, specifically, the composite stabilizer includes any one or more combinations of calcium stearate, zinc stearate, and hydrotalcite.

[0032] In some embodiments, the ASA weather-resistant surface layer specifically comprises the following components by weight: 80-90 parts ASA resin; 5-15 parts titanium dioxide; 0.5-1 part UV stabilizer; 0.3-0.5 parts antioxidant; 2-4 parts compatibilizer; 0.5-1 part lubricant; and 1-3 parts color masterbatch.

[0033] This disclosure also provides a polymer composite material guardrail manufactured using the method described above, comprising: a post, the bottom of which is inserted into the SMC die-cast sleeve; a horizontal tube that connects adjacent posts laterally; and the SMC die-cast sleeve, the post, and the horizontal tube are fixed together by nylon quick-release plugs and expansion screws.

[0034] In some embodiments, specifically, the inner wall of the column comprises, from the inside out, a steel lining, a molten composite material, and an ASA weather-resistant surface layer.

[0035] In some embodiments, specifically, the thickness of the inner wall ranges from 8 to 10 mm.

[0036] In some embodiments, specifically, the system further includes a handrail disposed on the top of an adjacent column; and the handrail is provided with an anti-slip texture.

[0037] This disclosure also provides an installation method for the polymer composite material guardrail as described above, including the following steps: fixing the SMC die-cast sleeve in the pre-installed area to be constructed, inserting the post into the SMC die-cast sleeve, inserting the nylon quick-release plug, and screwing in the expansion screw to achieve rapid expansion and locking; connecting the horizontal tube and the handrail to the post through the nylon quick-release plug, and screwing in the expansion screw to complete the lateral connection.

[0038] Example 1, the preparation method is as follows: S1. Modified PVC raw materials, glass fiber, and additives are mixed evenly to prepare a molten composite material. S2. A steel liner is perforated and embedded in the center of a mold. The molten composite material is then fed in and an ASA weather-resistant surface layer is laminated on the outside through an extrusion process. After cooling and shaping, the uprights and horizontal tubes are obtained. S3. SMC sheet molding compound is high-temperature molded to obtain an SMC die-cast sleeve. S4. The SMC die-cast sleeve is pre-installed in the area to be constructed. The bottom of the upright is inserted into the SMC die-cast sleeve, and adjacent uprights are connected laterally through the horizontal tube to obtain a polymer composite guardrail.

[0039] The molten composite material in S1 comprises the following components by mass: 73 parts modified PVC resin, 15 parts alkali-free chopped glass fiber with a length of 12 mm; 2 parts composite stabilizer, wherein the mass ratio of calcium stearate: zinc stearate: hydrotalcite is 1:1:1; 4 parts chlorinated polyethylene; 2 parts acrylate processing aid; 3 parts titanium dioxide; 0.1 parts UV stabilizer; 0.1 parts antioxidant; 1 part lubricant; and 3 parts color masterbatch.

[0040] The ASA weather-resistant surface layer in S2 comprises the following components by weight: 80 parts ASA resin; 5 parts titanium dioxide; 0.5 parts UV stabilizer; 0.3 parts antioxidant; 2 parts compatibilizer; 0.5 parts lubricant; and 1 part color masterbatch.

[0041] Specifically, the wall thickness of the column is 8mm.

[0042] Fix the SMC die-cast sleeve to the pre-installed area to be constructed, insert the column into the SMC die-cast sleeve, insert the nylon quick-release plug, and screw in the expansion screw to achieve rapid expansion and locking; connect the horizontal tube and the handrail to the column through the nylon quick-release plug, and screw in the expansion screw to complete the lateral connection.

[0043] Example 2 is the same as Example 1, except that: The molten composite material in S1 comprises the following components by mass parts: 73 parts modified PVC resin, 17 parts alkali-free chopped glass fiber with a length of 12 mm; 3 parts composite stabilizer, wherein the mass ratio of calcium stearate: zinc stearate: hydrotalcite is 1:1:1; 5 parts chlorinated polyethylene; 3 parts acrylate processing aid; 4 parts titanium dioxide; 0.3 parts UV stabilizer; 0.2 parts antioxidant; 2 parts lubricant; and 4 parts color masterbatch.

[0044] The ASA weather-resistant surface layer in S2 comprises the following components by weight: 85 parts ASA resin; 10 parts titanium dioxide; 0.7 parts UV stabilizer; 0.4 parts antioxidant; 3 parts compatibilizer; 0.7 parts lubricant; and 2 parts color masterbatch.

[0045] Specifically, the wall thickness of the column is 9mm.

[0046] Example 3 is the same as Example 1, except that: The molten composite material in S1 comprises the following components by mass parts: 75 parts modified PVC resin, 18 parts alkali-free chopped glass fiber with a length of 12 mm; 3 parts composite stabilizer, wherein the mass ratio of calcium stearate: zinc stearate: hydrotalcite is 1:1:1; 5 parts chlorinated polyethylene; 3 parts acrylate processing aid; 4 parts titanium dioxide; 0.3 parts UV stabilizer; 0.2 parts antioxidant; 2 parts lubricant; and 4 parts color masterbatch.

[0047] The ASA weather-resistant surface layer in S2 comprises the following components by weight: 85 parts ASA resin; 10 parts titanium dioxide; 0.7 parts UV stabilizer; 0.4 parts antioxidant; 3 parts compatibilizer; 0.7 parts lubricant; and 2 parts color masterbatch.

[0048] Specifically, the wall thickness of the column is 9mm.

[0049] Example 4 is the same as Example 1, except that: The molten composite material in S1 comprises the following components by mass parts: 77 parts modified PVC resin, 19 parts alkali-free chopped glass fiber with a length of 12 mm; 3 parts composite stabilizer, wherein the mass ratio of calcium stearate: zinc stearate: hydrotalcite is 1:1:1; 5 parts chlorinated polyethylene; 3 parts acrylate processing aid; 4 parts titanium dioxide; 0.4 parts UV stabilizer; 0.2 parts antioxidant; 2 parts lubricant; and 4 parts color masterbatch.

[0050] The ASA weather-resistant surface layer in S2 comprises the following components by weight: 87 parts ASA resin; 12 parts titanium dioxide; 0.8 parts UV stabilizer; 0.4 parts antioxidant; 3 parts compatibilizer; 0.8 parts lubricant; and 2 parts color masterbatch.

[0051] Specifically, the wall thickness of the column is 9mm.

[0052] Example 5 is the same as Example 1, except that: The molten composite material in S1 comprises the following components by mass parts: 80 parts modified PVC resin, 20 parts alkali-free chopped glass fiber with a length of 12 mm; 4 parts composite stabilizer, wherein the mass ratio of calcium stearate: zinc stearate: hydrotalcite is 1:1:1; 6 parts chlorinated polyethylene; 4 parts acrylate processing aid; 5 parts titanium dioxide; 0.5 parts UV stabilizer; 0.3 parts antioxidant; 3 parts lubricant; and 5 parts color masterbatch.

[0053] The ASA weather-resistant surface layer in S2 comprises the following components by weight: 90 parts ASA resin; 15 parts titanium dioxide; 1 part UV stabilizer; 0.5 parts antioxidant; 4 parts compatibilizer; 1 part lubricant; and 3 parts color masterbatch.

[0054] Specifically, the wall thickness of the column is 10mm.

[0055] The performance test results of the polymer composite guardrails obtained in Examples 1-5 are shown in Table 1 below: Table 1 In summary, this polymer composite material guardrail and its preparation method embed a steel liner within PVC material. During the one-piece molding process of the guardrail, the molten composite material fully penetrates the steel liner, and after cooling, a seamless, integrated structure is formed without delamination or loosening. Furthermore, the steel liner is completely sealed by the polymer material, eliminating the risk of rust. At the same time, the ASA weather-resistant surface layer further enhances the guardrail's resistance to ultraviolet aging and rainwater erosion. The quick-installation fixing components of the guardrail are made of nylon material, enabling rapid construction and installation without welding or complex tools.

[0056] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A method for preparing a polymer composite material guardrail, characterized in that, Includes the following steps: S1, Modified PVC raw materials, glass fiber and additives are mixed evenly to prepare a molten composite material; S2, take the steel lining and perform surface drilling, pre-embed it in the center of the mold, then feed in the molten composite material, and apply an ASA weather-resistant surface layer on the outside through extrusion process. After cooling and shaping, the column and horizontal tube are obtained. S3, SMC sheet molding compound is high temperature compression molded to obtain SMC die-cast sleeve; S4. Pre-install the SMC die-cast sleeve in the area to be constructed, insert the bottom of the column into the SMC die-cast sleeve, and connect adjacent columns laterally through the horizontal tube to obtain a polymer composite material guardrail.

2. The preparation method according to claim 1, characterized in that, The molten composite material comprises the following components by mass parts: 70-80 parts of modified PVC resin; 15-20 parts of alkali-free chopped glass fiber; 2-4 parts of compound stabilizer; 4-6 parts of chlorinated polyethylene; 2-4 parts of acrylate processing aid; 3-5 parts titanium dioxide; 0.1-0.5 parts of UV protectant; Antioxidant 0.1-0.3 parts; 1-3 parts lubricant; 3-5 parts of color masterbatch.

3. The preparation method according to claim 2, characterized in that, The length range of the alkali-free chopped glass fiber is 6-12 mm.

4. The preparation method according to claim 2, characterized in that, The composite stabilizer includes any one or more combinations of calcium stearate, zinc stearate, and hydrotalcite.

5. The preparation method according to claim 1, characterized in that, The ASA weather-resistant surface layer comprises the following components by weight: 80-90 parts of ASA resin; 5-15 parts titanium dioxide; 0.5-1 part UV protectant; Antioxidant 0.3-0.5 parts; 2-4 parts compatibilizer; Lubricant 0.5-1 part; 1-3 parts of color masterbatch.

6. A polymer composite material guardrail prepared by the method according to any one of claims 1-5, characterized in that, include: The column, the bottom of which is inserted into the SMC die-cast sleeve; A horizontal tube that connects adjacent columns laterally; Furthermore, the SMC die-cast sleeve, column, and horizontal tube are fixed together by nylon quick-release plugs and expansion screws.

7. The polymer composite material guardrail as described in claim 6, characterized in that, The inner wall of the column, from the inside out, consists of a steel lining, a molten composite material, and an ASA weather-resistant surface layer.

8. The polymer composite material guardrail as described in claim 7, characterized in that, The thickness of the inner wall ranges from 8 to 10 mm.

9. The polymer composite material guardrail as described in claim 6, characterized in that, It also includes handrails, which are provided on top of adjacent columns; In addition, the handrail is provided with anti-slip texture.

10. A method for installing a polymer composite material guardrail as described in any one of claims 6-9, characterized in that, Includes the following steps: Fix the SMC die-cast sleeve to the pre-installed area to be constructed, insert the column into the SMC die-cast sleeve, insert the nylon quick-release plug, and screw in the expansion screw to achieve rapid expansion and locking. Connect the horizontal tube and the handrail to the column using nylon quick-connect plugs, and screw in expansion bolts to complete the lateral connection.

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