Anti-corrosion light basalt fiber composite rib used in marine building field

Abstract

The utility model relates to the field of basalt fiber composite rebars, in particular to an anti-corrosion light basalt fiber composite rebar used in the marine building field, which comprises a plastic inner core and a basalt fiber outer cylinder, the basalt fiber outer cylinder is sleeved outside the plastic inner core, and the basalt fiber outer cylinder is formed by mixing basalt fibers and resin. And the resin is mixed and solidified to form a hard structure. The basalt fiber composite bar has the effect of reducing the density of the basalt fiber composite bar.

Description

Technical Field

[0001] This application relates to the field of basalt fiber composite reinforcement, and more particularly to a corrosion-resistant lightweight basalt fiber composite reinforcement for use in marine construction. Background Technology

[0002] With the rapid development of my country's marine economy and the significant improvement in the supporting capacity of major marine science and technology infrastructure, comprehensive benefits are increasing daily. Marine infrastructure plays an irreplaceable role in marine resource development, marine economic development, marine ecological environment protection, and safeguarding national maritime rights. However, corrosion prevention of ships and marine engineering facilities has become a critical issue that urgently needs to be addressed in development. Because they are exposed to the high salinity of the marine environment for extended periods, corrosion is extremely severe, leading to structural damage and destruction, resulting in frequent losses of property and even lives.

[0003] To improve the corrosion resistance of structural components in marine environments, basalt fiber composite bars and glass fiber composite bars can be applied to marine infrastructure. Basalt fiber composite bars have superior structural strength; when incorporated into cement mortar to replace steel bars, they can enhance the structural strength of the concrete structure after the cement mortar has hardened.

[0004] The aforementioned technical solutions have the following drawbacks: the density of basalt fiber composite reinforcement is relatively high, and the overall weight of the structural components is relatively large after being placed in concrete, causing inconvenience in design and use in actual construction. Utility Model Content

[0005] In order to reduce the density of basalt fiber composite reinforcement, this application provides a corrosion-resistant lightweight basalt fiber composite reinforcement for use in marine construction.

[0006] This application provides a corrosion-resistant lightweight basalt fiber composite reinforcement for marine construction, employing the following technical solution:

[0007] A corrosion-resistant lightweight basalt fiber composite reinforcement for marine construction includes a plastic inner core and a basalt fiber outer cylinder. The basalt fiber outer cylinder is fitted over the plastic inner core. The basalt fiber outer cylinder is made by mixing basalt fiber and resin. After the resin mixture solidifies, it forms a rigid structure.

[0008] By adopting the above technical solution, the basalt fiber composite reinforcement consists of four layers, from the inside out: a plastic inner core, a longitudinal fiber layer, a fabric covering layer, and a basalt sand outer layer. The plastic inner core, along with the longitudinal fiber layer, fabric covering layer, and basalt sand outer layer surrounding it, are heat-cured and formed using a resin matrix through a pultrusion mold. The plastic inner core and the basalt fiber outer cylinder together form the composite reinforcement. The plastic inner core has a lower density, which reduces the overall density of the composite reinforcement, thus making it lighter. The basalt fiber outer cylinder provides structural strength, resulting in strong compressive and shear resistance. When the composite reinforcement is placed in cement mortar, the structural component formed by the solidification of the cement mortar is supported by the composite reinforcement, exhibiting better structural strength and reduced overall weight, thus broadening its application scenarios.

[0009] Optionally, the basalt fiber outer cylinder includes a longitudinal fiber layer, a fabric layer, and a basalt sand outer layer. The longitudinal fiber layer is wrapped around the plastic inner core, the fabric layer is wrapped around the longitudinal fiber layer, and the basalt sand outer layer is placed outside the fabric layer. The basalt sand outer layer is formed by mixing and curing basalt sand and resin. The longitudinal fiber layer, the fabric layer, and the basalt sand are mixed with resin and solidified to form a rigid structure.

[0010] By adopting the above technical solution, the plastic core is wrapped with fabric, which is then mixed with resin and solidified to form a longitudinal fiber layer and a fabric covering layer. This results in continuous and complete fabric in the longitudinal fiber layer and the fabric covering layer, improving their shear resistance. When the composite reinforcement is subjected to transverse shear force, the transverse shear force needs to break the fabric in the longitudinal fiber layer and the fabric covering layer to cut the composite reinforcement, thus improving the structural strength of the composite reinforcement.

[0011] Optionally, the composite volume ratio of the fiber longitudinal layer, the fabric layer, the basalt sand outer layer and the plastic inner core is (3-5):(2-4):(1-2):1.

[0012] By adopting the above technical solution, the plastic core, the longitudinal fiber layer, the cloth layer, and the outer basalt sand layer are coaxially arranged. When the cross-sectional diameter of the plastic core is too small, the overall weight of the composite reinforcement is large, which is inconvenient to use. When the cross-sectional diameter of the plastic core is too large, the proportion of the longitudinal fiber layer, the cloth layer, and the outer basalt sand layer that bear the stress is too small, and the overall structural strength of the composite reinforcement is poor.

[0013] Optionally, the plastic core is configured as a flexible solid rod.

[0014] By adopting the above technical solution, the plastic core is made into a flexible rod, giving it a certain deformation capacity. When the plastic core is wrapped with fabric and absorbs resin, the resin volume may expand during the process of solidifying to form a longitudinal fiber layer, a fabric layer, and a basalt sand outer layer. This allows the plastic core to deform and adapt to the longitudinal fiber layer, the fabric layer, and the basalt sand outer layer, reducing the internal stress between the plastic core and the solidified longitudinal fiber layer.

[0015] Optionally, the surface of the plastic inner core is provided with coarse threads.

[0016] By adopting the above technical solution, and by opening threads on the outer surface of the plastic core, when the outer side of the plastic core is wrapped with fabric and forms a longitudinal fiber layer, the friction between the longitudinal fiber layer and the plastic core is greater, thereby making the overall structural strength and structural stability of the composite rib better.

[0017] Optionally, the longitudinal fiber layer is configured as basalt untwisted yarn.

[0018] By adopting the above technical solution, the plastic inner core is wrapped with untwisted yarn. The untwisted yarn has better flexibility and can fit on the outside of the small plastic inner core. The untwisted yarn has better water absorption and can absorb more resin. When the resin solidifies, there are fewer cavities and micropores in the longitudinal layer of the fiber, resulting in better structural strength.

[0019] Optionally, the fiber fabric of the covering layer is plain weave fabric, and the weight of the covering layer is 100-200g / ㎡.

[0020] By adopting the above technical solution, the covering layer is made of plain weave fabric. Plain weave fabric has a firm texture, a smooth surface, and good wear resistance, which can improve the structural strength and surface quality of the covering layer.

[0021] Optionally, the basalt sand has an average mesh size of 120-150 mesh.

[0022] By adopting the above technical solution, the outer layer of basalt sand is made by using fine basalt sand particles. The basalt sand outer layer formed after the basalt sand and resin are mixed and solidified has better wear resistance. The outer layer of basalt sand is the outermost part of the composite reinforcement and is in direct contact with the concrete. It can protect the longitudinal fiber layer and the wrapping layer, reduce the wear of the longitudinal fiber layer, the wrapping layer and the plastic core with the concrete, and improve the service life of the composite reinforcement in the concrete.

[0023] In summary, the beneficial technical effects of this application are as follows:

[0024] 1. By using a composite reinforcement consisting of a plastic inner core, a longitudinal fiber layer, a fabric covering layer, and a basalt sand outer layer, arranged from the inside out, the resin matrix heats and cures the plastic inner core and the surrounding longitudinal fiber layer, fabric covering layer, and basalt sand outer layer through a pultrusion mold. This achieves the effect of reducing the weight of the composite reinforcement while maintaining its strength. The plastic inner core has a lower density, which reduces the overall density of the composite reinforcement, thus making it lighter. The basalt fiber outer cylinder provides structural strength, resulting in strong overall compressive and shear resistance. When the composite reinforcement is placed in water... After cement mortar solidifies, the structural components formed by the cement mortar are supported by composite reinforcement, which has better structural strength, reduces the overall weight of the structural components, and makes them more widely applicable; 2. By wrapping the plastic core with fabric, the fabric is mixed with resin and solidified to form a fiber longitudinal layer and a fabric wrapping layer. This results in continuous and complete fabric in the fiber longitudinal layer and the fabric wrapping layer, which improves the shear resistance of the fiber longitudinal layer and the fabric wrapping layer. When the composite reinforcement is subjected to transverse shear force, the transverse shear force needs to break the fabric in the fiber longitudinal layer and the fabric wrapping layer before the composite reinforcement can be cut, thus improving the structural strength of the composite reinforcement;

[0025] 3. By making the plastic core a flexible rod, the plastic core has a certain deformation capacity. When the plastic core is wrapped with fabric and absorbs resin, the resin volume may expand during the process of solidifying to form the longitudinal fiber layer, the fabric layer and the basalt sand outer layer. This allows the plastic core to deform and adapt to the longitudinal fiber layer, the fabric layer and the basalt sand outer layer, reducing the internal stress between the plastic core and the solidified longitudinal fiber layer. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of an embodiment of this application.

[0027] Figure 2 This is a cross-sectional schematic diagram of an embodiment of this application.

[0028] Reference numerals: 1. Plastic inner core; 2. Fiber longitudinal layer; 3. Fabric covering layer; 4. Basalt sand outer layer. Detailed Implementation

[0029] The present application will be further described in detail below with reference to the accompanying drawings.

[0030] This application discloses a corrosion-resistant lightweight basalt fiber composite reinforcement for use in marine construction, referring to... Figure 1 and Figure 2The composite reinforcement consists of a plastic inner core 1, a longitudinal fiber layer 2, a fabric layer 3, and a basalt sand outer layer 4. The plastic inner core 1 is a cylindrical rod structure. The longitudinal fiber layer 2 wraps around the plastic inner core 1, the fabric layer 3 wraps around the longitudinal fiber layer 2, and the basalt sand outer layer 4 is positioned outside the fabric layer 3. The plastic inner core 1, longitudinal fiber layer 2, fabric layer 3, and basalt sand outer layer 4 are coaxially arranged to form a composite reinforcement, thereby giving the composite reinforcement better structural strength and corrosion resistance. The plastic inner core 1, longitudinal fiber layer 2, fabric layer 3, and basalt sand outer layer 4 are all immersed in resin. The longitudinal fiber layer 2, fabric layer 3, and basalt sand outer layer 4 are then molded by resin impregnation and heating in a pultrusion mold. After the longitudinal fiber layer 2, fabric layer 3, and basalt sand outer layer 4 are mixed and molded with resin, the longitudinal fiber layer 2 and fabric layer 3 have better shear strength, while the basalt sand outer layer 4 enhances the wear resistance and corrosion resistance of the composite reinforcement. The composite volume ratio of the longitudinal fiber layer 2, the fabric layer 3, the basalt sand outer layer 4, and the plastic inner core 1 is (3-5):(2-4):(1-2):1, with the resin matrix accounting for 18%-28% of the total volume of the composite reinforcement. The resin used to make the composite reinforcement is vinyl ester resin, which has been modified using basalt fiber micropowder with a diameter of 50-100 μm. This micropowder modification technology blocks the resin micropores, preventing the entry of alkaline substances and improving the material's corrosion resistance. After the vinyl ester resin is modified, the addition of the modified micropowder adds a bridging channel, which serves as a carrier connecting the fiber and resin, maximizing the overall strength of the interface and maintaining its consistency.

[0031] Reference Figure 1 and Figure 2 The plastic core 1 is a flexible solid PP or PE rod. PP is made of polypropylene, and PE is made of polyethylene. The plastic core 1 has excellent wear resistance and corrosion resistance. It provides structural strength to the longitudinal fiber layer 2 and the fabric layer 3, thus extending the service life of the composite rib. The surface of the plastic core 1 has coarse threads. When the longitudinal fiber layer 2 wraps around the outer surface of the plastic core 1, the friction between the longitudinal fiber layer 2 and the plastic core 1 is greater, thereby improving the interfacial strength between the plastic core 1 and the longitudinal fiber layer 2. The diameter of the plastic core 1 is 1-2 mm.

[0032] Reference Figure 1 The longitudinal layer 2 of the fiber is set as basalt untwisted yarn with a linear density of 2400 tex and a single filament diameter of 16 μm. The sizing agent is water-based epoxy.

[0033] In other embodiments, glass fiber, carbon fiber, or aramid fiber can be used instead of basalt untwisted yarn. Glass fiber has better insulation, heat resistance, and corrosion resistance; carbon fiber has excellent heat resistance, good friction resistance, and good corrosion resistance; and aramid fiber has better high-temperature resistance and chemical corrosion resistance. By using the above fibers mixed with modified phenolic resin and cured to form a composite profile, the composite profile can have better corrosion resistance and structural strength, and has stable structural performance in harsh environments such as at sea.

[0034] Reference Figure 1 The fiber cloth type of the covering layer 3 is plain weave or twill weave, preferably plain weave. The weight of the covering layer 3 is 100-200g / ㎡. The covering layer 3 can effectively balance the unbalanced loads in the longitudinal and transverse directions, thereby making the tensile strength and shear strength of the product more consistent.

[0035] Reference Figure 1 and Figure 2 The outer layer 4 of basalt sand is made of basalt sand with an average mesh size of 120-150 mesh. The consistency between basalt sand and basalt fiber is good, and the interfacial bonding force is strong, which can effectively ensure the comprehensive mechanical properties of basalt fiber composite reinforcement. When the composite reinforcement is manufactured, the outer surface of the composite reinforcement is the outer layer 4 of basalt sand, which improves the friction between the composite reinforcement and concrete.

[0036] This application discloses a production process for corrosion-resistant lightweight basalt fiber composite reinforcement for marine construction, including the following steps:

[0037] The basalt fiber composite reinforcement consists of four layers, from the inside out: a plastic inner core 1, a longitudinal fiber layer 2, a fabric layer 3, and a basalt sand outer layer 4. The plastic inner core 1, the longitudinal fiber layer 2, the fabric layer 3, and the basalt sand outer layer 4 surrounding the plastic inner core 1 are formed by heating and curing in a pultrusion mold using a resin matrix.

[0038] Example 1

[0039] In the pultrusion die heating and curing process, the pultrusion speed is 610 mm / min, the traction force is 0.5 t, the pressure is 1.0 MPa, and the temperature is 120℃.

[0040] The composite volume ratio of the above-mentioned longitudinal fiber layer 2, cloth layer 3, basalt sand outer layer 4 and plastic inner core 1 is 5:4:2:1, and the volume of the resin matrix accounts for 25% of the total volume of the corrosion-resistant lightweight basalt fiber composite reinforcement used in marine construction.

[0041] The plastic core 1 is made of flexible PP or PE solid rod, is white in color, has coarse threads on the surface, has a diameter of 2mm, and needs to be pre-impregnated with resin matrix for 30s before use.

[0042] The fibers used in the longitudinal layer 2 are basalt untwisted yarns with a linear density of 2400 tex and a single filament diameter of 16 μm. The sizing agent is a water-based epoxy type.

[0043] The fiber fabric of the covering layer 3 is plain weave fabric with a weight of 150g / ㎡.

[0044] The sand used in the sand layer is fine basalt sand with an average mesh size of 140 mesh.

[0045] The resin is a vinyl ester resin modified with basalt fiber micropowder, and the micropowder has a diameter of 50-100 μm.

[0046] Example 2

[0047] In the pultrusion die heating and curing process, the pultrusion speed is 610 mm / min, the traction force is 0.5 t, the pressure is 1.0 MPa, and the temperature is 120℃.

[0048] The composite volume ratio of the aforementioned longitudinal fiber layer 2, fabric layer 3, basalt sand outer layer 4, and plastic inner core 1 is 5:4:1:1, and the volume of the resin matrix accounts for 25% of the total volume of the corrosion-resistant lightweight basalt fiber composite reinforcement used in marine construction.

[0049] The plastic core 1 is made of flexible PP or PE solid rod, is white in color, has coarse threads on the surface, has a diameter of 2mm, and needs to be pre-impregnated with resin matrix for 30s before use.

[0050] The fibers used in the longitudinal layer 2 are basalt untwisted yarns with a linear density of 2400 tex and a single filament diameter of 16 μm. The sizing agent is a water-based epoxy type.

[0051] The fiber fabric of the covering layer 3 is plain weave fabric with a weight of 150g / ㎡.

[0052] The sand used in the sand layer is fine basalt sand with an average mesh size of 140 mesh.

[0053] The resin is a vinyl ester resin modified with basalt fiber micropowder, and the micropowder has a diameter of 50-100 μm.

[0054] Example 3

[0055] In the pultrusion die heating and curing process, the pultrusion speed is 610 mm / min, the traction force is 0.5 t, the pressure is 1.0 MPa, and the temperature is 120℃.

[0056] The composite volume ratio of the above-mentioned longitudinal fiber layer 2, the cloth layer 3, the basalt sand outer layer 4, and the plastic inner core 1 is 4:3:1:1, and the volume of the resin matrix accounts for 25% of the total volume of the corrosion-resistant lightweight basalt fiber composite reinforcement used in marine construction.

[0057] The plastic core 1 is made of flexible PP or PE solid rod, is white in color, has coarse threads on the surface, has a diameter of 2mm, and needs to be pre-impregnated with resin matrix for 30s before use.

[0058] The fibers used in the longitudinal layer 2 are basalt untwisted yarns with a linear density of 2400 tex and a single filament diameter of 16 μm. The sizing agent is a water-based epoxy type.

[0059] The fiber fabric of the covering layer 3 is plain weave fabric with a weight of 150g / ㎡.

[0060] The sand used in the sand layer is fine basalt sand with an average mesh size of 140 mesh.

[0061] The resin is a vinyl ester resin modified with basalt fiber micropowder, and the micropowder has a diameter of 50-100 μm.

[0062] Example 4

[0063] In the pultrusion die heating and curing process, the pultrusion speed is 610 mm / min, the traction force is 0.5 t, the pressure is 1.0 MPa, and the temperature is 120℃.

[0064] The composite volume ratio of the above-mentioned longitudinal fiber layer 2, cloth layer 3, basalt sand outer layer 4 and plastic inner core 1 is 3:2:1:1, and the volume of the resin matrix accounts for 25% of the total volume of the corrosion-resistant lightweight basalt fiber composite reinforcement used in marine construction.

[0065] The plastic core 1 is made of flexible PP or PE solid rod, is white in color, has coarse threads on the surface, has a diameter of 2mm, and needs to be pre-impregnated with resin matrix for 30s before use.

[0066] The fibers used in the longitudinal layer 2 are basalt untwisted yarns with a linear density of 2400 tex and a single filament diameter of 16 μm. The sizing agent is a water-based epoxy type.

[0067] The fiber fabric of the covering layer 3 is plain weave fabric with a weight of 150g / ㎡.

[0068] The sand used in the sand layer is fine basalt sand with an average mesh size of 140 mesh.

[0069] The resin is a vinyl ester resin modified with basalt fiber micropowder, the micropowder having a diameter of 50–100 μm.

[0070]

[0071]

[0072] In summary, the basalt fiber composite reinforcement prepared according to the technical solution described in Example 1 has superior performance.

[0073] The implementation principle of this application embodiment is as follows: by wrapping the plastic inner core 1 with a longitudinal fiber layer 2 and a fabric layer 3, the plastic inner core 1 supports the longitudinal fiber layer 2 and the fabric layer 3, forming a cylindrical structure. By setting a basalt sand outer layer 4 outside the fabric layer 3 and impregnating the longitudinal fiber layer 2, the fabric layer 3, and the basalt sand outer layer 4 with resin, the longitudinal fiber layer 2, the fabric layer 3, and the basalt sand outer layer 4 are mixed in the resin and cured to form a rigid structure, thereby giving the composite reinforcement better structural strength. The longitudinal fiber layer 2 and the fabric layer 3 give the composite reinforcement better shear resistance, and the basalt sand outer layer 4 gives the composite reinforcement better wear resistance and corrosion resistance.

[0074] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A corrosion-resistant lightweight basalt fiber composite rebar for use in marine construction, characterized in that: The basalt fiber outer cylinder includes a longitudinal fiber layer (2), a fabric layer (3), and a basalt sand outer layer (4). The longitudinal fiber layer (2) is wrapped around the plastic inner core (1), the fabric layer (3) is wrapped around the longitudinal fiber layer (2), and the basalt sand outer layer (4) is placed outside the fabric layer (3). The longitudinal fiber layer (2) and the fabric layer (3) are formed by mixing and curing fabric and resin to form a rigid structure. The basalt sand outer layer (4) is formed by mixing and curing basalt sand and resin. The longitudinal fiber layer (2), the fabric layer (3), and the basalt sand are mixed with resin and solidified to form a rigid structure.

2. The corrosion-resistant lightweight basalt fiber composite reinforcement for marine construction as described in claim 1, characterized in that: The composite volume ratio of the fiber longitudinal layer (2), the fabric layer (3), the basalt sand outer layer (4), and the plastic inner core (1) is (3-5):(2-4):(1-2):

1.

3. The corrosion-resistant lightweight basalt fiber composite reinforcement for marine construction as described in claim 2, characterized in that: The plastic inner core (1) is configured as a flexible solid rod.

4. The corrosion-resistant lightweight basalt fiber composite reinforcement for marine construction as described in claim 1, characterized in that: The surface of the plastic inner core (1) is provided with coarse threads.

5. The corrosion-resistant lightweight basalt fiber composite reinforcement for marine construction as described in claim 1, characterized in that: The longitudinal fiber layer (2) is set as basalt untwisted yarn.

6. The corrosion-resistant lightweight basalt fiber composite reinforcement for marine construction as described in claim 1, characterized in that: The fiber cloth type of the covering layer (3) is plain weave fabric, and the weight of the covering layer (3) is 100-200g / ㎡.

7. The corrosion-resistant lightweight basalt fiber composite reinforcement for marine construction as described in claim 1, characterized in that: The average mesh size of the basalt sand is 120-150 mesh.

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