A seamless bridge expansion joint based on polymer elastic materials and its repair method

Abstract

This invention relates to the field of bridge engineering component technology, specifically disclosing a seamless bridge expansion joint based on polymer elastic materials and its repair method. The expansion joint uses the main beam as its core load-bearing foundation, and achieves seamless expansion, waterproofing, and structural stability through layered interface adhesive layers, low-friction plates, built-in expansion joints, and polymer elastic components, combined with a metal protective connection structure. The repair method addresses different damage types to various components by employing modular disassembly, targeted repair and replacement, and integrated reassembly, achieving rapid and efficient repair. This invention solves the problems of uneven road surface transitions, high vehicle vibration and noise, easy leakage and damage, and inconvenient installation and maintenance associated with traditional bridge expansion joints. It possesses advantages such as adaptive expansion deformation, good sealing and water-stopping effect, and high driving comfort. Furthermore, the repair method is simple to operate, and the repaired structure exhibits strong stability, effectively extending the overall service life of the device.

Description

Technical Field

[0001] This invention relates to the field of bridge engineering component technology, specifically to a seamless bridge expansion joint based on polymer elastic materials and its repair method. Background Technology

[0002] Bridge expansion joints are key components in bridge engineering. Their main function is to accommodate the expansion and contraction of the bridge structure caused by temperature changes, loads, concrete shrinkage and creep, and foundation settlement. At the same time, they ensure waterproofing and seepage prevention at bridge joints, thus guaranteeing the structural stability and service life of the bridge.

[0003] Currently, traditional bridge expansion joints mostly adopt a split-type structure design, with obvious gaps and height differences between layers, failing to achieve a smooth transition to the road surface. This easily generates strong vibrations and noise when vehicles pass by, significantly reducing the driving experience. Moreover, the interlayer connection strength of the split structure is low, and after long-term impact from traffic loads, local damage and loosening are prone to occur, allowing rainwater and silt to seep into the device, causing component corrosion and jamming, affecting expansion performance, and even causing leakage at bridge joints, reducing the overall durability of the bridge. In addition, the installation of traditional expansion joints often uses a monolithic casting method, which is cumbersome and requires large-scale disassembly for later maintenance, making the operation difficult, time-consuming, and costly. At the same time, its core elastic components are mostly made of ordinary rubber materials, with poor elastic deformation capacity and insufficient weather resistance, making them prone to aging and cracking, further shortening the service life of the device.

[0004] To address the aforementioned issues, there is an urgent need to develop a seamless bridge expansion joint that features adaptive expansion and contraction deformation, smooth road surface transition, good waterproofing and seepage prevention, and strong structural stability. Simultaneously, it should be equipped with a simple and efficient repair method to achieve modular maintenance and extend the overall service life of the joint. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a seamless bridge expansion joint based on polymer elastic materials and its repair method, thereby solving the technical problems of uneven road surface transition, high noise from vehicle vibration, easy leakage and damage, and inconvenient installation and maintenance of traditional bridge expansion joints.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: On one hand, the present invention provides a seamless bridge expansion joint based on a polymer elastic material, comprising at least two main beams. The upper surface of each main beam is sequentially stacked with a first interfacial adhesive layer, a low-friction plate, a built-in expansion joint, a second interfacial adhesive layer, and a polymer elastic element. Specifically, the low-friction plate is provided on the upper surface of the main beam, with only the edges fixed to the main beam by the first interfacial adhesive layer, and the middle sliding surface not bonded. A metal protective connection structure is provided on the outer side of the main beam, and a rigid support waterproof structure is provided on the bottom surface of the main beam. The metal protective connection structure is rigidly anchored to the main beam and the rigid support waterproof structure through fastening components. The polymer elastic element is a continuous seamless block that covers the expansion joint and is flush with the road surface.

[0007] The main beam is the core load-bearing structure of the device. It is made of high-strength steel and provides a stable foundation support for the entire device, ensuring the structural stability of the bridge during expansion and contraction. Its number can be adjusted according to the width of the bridge joints to match the needs of bridge projects of different specifications.

[0008] Both the first and second interface adhesive layers are epoxy-modified polymer adhesive layers with a thickness of 2-5 mm and an interlayer bonding strength ≥3 MPa. This type of adhesive layer not only achieves high-strength tight bonding between components and eliminates interlayer gaps, but also elastically matches the slight deformation of the bridge, avoiding interlayer cracking caused by minor displacement of the bridge. At the same time, it has good anti-corrosion and water resistance properties, improving the durability of the interlayer connection.

[0009] The low-friction plate is made of ultra-high molecular weight polyethylene with a friction coefficient of ≤0.15. The upper surface of the low-friction plate is slidably connected to the bottom surface of the built-in telescopic device, which can significantly reduce the frictional resistance during the telescopic process, reduce wear between components, improve the smoothness of telescopic operation, avoid component jamming and wear, and extend the service life of the device. In addition, the edge of the low-friction plate is flush with the edge of the main beam to ensure the overall structural regularity of the device.

[0010] The built-in expansion joint is the core control component for seamless bridge expansion and contraction. It adopts an expansion joint structure design and can adaptively match the expansion and contraction displacement of the bridge caused by temperature changes, loads and foundation settlement. Its built-in installation method can effectively avoid problems such as external debris getting stuck and rainwater directly washing away, ensuring the stability of expansion and contraction performance.

[0011] The polymer elastic component is the core functional part of this device. It is made of polyurethane-rubber blended polymer elastic material with a Shore hardness of 60-80HA and an elongation at break of ≥500%. It combines the high elasticity and high wear resistance of polyurethane with the good flexibility of rubber. It can flexibly deform synchronously with the built-in telescopic device, fill the expansion gap in real time, and form a seamless sealing structure to completely block the infiltration of rainwater and mud, thus achieving the function of waterproofing and seepage prevention. At the same time, the upper surface of the polymer elastic component is a smooth arc surface flush with the road surface, which can achieve a smooth transition of the road surface, reduce driving vibration and noise, improve driving comfort, and also buffer the impact of driving loads, reducing stress damage to the device.

[0012] The metal protective connection structure includes a metal buckle plate fitted onto the outer surface of the main beam. Several extension plates are fixedly connected to the outer surface of the metal buckle plate. Fixing holes are formed on the outer surface of each extension plate, and anchoring components are fitted into these holes. The extension plates are fixedly connected to the bridge concrete pavement layer via these anchoring components. The metal buckle plate and extension plates are integrally stamped stainless steel components. Stainless steel possesses excellent structural strength and corrosion resistance. The integral stamping process ensures the integrity and stability of the components. The extension plates increase the contact area between the device and the concrete pavement layer, allowing for uniform force distribution and preventing structural damage caused by localized stress concentration. The anchoring components, in conjunction with the fixing holes, firmly connect the extension plates to the cast-in-place concrete strip, improving the installation stability of the metal buckle plate and preventing displacement.

[0013] As a further improvement to the technical solution of this invention, the outer surface of the metal panel is coated with a composite protective coating. This composite protective coating consists of a bottom epoxy anti-corrosion layer, a middle UV-resistant layer, and a surface wear-resistant layer, with a total coating thickness of 50-80 μm. The bottom epoxy anti-corrosion layer isolates the metal panel from air and moisture, preventing rust; the middle UV-resistant layer resists ultraviolet radiation from sunlight, preventing surface aging of the metal panel; and the surface wear-resistant layer resists scratches from sand and gravel, improving the wear resistance of the metal panel. The three coatings work synergistically to effectively extend the service life of the metal protective connection structure.

[0014] The rigid support waterproof structure is a steel plate structure. The upper surface of the steel plate structure is closely attached to the bottom surface of the main beam. The thickness of the steel plate structure is 8-15mm, which provides sufficient rigidity to provide rigid support for the bottom of the device, enhance the overall rigidity of the device, and at the same time bear the functions of bottom waterproofing and force transmission, preventing rainwater from seeping in from the bottom of the device. In addition, the outer surface of the steel plate structure is sprayed with an anti-corrosion and waterproof coating, which further improves its anti-corrosion and waterproof performance.

[0015] The fastening components are bolts. The outer surface of the metal buckle plate has an installation groove, the outer surface of the main beam has a first installation hole, and the outer surface of the steel plate structure has a second installation hole corresponding to the first installation hole. The bolts are matched in the installation groove, the first installation hole, and the second installation hole to achieve rigid anchoring connection of the metal protective connection structure, the main beam, and the rigid support waterproof structure, so that all components form a whole, ensuring that all components deform synchronously, preventing the connection from loosening, and improving the device's pull-out and shear resistance. Moreover, the bolt head is hidden in the installation groove, which can reduce the wear and corrosion of the bolt head, extend the service life of the fastening components, and ensure the flatness of the outer side of the device.

[0016] On the other hand, the present invention provides a method for repairing the above-mentioned seamless expansion joint of a bridge based on a polymer elastic material, comprising the following steps: S1. Damage Inspection: A combination of visual and performance inspections is used to comprehensively inspect all components of the expansion joint, including the polymer elastic components, interface adhesive layer, low-friction plate, metal protective connection structure, and fastening components. Damaged components and their severity are determined through visual observation, measurement, expansion performance testing instruments, and waterproof performance testing instruments. Damage levels are categorized as minor or severe. Minor damage refers to small-scale cracks, corrosion, or wear on the component surface that do not affect core performance. Severe damage refers to large-area cracking, detachment, severe corrosion, and deformation, resulting in loss of core performance.

[0017] S2. Modular Disassembly: Based on the location of the damaged components, special tools are used to disassemble the fastening components, thereby separating the metal protective connection structure, rigid support waterproof structure, and main beam. For surface-damaged components such as polymer elastic parts and interface adhesive layers, peeling tools are used directly for peeling. For internally damaged components such as low-friction plates and built-in telescopic devices, they are removed step by step through layer-by-layer disassembly. During the disassembly process, components are marked to avoid confusion and to ensure that intact components are not damaged.

[0018] S3. Substrate Treatment: Clean, grind, and remove contaminants from intact substrates such as the disassembled main beam, low-friction plate, and built-in expansion joint. Use tools such as high-pressure water guns, sandpaper, and rust remover to remove rust, aging layers, debris, and residual adhesive from the surface, ensuring that the substrate surface is flat, dry, and free of oil stains, providing a good bonding foundation for subsequent repairs and reassemblies.

[0019] S4. Targeted Repair and Replacement: Targeted treatment is carried out according to the damage level. Minorly damaged components are repaired using specialized repair materials, while severely damaged components are replaced with new components of the same specifications and performance. Specifically, minor damage to polymer elastic components is filled and polished using a polyurethane-rubber polymer repair agent to ensure a smooth surface flush with the road surface after repair. Minor damage to the interface adhesive layer is recoated using an epoxy-modified polymer adhesive to ensure uniform coating thickness. Minor rust on metal protective connection structures is removed with a rust remover and then a composite protective coating is sprayed on. Fasteners exhibiting stripped threads or rust are directly replaced. During repair and replacement, the dimensional accuracy and compatibility of each component are strictly guaranteed to ensure the structural stability of the reassembled device.

[0020] S5. Integrated Reassembly: Following the original layered structure, the first interface adhesive layer, low-friction plate, built-in expansion joint, second interface adhesive layer, and polymer elastic component are sequentially re-laid on the upper surface of the main beam. After each layer is laid, seamless, flat, and firm adhesion is ensured. Subsequently, the metal protective connection structure is fitted onto the outside of the main beam, and the rigid support waterproof structure is attached to the bottom surface of the main beam. The metal protective connection structure, main beam, and rigid support waterproof structure are re-anchored and connected using fastening components. During the fastening process, the tightening torque of the bolts is kept consistent to avoid uneven stress. After reassembly, the joints of the device are sealed with polymer sealant, and the upper surface of the polymer elastic component is leveled to ensure it is flush with the road surface.

[0021] S6. Acceptance Inspection: Conduct a comprehensive acceptance inspection on the reassembled expansion joint, including expansion performance testing to check whether the expansion stroke of the joint meets the design requirements and whether the expansion process is smooth and without jamming; waterproof performance testing to test the water tightness of the joint to check its water-proof effect; connection strength testing to check whether the connection strength between the metal protective connection structure, the rigid support waterproof structure and the main beam meets the standards; after all inspection items pass, the joint can be put into use. If any inspection fails, adjustments and repairs should be made in a timely manner until the inspection is passed.

[0022] The beneficial effects of this invention are: This invention utilizes an interface bonding layer, a low-friction plate, a built-in expansion joint, and a polymer elastic component stacked sequentially on the main beam. Combined with a metal protective connection structure on the outer side of the main beam, a rigid support waterproof structure on the bottom, and a rigid anchoring connection design for the fastening components, the polymer elastic component, made of high-polymer elastic material, achieves both adaptive elastic deformation and waterproofing / seepage prevention. This effectively enables adaptive adjustment of bridge expansion and contraction deformation and a smooth road surface transition, significantly reducing vehicle vibration and noise and improving driving comfort. Furthermore, the integrated connection of each component strengthens the overall connection strength and structural stability of the device, enhancing its load-bearing and deformation resistance. The layered structure and modular anchoring design facilitate installation, and the application of high-polymer elastic material further improves the device's wear resistance, weather resistance, and sealing performance. This effectively solves the problems of uneven road surface transition, poor driving comfort, easy leakage and damage, and insufficient structural stability in traditional bridge expansion joints, significantly extending the device's service life and meeting the expansion and waterproofing needs of various bridge projects. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0024] Figure 1 This is a front view structural schematic diagram of the seamless bridge expansion joint of the present invention; Figure 2 This is a schematic diagram of the planar structure of the seamless bridge expansion joint of the present invention; Figure 3 This is a schematic diagram of the front section of the seamless bridge expansion joint of the present invention; Figure 4 This is a side view of the seamless bridge expansion joint of the present invention. Figure 5 This is a schematic diagram of the planar structure of the metal buckle plate of the present invention.

[0025] The meanings of the labels in the attached diagram are as follows: 1-Main beam, 2-First interface adhesive layer, 3-Low friction plate, 4-Built-in telescopic device, 5-Second interface adhesive layer, 6-Polymer elastic element, 7-Metal buckle plate, 8-Extension plate, 9-Fixing hole, 10-Steel plate structure, 11-Mounting groove, 12-First mounting hole, 13-Second mounting hole, 14-Bolt. Detailed Implementation

[0026] 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 a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0027] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0028] In this invention, unless otherwise explicitly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or a structurally integral connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0029] Furthermore, in this invention, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed by this invention.

[0030] Reference Figures 1 to 5 In a first aspect, the present invention provides a seamless bridge expansion joint based on a polymer elastic material, comprising at least two main beams 1. The upper surface of the main beam 1 is sequentially stacked with a first interface adhesive layer 2, a low-friction plate 3, a built-in expansion joint 4, a second interface adhesive layer 5, and a polymer elastic element 6. A metal protective connection structure is provided on the outer side of the main beam 1, and a rigid support waterproof structure is provided on the bottom surface of the main beam 1. The metal protective connection structure is rigidly anchored to the main beam 1 and the rigid support waterproof structure through fastening components. The polymer elastic element 6 is an elastic component made of a polymer elastic material, possessing the dual functions of elastic deformation self-adaptation and waterproofing.

[0031] It should be noted that, with at least two main beams 1 as the core load-bearing foundation, a first interface adhesive layer 2, a low-friction plate 3, a built-in expansion joint 4, a second interface adhesive layer 5, and a polymer elastic component 6 are stacked sequentially on the upper surface of the main beams 1. A metal protective connection structure is configured on the outside of the main beams 1, and a rigid support waterproof structure is set on the bottom surface. The metal protective connection structure is rigidly anchored to the main beams 1 and the rigid support waterproof structure through fastening components, so that all components form an integrated structure. Among them, the polymer elastic component 6, made of high-polymer elastic material, is the core functional component. When the device expands and contracts with the bridge, it undergoes elastic deformation simultaneously and achieves the dual function of waterproofing and seepage prevention. The components at each level work together to complete the adaptive control of the bridge's expansion and contraction deformation and the seamless connection with the road surface.

[0032] This invention, through a layered, integrated structural design and the application of polymer elastic materials, achieves adaptive adjustment of bridge expansion and contraction deformation and smooth road surface transition, significantly reducing vehicle vibration and noise and improving driving comfort. The rigid anchoring connection method strengthens the overall connection strength and structural stability of the device, effectively improving its load-bearing capacity and deformation resistance. The dual function of the polymer elastic component 6 achieves excellent sealing and waterproofing effects, preventing damage to components caused by rainwater and cement seepage. The overall structural design matches the expansion and waterproofing requirements of various bridge projects, fundamentally solving the problems of uneven road surface transition, poor driving comfort, easy leakage and damage, and insufficient structural stability of traditional expansion joints, significantly extending the overall service life of the device.

[0033] In some embodiments, the metal protective connection structure includes a metal buckle plate 7 sleeved on the outer surface of the main beam 1. A plurality of extension plates 8 are fixedly connected to the outer surface of the metal buckle plate 7. The outer surface of the extension plates 8 is provided with fixing holes 9. An anchoring members are matched in the fixing holes 9. The extension plates 8 are fixedly connected to the bridge concrete pavement layer through the anchoring members.

[0034] It should be noted that the metal buckle plate 7 is fitted onto the outer surface of the main beam 1 to form a protective and connecting base. An extension plate 8 is fixed on the outer surface of the metal buckle plate 7. The fixing holes 9 on the outer surface of the extension plate 8 are matched with the anchoring components to fix the extension plate 8 to the bridge concrete pavement layer. The metal buckle plate 7 is used to protect the side and connection parts of the main beam 1. The extension plate 8 is used to increase the contact area between the device and the concrete pavement layer to achieve uniform force transmission.

[0035] The metal buckle plate 7 provides effective protection for the sides and connecting parts of the main beam 1, resisting the erosion of external media, while providing a stable connection base for the fastening components and strengthening the connection strength between the device and the main beam 1; the extension plate 8 increases the contact area between the device and the bridge concrete pavement layer, so that the force generated by traffic load and structural deformation is evenly transmitted, avoiding structural damage caused by local stress concentration; the cooperation between the anchoring component and the fixing hole 9 realizes the firm connection between the extension plate 8 and the concrete pavement layer, effectively preventing the metal protective connection structure from shifting, and further improving the overall installation stability of the device.

[0036] In some embodiments, the rigid support waterproof structure is a steel plate structure 10, the upper surface of the steel plate structure 10 is closely fitted with the bottom surface of the main beam 1, the thickness of the steel plate structure 10 is 8-15mm, and the outer surface of the steel plate structure 10 is sprayed with an anti-corrosion and waterproof coating.

[0037] It should be noted that a steel plate structure 10 is used as a rigid support waterproof structure, which is tightly attached to the bottom surface of the main beam 1. The rigidity of the steel plate structure 10 provides support for the bottom of the device, while its airtightness ensures bottom waterproofing. An anti-corrosion and waterproof coating is sprayed on the outer surface of the steel plate structure 10. This coating isolates external corrosive media and moisture, improving the anti-corrosion and waterproof performance of the steel plate structure 10. The steel plate structure 10 has a thickness of 8-15mm to ensure sufficient rigid support capacity. The 8-15mm thick steel plate structure 10 provides stable rigid support for the bottom of the device, effectively enhancing the overall rigidity of the device and improving its resistance to deformation. It also bears the functions of bottom waterproofing and force transmission, preventing rainwater from seeping into the bottom of the device and causing internal component corrosion. The anti-corrosion and waterproof coating on the outer surface of the steel plate structure 10 further enhances its anti-corrosion and waterproof performance, isolating it from the erosion of air, moisture, and other corrosive media, extending the service life of the rigid support waterproof structure, and ensuring the long-term stability of the bottom structure of the device.

[0038] In some embodiments, the outer surface of the metal buckle plate 7 is provided with a mounting groove 11, the outer surface of the main beam 1 is provided with a first mounting hole 12, the outer surface of the steel plate structure 10 is provided with a second mounting hole 13 corresponding to the first mounting hole 12, and the fastening component is a bolt 14 that matches the mounting groove 11, the first mounting hole 12 and the second mounting hole 13, and the head of the bolt 14 is hidden in the mounting groove 11.

[0039] It should be noted that an installation groove 11 is opened on the outer surface of the metal buckle plate 7, a first installation hole 12 is opened on the outer surface of the main beam 1, and a second installation hole 13 corresponding to and matching the first installation hole 12 is opened on the outer surface of the steel plate structure 10. The bolt 14 is matched in the installation groove 11, the first installation hole 12 and the second installation hole 13 to achieve a rigid anchoring connection between the metal buckle plate 7, the main beam 1 and the steel plate structure 10. At the same time, the head of the bolt 14 is hidden in the installation groove 11, thus completing the protection of the bolt head and the flat treatment of the outside of the device.

[0040] The mounting groove 11 provides precise installation positioning for the bolt 14, avoiding uneven stress on various components caused by bolt 14 installation misalignment, and ensuring the stability of the anchoring connection. The bolt 14 achieves reliable anchoring of the metal protective connection structure, main beam 1, and rigid support waterproof structure, making the components form a synchronously deforming whole, effectively preventing connection loosening, and improving the device's pull-out and shear resistance. The bolt 14 head is hidden in the mounting groove 11, reducing wear and corrosion on the bolt 14 head, extending the service life of the fastening components, and ensuring the flatness of the outer side of the device, avoiding protruding structures from affecting the driving experience or causing component scratches.

[0041] In some embodiments, the polymer elastic element 6 is a polyurethane-rubber blended polymer elastic element with a Shore hardness of 60-80HA and an elongation at break of ≥500%. The lower surface of the polymer elastic element 6 is seamlessly bonded to the upper surface of the second interface adhesive layer 5, and the upper surface of the polymer elastic element 6 is a smooth arc surface flush with the road surface.

[0042] It should be noted that the polymer elastic component 6 is prepared by using a polyurethane-rubber blended polymer elastic material, with its Shore hardness controlled at 60-80HA and its elongation at break not less than 500%, to ensure its excellent elastic deformation capacity. The lower surface of the polymer elastic component 6 is seamlessly bonded to the upper surface of the second interface adhesive layer 5, while its upper surface is set as a smooth arc surface flush with the road surface, so that the polymer elastic component 6 undergoes elastic deformation synchronously with the built-in expansion device 4, filling the expansion gap in real time and achieving a smooth connection of the road surface.

[0043] The polyurethane-rubber blend material properties give the polymer elastic component 6 high elasticity, high wear resistance, and good flexibility. Its Shore hardness of 60-80HA and elongation at break of ≥500% ensure that it can adapt to various expansion and contraction deformations of the bridge and is not prone to aging and cracking after long-term use. The seamless connection completely blocks the infiltration path of rainwater and silt, achieving excellent waterproof and seepage prevention effects and eliminating the problems of internal component corrosion and gap blockage. The smooth arc surface flush with the road surface achieves a smooth transition to the road surface, effectively buffering the impact of traffic loads, reducing traffic vibration and noise, further improving the comfort of travel, and reducing stress damage to the device caused by traffic impacts.

[0044] In some embodiments, the first interfacial adhesive layer 2 and the second interfacial adhesive layer 5 are both epoxy-modified polymer adhesive layers with a thickness of 2-5 mm, an interlayer bonding strength ≥3 MPa, and the interfacial adhesive layer can elastically match the slight deformation of the bridge and eliminate interlayer gaps.

[0045] It should be noted that the first interfacial adhesive layer 2 and the second interfacial adhesive layer 5 are prepared using epoxy-modified polymer elastic materials. The thickness of the adhesive layer is controlled at 2-5 mm to ensure that the interlayer bonding strength is not less than 3 MPa. The interfacial adhesive layer tightly bonds adjacent components, eliminating interlayer gaps. When the bridge undergoes slight deformation, the interfacial adhesive layer undergoes elastic deformation simultaneously to match the slight displacement of the bridge and maintain the sealing and integrity of the interlayer connection.

[0046] A thickness of 2-5mm and an interlayer bonding strength of ≥3MPa ensure that the interface adhesive layer can achieve a high-strength and tight fit between adjacent components, completely eliminating interlayer gaps and enhancing the sealing performance and structural integrity of the interlayer connection. The elastic properties of the epoxy-modified polymer elastic material allow the interface adhesive layer to elastically match the slight deformation of the bridge, avoiding interlayer cracking caused by minor bridge displacements and maintaining the overall structural stability of the device. At the same time, the epoxy-modified polymer elastic material has good anti-corrosion and water resistance properties, improving the durability of the interlayer connection, preventing the adhesive layer from failing due to corrosion and water immersion, and ensuring the long-term reliability of the connections between components at all levels of the device.

[0047] In some embodiments, the low-friction plate 3 is an ultra-high molecular weight polyethylene low-friction plate with a friction coefficient ≤0.15. The upper surface of the low-friction plate 3 is slidably connected to the bottom surface of the built-in telescopic device 4, and the edge of the low-friction plate 3 is flush with the edge of the main beam 1.

[0048] It should be noted that the low-friction plate is made of ultra-high molecular weight polyethylene material, and its friction coefficient is controlled to be ≤0.15. The low-friction plate 3 is placed between the first interface adhesive layer 2 and the built-in telescopic device 4, so that the upper surface of the low-friction plate 3 and the bottom surface of the built-in telescopic device 4 form a sliding connection. At the same time, the edge of the low-friction plate 3 is flush with the edge of the main beam 1. When the built-in telescopic device 4 moves in a telescopic motion, the frictional resistance between it and the low-friction plate 3 is reduced, ensuring the smoothness of the telescopic motion.

[0049] The low frictional resistance of ultra-high molecular weight polyethylene material results in a friction coefficient ≤0.15, which significantly reduces the frictional resistance during the extension and retraction of the built-in telescopic device 4, reduces wear and tear between components, avoids jamming during extension and retraction, ensures smooth and continuous extension and retraction, and effectively extends the service life of the built-in telescopic device 4 and the low-friction plate 3. The flush arrangement of the edge of the low-friction plate 3 with the edge of the main beam 1 ensures the regularity of the overall structure of the device, avoids uneven stress caused by edge protrusions or misalignments, and provides a flat foundation for the stacking of various components, maintaining the stability of the layered structure of the device.

[0050] In some embodiments, the metal buckle 7 and the extension plate 8 are integrally stamped stainless steel components. The outer surface of the metal buckle 7 is coated with a composite protective coating, which consists of a bottom epoxy anti-corrosion layer, a middle UV-resistant layer, and a surface wear-resistant layer, with a total coating thickness of 50-80 μm.

[0051] It should be noted that the metal buckle panel 7 and extension panel 8 are made of stainless steel through an integrated stamping process to ensure the integrity and structural strength of the components. A composite protective coating consisting of a bottom epoxy anti-corrosion layer, a middle UV-resistant layer and a surface wear-resistant layer is sprayed on the outer surface of the metal buckle panel 7. The total thickness of the coating is controlled at 50-80μm. Through the synergistic effect of the three coatings, all-round protection of the metal buckle panel 7 is achieved.

[0052] Stainless steel material possesses excellent structural strength and natural corrosion resistance. The integrated stamping process ensures the integrity of the metal buckle plate 7 and the extension plate 8, avoiding stress concentration or loosening at the joints and improving the overall structural stability of the metal protective connection structure. The composite protective coating with a total thickness of 50-80μm works synergistically through a three-layer structure: the bottom epoxy anti-corrosion layer isolates corrosive media to prevent metal rust, the middle UV-resistant layer resists sunlight exposure to prevent surface aging, and the surface wear-resistant layer resists sand and gravel abrasion to improve wear resistance. This comprehensively enhances the corrosion resistance, UV resistance, and wear resistance of the metal buckle plate 7, effectively extending the service life of the metal protective connection structure and adapting to the complex outdoor use environment of bridge engineering.

[0053] Secondly, the present invention provides a method for repairing a seamless expansion joint of a bridge based on a polymer elastic material, comprising the following steps: S1. Damage detection: Perform appearance and performance inspections on each component of the telescopic device to determine the damaged components and damage levels. The damaged components include one or more of the following: polymer elastic element 6, interface adhesive layer, low friction plate 3, metal protective connection structure, and fastening assembly. S2. Modular disassembly: Based on the location of the damaged components, the metal protective connection structure, rigid support waterproof structure and main beam 1 are separated by disassembling the fastening components. The surface damaged components are directly peeled off, and the internal damaged components are removed by layer disassembly. S3. Base treatment: Clean, grind and remove dirt from the base of the disassembled main beam 1, low friction plate 3 and built-in telescopic device 4 to remove rust, aging layer and debris from the surface and ensure that the base surface is flat and dry. S4. Targeted repair and replacement: Based on the damage level, minorly damaged parts are repaired, and severely damaged parts are replaced with new parts of the same specifications. During the repair and replacement process, the dimensional accuracy and matching of each part are ensured. S5. Integrated reassembly: The interface bonding layer, low friction plate 3, built-in expansion device 4 and polymer elastic component 6 are re-laid in sequence according to the original layered structure. The metal protective connection structure and rigid support waterproof structure are re-anchored to the main beam 1 through fastening components. After the reassembly is completed, the device is sealed and leveled. S6. Acceptance Inspection: The reassembled expansion joint shall be tested for its expansion performance, waterproof performance and connection strength. It shall be put into use after passing the inspection.

[0054] It should be noted that, for the damage to various components of the seamless expansion joint of the bridge based on polymer elastic materials, the repair is carried out in accordance with the following steps: damage detection, modular disassembly, substrate treatment, targeted repair and replacement, integrated reassembly, and acceptance testing. First, the damaged components and damage level are determined by detection. Then, modular disassembly is carried out according to the location of the damaged components to avoid damaging the intact components. Subsequently, the intact substrate is cleaned and polished. Then, the components are repaired or replaced according to the damage level. After that, the components are reassembled according to the original structure and sealed and leveled. Finally, performance testing is carried out to ensure that the repaired device meets the usage requirements.

[0055] This invention achieves targeted treatment of various types of damage to the device through a complete repair process. Damage detection can accurately locate damaged components and their severity, providing a precise basis for subsequent repairs. The modular disassembly method avoids large-scale damage to the road surface and device structure, preventing secondary damage to intact components and reducing the difficulty of disassembly operations. Base treatment ensures the robustness and sealing of component connections after repair and reassembly. Targeted repair and replacement reduce the cost of component replacement while ensuring the performance restoration of damaged components. Integrated reassembly and acceptance testing ensure that the structure and performance of the repaired device meet design requirements. The overall repair method is simple to operate, highly efficient, significantly reduces the maintenance cost of the device, enables rapid repair and reuse of the device, and effectively extends the overall service life of the device.

[0056] In some embodiments, in step S4, the repair of the polymer elastic element 6 is carried out by filling and polishing with a polymer repair agent, the repair of the interface adhesive layer is carried out by recoating with an epoxy modified polymer adhesive, and the rust repair of the metal protective connection structure is carried out by removing rust and then re-spraying a composite protective coating. The performance parameters of the repaired component are not less than 85% of those of the original component.

[0057] It should be noted that during the repair process, corresponding special materials and processes are used to repair the minor damage to different components. Polymer repair agent is used to fill and polish the damaged areas of polymer elastic component 6, epoxy modified polymer adhesive is used to recoat the damaged areas of the interface bonding layer, and rusted areas of the metal protective connection structure are first derusted and then re-sprayed with a composite protective coating. At the same time, it is ensured that the performance parameters of the repaired component are not less than 85% of the original component, so as to ensure the performance of the repaired component.

[0058] This invention employs specialized repair materials and processes tailored to different damage types of components, enabling efficient repair of slightly damaged parts and restoring their original function. The polymer repair agent effectively fills the damaged areas of the polished polymer elastic component 6, ensuring surface smoothness and elasticity. The epoxy-modified polymer adhesive effectively re-bonds the interface bonding layers, restoring the strength and sealing of the interlayer connections. Re-coating with a composite protective coating after rust removal completely solves the corrosion problem of the metal protective connection structure, restoring its protective performance. The repaired component's performance parameters are no less than 85% of the original component's requirements, ensuring that the repaired component meets the overall usage requirements of the device, avoiding the impact of substandard local component repairs on the overall performance of the device, and reducing the need to replace entirely new components, further lowering the device's maintenance costs.

[0059] To better understand the above technical solution, the following will refer to the appendix to the instruction manual. Figure 1-5 The specific implementation methods are described in detail below for the above technical solution: Example 1 A seamless bridge expansion joint based on a polymer elastic material includes two main beams 1, which are made of Q345 steel. The upper surface of the main beam 1 is sequentially layered with a first interfacial adhesive layer 2, a low-friction plate 3, an internal expansion joint 4, a second interfacial adhesive layer 5, and a polymer elastic element 6. The first and second interfacial adhesive layers 2 and 5 are epoxy-modified polymer adhesive layers with a thickness of 3 mm and an interlayer bonding strength of 3.5 MPa. The low-friction plate 3 is an ultra-high molecular weight polyethylene low-friction plate with a friction coefficient of 0.12, and its edges are flush with the edges of the main beam 1. The internal expansion joint 4 is a modular expansion joint with a telescoping stroke of 0-80 mm. The polymer elastic element 6 is a polyurethane-rubber blend polymer elastic element with a Shore hardness of 70 HA and an elongation at break of 600%. Its upper surface is a smooth arc surface flush with the road surface, and its lower surface is seamlessly bonded to the second interfacial adhesive layer 5.

[0060] The outer side of the main beam 1 is fitted with a stainless steel metal buckle plate 7. The outer surface of the metal buckle plate 7 is integrally stamped with four extension plates 8. The extension plates 8 are provided with fixing holes 9. Matching expansion bolts are installed in the fixing holes 9. The extension plates 8 are fixed to the bridge concrete pavement layer by the expansion bolts. The outer surface of the metal buckle plate 7 is sprayed with a composite protective coating, which consists of a bottom epoxy anti-corrosion layer, a middle UV-resistant layer and a surface wear-resistant layer, with a total thickness of 60μm.

[0061] The bottom surface of the main beam 1 is fitted with a steel plate structure 10, which is 10mm thick and has an epoxy coal tar pitch anti-corrosion and waterproof coating on its outer surface. The metal buckle plate 7 has an installation groove 11, the main beam 1 has a first installation hole 12, and the steel plate structure 10 has a second installation hole 13. Stainless steel bolts 14 are matched in the installation groove 11, the first installation hole 12, and the second installation hole 13. The head of the bolt 14 is hidden in the installation groove 11, so as to achieve a rigid anchoring connection between the metal buckle plate 7, the main beam 1, and the steel plate structure 10.

[0062] Example 2 The repair method for the seamless expansion joint of the bridge in Example 1 is used to repair the device that has developed small-scale cracks on the surface of the polymer elastic element 6, localized corrosion of the metal fastener 7, and stripped threads on some bolts after 5 years of use. The repair includes the following steps: S1. Damage Inspection: Through visual inspection and measurement, it was determined that the polymer elastic component 6 was slightly damaged, the metal buckle 7 was slightly corroded, the two bolts were severely damaged (stripped), and the rest of the components were intact. S2. Modular disassembly: Use a wrench to remove the stainless steel bolts and separate the metal buckle plate 7 from the main beam 1 and the steel plate structure 10. There is no need to disassemble the bottom part. The damaged parts of the polymer elastic component 6 can be marked directly. S3. Substrate treatment: Use sandpaper to polish the rusted parts of the metal buckle panel 7, use a high-pressure water gun to clean the cracked surface of the polymer elastic part 6, remove surface debris, and let it dry for later use. S4. Targeted repair and replacement: Replace the two stripped bolts with stainless steel bolts of the same specification; fill the cracks in the polymer elastic part 6 with polyurethane-rubber polymer repair agent, and polish after the repair agent has cured to ensure a smooth surface; spray the rusted parts of the metal buckle panel 7 with epoxy anti-corrosion layer, anti-ultraviolet layer and wear-resistant layer in sequence, with a total coating thickness of 60μm. S5. Integrated reassembly: The metal buckle plate 7 is re-sleeved onto the outside of the main beam 1. The metal buckle plate 7, the main beam 1, and the steel plate structure 10 are anchored and connected by new bolts. The tightening torque is kept consistent. The joint between the metal buckle plate 7 and the main beam 1 is sealed with polymer sealant. The surface of the polymer elastic component 6 after grinding is slightly leveled. S6. Acceptance Inspection: The telescopic stroke of the testing device is 0-80mm, and the telescopic process is smooth and without jamming; the water tightness test shows no leakage; the connection strength between the metal buckle plate 7 and the main beam 1 meets the standard, and it is put into use after passing the inspection.

[0063] After three years of continued use, the repaired device showed no significant damage or performance degradation, and all indicators met the requirements for bridge expansion joints.

[0064] Compared with the prior art, the present invention has the following significant advantages: The seamless expansion joint of the bridge in this invention adopts a layered and stacked integral structure design. It uses a polymer elastic component made of high-polymer elastic material as the core, combined with an epoxy-modified polymer interface adhesive layer, to achieve seamless expansion and contraction of the device and smooth transition of the road surface. This significantly reduces vehicle vibration and noise, improves driving comfort, and the polymer elastic component can fill the expansion gap in real time to form a seamless sealing structure with excellent waterproof and seepage prevention effects, completely eliminating the problems of component corrosion and jamming caused by rainwater and silt infiltration.

[0065] The device achieves rigid anchoring connection of each component through the cooperation of metal protective connection structure, rigid support waterproof structure and fastening components, so that the components form a whole, which significantly enhances the overall connection strength and structural stability, improves the load-bearing capacity and deformation resistance of the device, can effectively resist the long-term impact of traffic loads, and reduce local damage to the device.

[0066] The device adopts a modular assembly design, connecting various components with bolts and multiple sets of mounting holes, which simplifies construction and installation. It can also be modularly disassembled for later maintenance without causing large-scale damage to the road surface, making operation easy. The supporting repair methods are designed to repair and replace different types of damage to different components, resulting in high repair efficiency. The performance parameters of the device can be effectively guaranteed after repair, thus effectively extending the overall service life of the device.

[0067] All components of the device are made of high-performance materials. Low-friction plates reduce friction and wear between components. Metal components are coated with a composite protective coating. Polymer elastic parts have good weather resistance, wear resistance and elasticity. The synergistic effect of all components gives the device good anti-corrosion, wear resistance and weather resistance, making it suitable for the complex outdoor use environment of bridge engineering.

[0068] The technical solutions provided by the embodiments of the present invention have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of the embodiments of the present invention. The descriptions of the embodiments above are only for helping to understand the principles of the embodiments of the present invention. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the embodiments of the present invention. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A seamless bridge expansion joint based on a polymer elastic material, characterized in that, It includes at least two main beams. The upper surface of the main beams is sequentially stacked with a first interface adhesive layer, a low-friction plate, a built-in expansion joint, a second interface adhesive layer, and a polymer elastic element. The outer side of the main beams is provided with a metal protective connection structure, and the bottom surface of the main beams is provided with a rigid support waterproof structure. The metal protective connection structure is rigidly anchored to the main beams and the rigid support waterproof structure through fastening components. The polymer elastic element is a continuous seamless block that covers the expansion joint and is flush with the road surface.

2. The seamless bridge expansion joint based on polymer elastic material according to claim 1, characterized in that, The metal protective connection structure includes a metal buckle plate sleeved on the outer surface of the main beam. Several extension plates are fixedly connected to the outer surface of the metal buckle plate. Fixing holes are opened on the outer surface of the extension plates. Anchoring components are matched in the fixing holes. The extension plates are fixedly connected to the bridge concrete pavement layer through the anchoring components.

3. The seamless bridge expansion joint based on polymer elastic material according to claim 1, characterized in that, The rigid support waterproof structure is a steel plate structure. The upper surface of the steel plate structure is tightly fitted to the bottom surface of the main beam. The thickness of the rigid support waterproof structure is 8-15mm, and the outer surface of the steel plate structure is sprayed with an anti-corrosion and waterproof coating.

4. The seamless bridge expansion joint based on polymer elastic material according to claim 2, characterized in that, The outer surface of the metal buckle plate is provided with an installation groove, the outer surface of the main beam is provided with a first installation hole, the outer surface of the steel plate structure is provided with a second installation hole corresponding to the first installation hole, and the fastening component is a bolt that matches the installation groove, the first installation hole and the second installation hole, with the head of the bolt hidden in the installation groove.

5. The seamless bridge expansion joint based on polymer elastic material according to claim 1, characterized in that, The polymer elastic component is a polyurethane-rubber blend polymer elastic component with a Shore hardness of 60-80HA and an elongation at break of ≥500%. The lower surface of the polymer elastic component is seamlessly bonded to the upper surface of the second interface adhesive layer, and the upper surface of the polymer elastic component is a smooth arc surface flush with the road surface.

6. The seamless bridge expansion joint based on polymer elastic material according to claim 1, characterized in that, Both the first and second interfacial adhesive layers are epoxy-modified polymer adhesive layers with a thickness of 2-5 mm and an interlayer bonding strength ≥3 MPa. The interfacial adhesive layers can adapt to slight deformation of the bridge and eliminate interlayer gaps.

7. The seamless bridge expansion joint based on polymer elastic material according to claim 1, characterized in that, The low-friction plate is made of ultra-high molecular weight polyethylene with a friction coefficient of ≤0.

15. The upper surface of the low-friction plate is slidably connected to the bottom surface of the built-in telescopic device, and the edge of the low-friction plate is flush with the edge of the main beam.

8. The seamless bridge expansion joint based on polymer elastic material according to claim 2, characterized in that, The metal buckle and extension plate are integrally stamped stainless steel components. The outer surface of the metal buckle is coated with a composite protective coating, which consists of a bottom epoxy anti-corrosion layer, a middle UV-resistant layer, and a surface wear-resistant layer. The total thickness of the coating is 50-80μm.

9. The repair method for a seamless bridge expansion joint based on a polymer elastic material according to any one of claims 1-8, characterized in that, Includes the following steps: S1. Damage detection: Perform appearance and performance inspections on each component of the telescopic device to determine the damaged components and damage levels. The damaged components include one or more of the following: polymer elastic elements, interface adhesive layers, low-friction plates, metal protective connection structures, and fastening components. S2. Modular disassembly: Based on the location of the damaged components, the metal protective connection structure, rigid support waterproof structure and main beam are separated by disassembling the fastening components. The surface damaged components are directly peeled off, and the internal damaged components are removed by layer disassembly. S3. Substrate treatment: Clean, grind and remove dirt from the substrate of the disassembled main beam, low friction plate and built-in expansion device to remove rust, aging layer and debris from the surface and ensure that the substrate surface is flat and dry. S4. Targeted repair and replacement: Based on the damage level, minorly damaged parts are repaired, and severely damaged parts are replaced with new parts of the same specifications. During the repair and replacement process, the dimensional accuracy and matching of each part are ensured. S5. Integrated reassembly: The interface bonding layer, low friction plate, built-in expansion device and polymer elastic component are re-laid in sequence according to the original layered structure. The metal protective connection structure and rigid support waterproof structure are re-anchored to the main beam through fastening components. After the reassembly is completed, the device is sealed and leveled. S6. Acceptance Inspection: The reassembled expansion joint shall be tested for its expansion performance, waterproof performance and connection strength. It shall be put into use after passing the inspection.

10. The repair method for a seamless bridge expansion joint based on polymer elastic material according to claim 9, characterized in that, In step S4, the repair of the polymer elastic component is carried out by filling and polishing with a polymer repair agent, the repair of the interface adhesive layer is carried out by recoating with an epoxy modified polymer adhesive, and the rust repair of the metal protective connection structure is carried out by removing rust and then re-spraying a composite protective coating. The performance parameters of the repaired component are not less than 85% of the original component.

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