A method for manufacturing a fabricated polymer reinforced wear-resistant inner lining plate

Abstract

The application provides a manufacturing method of an assembled polymer reinforced wear-resistant inner lining plate and relates to the technical field of wear resistance and repair of industrial buildings, which comprises the following steps: firstly, processing a plurality of interval grooves on one side of an organic plate; secondly, preparing a polymer modified cement-based slurry, detecting the shrinkage rate after curing and hardening of the sample; combining the shrinkage rate and the linear thermal deformation coefficient calculation theory of the organic plate to calculate the theoretical processing temperature, and selecting three groups of test temperatures to carry out a control test. During the test, the slotted organic plate is used as a bottom mold, the slurry is poured to fill the grooves and the plate surface at the set temperature, and the composite sample plate is obtained after cooling and curing. The linear thermal deformation coefficient of each group of sample plates is detected, and the sample plate with the optimal matching degree of thermal deformation and cement concrete is screened, and the corresponding temperature is determined as the batch processing temperature. The application quantitatively matches the thermal expansion and cold shrinkage performance of the two types of substrates, i.e., the organic plate and the cement slurry, reduces the difference between the two temperature deformation values, relieves the internal stress generated at the composite interface under the alternating cold and hot conditions, and reduces the problems of interface cracking and delamination of the inner lining plate.

Description

Technical Field

[0001] This invention relates to the field of wear-resistant and repair technology for industrial buildings, specifically a method for manufacturing a prefabricated polymer-reinforced wear-resistant inner lining plate. Background Technology

[0002] In industries such as metallurgy, power generation, petrochemicals, coal, and chemicals, coal storage silos are common structures. Their inner walls are constantly subjected to the impact and abrasion of coal, resulting in severe damage. Therefore, a wear-resistant protective layer must be installed on the surface to protect the underlying concrete or steel plate. Currently, most coal mines in China experience coal adhesion and blockage issues in their coal storage silos, especially with powdered coal having a high moisture content. Blockage can lead to reduced silo capacity and decreased production efficiency; in severe cases, it can necessitate production shutdowns and silo cleanup, resulting in significant economic losses. While wear-resistant lining materials can address silo wear, solutions for blockage are lacking.

[0003] Existing technologies attempt to use organic sheets (nylon sheets, ultra-high molecular weight polyethylene sheets, polytetrafluoroethylene sheets, etc.) as lining materials to solve the problem of coal clogging. Organic sheets have a relatively smooth surface, a low coefficient of sliding friction with coal, and are non-absorbent and wear-resistant. They can be used as wear-resistant lining materials and can also alleviate clogging. However, because their linear thermal expansion coefficient differs from that of concrete by more than ten times, relatively wide expansion joints must be left between the sheets during installation to allow for stress release during temperature changes. However, these gaps are often filled with coal dust or coal gangue, losing their expansion function. Furthermore, because the surface of organic sheets is very smooth, it is difficult to bond them with adhesives. Therefore, drilling and using expansion bolts are necessary for installation. However, the bolt heads, being on the surface of the sheet, are prone to corrosion and wear from coal dust. After a period of time, the bolt heads lose their anchoring function, causing the sheet to gradually detach, thus losing its wear-resistant protection and clogging-relieving effects. Currently, some national and industry standards no longer recommend the use of this type of high-molecular wear-resistant sheet.

[0004] Some patents propose combining high-performance concrete and other cement-based materials with organic panels to address the shortcomings of organic panels. For example, utility model patent 202320646230.X, "Wear-resistant Composite Lining for Coal Storage Silos," discloses a structure combining cement-based materials and organic panels, but does not specify the exact manufacturing method. In reality, simply combining cement-based materials with organic panels is unlikely to achieve the desired effect because cement-based materials shrink during hardening and drying, preventing a tight bond between the two materials and hindering the cement-based material's ability to constrain the thermal deformation of the organic panel. Summary of the Invention

[0005] This invention provides a method for manufacturing an assembled polymer-reinforced wear-resistant inner lining plate, thereby solving the problem mentioned in the background art that the prior art does not disclose a method for manufacturing a composite structure of cement-based materials and organic boards.

[0006] To solve the above-mentioned technical problems, this invention discloses a method for manufacturing an assembled polymer-reinforced wear-resistant inner liner, comprising: Step 1: Process multiple grooves spaced apart on one surface of the organic board; Step 2: Prepare polymer-modified cementitious materials; Step 3: Take the polymer-modified cementitious material and mix it into a slurry, pour it into a mold to form a sample, cure it until the sample is completely hardened, and measure the shrinkage rate of the hardened sample. Step 3: Calculate the theoretical processing temperature of the composite lining board based on the shrinkage rate of the hardened sample and the linear thermal deformation coefficient of the organic board, and determine at least three test processing temperatures based on the theoretical processing temperature. Step 4: Based on different test processing temperatures, the grooved organic board is placed in the composite lining board mold as the casting bottom mold. The polymer-modified cement-based material is prepared into a slurry and then poured into the groove of the organic board and the board surface. After the slurry hardens, it is cooled to room temperature and cured to obtain the composite board sample. Step 5: Test the linear thermal deformation coefficient of each composite panel sample, determine the target composite panel sample whose linear thermal deformation coefficient is closest to that of cement concrete, and use the test processing temperature corresponding to the target composite panel sample as the batch processing temperature of the composite lining panel. Step 6: Prepare composite inner lining plates in batches at the batch processing temperature.

[0007] Preferably, the polymer-modified cementitious material includes: acrylic-modified cementitious material and epoxy-modified cementitious material.

[0008] Preferably, the width of the groove opening is smaller than the width of the groove bottom.

[0009] Preferably, the three test processing temperatures include: theoretical processing temperature -5℃, theoretical processing temperature, and theoretical processing temperature +5℃.

[0010] Preferably, step 6 includes: Step 61: Process multiple grooves spaced apart on one surface of the organic board; Step 62: Place the organic board obtained in step 61 into the composite lining board mold, and place it for a first time at the batch processing temperature of the composite lining board; Step 63: Prepare polymer-modified cement-based material, mix the polymer-modified cement-based material into a slurry, and pour the slurry into the composite lining plate mold; Step 64: Continue curing the composite lining at the batch processing temperature, and then cool it down to 20°C; Step 65: Remove the composite wear-resistant liner from the composite inner liner mold and continue curing.

[0011] Preferably, the first duration is 24 hours, the maintenance duration in step 64 is 24 hours, and the maintenance duration in step 65 is 28 days.

[0012] Preferably, the organic board is machined with positioning grooves or positioning protrusions around its perimeter. The positioning grooves and positioning protrusions between adjacent organic boards engage with each other to achieve the splicing and assembly of multiple composite inner lining boards.

[0013] Preferably, the theoretical processing temperature of the composite lining plate is calculated based on the shrinkage rate of the hardened sample and the linear heat distortion coefficient of the organic board, and is determined based on the following equation: ; in, T represents the theoretical processing temperature of the composite lining plate, and T represents the ambient processing temperature. is the linear thermal distortion coefficient of the organic board; The shrinkage rate of the hardened sample; is the linear thermal deformation coefficient of the hardened sample.

[0014] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0015] Compared with the prior art, the present invention has the following beneficial effects: 1. This scheme first determines the shrinkage rate of polymer-modified cementitious materials by casting standard samples, calculates the theoretical processing temperature based on the thermal deformation coefficient of organic boards, and prepares composite board samples with multiple temperature gradients. By testing the linear thermal deformation coefficient of each group of samples, the temperature that matches the thermal deformation performance of cement concrete is selected as the mass production temperature. This process quantitatively controls the matching degree of thermal expansion and contraction of the two substrates, effectively eliminating the internal stress at the composite interface during temperature alternation, and fundamentally preventing cracking, hollowing, and detachment of the inner lining layer. At the same time, the small-sample pre-testing and batch production mode avoids defects such as shrinkage and warping in advance, unifies the performance of each batch of products, reduces mass production scrap losses, and the entire process relies on objective test data to determine process parameters, with a high degree of standardization and strong production stability.

[0016] 2. The organic board features a narrow opening and a wide bottom groove on one side. After the refractory material is filled, it forms a mechanical interlocking structure, enhancing the bond strength between the organic substrate and the cement wear-resistant layer and dispersing interfacial stress. In the polymer-modified cement-based material, the polymer component improves cement brittleness and reduces hardening shrinkage. Combined with a segmented temperature-controlled curing process, the material is first cured at the optimal processing temperature to ensure full cement hydration and epoxy cross-linking, followed by cooling and demolding for long-term curing. This avoids micro-cracks caused by sudden cooling, resulting in a finished lining with comprehensive properties of low shrinkage, high toughness, and high wear resistance.

[0017] 3. The organic panels are equipped with positioning grooves and protrusions around their perimeter. The panels are directly interlocked by the interlocking structure to complete the splicing and assembly. On-site installation requires no additional adhesives or fixing materials, significantly shortening the lining construction cycle. The interlocking and limiting structure ensures uniform and narrow gaps in the splicing joints, reducing media leakage and localized erosion wear. At the same time, the modular splicing structure supports independent disassembly and assembly of individual panels. During equipment maintenance, only damaged lining panels need to be replaced, without the need to remove the entire lining. This reduces subsequent maintenance and replacement costs, fully meeting the usage requirements of prefabricated linings for rapid construction and easy maintenance. Attached Figure Description

[0018] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the method flow of the present invention; Figure 2 This is a schematic diagram of a groove according to the present invention. Detailed Implementation

[0019] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0020] Furthermore, in this invention, the use of terms such as "first" and "second" is for descriptive purposes only and does not specifically refer to any order or sequence, nor is it intended to limit the invention. They are merely used to distinguish components or operations described using the same technical terms and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions and features of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If a combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0021] The present invention provides the following embodiments: Example 1: This embodiment of the invention provides a method for manufacturing an assembled polymer-reinforced wear-resistant inner liner, such as... Figures 1-2 As shown, it includes: Step 1: Process multiple spaced grooves on one surface of an organic board (such as nylon board, ultra-high molecular weight polyethylene board, or polytetrafluoroethylene board). Step 2: Prepare polymer-modified cementitious materials; Step 3: Take the polymer-modified cementitious material (the polymer-modified cementitious material can be any existing polymer-modified cementitious material) and prepare a slurry (when the polymer-modified cementitious material is in dry powder state, water needs to be added to prepare it; when the polymer-modified cementitious material is a self-contained liquid slurry, water does not need to be added, just stir the polymer-modified cementitious material to prepare the slurry), pour it into a mold to form a sample, cure it until the sample is completely hardened, and measure the shrinkage rate of the hardened sample; Step 3: Calculate the theoretical processing temperature of the composite lining board based on the shrinkage rate of the hardened sample and the linear thermal deformation coefficient of the organic board, and determine at least three test processing temperatures based on the theoretical processing temperature. Step 4: Based on different test processing temperatures, the grooved organic board is placed in the composite lining board mold (the outer forming mold for preparing complete composite board samples and finished lining boards, limiting the overall dimensions of the lining board) as the casting bottom mold. The polymer-modified cement-based material is mixed into a slurry and then poured into the groove and surface of the organic board. After the casting material (the flowing slurry obtained by fully mixing polymer-modified cement-based material with water, which is the core material for forming the wear-resistant surface layer, can be poured to fill the groove and surface of the board) hardens, cools to room temperature, and is then cured to obtain the composite board sample. Step 5: Test the linear thermal deformation coefficient of each composite panel sample, determine the target composite panel sample whose linear thermal deformation coefficient is closest to that of cement concrete, and use the test processing temperature corresponding to the target composite panel sample as the batch processing temperature of the composite lining panel. Step 6: Prepare composite inner lining plates in batches at the batch processing temperature.

[0022] This invention achieves full contact between polymer-reinforced cementitious materials and organic boards, thereby providing support and limiting the thermal deformation of the organic boards.

[0023] Curing: After the cast-in-place material has hardened, it is left to stand in a stable temperature and humidity environment for curing to ensure that the cement-based material is fully hydrated and achieves the designed strength and wear resistance.

[0024] The linear thermal deformation coefficient of each composite board sample can be tested as follows: Take a cured, crack-free, and warped composite board sample and cut it into standard-sized specimens (100mm × 10mm × original board thickness is commonly used); place the specimen in a 25℃ ambient temperature environment for 24 hours to eliminate residual temperature and humidity stress from curing. Stably install the standard specimen onto the linear thermal expansion coefficient tester (thermal deformation tester), using low-friction pins at both ends, and record the initial specimen length L0; set a heating range covering the actual operating temperature range of the lining (e.g., 0℃~60℃), and heat at a uniform rate of 1~2℃ / min; the instrument simultaneously records the change in specimen length ΔL (specimen length at ΔT temperature increase - initial specimen length) corresponding to each ΔT temperature increase (temperature after heating - initial temperature before heating); multiple sets of temperature-length data are automatically recorded throughout the process. Linear thermal deformation coefficient. formula: The average linear thermal deformation coefficient calculated from multiple ΔT segments within the heating range can be taken as the linear thermal deformation coefficient of a single sample. Multiple parallel samples are prepared at the same test processing temperature, and the linear thermal deformation coefficient of each sample is tested and calculated. The arithmetic mean of the linear thermal deformation coefficients of all parallel samples is then taken as the final linear thermal deformation coefficient of the composite board at that test processing temperature. The final linear thermal deformation coefficients corresponding to each group of test processing temperatures are compared with the linear thermal deformation coefficient of standard cement concrete. The group with the value closest to that of cement concrete is selected, and its corresponding test processing temperature is the batch processing temperature.

[0025] The polymer-modified cementitious materials include: acrylic-modified cementitious materials and epoxy-modified cementitious materials.

[0026] The width of the groove opening is smaller than the width of the groove bottom.

[0027] The three test processing temperatures include: theoretical processing temperature -5℃, theoretical processing temperature, and theoretical processing temperature +5℃.

[0028] Step 6 includes: Step 61: Process multiple grooves spaced apart on one surface of the organic board; Step 62: Place the organic board obtained in step 61 into the composite lining board mold, and place it for a first time at the batch processing temperature of the composite lining board; Step 63: Prepare polymer-modified cement-based material, mix the polymer-modified cement-based material into a slurry, and pour the slurry into the composite lining plate mold; Step 64: Continue curing the composite lining at the batch processing temperature, and then cool it down to 20°C; Step 65: Remove the composite wear-resistant liner from the composite inner liner mold and continue curing.

[0029] Preferably, the first duration is 24 hours, the maintenance duration in step 64 is 24 hours, and the maintenance duration in step 65 is 28 days.

[0030] The organic board has positioning grooves or positioning protrusions processed around its perimeter. The positioning grooves and positioning protrusions between adjacent organic boards engage with each other to achieve the splicing and assembly of multiple composite inner lining boards. Specific Implementation Example 1: (1) A piece of ultra-high molecular weight polyethylene (UHMWPE) sheet with dimensions of 1000mm x 500mm and a thickness of 10mm is used. A certain number of conical grooves are machined on one surface of the sheet. The grooves have an upper diameter of 15mm, a bottom diameter of 20mm, and a depth of 5mm. Figure 2 As shown: (2) Prepare epoxy-modified ultra-high performance concrete, with the following specific mix proportions: The mixture consists of 800 parts P.II silicate cement, 100 parts fly ash microspheres, 200 parts silica fume, 1000 parts graded quartz sand, 10 parts water-reducing agent, 1 part defoamer, 150 parts steel fiber, 100 parts epoxy emulsion, and 100 parts curing agent emulsion. The powder components are premixed uniformly to form the powder component. The epoxy emulsion and curing agent emulsion are premixed uniformly to form the liquid component. The liquid component and powder component are then added separately to a high-speed forced mixer and mixed uniformly. Steel fiber is then added, and mixing continues until uniform. The mixture is then poured into a mold and allowed to harden to produce epoxy-modified ultra-high performance concrete.

[0032] (3) Using a non-contact concrete deformation measuring device, the shrinkage rate of the epoxy-modified ultra-high performance concrete prepared in (2) above after complete hardening was measured. In this implementation case, the measured shrinkage rate was 560×10. -6 This shrinkage value includes early plastic shrinkage, autogenous shrinkage, and drying shrinkage. Simultaneously, the linear thermal expansion coefficient of the ultra-high molecular weight polyethylene sheet (within a temperature range of -30℃ to 30℃) was measured to be 180 × 10⁻⁶. -6 ℃ -1 The linear thermal expansion coefficient (within the temperature range of -30℃ to 30℃) of epoxy-modified ultra-high performance concrete was measured to be 9.5 × 10⁻⁶. -6 ℃ -1 Considering that the ambient temperature of the composite lining panel during use will generally not exceed 30℃, the epoxy-modified ultra-high performance concrete and the ultra-high molecular weight polyethylene board will remain in close contact as long as the temperature is 30℃. When the temperature continues to decrease, due to the larger linear thermal expansion coefficient of the ultra-high molecular weight polyethylene board, its shrinkage value will be higher than that of the epoxy-modified ultra-high performance concrete, and the two will still maintain close contact.

[0033] Assuming the processing temperature is X℃, when the temperature recovers to 30℃, The heat distortion rate of ultra-high molecular weight polyethylene sheet is: (X-30)×180×10 -6 ; The thermal deformation rate of epoxy-modified ultra-high performance concrete is: (X-30)×9.5×10 -6 ; The shrinkage rate of epoxy-modified ultra-high performance concrete is: 560 × 10⁻⁶ -6 ; When the thermal deformation rate of ultra-high molecular weight polyethylene (UHMWPE) sheets is the same as the total deformation rate (thermal deformation and shrinkage deformation) of epoxy-modified ultra-high performance concrete, the two can be in close contact, thus yielding the following equation: (X-30)×180×10 -6 = (X-30)×9.5×10 -6 +560×10 -6 ; Solving the equation, we get X≈33; Therefore, in this implementation case, the theoretical processing temperature of the wear-resistant inner lining plate is 33℃.

[0034] (4) Take three ultra-high molecular weight polyethylene (UHMWPE) sheets prepared in step 1 and place them in silicone molds with dimensions of 1001mm × 501mm and a thickness of 20mm. Place them at 28℃, 33℃, and 38℃ for more than 12 hours respectively. Then pour the epoxy-modified ultra-high performance concrete slurry prepared in step 2 into the three molds, ensuring that the slurry flows completely into the grooves and is flush with the silicone molds. After that, place the three molds at 28℃, 33℃, and 38℃ for 24 hours respectively, and then place them at room temperature (around 20℃) for 28 days. At this time, the epoxy-modified ultra-high performance concrete has basically reached its final strength, and its shrinkage value has also tended to stabilize. Take the above-mentioned composite wear-resistant inner lining plates out of the silicone molds and measure the linear thermal expansion coefficient of the surface UHMWPE sheets (within the temperature range of -30℃ to 30℃). The results are as follows:

[0035] As shown in the table above, if the molding temperature is lower than the theoretical processing temperature calculated in step (3), the epoxy-modified ultra-high performance concrete cannot effectively constrain the ultra-high molecular weight polyethylene (UHMWPE) board. Its linear thermal expansion coefficient is basically the same as before the composite. This is because the epoxy-modified ultra-high performance concrete shrinks significantly, resulting in gaps between the epoxy-modified ultra-high performance concrete and the UHMWPE board in the groove, which cannot play a constraining role. When the temperature reaches the theoretical processing temperature, the epoxy-modified ultra-high performance concrete forms a better constraint on the UHMWPE board, which is reflected in a very significant reduction in its linear thermal expansion coefficient. When the temperature exceeds the theoretical processing temperature by 5°C, the constraint is more obvious, and the linear thermal expansion coefficient of the UHMWPE board is basically the same as that of the epoxy-modified ultra-high performance concrete, and is also very close to that of ordinary cement concrete. Therefore, when mass-producing composite wear-resistant inner lining plates, the molding and initial 24-hour curing temperature can be set to 38°C.

[0036] Example 2:

[0037] A nylon sheet with dimensions of 500mm x 500mm and a thickness of 20mm is used. A certain number of conical grooves are machined on one surface of the sheet. The grooves have an upper diameter of 10mm, a bottom diameter of 15mm, and a depth of 10mm.

[0038] Commercially available acrylic emulsion reinforced cementitious grouting material is used as a composite material.

[0039] The shrinkage rate of the acrylic emulsion-reinforced cementitious grout was measured to be 1250 × 10⁻⁶. -6 The linear thermal expansion coefficient of the nylon sheet (within the temperature range of -30℃ to 30℃) was measured to be 95×10⁻⁶. -6 ℃ -1 The linear thermal expansion coefficient (within the temperature range of -30℃ to 30℃) of the acrylic emulsion-reinforced cementitious grout was measured to be 9.0 × 10⁻⁶. -6 ℃ -1 .

[0040] The theoretical processing temperature for the composite wear-resistant liner is calculated to be approximately 45℃, but 50℃ is used as the processing temperature. The nylon sheet from step 1 is placed in a 501mm × 501mm, 40mm thick silicone mold and placed at 50℃ for 24 hours. The acrylic emulsion-reinforced cementitious grout from step 2 is stirred evenly and poured into the mold. Curing continues at 50℃ for another 24 hours, then the temperature is slowly lowered to approximately 20℃. The composite wear-resistant liner is removed from the mold and cured for another 28 days. The linear thermal expansion coefficient of the nylon sheet on the composite wear-resistant liner (within the temperature range of -30℃ to 30℃) is measured to be 11.5 × 10⁻⁶. -6 ℃ -1 .

[0041] The cement-based material used in this invention is polymer-modified to improve its corrosion resistance. During the use of the lining plate, the moisture in the coal dust often contains corrosive media such as sulfur, which can penetrate into the interior through the gaps and corrode the cement-based material at the bottom of the lining plate. However, polymer modification can improve the corrosion resistance of the cement-based material at the bottom of the lining plate, thereby increasing the service life of the lining plate.

[0042] This invention provides a method for manufacturing a prefabricated polymer-reinforced wear-resistant inner lining plate. It uses polymer-reinforced cement-based materials to composite with organic boards to produce a new type of wear-resistant inner lining plate, which solves the shortcomings of conventional organic boards, such as large thermal deformation coefficient, only bolt anchoring installation, and easy detachment.

[0043] A narrow-faced, wide-bottomed groove is machined into the surface of the organic wear-resistant sheet. The grooves are spaced apart and are used to physically anchor the polymer-reinforced cement-based material to the organic sheet. Grooves or bosses are also machined around the perimeter of the sheet for connection between each sheet during prefabricated installation. After the panels are formed, they are fixed to the concrete silo wall using a rebar anchoring process. The cement-based material surface of the panels faces the silo wall, and the cavity formed is bonded to the panels and the silo wall with high-strength cement-based grout. This results in the cement-based material surface of the panels, the grout, and the concrete silo wall all being cement-based inorganic materials. The linear thermal deformation coefficients of the three are consistent, which greatly reduces the occurrence of cracking and falling off.

[0044] The beneficial effects of this invention are as follows: 1. This scheme first determines the shrinkage rate of polymer-modified cementitious materials by casting standard samples, calculates the theoretical processing temperature based on the thermal deformation coefficient of organic boards, and prepares composite board samples with multiple temperature gradients. By testing the linear thermal deformation coefficient of each group of samples, the temperature that matches the thermal deformation performance of cement concrete is selected as the mass production temperature. This process quantitatively controls the matching degree of thermal expansion and contraction of the two substrates, effectively eliminating the internal stress at the composite interface during temperature alternation, and fundamentally preventing cracking, hollowing, and detachment of the inner lining layer. At the same time, the small-sample pre-testing and batch production mode avoids defects such as shrinkage and warping in advance, unifies the performance of each batch of products, reduces mass production scrap losses, and the entire process relies on objective test data to determine process parameters, with a high degree of standardization and strong production stability.

[0045] 2. The organic board features a narrow opening and a wide bottom groove on one side. After the refractory material is filled, it forms a mechanical interlocking structure, enhancing the bond strength between the organic substrate and the cement wear-resistant layer and dispersing interfacial stress. In the polymer-modified cement-based material, the polymer component improves cement brittleness and reduces hardening shrinkage. Combined with a segmented temperature-controlled curing process, the material is first cured at the optimal processing temperature to ensure full cement hydration and epoxy cross-linking, followed by cooling and demolding for long-term curing. This avoids micro-cracks caused by sudden cooling, resulting in a finished lining with comprehensive properties of low shrinkage, high toughness, and high wear resistance.

[0046] 3. The organic panels are equipped with positioning grooves and protrusions around their perimeter. The panels are directly interlocked by the interlocking structure to complete the splicing and assembly. On-site installation requires no additional adhesives or fixing materials, significantly shortening the lining construction cycle. The interlocking and limiting structure ensures uniform and narrow gaps in the splicing joints, reducing media leakage and localized erosion wear. At the same time, the modular splicing structure supports independent disassembly and assembly of individual panels. During equipment maintenance, only damaged lining panels need to be replaced, without the need to remove the entire lining. This reduces subsequent maintenance and replacement costs, fully meeting the usage requirements of prefabricated linings for rapid construction and easy maintenance.

[0047] In one optional embodiment, a casting matching process is performed before the current batch casting, the casting matching process including: Step a1: Obtain the key dimensional parameters of the grooved organic board corresponding to the current batch casting, including: the groove depth of the grooved organic board and the angle between the groove sidewall and the groove bottom; Step a2: Determine the initial casting parameters based on the key dimensional parameters of the grooved organic board corresponding to the current batch casting and the preset initial matching casting rules; Step a3: Obtain the fluidity, air content, and density of the slurry to be poured. Combine the air content, fluidity, and groove depth of the corresponding slotted organic board to be poured in the current batch. Correct the initial pouring discharge flow rate of the initial pouring parameters by bubble constraint. Correct the air pressure in the initial pouring discharge tank by combining the fluidity, density, and corrected initial pouring discharge flow rate of the slurry to be poured. Step a4: The corrected discharge pouring flow rate and the corrected air pressure inside the pouring tank determined in step a3 are used to pour the grooved organic board corresponding to the current batch of pouring. Step a5: After pouring, keep the grooved organic board with the groove facing upwards and let it stand still. Determine the matching settling time based on the ratio R of the corrected pouring flow rate to the initial pouring flow rate obtained in step a2 (under the following benchmark calibration conditions, the matching settling time is 10 min; when R≥0.9, the matching settling time is 10 min; when R<0.9, the matching settling time is 12~14 min; the settling environment is 18℃~28℃). During the batch pouring process, the batch pouring is carried out based on the foundation pouring flow rate and foundation pouring pressure, and the foundation is left to stand after pouring based on the matching settling time (after pouring is completed, the foundation is left to stand for the matching settling time before being transported for curing).

[0048] The final internal pressure of the tank should be controlled at 0.02~0.08 MPa, and the discharge flow rate should be controlled at 142-252 mL / min. (1) Groove depth: The vertical depth from the top of the groove of the groove of the grooved organic board to the bottom of the groove; the depth of the groove determines the size of the slurry filling space inside the groove. The greater the groove depth, the more difficult it is to remove air from the bottom of the groove, and higher pouring pressure is required. The angle between the sidewall of the groove and the bottom of the groove: the inner angle formed between the inner wall surface of the sidewall of the groove and the plane of the bottom of the groove; when the sidewall is inclined inward, the angle is smaller and the upper opening of the groove is narrower; when the sidewall is inclined outward, the angle is larger and the upper opening of the groove is wider; the smaller the angle, the narrower the slurry flow space and the greater the flow resistance.

[0049] (2) The method for determining the initial matching pouring rules is as follows: ① Select a slurry (you can choose the most commonly used polymer-modified cement-based material to prepare the slurry) as the calibration slurry. Test the slurry fluidity, slurry air content, and slurry density according to the industry standard testing methods. Use these values ​​as the reference slurry fluidity, reference slurry air content, and reference slurry density.

[0050] Based on the actual processing dimensions of the plates processed in the factory over a long period of time and the fluctuation range of machine tool processing in the actual application scenario of this invention, several groove depth intervals and the included angle intervals between the groove sidewall (inner sidewall) and the groove bottom are divided. The range of intervals covers all dimensions that occur in actual production. Within the combination range of each groove depth interval and included angle interval, representative dimensions (groove depth and the above included angle) are selected in that interval to carry out casting tests.

[0051] ② Conduct tests on a closed pressure tank-peristaltic pump casting equipment; the installation height of the equipment storage tank is fixed, and the static pressure generated by the weight of the slurry remains constant and is not used as an adjustment parameter; for each combination of groove depth range and the angle range between the groove sidewall and the groove bottom (e.g., 4-6mm, 60-65°), select at least the upper limit dimension, lower limit dimension, and middle dimension of the range to conduct plate sample casting tests; adjust the tank pressure and slurry discharge flow rate multiple times; obtain the tank pressure range and discharge flow rate range that meet the casting quality requirements under the combination of groove depth range and the angle range between the groove sidewall and the groove bottom (these are the initial tank pressure range and initial discharge flow rate range corresponding to the combination range, respectively).

[0052] ③ When the slurry is poured and reaches the initial setting state, observe the air bubbles inside the groove and the overflow of slurry at the top to preliminarily determine the initial range of tank pressure and discharge flow rate corresponding to the qualified formation in the initial setting stage. Within the above-mentioned preliminarily determined initial range of tank pressure and discharge flow rate, select multiple sets of samples corresponding to different combinations of tank pressure and discharge flow rate for preservation and curing; after the slurry is completely cured, dissect each set of samples to conduct internal forming quality testing. Based on the test results of the samples after curing corresponding to the upper limit, lower limit, and middle limit of the interval, the pressure and flow rate conditions that failed to meet the molding requirements were eliminated. The preliminary range of in-tank pressure and discharge flow rate obtained in the initial setting stage were further narrowed to obtain the final usable in-tank pressure range and discharge flow rate range. Only when the sample meets all of the following conditions is the current narrowed parameter range determined to be the in-tank pressure range and discharge flow rate range that meet the casting quality requirements (the initial in-tank pressure range and initial discharge flow rate range corresponding to this combination range, respectively): no independent air bubbles with a diameter > 0.5 mm, no clustered air bubbles inside the groove; the slurry is dense and uniform after curing, and the slurry adheres tightly to the side wall and bottom of the groove; there is only a small amount of floating slurry (less than 2 mm thick) at the top of the groove, which can be easily wiped clean, and the slurry will not overflow out of the groove.

[0053] The data table's row dimension represents the divided groove depth intervals, and the column dimension represents the angle intervals between the sidewalls and bottom of the grooves. Each cell in the data table corresponds to a set of groove depth intervals and angle intervals, which are selected as the benchmark tank pressure range and benchmark discharge flow rate range after being verified through casting tests. During actual production, the groove depth and the angle between the sidewalls and bottom of the grooves of the current batch of plates are detected to determine the groove depth interval and angle interval to which the plate size belongs. The initial casting pressure and initial discharge flow rate corresponding to that interval are then directly retrieved as the initial casting parameters.

[0054] (3) The fluidity of the slurry characterizes the viscosity and flow properties of the polymer-modified cement slurry. It is tested by sampling and inspection according to GB / T2419-2005. Samples are taken within 3-8 minutes after mixing. The spread diameter is measured by using a slab table and a truncated cone mold, which is the fluidity value. Each batch of slurry is sampled and tested once after mixing.

[0055] Air content in slurry (specific measurement is based on existing technology): Air content in slurry is the percentage of air volume in freshly mixed slurry to the total volume of slurry, and does not require continuous online monitoring; factories can calculate the air content by weighing the slurry density; each batch of slurry is sampled and measured once.

[0056] (4) In step a3: ① Determine the ratio of the fluidity, air content, and density of the grout to the corresponding reference values; K = fluidity of the slurry to be cast ÷ fluidity of the reference slurry; L = gas content of the slurry to be cast ÷ gas content of the reference slurry; M = density of the slurry to be cast ÷ density of the reference slurry; ② In combination with the slurry gas content and slurry fluidity of the slurry to be cast, and the groove depth of the grooved organic plate corresponding to the current batch casting, perform air bubble constraint correction on the initial casting discharge flow rate of the initial casting parameters, specifically: Based on L and the groove depth of the grooved organic plate corresponding to the current batch casting, perform main adjustment on the initial casting discharge flow rate (the higher the gas content and the greater the groove depth, the higher the difficulty of gas exhaust, so it is necessary to reduce the discharge flow rate to prolong the exhaust time. Match the first main adjustment correction ratio through L, and perform main adjustment on the initial flow rate): The first main adjustment correction ratio in this table is determined based on the fluid filling mechanism that the larger the groove depth and the higher the slurry gas content, the greater the exhaust resistance at the groove bottom; Prepare slurries with different gas content ratios L, and carry out multiple groups of casting tests in combination with different groove depth conditions; take the number of internal bubbles in the sample after curing and dissection, the slurry adhesion state, and the slurry overflow condition as the qualification judgment criteria, and screen out the interval values after eliminating unqualified forming working conditions;

[0057] Casting discharge flow rate after main adjustment = initial casting discharge flow rate × first main adjustment correction ratio; The higher the fluidity, the stronger the self-leveling ability of the slurry, and the flow rate can be appropriately increased; the lower the fluidity, the greater the filling resistance, and the flow rate needs to be reduced.

[0058] When K≥1.2, the fluidity flow correction coefficient is 0.98 (the fluidity of the slurry is too strong. If the flow rate is too high, the slurry will fill the groove instantly, and air will be sealed at the groove bottom); When 0.8<K<1.2, the fluidity flow correction coefficient is 1.00; When K≤0.8, the fluidity flow correction coefficient is 0.93 (the flow resistance of the slurry itself is large, and the flow rate must be reduced to prevent uneven filling).

[0059] Corrected casting discharge flow rate = casting discharge flow rate after main adjustment × fluidity flow correction coefficient; ③ In combination with the fluidity and slurry density of the slurry to be cast, and the corrected initial casting discharge flow rate, correct the air pressure in the initial casting discharge tank, specifically: Based on L and the groove depth of the grooved organic plate corresponding to the current batch casting, perform main adjustment on the initial casting discharge flow rate: the second main adjustment correction ratio in this table determines the exhaust condition based on the bubble constraint (the interval of the first main adjustment correction ratio), determines the slurry flow resistance through the slurry density ratio M, and determines the value range through gradient air pressure casting tests combined with the curing quality of the sample;

[0060] Air pressure for pouring and discharging after main adjustment = initial air pressure in the pouring and discharging tank × second main adjustment correction ratio; Based on the slurry fluidity, readjust the air pressure in the pouring and discharging tank after main adjustment; When K≥1.2, the fluidity air pressure correction coefficient is 0.96 (the slurry has good fluidity, and the air pressure is appropriately reduced); When 0.8<K<1.2, the fluidity air pressure correction coefficient is 1.00; When K≤0.8, the fluidity air pressure correction coefficient is 1.05 (the flow resistance increases significantly, and the air pressure is increased to compensate the power).

[0061] Corrected air pressure in the pouring and discharging tank = air pressure in the pouring and discharging tank after main adjustment × fluidity air pressure correction coefficient; The first main adjustment correction ratio, the second main adjustment correction ratio, and the correction coefficients are determined in combination with the slurry exhaust mechanism and multiple sets of pouring test results.

[0062] The beneficial effects of the above technical solution are: In this solution, two decisive geometric parameters, namely the groove depth and the included angle between the groove side wall and the groove bottom, are collected in a targeted manner, which abandons the general and extensive parameter selection mode and enables accurately obtaining the actual exhaust conditions and slurry flow resistance of the current batch of plates; and it provides an objective quantitative basis for the subsequent initial parameter selection and the bubble constraint correction of the discharging flow rate, and solves the inherent problems of difficulty in exhausting due to excessive groove depth and inadequate slurry filling due to too small included angle from the source; In the traditional production process, pouring parameters are adjusted by workers based on on-site experience. Each production requires multiple trial pourings to explore parameters, which consumes sample materials and production man-hours, and human factors are very likely to cause large dispersion in product quality. In the present step, based on the pre-divided groove depth and included angle intervals, a preset matching rule is formed through two levels of strict test screening, namely initial setting observation and curing and cutting detection, and the initial tank internal air pressure and discharging flow rate that have been verified and qualified through multi-gradient samples can be called only through the size interval to which the plate belongs.

[0063] In this solution, ratio coefficients K, L, and M are introduced to carry out parameter correction in layers: the main bubble constraint correction of the discharging flow rate is completed in combination with the slurry gas content and groove depth, and then the slurry fluidity is used for secondary flow rate adjustment; afterwards, the tank internal air pressure is further optimized in combination with the slurry density, corrected flow rate and fluidity, the flow rate is actively slowed down to prolong the exhaust time according to the exhaust difficulty, and the tank pressure is adjusted as required to supplement the filling power, which realizes the matching between the geometric conditions of the plate and the real-time performance of the slurry, and overcomes the hidden quality trouble caused by the performance fluctuation of different slurry batches.

[0064] This scheme uses the ratio R of the corrected flow rate to the initial discharge flow rate as the indicator for determining the settling time: when the discharge flow rate decreases, it means that the slurry has a higher gas content and is more difficult to degas, so the settling time is extended. Only after the settling is completed can the slurry be transferred and cured, which not only prevents the slurry from being moved and disturbed too early, but also avoids meaningless long-term settling that reduces production efficiency.

[0065] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A method for manufacturing an assembled polymer-reinforced wear-resistant inner liner, characterized in that: include: Step 1: Process multiple grooves spaced apart on one surface of the organic board; Step 2: Prepare polymer-modified cementitious materials; Step 3: Take the polymer-modified cementitious material and mix it into a slurry, pour it into a mold to form a sample, cure it until the sample is completely hardened, and measure the shrinkage rate of the hardened sample. Step 4: Calculate the theoretical processing temperature of the composite lining board based on the shrinkage rate of the hardened sample and the linear thermal deformation coefficient of the organic board, and determine at least three test processing temperatures based on the theoretical processing temperature. Step 5: Based on different test processing temperatures, the grooved organic board is placed in the composite lining board mold as the casting bottom mold. The polymer-modified cement-based material is prepared into a slurry and then poured into the groove of the organic board and the board surface. After the slurry hardens, it is cooled to room temperature and cured to obtain the composite board sample. Step 6: Test the linear thermal deformation coefficient of each composite panel sample, determine the target composite panel sample whose linear thermal deformation coefficient is closest to that of cement concrete, and use the test processing temperature corresponding to the target composite panel sample as the batch processing temperature of the composite lining panel. Step 7: Prepare composite inner lining plates in batches at the batch processing temperature.

2. The method for manufacturing an assembled polymer-reinforced wear-resistant inner liner according to claim 1, characterized in that: The polymer-modified cementitious materials include: acrylic-modified cementitious materials and epoxy-modified cementitious materials.

3. The method for manufacturing an assembled polymer-reinforced wear-resistant inner liner according to claim 1, characterized in that: The width of the groove opening is smaller than the width of the groove bottom.

4. The method for manufacturing an assembled polymer-reinforced wear-resistant inner liner according to claim 1, characterized in that: The three test processing temperatures include: theoretical processing temperature -5℃, theoretical processing temperature, and theoretical processing temperature +5℃.

5. The method for manufacturing an assembled polymer-reinforced wear-resistant inner liner according to claim 1, characterized in that: Step 6 includes: Step 61: Process multiple grooves spaced apart on one surface of the organic board; Step 62: Place the organic board obtained in step 61 into the composite lining board mold, and place it for a first time at the batch processing temperature of the composite lining board; Step 63: Prepare polymer-modified cement-based material, mix the polymer-modified cement-based material into a slurry, and pour the slurry into the composite lining plate mold; Step 64: Continue curing the composite lining at the batch processing temperature, and then cool it down to 20°C; Step 65: Remove the composite wear-resistant liner from the composite inner liner mold and continue curing.

6. The method for manufacturing an assembled polymer-reinforced wear-resistant inner liner according to claim 5, characterized in that: The first duration is 24 hours, the maintenance duration in step 64 is 24 hours, and the maintenance duration in step 65 is 28 days.

7. The method for manufacturing an assembled polymer-reinforced wear-resistant inner liner according to claim 1, characterized in that: The organic board is machined with positioning grooves or positioning protrusions around its perimeter. The positioning grooves and positioning protrusions between adjacent organic boards engage with each other to achieve the splicing and assembly of multiple composite inner lining boards.

8. The method for manufacturing an assembled polymer-reinforced wear-resistant inner liner according to claim 1, characterized in that: Based on the shrinkage rate of the hardened sample and the linear thermal deformation coefficient of the organic board, the theoretical processing temperature of the composite lining board is calculated and determined based on the following equation: ； in, T represents the theoretical processing temperature of the composite lining plate, and T represents the ambient processing temperature. is the linear thermal distortion coefficient of the organic board; The shrinkage rate of the hardened sample; is the linear thermal deformation coefficient of the hardened sample.

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