CN101378857B - 制造细长产品的方法及一种细长产品 - Google Patents
制造细长产品的方法及一种细长产品 Download PDFInfo
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Abstract
一种细长产品,其形成如下:首先形成芯,该芯的外表面由塑料制成。然后,挤塑管状金属层,使得该层是无缝的。当挤塑金属层时,在金属层和芯之间形成间隙(16)。在金属层冷却之后,将芯的外表面布置为贴靠金属层的内表面。在芯和金属层之间实施粘合作用,并且施加永久性压缩力,所述压缩力将芯和金属层压缩在一起。
Description
背景技术
本发明涉及一种制造细长产品(elongated products)的方法,包括形成具有塑料外层的芯、将无缝金属层挤塑到芯上(允许在金属层和芯之间具有间隙)、冷却金属层和将芯的外表面布置为贴靠金属层的内表面。
本发明还涉及一种包括具有塑料外表面的芯和挤塑到芯上的无缝管状金属层的细长产品。
具有塑料内层和外层以及在内层和外层之间的铝层的多层复合管是公知的。例如,通过挤塑内层并涂覆结合材料(tie material)来制备这种管。此后,将铝带围绕内层缠绕并焊接,从而形成纵向焊缝。校准焊接的铝层并活化结合材料以使内层和铝层结合。此后,用结合材料涂覆铝层并且将外塑料层挤塑到铝层上。该技术方案记载于例如EP0691193中。还可以如下制备该管:首先缠绕铝带以形成管而使得铝带边缘重叠。然后,利用超声焊接来纵向焊接重叠区域。还可以以边缘不重叠的方式缠绕带,然后使用对焊。然后,利用结合材料和形成内层的塑料从内部涂覆所形成的铝管,并且利用结合材料和形成外层的塑料涂覆铝层的外侧。该系统中最大的弱点之一在于当塑料试图收缩离开金属层时结合层仍然保持恒定的张力。在这两种技术中,很难以可靠的方式形成焊缝和使得焊缝的质量均匀。焊缝不均匀可能导致管破裂,并且在管末端扩展期间焊缝非常容易破裂。
DE 2139388公开了具有由塑料制成的内层的管的制备。将例如由铝制成的无缝金属层压制到塑料层的外侧上。将铝直接压制到塑料芯上。压制的铝的温度非常高,以致容易熔化并损伤塑料芯。
EP 0125788也公开了将无缝金属层挤塑到塑料芯外侧。心轴配有内部冷却套以保护芯免受到热的压制金属损伤。将金属挤塑为具有大于芯外径的内径以允许插入冷却套的一部分,并且使金属经历冷却空气流。为了消除芯和压制金属之间的空间以使芯紧密地包覆在管状护套中,在挤塑阶段之后进行金属管的拉拔变细或锻造变细(draw or swage down)的步骤是必要的。然而,该步骤使包覆层加工硬化(workharden),从而使产品难以操控。因此,产品的硬度增加,并且产品变得更具刚性。
US 5222284公开了制备同轴电缆。连续压实由涂有绝缘体的导体构成的细长芯来减小芯的横截面。将管状金属包覆层连续挤塑到细长芯的外侧,同时将压实的芯连续输入包覆层中,由此使压实的芯恢复到其初始横截面以填充包覆层。因此,在金属尚热的时候芯不接触金属包覆层,由此可避免损伤绝缘体。此外,由于金属包覆层直径没有减小,所以避免了金属硬化。然而,芯的外层必须由可以通过施加压缩力来压实以减小其横截面的绝缘材料制成。此外,绝缘材料必须为逐渐恢复的绝缘材料,以使芯在压缩力撤消时趋向恢复初始尺寸。该技术方案相当复杂。此外,非常难以确保芯和金属包层之间的附着。该专利完全没有记载层间的附着水平。
发明内容
本发明的目的是提供一种制备细长产品的新型方法和细长产品。
本发明方法的特征在于,在芯和金属层之间设置粘合作用,并且设置用于将芯和金属层压缩在一起的永久性压缩力。
此外,本发明产品的特征在于,芯和金属层之间的粘合作用以及将芯和金属层压在一起的永久性压缩力。
在本发明中,形成细长产品。首先形成芯,芯的外表面由塑料制成。然后,挤塑管状金属层以使该层无缝。挤塑时,金属层的内径大于芯的外径,以使金属不接触芯。在金属层冷却之后,将芯的外表面布置为贴靠金属层的内表面。在芯和金属层之间实施粘合作用。此外,施加永久性压缩力,所述压缩力将芯和金属层压缩在一起。存在几种提供压缩力的技术方案。一个技术方案是在芯的外表面中存在发泡剂并活化发泡剂以使泡沫压靠金属层。另一技术方案是:起初,芯的外径大于金属层的内径,在将无缝的金属层挤塑到芯上之前减小芯的外径,并且芯材具有记忆效应,由此芯趋向膨胀到初始直径。又一技术方案是将金属层的直径减小到一定程度,使得产生将芯和金属层压缩到一起的压缩力。 还可以通过组合应用这些技术方案中的两个或更多个来提供压缩力。这些技术方案提供的优点是芯和金属层之间的粘合界面不受张应力。因此,芯和金属层之间非常牢固地粘附在一起。因此,管的长期性能极其优异。
附图说明
将结合附图更详细地描述本发明,其中:
图1是管制造设备的侧视示意图,
图2是多层复合管的截面端视图,和
图3是金属挤出机的详细的截面侧视示意图。
在附图中,为了清楚起见,以简化的方式表示本发明。在图中,相同的部件用相同的附图标记表示。
具体实施方式
图1公开了如何形成在塑料层之间具有无缝铝层的多层复合管。图2显示这种管的一个实例。
首先,利用第一塑料挤出机1来挤塑管的内层2。内层2形成管芯。在第一塑料挤出机之后具有校准/冷却池13。用结合层(tie layer)涂覆内层2。因此,在形成的管中具有在内层2和铝层4之间的内结合层10。内结合层10和内层2可以共挤塑成型。如果内层2由例如因接枝官能端基而自身具有良好粘附性能的高分子量塑料制成,则不需要结合层。
内层可由例如聚乙烯PE、交联的聚乙烯PEX、聚丙烯PP或聚丁烯-1PB等挤塑而成。结合层可以包含例如具有马来酸酐的聚乙烯PE。
将内层2输入金属挤出机3中。金属挤出机3包括可转动地安装的具有环形圆周槽的轮(wheel)。模圈(shoe)适合于所述槽和安装工具(mount tooling)的闭合部分(close part),其包括布置为至少部分阻挡所述槽的拱座(abutment)和导入口模结构(die structure)的通道。将金属进料插入转动的具有槽的挤出轮中。加热金属并通过摩 擦加压。该材料与拱座在一定条件下配合,在该条件下所述材料流过通道并经口模结构挤塑。口模结构产生管状无缝金属层,并且内层2穿过口模结构中的中空心轴。金属层和内层之间可形成足够的间隙以防止对内层造成热损伤。挤出的金属可以是铝,从而形成铝层4。金属也可以是例如铜或镁或具有相当低的熔点的一些其它金属。例如,可以通过用铝和其它金属形成合金来获得合适的低熔点。
挤出之后,铝层4冷却下来。此时,可以使用外部的冷却装置。冷却装置可以为例如将冷却空气吹到铝层4上的环形冷却喷嘴14。挤出的铝的温度为约450℃,这意味着,如果在铝层4接触内层2的表面之前铝层4不冷却,则内层2的表面会受到损伤。
冷却之后,可以引导铝层4穿过成形辊5。成形辊的数量可以是2、3或4或更多,这取决于成形辊的结构。成形辊5进行拉拔变细工艺(draw down process),这意味着减小铝层4的直径以使铝层4接触塑料内层2。优选将铝层4的直径减小到在内层2和铝层4之间存在压缩力的程度。例如,还可以通过使用锥形收敛口模或通过使用其他合适的方法来减小铝层的直径。
此后,活化内结合层10的材料或内层2的材料本身(如果不使用结合层),使得内层2和铝层4粘附在一起。例如,可以通过加热来活化内结合层10的材料。结合层10的材料可以包括未反应的发泡剂。当加热材料时,发泡剂起作用,并且材料有效地填充内层2和铝层4之间的间隙。因此,层间的间隙不需要非常严格。如果发泡的结合材料不是闭孔泡沫(closed cell),则其形成用于聚集的冷凝物的泄漏通路,使得可以除去塑料层和屏障层之间聚集的水分或某种其它流体。优选地,内结合层10的材料量和/或发泡剂的量和/或结合材料的发泡程度使得发泡的结合材料压靠在铝层4上。因此,在包括内层2和内结合层10的芯和铝层4之间存在压缩力。
在生产线上,紧接着是加热装置6。优选地,加热装置6是用于加热铝层4的感应加热装置。利用加热装置6将铝层4加热到退火温度或加热到足以活化粘合材料的温度。例如,退火温度可以是高于300℃。
由于退火不能损伤内层2的材料,所以其耐温性必须适合于可能 的退火。优选的材料实例是交联的聚乙烯PEX、聚四氟乙烯PTFE、氟化乙丙稀FEP、全氟烷氧基烷烃PFA、乙烯四氟乙烯共聚物ETFE、乙烯-三氟氯乙烯E-CTFE、聚偏氟乙烯PVDF和聚氟乙烯PVE。
如果使用退火,则结合材料的耐温性也必须是合适的。例如,可以通过由通过将官能端基接枝到基材上形成的具有相当高的分子量和粘附性的材料形成所述结合材料来实现足够的耐温性。还可以通过将合适的一种或更多种添加剂添加到结合材料来提高结合材料的耐温性。在塑料管领域中使用的防火剂是合适的添加剂。这类添加剂的实例是短切纤维玻璃、陶瓷晶须纤维、三水合铝ATH、蛭石(ermiculite)、硅酸盐、磷酸盐、碳和碳质剂(carbonaceous agent)。
如果结合材料具有良好的耐温性,则其还可以同时保护内层材料。结合材料还可以包含当铝层4退火时起作用的诸如偶氮二甲酰胺的发泡剂。因此,发泡的结合材料形成热保护所述内层2的绝缘层。
使铝层4退火以赋予管更高的柔性。可以通过选择退火温度的高低和退火时间的长短来控制管的刚性。例如,如果管用于安装在结构内部例如楼板暖气内而需要高柔性,则退火温度较高和/或退火时间较长。相应地,如果用于表面安装例如更新而需要较刚性的管,则退火温度较低和/或退火时间较短。铝层4的退火和内结合层10中的材料活化可以结合,以便通过加热装置6来完成这两个步骤。
在加热装置6之后,用结合层涂覆铝层4的外表面,从而形成外结合层11。之后,形成塑料外层。可以利用第二塑料挤出机7来共挤塑外结合层11的材料和形成外层8的塑料。外结合层11的材料可以与用于内结合层10的材料相同。类似地,用于塑料外层8的材料可以选自与用于塑料内层2的材料相同的材料。
管的直径通常为2~2000mm。壁厚相应变化。通常地,使粘合材料的量尽可能的低。在一个实例中,如果管的外径为17mm,内层2的厚度和外层8的厚度通常接近1mm,铝制屏障层4为约0.3mm,并且粘合材料的厚度为约50微米。
在挤塑外层8之后,通过冷却装置9来冷却管。冷却之后,将管 缠绕在滚筒12上。
如果芯由具有记忆效应的材料例如交联的聚乙烯PEX制成,则在芯穿过金属挤出机3之前可以存在减小芯外径的缩径装置(reducingmeans)。在该情况下,不必将金属层的直径减小太多或根本不减小,这减少或避免金属硬化。例如,当通过加热装置6加热芯时,芯膨胀到初始直径。
在图3所示的技术方案中,利用锥形缩径环15来减小内层2的直径。例如,可用成形辊形成缩径装置来代替锥形缩径环。因此,在内层2和铝层4之间形成间隙16。内层2的初始外径比铝层4的内径更大。由于内层2的材料具有记忆效应,所以它试图膨胀到其初始直径。由于铝层4的内径小于该初始直径,所以在内层2膨胀贴靠铝层4之后在内层2和铝层4之间存在压缩力。
如果间隙16是气密性封闭的,则可以通过例如经过通道18连接到间隙16的抽吸泵17来控制其内压。通过控制间隙16内的压力,可以控制内层接触铝层4的快慢。间隙16内的高压阻止内层2过早地接触铝层4。如果压力越低,则内层2接触铝层4越早。可以通过在间隙16内抽真空来提高内层2和铝层4之间的粘附。
可以控制内层2的进料速度。可以将内层的进料速度设置为略高于铝层4的挤出速度。这种技术方案改进了内层2和铝层4之间的接触。
可以将细长的心轴置于内层2的内部。例如,该心轴可以是第一塑料挤出机1的心轴。该心轴可用于将内层2压靠到铝层4上。还可以封闭管的输出端,并且在内层2内施加内部过压。例如,可以通过心轴供给加压空气来施加过压。内部过压可以用于将内层2压靠到铝层4上。
例如,可以通过将诸如氮气的冷却气体施加到挤出喷嘴来使挤出铝层4的挤出喷嘴冷却。喷嘴的冷却也使铝层4冷却。
不需要与金属层的挤出同时在线挤出芯。可以在单独的过程中预先制备芯。甚至可以在单独的工厂制备芯,然后输送到金属挤出机所在的工厂。可以在输送和/或储存之后将预制的芯进料到金属挤出机3。
在一些情况下,可以按描述的方式使用本说明书中公开的特征,而不管其它特征如何。另一方面,本说明书中公开的特征可以结合用于形成各种组合方案。
对于本领域的技术人员,在技术进步的过程中,可以以多种方式来实施本发明的基本构思是显而易见的。因此,本发明和其实施方案不受前述实例限制,而是可以在所附权利要求的范围内变化。因此,用上述方法和设备形成的细长产品也可以为例如电缆,来代替如上所述的管。
Claims (14)
1.一种制造细长产品的方法,包括:
形成具有塑料外层的芯,
在所述芯上挤塑无缝金属层,允许在所述金属层和所述芯之间形成间隙(16),
冷却所述金属层,和
将所述芯的外表面布置为贴靠所述金属层的内表面,
其特征在于,在不加热所述金属层的情况下或在另外加热所述金属层之前,通过活化将所述芯和所述金属层粘附在一起的材料,从而在所述芯和所述金属层之间设置粘合作用,
并且设置永久性压缩力用于将所述芯和所述金属层压缩在一起。
2.根据权利要求1所述的方法,其特征在于所述芯包含发泡剂,并且活化所述发泡剂以使泡沫压靠所述金属层。
3.根据权利要求1或2所述的方法,其特征在于将所述金属层的直径减小到所述金属层压靠所述芯的程度。
4.根据权利要求3所述的方法,其特征在于在减小所述金属层的所述直径之后,使所述金属层退火以增加其柔性。
5.根据前述权利要求中任一项所述的方法,其特征在于在将所述无缝金属层挤塑到所述芯上之前,所述芯的初始直径大于所述金属层的内径,在将所述无缝金属层挤塑到所述芯上之前,减小所述芯的外径,所述芯的材料具有记忆效应,使得在将所述无缝金属层挤塑到所述芯上之后所述芯趋向膨胀到其初始直径。
6.根据权利要求5所述的方法,其特征在于通过加热所述芯来使所述芯的所述外径变大。
7.根据前述权利要求中任一项所述的方法,其特征在于通过在所间隙(16)中抽吸真空来提高所述芯和所述金属层之间的粘附。
8.根据前述权利要求中任一项所述的方法,其特征在于所述芯是中空的以便形成管。
9.一种细长产品,包括具有塑料外表面的芯和在所述芯上挤塑的无缝管状金属层,其特征在于存在所述芯和所述金属层之间的粘合作用以及将所述芯和所述金属层压缩在一起的永久性压缩力,其中所述粘合作用是在不加热所述金属层的情况下或在另外加热所述金属层之前,通过活化将所述芯和所述金属层粘附在一起的材料而导致的。
10.根据权利要求9所述产品,其特征在于在所述芯的外表面上,所述芯包括压靠所述金属层的发泡材料。
11.根据权利要求9或10所述产品,其特征在于将所述金属层在所述芯上拉拔变细。
12.根据权利要求11所述产品,其特征在于在将所述金属层拉拔变细之后,使其退火以增加其柔性。
13.根据权利要求9~12中任一项所述的产品,其特征在于所述芯由具有记忆效应的材料制成,在将所述无缝金属层挤塑到所述芯上之前减小所述芯的外径,在将所述无缝金属层挤塑到所述芯上之前所述芯的初始外径大于所述无缝金属层的内径。
14.根据权利要求9~13中任一项所述的产品,其特征在于所述芯是中空的,使得所述产品是管。
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DE102017106979A1 (de) * | 2017-03-31 | 2018-10-04 | Doege Beteiligungs Gmbh | Verfahren zur Rohrbeschichtung und Beschichtungsanlage |
CN109821925A (zh) * | 2019-01-29 | 2019-05-31 | 张正周 | 一种复合管材的生产工艺 |
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EP1815918A1 (en) | 2007-08-08 |
EA200801618A1 (ru) | 2008-12-30 |
JP2013099787A (ja) | 2013-05-23 |
KR101359359B1 (ko) | 2014-02-07 |
AU2007211455A1 (en) | 2007-08-09 |
EA013855B1 (ru) | 2010-08-30 |
PL1986799T3 (pl) | 2017-04-28 |
WO2007088253A1 (en) | 2007-08-09 |
AU2007211455B2 (en) | 2012-07-05 |
AU2007211455A8 (en) | 2008-09-18 |
EP1986799B1 (en) | 2016-11-30 |
US8453310B2 (en) | 2013-06-04 |
CN101378857A (zh) | 2009-03-04 |
KR20080106507A (ko) | 2008-12-08 |
US20090304967A1 (en) | 2009-12-10 |
EP1986799A1 (en) | 2008-11-05 |
ES2608889T3 (es) | 2017-04-17 |
JP2009525188A (ja) | 2009-07-09 |
CA2640821C (en) | 2014-07-29 |
EP1986799A4 (en) | 2010-01-13 |
CA2640821A1 (en) | 2007-08-09 |
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