CN116871139A - 一种抗结泥饼的盾构刀盘组合结构及制备方法和应用 - Google Patents
一种抗结泥饼的盾构刀盘组合结构及制备方法和应用 Download PDFInfo
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Abstract
本发明提供了一种抗结泥饼的盾构刀盘组合结构及制备方法和应用,该制备方法包括步骤S1、在所述盾构刀盘上制作喷砂层;步骤S2、在喷砂层上制作涂层;所述涂层包括以下质量百分数的原料组分:复合陶瓷颗粒70%‑80%、高分子疏水剂15%‑20%、功能性添加剂2%‑7%和有机溶剂3%‑5%。该组合结构由该制备方法制得。该组合结构能够在抗结泥饼方面应用。本发明具有抗结泥饼效果,同时具有适宜的作业强度。
Description
技术领域
本发明涉及隧道工程及盾构维护技术领域,具体涉及一种抗结泥饼的盾构刀盘组合结构及制备方法和应用。
背景技术
随着盾构技术的发展,在隧道工程中土压平衡盾构施工方法凭借安全高效的施工特点被广泛应用。而盾构刀盘结泥饼是影响土压平衡盾构施工方法掘进效率的一个关键因素。近些年来,相关科研人员研制了多种防治盾构刀盘结泥饼的处理方法,但并未全面解决刀盘结泥饼的问题。
如申请号为201410368497.2的发明专利公开了一种盾构结泥饼处理方法,该处理方法采用的技术原理是在盾构施工前20~40m位置处提前施工刷泥墙,该刷泥墙优选碎砖和砂浆组成;当结有泥饼的盾构刀盘接触刷泥墙时,控制盾构刀盘顺时针和逆时针交替旋转,通过碎砖和砂浆的摩擦去除刀盘上的泥饼。该处理方法增加了工程造价,对盾构刀盘上的泥饼清理不彻底,使用效果无法保证,并且受地质条件的影响,会存在施工难度较大的情况。
申请号为201811486293.3的发明专利公开了一种泥饼剥除剂及其制备方法,该泥饼剥除剂由芥酸酰胺丙基甜菜碱、椰子油脂肪酸二乙醇酰胺、硬脂酸盐、C14H29(OCOCH(CH3))2OSO3K、琥珀酸二辛脂磺酸钠、助分散剂和强化剂组成,通过破坏粘土性能,降低了粘土在盾构刀盘上的附着力;同时,利用低速空转刀盘或借助泥饼自身的离心力达到泥饼脱离刀盘表面的效果。该剥除剂适用土体范围有限,对于粘性矿物含量较高的易结泥饼的粘性土地层的改良效果较差。
申请号为201911051071.3的发明专利公开了一种利用草酸溶液处理盾构机结泥饼的方法,该方法通过改装盾构机上的泡沫管路以实现边掘进边注入草酸溶液;当盾构刀盘上结泥饼时,停稳盾构机,向其土仓和盾构刀盘中注入泡沫剂和草酸溶液浸泡8-12小时,然后盾构机恢复掘进。该方法需对原盾构设备进行改造,操作复杂,并需停机处理泥饼,泡沫剂和草酸溶液发挥作用等待时间较长,影响工期进度,且盾构机恢复掘进后若出现喷涌现象,需注入额外的高分子聚合物,增加了工程成本。
综上所述,如何提供一种抗结泥饼的盾构刀盘组合结构及制备方法和应用,用于全面解决刀盘结泥饼的问题,具有重要意义。
发明内容
本发明目的在于提供一种抗结泥饼的盾构刀盘组合结构及制备方法和应用,具体技术方案如下:
在第一方面,本发明提供了一种抗结泥饼的盾构刀盘组合结构的制备方法,包括以下步骤:
步骤S1、在所述盾构刀盘上制作喷砂层;
步骤S2、在喷砂层上制作涂层;
所述涂层包括以下质量百分数的原料组分:复合陶瓷颗粒70%-80%、高分子疏水剂15%-20%、功能性添加剂2%-7%和有机溶剂3%-5%;
所述高分子疏水剂包括氟碳树脂和三甲氧基硅烷;
所述功能性添加剂包括二氧化钛粉末和硅烷偶联剂;
所述复合陶瓷颗粒采用质量比为1:1的微米氧化铝粉末和纳米氧化铝粉末。
可选的,在步骤S2中,所述高分子疏水剂采用质量比为3:1的氟碳树脂和三甲氧基硅烷。
可选的,在步骤S2中,所述功能性添加剂采用质量比为1:2的二氧化钛粉末和硅烷偶联剂。
可选的,在步骤S2中,所述有机溶剂包括醇、酮类及烷基酸中的至少一种。
可选的,在步骤S2中制作涂层的过程如下:
步骤S2.1、熟化
将所述涂层中的各原料组分按所需质量投入熟化机内密封滚动、熟化至无沉淀,得到熟化物料;其中,所述熟化采用的工艺条件为熟化温度20±2℃,熟化湿度65±20%rh,熟化时间为30-45min;
步骤S2.2、过滤
采用过滤网过滤所述熟化物料,得到滤料;其中,所述过滤网的网孔尺寸为300-400目;
步骤S2.3、喷涂
采用喷枪将所述滤料均匀喷涂在所述喷砂层上以形成预制涂层;其中,在喷涂时采用十字喷涂;所述预制涂层的厚度为50-100μm;
步骤S2.4、干燥、固化
将所述预制涂层干燥处理获得固化后的涂层。
可选的,在步骤S2.3中,所述喷枪的口径为1.0-1.8mm;
所述喷枪与空气压缩机连接,且在二者间设置空气过滤器。
可选的,在步骤S2.4中,所述干燥包括自然干燥或加热干燥;
所述自然干燥采用的工艺条件是在25±2℃下放置至少24h;
所述加热干燥采用的工艺条件是加热温度为140±10℃,加热时间是30-45min;且在加热干燥前还包括自然晾干,所述自然晾干采用的工艺条件是在25±2℃下放置至少30min。
可选的,在步骤S1中,所述喷砂层采用的原料的为金刚砂,粒径为40-60目;
所述步骤S1的过程是先将盾构刀盘表面除油除锈,再制作喷砂层,喷砂等级至少为Sa2.5级,喷砂层表面粗糙度为40-50μm。
在第二方面,本发明提供了一种抗结泥饼的盾构刀盘组合结构,其采用所述抗结泥饼的盾构刀盘组合结构的制备方法制备得到。
在第三方面,本发明提供了一种抗结泥饼的盾构刀盘组合结构的应用,其采用所述抗结泥饼的盾构刀盘组合结构在抗结泥饼方面的应用。
应用本发明的技术方案,至少具有以下有益效果:
本发明采用所述抗结泥饼的盾构刀盘组合结构的制备方法制备得到抗结泥饼的盾构刀盘组合结构,所述抗结泥饼的盾构刀盘组合结构能够在抗结泥饼方面应用,有效解决了在盾构刀盘表面结泥饼的问题,实现抗结泥饼的效果,另外,还能够确保盾构刀盘的作业强度。具体工作原理如下:
在抗结泥饼方面,在盾构刀盘涂层中含有高分子疏水剂,能够在盾构刀盘涂层表面形成疏水膜层,由于在盾构刀盘掘进施工中产生的渣土含有水分,使得渣土与疏水膜层的水接触角α增大,即减小了渣土与盾构刀盘涂层表面的接触面积,进而降低了渣土在盾构刀盘涂层表面的附着力,在盾构刀盘掘进施工中渣土很难在盾构刀盘涂层表面附着形成泥饼,即所述盾构刀盘涂层具有抗结泥饼效果,有效解决了在盾构刀盘表面结泥饼的问题。
在作业强度方面,在盾构刀盘涂层中组合采用所需质量的复合陶瓷颗粒、高分子疏水剂、功能性添加剂和有机溶剂混合制作涂层,能够确保涂层整体结构的均一性;其中,在复合陶瓷颗粒中采用微米氧化铝粉末和纳米氧化铝粉末,使得微米氧化铝粉末间的间隙被纳米氧化铝粉末填充,且纳米氧化铝粉末完好包裹微米氧化铝粉末,确保涂层致密耐磨;采用功能性添加剂确保所述涂层牢固附着在喷砂层上,且能够提升涂层结构的稳定性;所述喷砂层能够确保涂层牢固结合在盾构刀盘上,确保盾构刀盘组合层结构的作业强度。
除了上面所描述的目的、特征和优点之外,本发明还有其它的目的、特征和优点。下面将参照图,对本发明作进一步详细的说明。
附图说明
构成本申请的一部分的附图用来提供对本发明的进一步理解,本发明的示意性实施例及其说明用于解释本发明,并不构成对本发明的不当限定。在附图中:
图1是本发明实施例1中的一种抗结泥饼的盾构刀盘组合结构的结构示意图;
图2为实验一与实验二在掘进作业时的总推力数据图;
其中,1、盾构刀盘,2、喷砂层,3、涂层,4、微米氧化铝粉末,5、纳米氧化铝粉末。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员所获得的所有其他实施例,都属于本发明保护的范围。
实施例1:
参见图1,一种抗结泥饼的盾构刀盘组合结构的制备方法,包括以下步骤:
步骤S1、在所述盾构刀盘1上制作喷砂层2,所述喷砂层2采用的原料的为金刚砂,粒径为40-60目;
所述步骤S1的过程是先将盾构刀盘1表面除油除锈,再制作喷砂层2,喷砂等级至少为Sa2.5级,喷砂层2表面粗糙度为40-50μm;具体的,在制作喷砂层2时采用粒径为46目的金刚砂(具体为白刚玉)喷砂效果最佳,将喷砂层2用无水乙醇清洗干净,并用压缩空气吹干;
步骤S2、在喷砂层2上制作涂层3;
所述涂层3包括以下质量百分数的原料组分:复合陶瓷颗粒70%、高分子疏水剂20%、功能性添加剂7%和有机溶剂3%;
所述高分子疏水剂采用质量比为3:1的氟碳树脂和三甲氧基硅烷,用于在盾构刀盘涂层3表面形成疏水膜层,降低渣土在盾构刀盘涂层3表面的附着力,起到抗结泥饼效果;
所述功能性添加剂采用质量比为1:2的二氧化钛粉末和二甲氧基甲基硅烷,用于确保涂层3牢固附着在喷砂层2上。
所述有机溶剂为质量比为1:1的丙酮和乙酸乙酯,用于调节涂层3的流变性、干燥速度;
所述复合陶瓷颗粒采用质量比为1:1微米氧化铝粉末4(粒径为1~5μm)和纳米氧化铝粉末5(粒径为10~50nm),使得微米氧化铝粉末4间的间隙被纳米氧化铝粉末5填充,且纳米氧化铝粉末5完好包裹微米氧化铝粉末4,确保涂层3致密耐磨。
在步骤S2中制作涂层3的过程如下:
步骤S2.1、熟化
将所述涂层3中的各原料组分按所需质量投入熟化机内密封滚动、熟化至无沉淀,得到熟化物料;其中,所述熟化采用的工艺条件为熟化温度20℃,熟化湿度65%rh,熟化时间为40min;
步骤S2.2、过滤
采用过滤网过滤所述熟化物料,得到滤料;其中,所述过滤网的网孔尺寸为400目;步骤S2.3、喷涂
采用喷枪将所述滤料均匀喷涂在所述喷砂层2上以形成预制涂层3;其中,在喷涂时采用十字喷涂,用于提高涂层3均匀性,减少喷涂缺陷,同时,用于提高施工效率;所述预制涂层3的厚度为100μm;
步骤S2.4、干燥、固化
将所述预制涂层3干燥处理获得固化后的涂层3。
在步骤S2.3中,所述喷枪的口径为1.0mm,采用小口径喷枪的雾化效果更好,确保涂层3更加均匀;
所述喷枪与空气压缩机连接,且在二者间设置空气过滤器。
在步骤S2.4中,所述干燥包括自然干燥或加热干燥;
所述自然干燥采用的工艺条件是在25℃下放置24h;
所述加热干燥采用的工艺条件是在在电热鼓风干燥箱或热风循环烘箱中加热温度为140℃,加热时间是40min;且在加热干燥前还包括自然晾干,所述自然晾干采用的工艺条件是在25℃下放置30min。
本实施例1采用所述抗结泥饼的盾构刀盘组合结构的制备方法制备得到抗结泥饼的盾构刀盘组合结构,所述抗结泥饼的盾构刀盘组合结构能够在抗结泥饼方面应用,有效解决了在盾构刀盘1表面结泥饼的问题,实现抗结泥饼的效果,另外,还能够确保盾构刀盘1的作业强度。具体工作原理如下:
在抗结泥饼方面,在盾构刀盘涂层3中含有高分子疏水剂,能够在盾构刀盘涂层3表面形成疏水膜层,由于在盾构刀盘1掘进施工中产生的渣土含有水分,使得渣土与疏水膜层的水接触角α增大,即减小了渣土与盾构刀盘涂层3表面的接触面积,进而降低了渣土在盾构刀盘涂层3表面的附着力,在盾构刀盘1掘进施工中渣土很难在盾构刀盘涂层3表面附着形成泥饼,即所述盾构刀盘涂层3具有抗结泥饼效果,有效解决了在盾构刀盘1表面结泥饼的问题。
在作业强度方面,在盾构刀盘涂层3中组合采用所需质量的复合陶瓷颗粒、高分子疏水剂、功能性添加剂和有机溶剂混合制作涂层3,能够确保涂层3整体结构的均一性;其中,在复合陶瓷颗粒中采用质量比为1:1的微米氧化铝粉末4和纳米氧化铝粉末5,使得微米氧化铝粉末4间的间隙被纳米氧化铝粉末5填充,且纳米氧化铝粉末5完好包裹微米氧化铝粉末4,确保涂层3致密耐磨;采用功能性添加剂确保所述涂层3牢固附着在喷砂层2上,且能够提升涂层3结构的稳定性;所述喷砂层2能够确保涂层3牢固结合在盾构刀盘1上,确保盾构刀盘组合层结构的作业强度。
为了验证本发明中所述抗结泥饼的盾构刀盘组合结构在抗结泥饼方面的应用效果,本发明还做了以下对比实验:
实验一、本发明采用常规盾构刀盘(即无涂层组)进行掘进作业。
实验二、本发明采用与实验一中同批次生产的常规盾构刀盘,并结合实施例1的制备方法制备得到抗结泥饼的盾构刀盘组合结构(即有涂层组)进行掘进作业。
在掘进作业时,实验一(即无涂层组)和实验二(即有涂层组)掘进作业的土质条件相同,且分别掘进360环,并实时记录盾构刀盘表面在每一环掘进时的总推力,具体数据参见图2所示。
由图2数据知,相比于无涂层组,有涂层组平均总推力降低了20.19%,且总推力分布更加均匀,说明涂层对盾构刀盘结泥饼防治效果良好。
以上所述仅为本发明的优选实施例而已,并不用于限制本发明,对于本领域的技术人员来说,本发明可以有各种更改和变化。凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (10)
1.一种抗结泥饼的盾构刀盘组合结构的制备方法,其特征在于,包括以下步骤:
步骤S1、在所述盾构刀盘上制作喷砂层;
步骤S2、在喷砂层上制作涂层;
所述涂层包括以下质量百分数的原料组分:复合陶瓷颗粒70%-80%、高分子疏水剂15%-20%、功能性添加剂2%-7%和有机溶剂3%-5%;
所述高分子疏水剂包括氟碳树脂和三甲氧基硅烷;
所述功能性添加剂包括二氧化钛粉末和硅烷偶联剂;
所述复合陶瓷颗粒采用质量比为1:1的微米氧化铝粉末和纳米氧化铝粉末。
2.根据权利要求1所述的抗结泥饼的盾构刀盘组合结构的制备方法,其特征在于,在步骤S2中,所述高分子疏水剂采用质量比为3:1的氟碳树脂和三甲氧基硅烷。
3.根据权利要求1所述的抗结泥饼的盾构刀盘组合结构的制备方法,其特征在于,在步骤S2中,所述功能性添加剂采用质量比为1:2的二氧化钛粉末和硅烷偶联剂。
4.根据权利要求1所述的抗结泥饼的盾构刀盘组合结构的制备方法,其特征在于,在步骤S2中,所述有机溶剂包括醇、酮类及烷基酸中的至少一种。
5.根据权利要求1-4任意一项所述的抗结泥饼的盾构刀盘组合结构的制备方法,其特征在于,在步骤S2中制作涂层的过程如下:
步骤S2.1、熟化
将所述涂层中的各原料组分按所需质量投入熟化机内密封滚动、熟化至无沉淀,得到熟化物料;其中,所述熟化采用的工艺条件为熟化温度20±2℃,熟化湿度65±20%rh,熟化时间为30-45min;
步骤S2.2、过滤
采用过滤网过滤所述熟化物料,得到滤料;其中,所述过滤网的网孔尺寸为300-400目;
步骤S2.3、喷涂
采用喷枪将所述滤料均匀喷涂在所述喷砂层上以形成预制涂层;其中,在喷涂时采用十字喷涂;所述预制涂层的厚度为50-100μm;
步骤S2.4、干燥、固化
将所述预制涂层干燥处理获得固化后的涂层。
6.根据权利要求5所述的抗结泥饼的盾构刀盘组合结构的制备方法,其特征在于,在步骤S2.3中,所述喷枪的口径为1.0-1.8mm;
所述喷枪与空气压缩机连接,且在二者间设置空气过滤器。
7.根据权利要求5所述的抗结泥饼的盾构刀盘组合结构的制备方法,其特征在于,在步骤S2.4中,所述干燥包括自然干燥或加热干燥;
所述自然干燥采用的工艺条件是在25±2℃下放置至少24h;
所述加热干燥采用的工艺条件是加热温度为140±10℃,加热时间是30-45min;且在加热干燥前还包括自然晾干,所述自然晾干采用的工艺条件是在25±2℃下放置至少30min。
8.根据权利要求5所述的抗结泥饼的盾构刀盘组合结构的制备方法,其特征在于,在步骤S1中,所述喷砂层采用的原料的为金刚砂,粒径为40-60目;
所述步骤S1的过程是先将盾构刀盘表面除油除锈,再制作喷砂层,喷砂等级至少为Sa2.5级,喷砂层表面粗糙度为40-50μm。
9.一种抗结泥饼的盾构刀盘组合结构,其特征在于,采用如权利要求5所述的抗结泥饼的盾构刀盘组合结构的制备方法制备得到。
10.一种抗结泥饼的盾构刀盘组合结构的应用,其特征在于,采用如权利要求9所述的抗结泥饼的盾构刀盘组合结构在抗结泥饼方面的应用。
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