Basalt fiber and carbon fiber blended structure filled foam concrete and preparation method thereof

Abstract

This invention discloses a basalt fiber and carbon fiber blended structure for filling foamed concrete and its preparation method. The concrete includes a foamed concrete core layer, with a fiber layer covering the outer side of the core layer. The fiber layer comprises the following components by volume percentage: 15-80% basalt fiber, 15-75% carbon fiber, and 5-10% cementitious layer. The basalt fiber and carbon fiber are interwoven in a warp and weft direction and fixed to the surface of the foamed concrete core layer by the cementitious layer. The preparation method includes the following steps: Step A, mixing and shaping the foamed concrete slurry uniformly in a mold cavity; Step B, clamping the foamed concrete core layer between the inner and outer mixed fiber skeletons; Step C, using a roller to roll and remove air bubbles from the adhesive. This invention has strong complementary mechanical properties, significantly improving crack resistance, lightweight, and outstanding thermal insulation and sound insulation effects. The method is simple and conducive to improving processing efficiency.

Description

Technical Field

[0001] This invention belongs to the field of concrete technology, specifically relating to a basalt fiber and carbon fiber blended structure filled foam concrete and its preparation method. Background Technology

[0002] Prefabricated space capsule buildings are widely used in scenic areas, homestays, camping bases, and emergency housing. Existing prefabricated space capsule buildings mainly consist of steel sheet structures or pure foam concrete structural components. While these can meet the usage requirements, steel sheet structures are not only heavy but also have high corrosion and maintenance costs, resulting in significant subsequent maintenance investment. Pure foam concrete structural components have low tensile strength and are brittle, making them prone to cracking during use and affecting operational stability. Therefore, developing a material that is strong, low-cost, and corrosion-resistant is a technical challenge that needs to be addressed by those skilled in the art. Summary of the Invention

[0003] The purpose of this invention is to provide a basalt fiber and carbon fiber blended structure for filling foam concrete and its preparation method.

[0004] One of the technical solutions to achieve the purpose of this invention is: a basalt fiber and carbon fiber blend structure for filling foamed concrete, comprising a foamed concrete core layer, wherein the outer side of the foamed concrete core layer is covered with a fiber layer;

[0005] The fiber layer comprises the following components by volume percentage: 15-80% basalt fiber, 15-75% carbon fiber, and the remainder being a cementitious layer.

[0006] The basalt fibers and carbon fibers are interwoven in a warp and weft direction and are fixed to the surface of the foamed concrete core layer by a cementitious layer.

[0007] A further preferred embodiment is that the basalt fibers are arranged in the weft direction, and the carbon fibers are arranged in the warp direction;

[0008] Furthermore, the carbon fiber accounts for 60-75% of the volume, the basalt fiber accounts for 15-20% of the volume, and the remainder is a cementitious layer.

[0009] A further preferred embodiment is that the basalt fibers are arranged in the warp direction, and the carbon fibers are arranged in the weft direction;

[0010] Furthermore, the carbon fiber accounts for 60-80% of the volume, the basalt fiber accounts for 10-15% of the volume, and the remainder is a cementitious layer.

[0011] A further preferred embodiment is that the dry density of the foamed concrete core layer is 600~1000 kg / m³, and the compressive strength is ≥5 MPa;

[0012] The basalt fiber is woven basalt fiber with an areal density of 200~400g / ㎡;

[0013] The carbon fiber is plain weave carbon fiber with an areal density of 150~300g / ㎡;

[0014] The gelling layer is a two-component epoxy resin adhesive, and the bond strength between the fiber and the foamed concrete interface after impregnation is ≥1.8MPa.

[0015] The second technical solution to achieve the objective of this invention is: a method for preparing basalt fiber and carbon fiber blended structure filled foam concrete, comprising the following steps:

[0016] Step A: Pour and stir the foamed concrete slurry into the mold cavity to make it evenly mixed, and seal and foam it to form the foamed concrete core layer.

[0017] Step B, the initial setting stage of foamed concrete: an inner layer of basalt fiber and carbon fiber mixed fiber skeleton is laid on the inner side of the foamed concrete core layer, and a cementitious layer is rolled on again. An outer layer of basalt fiber and carbon fiber mixed fiber skeleton is laid on the outer side of the foamed concrete core layer, so that the inner layer of mixed fiber skeleton and the outer layer of mixed fiber skeleton clamp the foamed concrete core layer.

[0018] Step C: After the mixed fiber skeleton is laid, use a roller to roll it out to remove air bubbles in the adhesive, ensuring that the fibers are completely soaked and there are no dry strands.

[0019] A further preferred embodiment is that in step B, the basalt fiber is a 300g / ㎡ woven fabric, the carbon fiber is a 200g / ㎡ plain weave fabric, and the dry density of the foamed concrete core layer is 800kg / m³.

[0020] Compared with the prior art, the present invention has the following positive effects: The present invention has strong complementary mechanical properties, which can greatly improve crack resistance. The high modulus of carbon fiber bears the vertical pressure load, while the high toughness, acid and alkali resistance, and low cost of basalt fiber bear the crack resistance and shear load. The hybrid composite structure completely solves the performance shortcomings of single fiber reinforcement, and the overall bending and crack resistance is increased by more than 45%, eliminating the problem of brittle cracking of foamed concrete from the root.

[0021] Lightweight and with outstanding thermal insulation and soundproofing effects: The main body is made of closed-cell foam concrete, and the overall dry weight is only 1 / 3 of that of traditional steel structure cabins. No additional insulation layer is required, and the thermal insulation, sound insulation and heat insulation performance are excellent.

[0022] High cost-effectiveness and suitable for large-scale applications: The high proportion of carbon fiber in key stress-bearing parts ensures structural strength, and the use of low-cost basalt fiber in the enclosure wall controls the cost. The overall material cost is reduced by more than 50% compared to the full carbon fiber reinforced structure, achieving the optimal balance between performance and cost.

[0023] Weather-resistant and durable, maintenance-free: Basalt fiber and carbon fiber are both rust-free, seawater corrosion-resistant, and UV-resistant, making them suitable for harsh working conditions such as seaside and outdoor open-air environments. Their service life can reach more than 50 years, and no regular anti-corrosion maintenance is required.

[0024] This method is simple and helps to improve processing efficiency and reduce processing difficulty. Detailed Implementation

[0025] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all 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.

[0026] A basalt fiber and carbon fiber blend structure for filling foamed concrete includes a foamed concrete core layer, the outer side of which is covered with a fiber layer.

[0027] The fiber layer comprises the following components by volume percentage: 15-80% basalt fiber, 15-75% carbon fiber, and the remainder being a cementitious layer.

[0028] The basalt fibers and carbon fibers are interwoven in a warp and weft direction and are fixed to the surface of the foamed concrete core layer by a cementitious layer.

[0029] In this embodiment, the basalt fiber is laid in the weft direction, and the carbon fiber is laid in the warp direction; the carbon fiber accounts for 60-75% of the volume, the basalt fiber accounts for 15-20% of the volume, and the remainder is a cementitious layer. In this formulation, the carbon fiber serves as the main load-bearing fiber and is primarily used in vertical bearing plates, such as the bottom or top plates.

[0030] Alternatively, the basalt fiber may be arranged in the warp direction, and the carbon fiber in the weft direction; with the carbon fiber accounting for 60-80% of the volume, the basalt fiber accounting for 10-15%, and the remainder being a cementitious layer. In this formulation, the basalt fiber serves as the main load-bearing fiber, and the carbon fiber is arranged in a discontinuous mesh pattern in the weft direction, primarily for use in the surrounding vertical wall panels.

[0031] The foamed concrete core layer has a dry density of 600~1000 kg / m³ and a compressive strength ≥5 MPa; the basalt fiber is woven basalt fiber with an areal density of 200~400 g / m²; the carbon fiber is plain-weave carbon fiber with an areal density of 150~300 g / m²; the cementing layer is a two-component epoxy resin adhesive, and the bond strength between the fiber and the foamed concrete interface after impregnation is ≥1.8 MPa. In practical applications, other suitable resins can also be selected for the cementing layer according to the application scenario.

[0032] The material in this embodiment has high plasticity and can be made into various boards, blocks, and various irregularly shaped components depending on the application field and application scenario; it can be used as a high-quality thermal insulation material.

[0033] Compared with the prior art, the present invention has the following positive effects: The present invention has strong complementary mechanical properties, which can greatly improve crack resistance. The high modulus of carbon fiber bears the vertical pressure load, while the high toughness, acid and alkali resistance, and low cost of basalt fiber bear the crack resistance and shear load. The hybrid composite structure completely solves the performance shortcomings of single fiber reinforcement, and the overall bending and crack resistance is increased by more than 45%, eliminating the problem of brittle cracking of foamed concrete from the root.

[0034] Lightweight and with outstanding thermal insulation and soundproofing effects: The main body is made of closed-cell foam concrete, and the overall dry weight is only 1 / 3 of that of traditional steel structure cabins. No additional insulation layer is required, and the thermal insulation, sound insulation and heat insulation performance are excellent.

[0035] High cost-effectiveness and suitable for large-scale applications: The high proportion of carbon fiber in key stress-bearing parts ensures structural strength, and the use of low-cost basalt fiber in the enclosure wall controls the cost. The overall material cost is reduced by more than 50% compared to the full carbon fiber reinforced structure, achieving the optimal balance between performance and cost.

[0036] Weather-resistant and durable, maintenance-free: Basalt fiber and carbon fiber are both rust-free, seawater corrosion-resistant, and UV-resistant, making them suitable for harsh working conditions such as seaside and outdoor open-air environments. Their service life can reach more than 50 years, and no regular anti-corrosion maintenance is required.

[0037] A method for preparing basalt fiber and carbon fiber blended structure filled foam concrete includes the following steps:

[0038] Step A: Pour and stir the foamed concrete slurry into the mold cavity to make it evenly mixed, and seal and foam it to form the foamed concrete core layer.

[0039] Step B, the initial setting stage of foamed concrete: an inner layer of basalt fiber and carbon fiber mixed fiber skeleton is laid on the inner side of the foamed concrete core layer, and a cementitious layer is rolled on again. An outer layer of basalt fiber and carbon fiber mixed fiber skeleton is laid on the outer side of the foamed concrete core layer, so that the inner layer of mixed fiber skeleton and the outer layer of mixed fiber skeleton clamp the foamed concrete core layer.

[0040] Step C: After the mixed fiber skeleton is laid, use a roller to roll it out to remove air bubbles in the adhesive, ensuring that the fibers are completely soaked and there are no dry strands.

[0041] In step B, basalt fiber is a 300g / ㎡ woven fabric, and carbon fiber is a 200g / ㎡ plain weave fabric; the dry density of the foamed concrete core layer is 800kg / m³.

[0042] This method is simple and helps to improve processing efficiency and reduce processing difficulty.

[0043] The standard parts used in this embodiment can be purchased directly from the market, and the non-standard structural parts described in the instruction manual can also be processed without any doubt based on existing technical common sense. At the same time, the connection methods of each component adopt mature conventional methods in the existing technology, and the machinery, parts and equipment all adopt conventional models in the existing technology, so they will not be described in detail here.

[0044] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, these obvious variations or modifications derived from the essential spirit of the present invention still fall within the scope of protection of the present invention.

Claims

1. A basalt fiber and carbon fiber blend structure for filling foamed concrete, comprising a foamed concrete core layer, characterized in that: The outer side of the foamed concrete core layer is covered with a fiber layer; The fiber layer comprises the following components by volume percentage: 15-80% basalt fiber, 15-75% carbon fiber, and the remainder being a cementitious layer. The basalt fibers and carbon fibers are interwoven in a warp and weft direction and are fixed to the surface of the foamed concrete core layer by a cementitious layer.

2. The basalt fiber and carbon fiber blend structure for filling foamed concrete according to claim 1, comprising a foamed concrete core layer, characterized in that: The basalt fibers are arranged in the weft direction, and the carbon fibers are arranged in the warp direction; Furthermore, the carbon fiber accounts for 60-75% of the volume, the basalt fiber accounts for 15-20% of the volume, and the remainder is a cementitious layer.

3. The basalt fiber and carbon fiber blend structure for filling foamed concrete according to claim 1, comprising a foamed concrete core layer, characterized in that: The basalt fibers are arranged in the warp direction, and the carbon fibers are arranged in the weft direction; Furthermore, the carbon fiber accounts for 60-80% of the volume, the basalt fiber accounts for 10-15% of the volume, and the remainder is a cementitious layer.

4. The basalt fiber and carbon fiber blend structure for filling foamed concrete according to claim 1, comprising a foamed concrete core layer, characterized in that: The dry density of the foamed concrete core layer is 600~1000 kg / m³, and the compressive strength is ≥5 MPa; The basalt fiber is woven basalt fiber with an areal density of 200~400g / ㎡; The carbon fiber is plain weave carbon fiber with an areal density of 150~300g / ㎡; The gelling layer is a two-component epoxy resin adhesive, and the bond strength between the fiber and the foamed concrete interface after impregnation is ≥1.8MPa.

5. A method for preparing basalt fiber and carbon fiber blended structure filled foam concrete, characterized in that: Includes the following steps: Step A: Pour and stir the foamed concrete slurry into the mold cavity to make it evenly mixed, and seal and foam it to form the foamed concrete core layer. Step B, the initial setting stage of foamed concrete, lays an inner layer of basalt fiber and carbon fiber mixed fiber skeleton on the inner side of the foamed concrete core layer, rolls a cementitious layer again, and lays an outer layer of basalt fiber and carbon fiber mixed fiber skeleton on the outer side of the foamed concrete core layer, so that the inner layer of mixed fiber skeleton and the outer layer of mixed fiber skeleton clamp the foamed concrete core layer. Step C: After the mixed fiber skeleton is laid, use a roller to roll it out to remove air bubbles in the adhesive, ensuring that the fibers are completely soaked and there are no dry strands.

6. The method for preparing basalt fiber and carbon fiber blended structure filled foam concrete according to claim 5, characterized in that: In step B, basalt fiber is a 300g / ㎡ woven fabric, and carbon fiber is a 200g / ㎡ plain weave fabric; the dry density of the foamed concrete core layer is 800kg / m³.