RU94253U1 - TECHNOLOGICAL LINE FOR PRODUCING COMPOSITE REINFORCES - Google Patents

Abstract

 A technological line for manufacturing composite reinforcement, consisting of two blocks of basic equipment: a unit for preparing and impregnating rovings with a polymer binder, including creel crest with rovings, a leveling device, an annealing chamber, an impregnating bath, a tension device, a forming device, and a unit for forming the structure of the outer surface of the reinforcement comprising two nodes of the spiral winding, polymerization chambers, a cooling bath, a pulling device, a cutting and reeling unit, characterized in that the sleep line It is supplied with one or several additional units of equipment for performing spiral windings of the inner layers of reinforcement, including a unit for preparing and impregnating rovings with a polymer binder, a spiral winding device, a polymerization chamber, and a spiral winding device, a polymerization chamber and part of the unit for preparing and impregnating rovings with a polymer binder, namely molding node installed in series between blocks of basic equipment.

Description

The utility model relates to technological lines for the manufacture of composite reinforcement used in the reinforcement of conventional and prestressed building structures.

Known production line for the manufacture of non-metallic composite reinforcement described in the book of the author N. Frolov “Fiberglass reinforcement and glass-concrete constructions” (M., Stroyizdat, 1980, pp. 20-24), including creel for hair with roving spools, leveling device, annealing chamber, impregnating bath with a tension device, squeezing device, molding unit with a die block gradually decreasing cross-section, spiral winding device, polymerization chambers, pulling device, reinforcement cutting and winding units.

The disadvantage of this line, based on spunbond technology for manufacturing composite reinforcement (pultrusion method), is the impossibility of producing composite reinforcement with continuous relief.

The technological line for manufacturing composite reinforcement according to the patent for utility model patent of the Russian Federation No. 76659 (published on September 27, 2008), including creel with roving bobbins, leveling device, annealing chamber, impregnating bath with a tension device, squeezing device, molding, is free from this drawback site, two spiral winding devices containing one winding coil, devices to prevent twisting of fibers and the distribution of the polymer binder along the length of the reinforcement, polymerization chambers, pulling device, cutting and reeling units.

The disadvantage of this production line, based on the filter-free technology for manufacturing composite reinforcement (the “plate extrusion” method), is the low productivity of the equipment and the low strength properties of the manufactured composite reinforcement, especially large diameters.

The closest analogue is a high-performance production line for manufacturing composite reinforcement with continuous rhombic relief, made according to the patent for utility model of the Russian Federation No. 82247 (publ. 04/20/2009), including creel with roving bobbins, leveling device, annealing chamber, impregnating bath with tensioning device, squeezing device, molding unit, two spiral winding devices containing at least two coils of a winding bundle, devices for preventing fiber twisting and distribution I have a polymer binder along the length of the reinforcement, polymerization chambers, pulling device, cutting and reeling units.

The disadvantage of this production line, based on the filter-free technology for manufacturing composite reinforcement (the “paintrudge” method), is the low strength properties of the manufactured composite reinforcement, especially large diameters.

The proposed utility model solves the problem of creating equipment for the production of high-strength composite reinforcement in the entire range of manufactured diameters.

To achieve the specified technical result in the production line for manufacturing composite reinforcement, consisting of two blocks of basic equipment: a unit for preparing and impregnating rovings with a polymer binder and a unit for forming the structure of the outer surface of the reinforcement structure, the line is equipped with one or more additional equipment blocks for performing spiral windings of the inner layers of the reinforcement including unit for preparation and impregnation of rovings with a polymer binder, spiral winding device, polymers the chamber, and the spiral winding device, the polymerization chamber and part of the unit for preparing and impregnating rovings with a polymer binder, namely a molding unit, for each layer are installed in series between the blocks of the main equipment.

Distinctive features of the proposed production line from the above known, closest to it, is that the line is equipped with one or more additional units of equipment for making spiral windings of the inner layers of the reinforcement, including a unit for preparing and impregnating rovings with a polymer binder, a spiral winding device, and a polymerization chamber. The spiral winding device, the polymerization chamber, and part of the unit for preparing and impregnating rovings with a polymer binder, namely, a molding unit, for each layer are installed in series between the units of the main equipment.

Due to the presence of these features, the proposed production line allows us to produce layered composite reinforcement of continuous relief with high strength properties in the entire range of manufactured diameters.

The proposed production line for the manufacture of composite reinforcement is illustrated by the drawings shown in figures 1-5.

Figure 1 shows the production line for the manufacture of composite reinforcement with a layered rod (General view).

Figure 2 shows the production line for the manufacture of composite reinforcement with a solid rod (prototype, structural diagram).

Figure 3 shows the production line for the manufacture of composite reinforcement with a 2-layer rod (structural diagram).

Figure 4 shows the production line for the manufacture of composite reinforcement with a 3-layer rod (structural diagram).

Figure 5 shows the production line for the manufacture of composite reinforcement with a 4-layer rod (structural diagram).

Technological lines for the manufacture of composite reinforcement with a different number of core layers are completed from blocks of various functional purposes.

The production line for the manufacture of composite layered reinforcement, for example, 3-layer (Fig. 1) includes creel creams with roving bobbins 1, leveling devices 2, annealing chambers 3, impregnation baths 4, squeezing devices 5, molding units 6, spiral winding units 7 , polymerization chambers 8, a cooling bath 9, a pulling device 10, a cutting and reeling unit 11.

The production line for the production of composite reinforcement according to the prototype (figure 2) consists of two blocks of functional purpose: a unit for preparing and impregnating rovings with a polymer binder (block No. 1) and a block for forming the structure of the outer surface of the reinforcement (block No. 3).

Block No. 1 includes a creel with roving bobbins 1, a leveling device 2, an annealing chamber 3, an impregnating bath with a tensioning device 4, an squeezing device 5, a molding unit 6.

Block No. 3 includes a spiral winding device 7, a polymerization chamber 8, a cooling bath 9, a pulling device 10, a cutting and reeling unit 11.

The proposed production line for the manufacture of layered composite reinforcement (Fig.3-5) consists of equipment units: No. 1, No. 3 and an additional unit No. 2. The production line is equipped with a certain number of blocks No. 1 and No. 2, depending on what design is supposed to produce fittings. Block number 3 for all versions of the lines is the same and is designed to form the outer surface of the reinforcement. Block No. 2 includes a spiral winding device and a polymerization chamber.

The number of blocks No. 1 and No. 2, which are included in the line, depends on what type of product it is planned to produce, for example, if the product requires a 2-layer, then the number of blocks No. 1 should be double (Fig. 3), if 3 x layer, then triple (Fig. 4), etc., and the number of blocks No. 2 is less than the number of blocks No. 1 per unit.

In the production line for the manufacture of layered composite reinforcement, the first layer (core) of the rod (Fig. 3) is made in block No. 1, which includes creel with roving bobbins 1, leveling device 2, annealing chamber 3, impregnating bath 4, squeezing device 5, molding node 6.

To form the 2nd reinforcement layer in the main line after the devices of unit No. 1, an additional set of devices is installed, consisting of blocks No. 1 and No. 2, and the molding unit 6 from block No. 1 is located after the polymerization furnace 8 of block No. 2.

To form the 3rd and subsequent reinforcement layers (Figs. 4, 5), additional devices of blocks No. 1 and No. 2 are installed in the main line in a similar and sequential manner one after another.

The formation of the structure of the outer surface of the layered composite reinforcement is carried out in block No. 3, including spiral winding devices 7, a polymerization furnace 8, a cooling bath 9, a pulling device 10, a cutting and reeling unit 11.

Thus, in the manufacture of 2-layer reinforcement, the line consists of 2 blocks No. 1 and one block No. 2 and No. 3; in the preparation of 3-layer reinforcement, the line consists of 3 blocks No. 1, 2 blocks No. 2 and one block No. 3, in the manufacture of 4-layer reinforcement, the line consists of 4 blocks No. 1, 3 blocks No. 2 and one block No. 3.

The production line for the manufacture of layered composite reinforcement, for example 3-layer (figure 1), works as follows. In blocks No. 1, rovings made of glass, basalt, carbon and other fibers from creel pulleys 1, the number of which determines the core or layer of the supporting reinforcement rod, pass through a leveling device 2, which divides the roving into separate bundles, an annealing chamber 3, which removes moisture at temperature 200-250 ° C. Then the roving bundles enter the impregnation bath 4, filled with a polymer binder with a temperature of 40-60 ° C, the squeezing roller device 5, which removes excess polymer binder from the fibers, and enter the molding unit 6, combining the roving bundles into a core or reinforcement layer.

After this, the impregnated fibers enter the first block No. 2, in which the first spiral winding device 7 winds thin filaments or flat rovings on the core. The node 7 can be equipped with known elements of multiple windings.

Next, the core of the reinforcement with the first internal spiral winding passes through the polymerization chamber 8 of the first additional unit No. 2, in which the rod is preheated to a temperature of 100-120 ° C, and enters the molding unit 6 from the first additional unit No. 1. In molding unit 6, prepared and impregnated with a polymer binder rovings from the first additional unit No. 1 are uniformly located around the core and form a uniform thickness of the fibers of the second layer. The number of rovings in the additional block No. 1 should be such as to provide the necessary thickness of the second layer of reinforcement. This arrangement of the equipment provides for the compaction of the core fibers, pre-heating to a temperature below the curing temperature of the polymer binder, and produces the formation of the second layer of the rod from rovings pre-impregnated with the polymer binder.

Then the core of the reinforcement with the first inner spiral winding and the prepared second layer of reinforcement simultaneously enters the second block No. 2, where the second spiral winding device 7 carries out the second inner spiral winding with thin threads or flat rovings, the second polymerization furnace 8, heating the laminated rod to a temperature of 100- 120 ° C, and enters the molding unit 6 from the second additional unit No. 1.

In the second additional unit No. 1, the rovings of the third reinforcement layer are prepared and impregnated with a polymer binder, which are uniformly distributed around the 2-layer rod in the forming unit 6 and form the required layer thickness.

To perform the external structure of the surface of the reinforcement, a preheated layered rod with 2 internal spiral windings enters the device of unit No. 3. Block number 3 in the devices of the spiral winding 7 produces a relief surface, in the polymerization furnace 8 heats up to a temperature of 150-250 ° C and cures the rod. In the bath 9, the reinforcement is cooled to prevent deformation in the rollers of the pulling device 10. In the cutting unit 11, the reinforcement is cut to the required length and wound into a bay.

In the case of manufacturing composite reinforcement with a different number of layers, the number of additional blocks No. 1 will correspond to the number of layers.

On the proposed production line for the production of composite reinforcement manufactured by KNPO Ural Reinforcing Company LLC Perm (www.armatura-liana.com), 2-layer basalt-plastic reinforcement with a diameter of 20 mm with continuous rhombic relief formed by spiral windings of opposite directions windings was manufactured harnesses and ribbons (RF patent PM No. 82246).

The structural diagram of the processing line is shown in figure 3.

The experimental layered reinforcement was made of a core with a diameter of 10 mm with an internal spiral winding with a flat roving with a density of 630 tex and a subsequent layer with a diameter of 18 mm, on which a spiral relief winding was applied with bundles of opposite directions with the formation of an outer diameter of 20 mm.

On the creel of the main line, which determines the diameter of the core, 52 forgings of basalt roving with a density of 2520 tex were installed, and on the creel of the additional block that determines the thickness of the core layer, 67 forgings of basalt roving with a density of 2520 tex were installed.

The inner multi-start spiral winding of the core was carried out by two flat basalt rovings with a density of 630 tex. Both baths used a polymeric binder based on epoxy resins of a hot curing system.

The temperature of the first polymerization chamber was 100-120 ° C, and the second chamber was 150-250 ° C. The linear productivity of the line was 120 m / h.

The experimental layered composite reinforcement has the following physical and mechanical properties:

- breaking stress at break σ _B = 1350 MPa;

tensile modulus E _p = 70,000 MPa.

The proposed production line allows you to get a layered composite reinforcement with compacted inner fibers, which increases the strength properties of composite reinforcement of large diameters. The resulting composite reinforcement with a diameter of 20 mm has high physical and mechanical properties.

Claims (1)

A technological line for manufacturing composite reinforcement, consisting of two blocks of basic equipment: a unit for preparing and impregnating rovings with a polymer binder, including creel crest with rovings, a leveling device, an annealing chamber, an impregnating bath, a tension device, a forming device, and a unit for forming the structure of the outer surface of the reinforcement comprising two nodes of the spiral winding, polymerization chambers, a cooling bath, a pulling device, a cutting and reeling unit, characterized in that the sleep line It is supplied with one or several additional units of equipment for performing spiral windings of the inner layers of reinforcement, including a unit for preparing and impregnating rovings with a polymer binder, a spiral winding device, a polymerization chamber, and a spiral winding device, a polymerization chamber and part of the unit for preparing and impregnating rovings with a polymer binder, namely molding node installed in series between blocks of basic equipment.