A method of manufacturing a warp-knitted lattice net cage

Abstract

The application provides a manufacturing method of a warp-knitted grid net cage, relates to the field of geosynthetic materials and mine support, and cuts a warp-knitted polyester geogrid sheet to form a half cut and a cut to divide a top cover area, a bottom plate area and four side edge areas, then folds the left side edge area, the right side edge area, the front side edge area and the rear side edge area by 90 degrees along the half cut to form a vertical open cage structure, the folding area is folded along the half cut to form a triangular fold at the corner of the cage, and finally, adjacent sheets are bound and fixed to form a three-dimensional warp-knitted grid net cage. The stone cage net prepared by the method has the advantages of factory prefabrication, folding transportation and on-site rapid deployment and use, does not need other connecting rods, has higher connecting strength and is not prone to loosening, has high integrity of the net cage, and is convenient for transportation.

Description

Technical Field

[0001] This invention relates to the field of geosynthetic materials and mine support technology, specifically to a method for manufacturing warp-knitted geogrid cages applicable to engineering fields such as slope protection, retaining walls, and river management. Background Technology

[0002] Gabion mesh is a flexible retaining structure widely used in civil engineering. Traditional gabion mesh is made of low-carbon steel wire woven into hexagonal mesh, and multiple mesh panels are assembled into box-shaped cages by welding or binding. The cages are filled with stones for purposes such as retaining soil and slope protection. However, traditional steel wire gabion mesh has the following problems: 1. Steel wire has poor corrosion resistance and has a limited service life in humid, acidic, or salty environments. In particular, in mining environments, acidic drainage causes more severe corrosion to steel wire.

[0003] 2. The steel wire woven mesh is a rigid connection, and stress concentration is prone to occur at the welded joints. Under the impact of stones or long-term load, the joints are prone to breakage, resulting in a reduction in the overall integrity of the cage.

[0004] Assembling multiple mesh panels requires a large number of welding or binding processes, resulting in low on-site assembly efficiency, and the connection points are often the weakest links in the entire structure.

[0005] 4. Steel wire mesh is heavy, resulting in high transportation and handling costs, and high labor intensity on the construction site.

[0006] To address the aforementioned issues, existing technologies include the use of polyester mesh to manufacture gabion nets. However, such solutions generally suffer from the following drawbacks: multiple mesh panels still need to be cut separately and assembled on-site, resulting in a cumbersome assembly process and insufficient connection strength between the mesh panels.

[0007] Therefore, there is an urgent need in this field for a manufacturing method of gabion mesh that can achieve integrated prefabrication in the factory, foldable transportation, and rapid deployment on site, in order to solve the problems of multiple assembly steps, insufficient connection strength, and low transportation efficiency in the existing technology. Summary of the Invention

[0008] This invention addresses the aforementioned problems in the prior art by providing a method for manufacturing a warp-knitted gabion cage, namely, a method for manufacturing gabion mesh for civil engineering.

[0009] The technical solution of the present invention to solve the above-mentioned technical problems is as follows: A method for manufacturing a warp-knitted wire mesh cage, characterized by comprising the following steps: S1. Mesh preparation: Prepare a warp-knitted polyester geogrid mesh, which is roughly rectangular and its surface is divided into multiple mesh areas as follows: along its x-direction, it is a top cover area, a left side area, a bottom plate area, and a right side area. The bottom plate area is divided into a front side area and a rear side area on both sides in the y-direction. The left side area and the right side area are divided into folded areas on both sides in the y-direction. The front side area is located between two folded areas, and the rear side area is located between two folded areas. S2, Cutting: Make half-cuts on the mesh surface at the following locations: the junction of the bottom plate area and the four side plate areas; the junction of the top cover area and the left side plate area; the junctions of the left side plate area, right side plate area, front side plate area, and rear side plate area with the adjacent folded areas; and the diagonal line of the path of the folded area to the apex of the bottom plate area. A half-cut refers to not cutting the mesh completely. Cut slits on the edge surface of the mesh and at the junction of the folded area and the top cover area. The slits refer to cutting the mesh at the corresponding positions. Furthermore, the x-axis dimensions of the left and right side regions are equal to the y-axis dimensions of the front and rear side regions; S3, Folding and shaping: Fold the left, right, front, and rear side sections upwards at 90 degrees along the half-cut to form a vertical open cage structure. The folded area is then folded along the half-cut to form a triangular overlapping piece at the inner corner of the cage. The adjacent mesh pieces are then tied and fixed. Independent warp-knitted polyester geogrid partition mesh is vertically inserted into the cage and fixed to the inner wall of the cage. The partition mesh divides the inside of the cage into at least two compartments. Fold the top cover area downwards at a 90-degree angle along the half-cut to cover the opening of the cage, thus serving as the top cover of the cage.

[0010] Furthermore, adjacent mesh panels are bound and secured together using high-strength polyester ropes in a figure-eight weave.

[0011] Furthermore, the top cover is larger than the bottom plate area, and the overlap allowance of the top cover beyond the edge of its side wall when it covers the cage is 10cm to 20cm.

[0012] Furthermore, the surface of the warp-knitted polyester geogrid is coated with a styrene-butadiene rubber coating, and its warp and weft tensile strengths are both 80kN / m to 600kN / m.

[0013] The beneficial effects of this invention are as follows: This invention produces a gabion cage structure by cutting, folding, and fastening a one-piece polyester warp-knitted geogrid. In its unfolded state, it is a one-piece warp-knitted polyester geogrid, including an integrally formed first main mesh, a second main mesh, and four side meshes. A bending transition zone is set at the adjacent points of two meshes, and a folding zone is set between adjacent side meshes as an integral transition. The cage is formed by integrally cutting the bottom, sides, and top cover on the same warp-knitted coated geogrid fabric, and directly forming a three-dimensional cage structure by bending using the flexible properties of the material. This allows for factory prefabrication, folding and transportation, and rapid on-site deployment without the need for other connecting rods, resulting in higher connection strength, less loosening, strong overall cage integrity, and convenient transportation. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of the warp-knitted polyester geogrid of the present invention; Figure 2 This is a schematic diagram of the partitioning and cutting of the warp-knitted polyester geogrid of the present invention (the geogrid structure is not shown). Figure 3 This is a schematic diagram of the cut structure of the warp-knitted polyester geogrid of the present invention; Figure 4 This is a schematic diagram of the structure of the warp-knitted gabion mesh manufactured by the present invention (the binding rope and the overlap allowance of the top cover are not shown). In the diagram: 10. Cage body, 11. Bottom panel, 12. Top cover, 13. Side panel, 14. Stacked panels, 20. Partition mesh; 1. First main mesh, 2. Second main mesh, 3. Side mesh, 4. Bending transition area, 5. Folding area, 6. Grid mesh, 7. Warp strip, 8. Weft strip. Detailed Implementation

[0015] The principles and features of the present invention are described below. The embodiments given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0016] The manufacturing method of the warp-knitted wire mesh cage of this embodiment is characterized by including the following steps: S1. Mesh preparation: Prepare warp-knitted polyester geogrid sheets, which are made of high-strength polyester warp strips 7 and high-strength polyester weft strips 8 (using a Raschel warp knitting machine, with high-strength polyester yarn as raw material). The surface of the warp-knitted polyester geogrid is coated with SBR styrene-butadiene rubber coating, and its warp and weft tensile strengths are both 80kN / m~600kN / m. See Figure 1As shown, it is roughly rectangular, and its surface is divided into multiple mesh areas as follows: along its x-axis, these are the top cover area 2, the left side area 31, the bottom plate area 1, and the right side area 32. The bottom plate area has a front side area 33 and a rear side area 34 on either side of its y-axis. The left side area 31 and the right side area 32 have folding areas 5 on either side of their y-axis sides (the folding areas 5 achieve mesh continuity, reduce processing steps in cage manufacturing, and also strengthen the cage after folding, thus improving the connection strength of the cage). The front side area 33 is located between two folding areas 5, and the rear side area 34 is located between two folding areas 5. Figure 2 As shown; the top cover area 2 is larger than the bottom plate area 1; S2, Cutting: Make half-cuts 4 on the mesh surface at the following locations (to eliminate interference from subsequent bending): the junction of the bottom plate area 1 and the four side plate areas; the junction of the top cover area 2 and the left side plate area 31; the junctions of the left side plate area 31, the right side plate area 32, the front side plate area 33, and the rear side plate area 34 with the adjacent folded area 5; and the diagonal line of the folded area 5 along the apex of the bottom plate area. The half-cut 4 refers to not cutting the mesh. Cut slits 41 on the edge surface of the mesh and at the junction of the folded area 5 and the top cover area 2. The cut 41 refers to cutting the mesh at the corresponding position. Furthermore, the x-axis dimensions of the left side region 31 and the right side region 32 are equal to the y-axis dimensions of the front side region 33 and the rear side region 34; See the cut grating mesh. Figure 3 As shown; S3, Folding and shaping: The left side section 31, right side section 32, front side section 33 and rear side section 34 are folded upwards at 90 degrees along the half-cut 4 to form a vertical open cage structure. The folding section 4 is then folded along the half-cut and forms a triangular overlapping piece 14 at the inner corner of the cage. Adjacent mesh pieces are tied and fixed with high-strength polyester rope in a figure-eight weave. Independent warp-knitted polyester geogrid partition mesh pieces are vertically inserted into the cage and fixed to the inner wall of the cage. The partition mesh pieces divide the interior of the cage into at least two compartments. Fold the top cover area downwards at a 90-degree angle along the half-cut to cover the opening of the cage, forming the top cover 12 of the cage. Figure 4 As shown, during production, the overlap allowance of the top cover extending beyond the edge of the cage wall is controlled to be 10cm to 20cm (not shown in the figure).

[0017] The resulting gabion structure is shown in Figure 4As shown, the cage includes a cage body 10 and at least one partition mesh 20 disposed within the cage body 10. In this embodiment, two partition meshes 20 are provided, with a spacing of 1.0m between adjacent partition meshes 20, dividing the cage body 10 into three compartments. The bottom plate area 1 serves as the bottom panel 11 of the cage body 10. The left side area 31, right side area 32, front side area 33, and rear side area 34 are each bent around the half-cut 4 to form the four side panels 13 of the cage body 10. The top cover area 2 is bent around the half-cut 4 to form the top cover 12 of the cage body 10. The folding area 5 is folded in half and forms a triangular overlapping piece 14 at the inner corner of the cage body 10 for reinforcement. Adjacent panels are fixedly connected by binding (not shown in the figure). The partition meshes 20 are fixed to the side panels 13 and the bottom panel 11 by binding.

[0018] As described above, the binding method uses high-strength polyester rope with a diameter of 5mm to 10mm, which is passed through the grid nodes at the bends of adjacent panels in a figure-eight braiding pattern to fix and connect the panels.

[0019] The above method describes the manufacturing process of gabion mesh, which offers the advantage of being foldable for transportation. When transportation or storage is required, the bound cages can be folded back along the half-cut, flattened into a board shape, and packaged for easy transport and storage. The gabion mesh has strong overall integrity and is not easily deformed or disintegrated during transportation and construction.

Claims

1. A method for manufacturing a warp-knitted wire mesh cage, characterized in that, Includes the following steps: S1. Mesh preparation: Prepare a warp-knitted polyester geogrid mesh, which is roughly rectangular and its surface is divided into multiple mesh areas as follows: along its x-direction, it is a top cover area, a left side area, a bottom plate area, and a right side area. The bottom plate area is divided into a front side area and a rear side area on both sides in the y-direction. The left side area and the right side area are divided into folded areas on both sides in the y-direction. The front side area is located between two folded areas, and the rear side area is located between two folded areas. S2, Cutting: Make half-cuts on the mesh surface at the following locations: the junction of the bottom plate area and the four side plate areas; the junction of the top cover area and the left side plate area; the junctions of the left side plate area, right side plate area, front side plate area, and rear side plate area with the adjacent folded areas; and the diagonal line of the path of the folded area to the apex of the bottom plate area. A half-cut refers to not cutting the mesh completely. Cut slits on the edge surface of the mesh and at the junction of the folded area and the top cover area. The slits refer to cutting the mesh at the corresponding positions. Furthermore, the x-axis dimensions of the left and right side regions are equal to the y-axis dimensions of the front and rear side regions; S3, Folding and shaping: Fold the left, right, front, and rear side sections upwards at 90 degrees along the half-cut to form a vertical open cage structure. The folded area is then folded along the half-cut to form a triangular overlapping piece at the inner corner of the cage. The adjacent mesh pieces are then tied and fixed. Independent warp-knitted polyester geogrid partition mesh is vertically inserted into the cage and fixed to the inner wall of the cage. The partition mesh divides the inside of the cage into at least two compartments. Fold the top cover area downwards at a 90-degree angle along the half-cut to cover the opening of the cage, thus serving as the top cover of the cage.

2. The manufacturing method according to claim 1, characterized in that, Adjacent mesh panels are tied and secured together with high-strength polyester ropes in a figure-eight weave.

3. The manufacturing method according to claim 1, characterized in that, The top cover is larger than the bottom plate area, and the overlap allowance of the top cover beyond the edge of its side wall when it covers the cage is 10cm to 20cm.

4. The manufacturing method according to claim 1, characterized in that, The surface of the warp-knitted polyester geogrid is coated with styrene-butadiene rubber.

5. The manufacturing method according to claim 4, characterized in that, The warp-knitted polyester geogrid has a warp and weft tensile strength of 80kN / m to 600kN / m.

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