CN112940476A - 一种新型复合井盖及其制备方法 - Google Patents
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Abstract
本申请涉及井盖领域,具体公开了一种新型复合井盖及其制备方法。新型复合井盖包括钢筋骨架和新型复合材料,所述新型复合材料主要由以下重量份数的原料组成:80‑100份不饱和聚酯树脂,5‑10份填料,2‑5份聚苯乙烯,5‑8份ABS树脂,0.2‑0.6份固化剂,20‑30份玻璃纤维,3‑7份钢纤维,0.1‑0.5份促进剂,0.3‑0.7份硬脂酸锌,0.1‑0.5份抗氧化剂;其制备方法为:按比例称取各原料并经熔融共混挤出切粒,再经加热模压成型,冷却固化得到新型复合井盖。本申请的新型复合井盖具有不易损坏的优点。
Description
技术领域
本申请涉及井盖领域,更具体地说,它涉及一种新型复合井盖及其制备方法。
背景技术
井盖按照制造材质可分为铸铁井盖、钢筋混凝土井盖和树脂基复合材料井盖。铸铁井盖具有承载力强、温度适应性好、成型简便和使用寿命长的优点,但是铸铁井盖具有不耐冲击、容易发生腐蚀、车辆行驶时噪音大、回收价值高而容易造成丢失的缺点。钢筋混凝土井盖的回收价值低于铸铁井盖,不易丢失,制造成本也低于铸铁井盖,但是钢筋混凝土井盖具有抗震性差、制造工艺困难、容易发生断裂、井盖重量过大导致一个人开启困难等缺陷。
树脂基复合材料井盖具有质量轻、耐腐蚀、噪声低、无任何回收价值等优点,同时解决了铸铁井盖回收价值高易丢失和钢筋混凝土井盖抗震性差、重量过大的问题。但是因为材料的原因,在一定程度上,其强度和使用寿命会受到影响,在车辆反复碾压和风吹雨淋作用下容易造成损坏。
发明内容
为了改善树脂基复合材料井盖在车辆反复碾压和风吹雨淋作用下容易发生损坏的问题,本申请提供一种新型复合井盖及其制备方法。
第一方面,本申请提供一种新型复合井盖,采用如下的技术方案:
一种新型复合井盖,所述新型复合井盖包括钢筋骨架和新型复合材料,所述新型复合材料主要由以下重量份数的原料组成:80-100份不饱和聚酯树脂,5-10份填料,2-5份聚苯乙烯,5-8份ABS树脂0.2-0.6份固化剂,20-30份玻璃纤维,3-7份钢纤维,0.1-0.5份促进剂,0.3-0.7份硬脂酸锌,0.1-0.5份抗氧化剂。
通过采用上述技术方案,由于采用不饱和聚酯树脂和ABS树脂的复合树脂体系,该复合树脂体系具有耐介质、耐磨性和尺寸稳定性等优点,使制得的新型复合井盖具有高耐冲击强度、高耐压强度等优点,能够在车辆反复碾压和风吹雨淋作用下也不容易发生损坏。
同时聚苯乙烯的添加,使新型复合井盖具有噪声低的特点,且进一步提高了新型复合井盖的耐腐蚀性能,从而延长新型复合井盖的使用寿命。
优选的,所述填料为碳酸钙、二氧化硅、粉煤灰中的其中一种或两种以上的混合物。
通过采用上述技术方案,填料作为无机粒子,添加后能够提高新型复合材料的结构强度。
其中粉煤灰的添加,既能够降低不饱和聚酯树脂的体积收缩率,还能够提高新型复合材料的刚性和硬度。但粉煤灰的添加量不宜过多,过多粉煤灰的添加会对纤维的浸润,纤维、树脂和填料三者之间界面的形成有很大影响,且粉煤灰不易在不饱和聚酯树脂内分散均匀。
优选的,所述新型复合材料还包括2-5份泡沫铝材料。
通过采用上述技术方案,泡沫铝材料的多孔结构使其具有缓冲吸能的特性,降低了车辆驶过新型复合井盖后造成的噪声。
优选的,所述钢纤维的长度为5-10mm。
通过采用上述技术方案,5-10mm的钢纤维能够均匀分布在不饱和聚酯树脂体系内。若长度小于5mm,则钢纤维容易发生堆积现象,导致制得的新型复合材料性能不均衡;若长度大于10mm,钢纤维无法均布在不饱和聚酯树脂体系中,导致制得的新型复合材料性能不均衡。
优选的,所述钢纤维通过酸处理。
通过采用上述技术方案,钢纤维经酸处理后,其抗压强度和抗冲击强度有所提高,同时其与树脂之间的连接强度也有所提高。
优选的,所述酸处理包括将钢纤维浸泡在浓度为1mol/L的硫酸中18-24h,清洗并干燥后得到酸刻蚀改性纤维。
通过采用上述技术方案,钢纤维经过充分的酸处理后性能均衡。若硫酸的浓度低于1mol/L,则需要延长浸泡时间。
优选的,所述固化剂为过氧化苯甲酸叔丁酯、过苯甲酸叔丁酯、过氧化甲乙酮中的其中一种。
通过采用上述技术方案,过氧化苯甲酸叔丁酯、过苯甲酸叔丁酯和过氧化甲乙酮均能够使不饱和聚酯树脂固化。
其中,过氧化甲乙酮在不饱和聚酯树脂生产中用作催化剂,是最安全的过氧化物,固化能够在常温下进行。
优选的,所述促进剂为异辛酸钴。
通过采用上述技术方案,异辛酸钴对不饱和聚酯树脂固化具有促进作用,能够提高不饱和聚酯树脂的固化速度,从缩短固化所需时间。且异辛酸钴较传统环烷酸钴而言,具有气味小,催干效果好等优点。
第二方面,本申请提供一种新型复合井盖的制备方法,采用如下的技术方案:
一种新型复合井盖的制备方法,包括如下制备步骤:
S1、按比例称取各原料并经熔融共混挤出切粒,得到粒料;
S2、粒料经加热模压成型,冷却固化得到新型复合井盖。
通过采用上述技术方案,上述新型复合井盖的制备过程非常简单,成品率高且回收价值低不易丢失,尺寸稳定性好。
模压成型能够克服原料中挥发物产生的蒸汽压,避免新型复合井盖产生气泡、分层、机构松散等缺陷。同时也可以增加原料的流动性,便于原料充满模具型腔的各个角落,使新型复合井盖结构密实,机械强度提高。
综上所述,本申请具有以下有益效果:
1、由于本申请采用不饱和聚酯树脂和ABS树脂的复合树脂体系,且添加有聚苯乙烯,使制得的新型复合井盖具有高耐冲击强度、高耐压强度的优点,且在车辆反复碾压和风吹雨淋作用下也不容易发生损坏;
2、本申请中优选采用泡沫铝材料,由于泡沫铝材料具有多孔结构,使其具有缓冲吸能的特性,从而使新型复合井盖具有噪声低的优点;
3、本申请中优选钢纤维经过酸处理,钢纤维经过酸处理后,抗压强度和抗冲击强度得到提升,从而提高了新型复合井盖的抗压强度和抗冲击强度;
4、本申请的方法,具有制备过程简单,成品率高等优点,制得的新型复合井盖具有结构密实、机械强度高的优点。
具体实施方式
以下结合实施例对本申请作进一步详细说明。
钢纤维的制备例
将5-10mm的钢纤维进行酸处理,包括将钢纤维浸泡在浓度为1mol/L的硫酸中18-24h,浸泡完毕后进行清洗并干燥。
实施例
实施例1
一种新型复合井盖的制备方法,包括如下制备步骤:
S1、称取80-100份不饱和聚酯树脂,5-10份填料,2-5份苯乙烯,0.2-0.6份固化剂,20-30份玻璃纤维,3-7份制备例中制得的钢纤维,0.1-0.5份促进剂,0.3-0.7份硬脂酸锌;
S2、将S1中除促进剂之外的各原料混合均匀,再加入促进剂搅拌混合均匀后经熔融挤出切粒,得到粒料;
S3、将粒料经加热模压成型,冷却固化得到新型复合井盖。
实施例2-6
实施例2-6中新型复合井盖的制备方法与实施例相同,区别仅在于原料组分及用量不同,具体如表1所示。
表1 实施例1-6中新型复合材料的原料组分及用量
实施例7
本实施例中新型复合井盖的制备方法与实施例1相同,区别仅在于固化剂为过苯甲酸叔丁酯,添加量为0.4份,其余组分及用量与实施例1相同。
实施例8
本实施例中新型复合井盖的制备方法与实施例1相同,区别仅在于固化剂为过氧化甲乙酮,添加量为0.4份,其余组分及用量与实施例1相同。
实施例9
本实施例中新型复合井盖的制备方法与实施例1相同,区别仅在于填料仅为3份碳酸钙和2份二氧化硅,其余组分及用量与实施例1相同。
实施例10
本实施例中新型复合井盖的制备方法与实施例1相同,区别仅在于填料仅为2份粉煤灰和2份二氧化硅,其余组分及用量与实施例1相同。
实施例11
本实施例中新型复合井盖的制备方法与实施例1相同,区别仅在于填料仅为3份碳酸钙和2份粉煤灰,其余组分及用量与实施例1相同。
实施例12
本实施例中新型复合井盖的制备方法与实施例1相同,区别仅在于填料仅为3份碳酸钙,其余组分及用量与实施例1相同。
实施例13
本实施例中新型复合井盖的制备方法与实施例1相同,区别仅在于填料仅为2份二氧化硅,其余组分及用量与实施例1相同。
实施例14
本实施例中新型复合井盖的制备方法与实施例1相同,区别仅在于填料仅为2份粉煤灰,其余组分及用量与实施例1相同。
对比例
对比例1
本对比例中新型复合井盖的制备方法与实施例1相同,区别仅在于钢纤维不经过酸处理,其余组分及用量与实施例1相同。
性能检测试验
抗压强度:按照GBJ81-1985抗压强度及抗折强度试验标准;
抗冲击强度:按照GB/T 1043--1993硬质塑料简支梁冲击试验方法;
耐介质性:分别用质量浓度为2%的盐酸和NaOH溶液以及水对新型复合井盖进行耐介质性测试,观察是否发生变形、膨胀、龟裂的现象。
表2 实施例1-14和对比例1的测试结果
结合实施例1-3并结合表2可以看出,本申请制得的新型复合井盖具有良好的抗压和抗冲击性能,从而新型复合井盖在使用过程中被车辆反复碾压和风吹雨淋作用下也不易发生损坏。
结合实施例1和实施例4-6并结合表2可以看出,实施例4-6中新型复合井盖产生的噪声均低于实施例1中新型复合井盖产生的噪声,说明泡沫铝材料的添加有利于降低噪声。同时,泡沫铝材料的添加有利于提高新型复合井盖的抗冲击强度。
其原因可能在于:泡沫铝材料具有多孔结构使其具有缓冲吸能的特性,从而降低汽车驶过新型复合井盖的噪声。
结合实施例1和实施例7-8并结合表2可以看出,过氧化苯甲酸叔丁酯、过苯甲酸叔丁酯、过氧化甲乙酮均具有良好的固化效果。
结合实施例1和实施例9-14并结合表2可以看出,填料的添加能够提高新型复合井盖的抗压强度和抗冲击强度,且单一添加一种填料对新型复合井盖的抗压强度和抗冲击强度的提升效果不明显。
结合实施例1和对比例1并结合表2可以看出,对比例1中新型复合井盖的抗压强度和抗冲击强度均小于实施例1中新型复合井盖的抗压强度和抗冲击强度,说明钢纤维经酸处理后提高了抗压强度和抗冲击强度。
本申请制得的新型复合井盖压面平整,无裂纹,无影响使用性能的局部凸凹缺陷,车辆驶过时平衡无跳动、无噪音。
本具体实施例仅仅是对本申请的解释,其并不是对本申请的限制,本领域技术人员在阅读完本说明书后可以根据需要对本实施例做出没有创造性贡献的修改,但只要在本申请的权利要求范围内都受到专利法的保护。
Claims (9)
1.一种新型复合井盖,其特征在于,所述新型复合井盖包括钢筋骨架和新型复合材料,所述新型复合材料主要由以下重量份数的原料组成:80-100份不饱和聚酯树脂,5-10份填料,2-5份聚苯乙烯,5-8份ABS树脂0.2-0.6份固化剂,20-30份玻璃纤维,3-7份钢纤维,0.1-0.5份促进剂,0.3-0.7份硬脂酸锌,0.1-0.5份抗氧化剂。
2.根据权利要求1所述的一种新型复合井盖,其特征在于:所述填料为碳酸钙、二氧化硅、粉煤灰中的其中一种或两种以上的混合物。
3.根据权利要求1所述的一种新型复合井盖,其特征在于:所述新型复合材料还包括2-5份泡沫铝材料。
4.根据权利要求1所述的一种新型复合井盖,其特征在于:所述钢纤维的长度为5-10mm。
5.根据权利要求4所述的一种新型复合井盖,其特征在于:所述钢纤维通过酸处理。
6.根据权利要求5所述的一种新型复合井盖,其特征在于:所述酸处理包括将钢纤维浸泡在浓度为1mol/L的硫酸中18-24h,清洗并干燥。
7.根据权利要求1所述的一种新型复合井盖,其特征在于:所述固化剂为过氧化苯甲酸叔丁酯、过苯甲酸叔丁酯、过氧化甲乙酮中的其中一种。
8.根据权利要求1所述的一种新型复合井盖,其特征在于:所述促进剂为异辛酸钴。
9.如权利要求1-8任一项所述的一种新型复合井盖的制备方法,其特征在于,包括如下制备步骤:
S1、按比例称取各原料并经熔融共混挤出切粒,得到粒料;
S2、粒料经加热模压成型,冷却固化得到新型复合井盖。
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