CN113978044B - 一种缝合加筋复合防排水板及其制备方法 - Google Patents
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Abstract
本发明公开了一种缝合加筋复合防排水板，上层复合至少一层土工布的防排水板，其中一层土工布外侧连接加筋层，加筋层为由经线、纬线交织组成的网格结构，经线和纬线固定连接。本发明的有益效果为：该防排水板结构简单，通过土工布层固定加筋层，增强了排水板的强度，且不易变形，对下层的排水板进行了充分的保护，此外排水板不仅可以起到导排水的效果，也增强了复合防排水板整体的强度。土工布层和加筋层连接牢固，由于加筋层的经线和纬线牢固的固定在土工布层，不会出现滑动而导致加筋层的网格出现漏洞，同时也提高了复合防排水板复合体的抗拉强度，抵抗塑性形变的能力得到加强。
Description
技术领域：
本发明涉及建筑工程施工技术领域，具体而言，涉及一种高强防排水板的缝合加筋复合排水板的制备方法。
背景技术：
1、针刺土工布与排水板的复合产品(以下简称防排水板)，在上表面覆土或承压后易产生土工布的塌陷，会减小或堵塞原有的排水板导排水空间，导致排水截面积和纵向排水量指标降低，严重时甚至会导致排水不畅，导排水作用失效。
2、防排水板力学性能较低，在边坡施工或其他高载荷作用下，易产生材料破坏，造成土体失稳。经过加筋后的防排水板，拉伸、撕裂以及顶破等力学性能得到显著提高，增强了材料的抗形变、抗破坏能力，最终提高了工程系统的整体稳定性和安全性。
3、在施工或运输过程中，防排水板的针刺土工布层易被土石块等尖锐物刺破，从而导致上层砂石粒料进入到下层的排水板，最终淤塞排水通道，使排水层的导排水功能失效。经过加筋复合后的防排水板抗穿刺能力得到明显的提升，有效的阻止了目前普遍存在的尖锐物穿刺土工布层堵塞排水通道的情况的发生。
发明内容：
为解决现有技术中防排水板存在的施工中易于刺破、堵塞导排通道、抗拉强度偏低，从而出现导排层失效，进而影响到工程系统的稳定性等隐患，本发明的目的在于提供一种缝合加筋复合防排水板。
为实现上述目的，本发明公开了一种缝合加筋复合防排水板，上层复合至少一层土工布的防排水板，其中一层土工布外侧连接加筋层，加筋层为由经线、纬线交织组成的网格结构，经线和纬线固定连接。
1、本发明提供的防排水板具有加筋层、土工布层、排水板及土工布复合形成缝合加筋防排水板；加筋层和土工布连接后作为表层结构，对排水板起到保护作用，增强了排水板的抗拉伸、撕裂以及顶破等力学性能，复合体具有了更优异的抗形变、抗破坏能力。
进一步的，加筋层不仅具有增强复合体整体强度的作用，而且通过经线、纬线之间的牢固连接，避免了复合体各层之间的滑动移位。
进一步的，上层复合至少一层土工布。土工布除了起到反滤、保护作用外，还具有固定加筋层，为加筋层提供载体支撑的作用，加筋层与一层或多层土工布的紧密连接，增强了防排水板复合体的机械强度和韧性。
进一步的，加筋层与一层或多层土工布之间通过缝合/胶粘/针刺的方式连接，连接方式更为牢固，有尖锐异物刺向排水板时，可以起到更优异的防护效果。
进一步的，土工布与排水板之间通过粘结层粘接。粘接层为热熔复合物理粘接层/胶粘复合层中的一种,利于规模化生产、降低生产成本。通过粘接层的固定作用，利于施工操作，减少外物对排水板的穿刺、撞击等机械性损坏；即便边坡施工时，外物在复合体表面的滑动，上保护层也可以起到很好的缓冲效果，从而增强了复合体的环境适应性和使用寿命。
进一步的，至少由两根线捻成的经、纬线制备的经编线束，具有更高的力学强度，增强了复合体整体的稳定性。
优选的，所述排水板的材质为聚乙烯、聚氯乙烯、聚丙烯、EVA树脂或HIPS树脂原料中的一种或几种的混合。
优选的，衬入纱的材质为丙纶、涤纶、维纶、乙纶、锦纶、玻璃纤维、芳纶纤维、碳纤维、裂膜丝、玄武岩纤维、石墨烯纤维中的一种或几种的混合。
本发明的应用优势为：
1、土工布反滤层不易塌陷，避免造成排水通道淤堵的情况发生，充分保障排水板的纵向通水量。
2、防排水板的物理机械性能得到增强，土工布层和加筋层的复合，起到功能互补的效果，可以起到隔离，反滤，导排水，保护的作用。短纤/长丝针刺土工布可以起到反滤，保护的作用，加筋层与针刺土工布的复合增强了整体的力学性能，从而使防排水板整体具有了更强的拉伸强度，撕裂强度以及顶破强度，从而更好的对下层的排水板层进行保护，更好的防止导排水层受到损坏，也增强了整个工程系统的稳定性，防止失稳垮塌现象的发生。
3、减少了传统导排层对非可再生资源砾石、卵石层的使用，有利于环境保护，且降低了工程施工的材料成本。相同的导排水能力下，加筋复合防排水板的使用，可以将垃圾填满场厚度大于30cm的卵石导排层减少到10cm，替代了约20cm厚的卵石导排层，节约了更多的库容空间，为后期的运营创造效益。
4、加筋复合防排水板用于建筑种植屋面防水设计时，可以铺设于种植层和防水层之间，不仅能及时的将积水排出，与此同时还可以起到阻止植物根系穿刺破坏防水层的作用。
具体实施方式：
下面通过具体的实施例并结合附图对本发明做进一步的描述。
实施例1，如图1所示，本发明实施例所述的一种缝合加筋复合防排水板，包括至少一层针刺土工布2和铺垫于土工布之下的排水板1，其中一层土工布外侧连接加筋层3，加筋层为经线4、纬线5交织组成的网格状结构形式，经线和纬线也分别固定连接。进一步的加筋层与针刺土工布通过缝合/胶粘/针刺的方式连接。进一步的，针刺土工布与排水板之间通过粘接层连接。粘接层可以选用热熔复合物理粘接层/胶粘复合层中的一种。进一步的，加筋层的网格面积为0-11cm2。进一步的经线和纬线均为至少由两根丝线捻成的衬入纱。优选的，衬入纱的材质为丙纶、涤纶、维纶、乙纶、锦纶、玻璃纤维、芳纶纤维、碳纤维、裂膜丝、玄武岩纤维、石墨烯纤维中的一种或几种的混合。
本技术方案中，优选的所述排水板的材质为聚乙烯、聚氯乙烯、聚丙烯、EVA树脂或HIPS树脂原料中的一种或几种的混合。
本技术方案中，本发明提供的缝合加筋复合防排水板的制备方法包括以下步骤：
(1)制备至少一层土工布和排水板
(2)制备经编网格的加筋层：首先将至少两根丝线捻成的衬入纱作为经线和纬线，然后编织经线和纬线，形成网孔长度0—3.33cm的网格，最后将经线和纬线通过缝纫机进行缝合/编织/针刺三种方式固定，防止经线和纬线之间产生滑动。
(3)按照上述技术方案中提供的结构，将加筋层与土工布通过缝合/针刺/胶粘三种方式结合固定，做成缝合加筋高强土工布；
(4)土工布与排水板通过热熔复合或者胶粘复合在一起，形成缝合加筋复合防排水板。在所述步骤(1)中加工排水板可采用高温熔融挤出，辊压吸塑成型，或者采用高温加热模压/冲压成型工艺制得。
(5)缝合加筋高强土工布与排水板通过热熔复合或者胶粘复合成型。缝合高强土工布型号可根据需要选用普通针刺土工布的原料，加筋层可根据需要选用普通网布、高强度网布或各种柔性网格布等，经线和纬线的丝线材质可以为丙纶、涤纶、维纶、乙纶、锦纶、玻璃纤维、芳纶纤维、碳纤维、裂膜丝、玄武岩纤维、石墨烯纤维中的一种或几种的混合。
实验一：利用发明提供的缝合加筋复合排水板和现有的复合排水板做对比试验，分别将两种复合排水板应用到生活垃圾填埋场导排层中，两种复合排水板均以厚度1.0mm，柱高20mm，土工布层克重600克为例，经测试后，对比数据如下所示：
由上表数据可知，本发明提供的缝合加筋复合排水板具有抗拉强度高，标称断裂强度对应伸长率低的特点；对比于现有的复合防排水板，更难于被尖锐异物刺破，抗变形能力强，可以充分保证下层排水板的排水空间不被挤压，保证排水效果，从而达到导排水的作用。
实施例2，如图3所示，本发明实施例所述的一种缝合加筋复合防排水板，包括至少两层针刺土工布2和铺垫于土工布之下的排水板1，其中至少一层加筋层3衬垫于土工布之间，加筋层为经线4、纬线5交织组成的网格状结构形式，经线和纬线也分别固定连接。
本技术方案中，进一步所述两层土工布内衬垫连接加筋层。两层针刺土工布复合加筋层增强了排水板的整体强度，抗拉伸变形能力增强，复合层中更不容易产生错层滑动现象，增加了排水板的使用寿命、拓宽了排水板的应用环境，提高了排水板的实用性。
本技术方案中，进一步所述土工布与加筋层之间通过缝合/胶粘/针刺方式连接。本技术方案中，进一步所述土工膜与排水板之间通过粘接层连接。粘接层可以选用热熔复合物理粘接层/胶粘复合层中的一种。
本技术方案中，进一步的，加筋层的网格面积为0-11cm2。本技术方案中，进一步的经线和纬线均为至少为由两根丝线捻成的衬入纱。本技术方案中，优选的所述衬入纱的材质为丙纶、涤纶、维纶、乙纶、锦纶、玻璃纤维、芳纶纤维、碳纤维、裂膜丝、玄武岩纤维、石墨烯纤维中的一种或几种的混合。
本技术方案中，优选的所述排水板的材质为聚乙烯、聚氯乙烯、聚丙烯、EVA树脂或HIPS树脂原料中的一种或几种的混合。
本发明提供的缝合加筋复合防排水板的制备方法包括以下步骤：
(1)制备至少两层土工布和排水板
(2)制备经编网格的加筋层：首先将至少两根丝线捻成的衬入纱作为经线和纬线，然后编织经线和纬线，形成网孔长度0—3.33cm的网格，最后将经线和纬线通过缝纫机进行缝合/编织/针刺三种方式固定，防止经线和纬线之间产生滑动。
(3)按照上述技术方案中提供的结构，将加筋层与土工布通过缝合/针刺/胶粘三种方式结合固定，做成缝合加筋高强土工布；
(4)缝合加筋高强土工布与排水板通过热熔复合或者胶粘复合成型。缝合高强土工布型号可根据需要选用普通针刺土工布的原料，加筋层可根据需要选用普通网布、高强度网布或各种柔性网格布等，经线和纬线的丝线材质可以为丙纶、涤纶、维纶、乙纶、锦纶、玻璃纤维、芳纶纤维、碳纤维、裂膜丝、玄武岩纤维、石墨烯纤维中的一种或几种的混合。
实验二：利用发明提供的缝合加筋复合排水板和现有的复合排水板做对比试验，分别将两种复合排水板应用到生活垃圾填埋场导排层中，两种排水板均以厚度1.0mm，柱高20mm,土工布层克重600克为例，经测试后，对比数据如下所示：
由上述数据可知，本发明所述的缝合加筋复合排水板抗拉强度高，标称断裂强度对应伸长率低的特点；本发明所述的复合排水板与现有的复合排水板相比，更难于被尖锐物刺穿，具有更高的抗顶破，抗形变能力，可以充分保护下层的排水板不被破坏，防止排水板受力后被撕裂或穿破，加筋层可以降低或防止土工布层的塌陷，从而保证了土工布层与排水板之间的排水空间不被压缩，充分保证了排水板的排水能力，从而优化了复合排水板导排水的作用。
综上所述，本发明提供的缝合加筋复合防排水板采用的土工布层和加筋层之间通过缝合/胶粘/针刺三种方式固定，结构更为紧密，不易产生滑动；另外，土工布层和加筋层可以与下层的排水板通过高温热熔压合或者胶粘压合的方式成为完整的加筋复合防排水板结构，增强了复合防排水板的强度，提高了整体结构的抗形变、耐穿刺等物理机械性能。此外，加筋层为由经、纬线结构编织成的柔性网格，网格结构的选择增加了土工布之间、土工布层与加筋层之间的接触面积，使得土工布层与加筋层的结合更为紧密牢固，编织后的经线、纬线可选择通过缝合/胶粘/针刺三种方式进行相对位置的固定，防止复合防排水板在施工作业或运输过程中受到外力作用时，经、纬线之间产生相互之间的滑动位移，形成防护结构的薄弱点，增强了复合防排水板的抗冲击性能、抗拉伸、撕裂性能，增强了复合体的整体强度，拓宽了复合体的使用领域。
本发明适用于各类填埋场封场、边坡或库底的导排水材料、种植屋面建筑领域的导排水材料，在满足排水功能的基础上，可以对防水层提供保护，加筋层、无纺布层和排水板的复合，增强了复合体的物理机械性能，具有更高的强度，更宽泛的应用领域，有利于材料的应用与推广。
本发明的范围并不仅限于上述详细的说明，而是根据下述的权利要求书体现出来。权利要求书的意义和范围，由它均等概念引出的所有变化或者修改都应包含在本发明的范围内。尽管参照前述各实施例对本发明进行了详细的说明，但本发明不限于上述具体实施方式，本领域的技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分或者全部技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明各实施例技术方案的范围，其均应涵盖在本发明的权利要求和说明书的范围之内。
附图说明
图1为本发明实施例1所述的一种缝合加筋复合防排水板的结构示意图；
图2为本发明实施例1所述的一种缝合加筋复合防排水板的主视图；
图3为本发明实施例2所述的一种缝合加筋复合防排水板的结构示意图；
图4为本发明实施例2所述的一种缝合加筋复合防排水板的主视图；
图中
1、排水板；2土工布；3、加筋层；4、经线；5纬线；6粘结层。
Claims (4)
1.一种缝合加筋复合防排水板，包括如下结构：包括两层针刺土工布和铺垫于土工布之下的排水板，至少一层加筋层衬垫于两层土工布之间，加筋层为经线、纬线交织组成的网格状结构形式，经线和纬线固定连接；所述缝合加筋复合防排水板由以下具体步骤加工制备：
①加工排水板和土工布；
②加工加筋层：将至少两根丝线捻成线束分别作为经线和纬线，然后编织经线和纬线，使其形成网孔长度0～3.33cm的网格，最后将经线和纬线分别通过缝纫机进行缝合/编织/针刺三种方式进行固定，防止相互之间的错位滑动；
③按照缝合加筋复合防排水板的结构形式，将土工布与加筋层通过缝合/胶粘/针刺三种方式进行固定，所得复合体即为缝合加筋土工布；
④所述缝合加筋土工布与排水板之间通过粘结层，经过热熔复合或胶粘复合的方式复合在一起，即得到缝合加筋复合防排水板。
2.根据权利要求1所述的缝合加筋复合防排水板，其特征在于，加筋网格面积为0～11cm2。
3.根据权利要求1所述的缝合加筋复合防排水板，其特征在于，丝线的材质为丙纶、涤纶、维纶、乙纶、锦纶、玻璃纤维、芳纶纤维、碳纤维、裂膜丝、玄武岩纤维、石墨烯纤维中的一种或几种的混合。
4.根据权利要求1所述的缝合加筋复合防排水板，其特征在于，排水板的材质为聚乙烯、聚氯乙烯、聚丙烯、EVA树脂或HIPS树脂原料中的一种或几种的混合。
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