CN102947634A - 用于供水和供热系统的多层塑料管 - Google Patents
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Abstract
本发明提供用于供水和供热系统的多层塑料管,该塑料管属于工业和住房中使用的设备,包括用于供水和供热建筑和结构、商店,等等。本发明的技术效果由管子的结构实现,其中安装和生产技术,以及基于此的供水和供热系统得到简化,而所需的物理机械参数,如机械寿命、抗氧气扩散能力和管子的线性热膨胀系数有所降低。通过引入不少于三层的管子获取所述的技术效果,其中管子的一层由玻璃纤维或玄武岩纤维制成的稳定管子热膨胀系数的添加剂组成,添加剂的质量百分比为15-29%,剩下的是聚丙烯。含有稳定添加剂的层的厚度与由聚丙烯制成的内层和外层总厚度的比的范围为0.4-0.86,该比例取决于稳定添加剂的百分比含量。用于通过挤压制成的层的乙烯-乙烯醇和聚丙烯相互作用,该聚丙烯含有不同密度的聚丙烯形式,防止氧气扩散到管内。
Description
本发明涉及用于供水和供热系统的多层塑料管,其属于工业和住房中使用的设备,包括用于供水和供热建筑及结构、商店,等等。
用聚丙烯、聚丁烯制成的管子用于热水和冷水供应系统,如规格为PN10、PN16、PN20(政府标准P 52134-2003“适于供水和供热系统的热塑性塑料制成的压力管的一般技术说明”)。它们的缺点是有较高的线性热膨胀系数Ce=0.15mm/m.T(C,gr)。
热膨胀补偿通过系统中多种结构的补偿装置实现:如“∏”型、圆形或波纹管等。补偿装置的使用使得冷水、热水和热的供应系统的费用较高,增加了这些供应工作和服务的难度,并增加了系统的体积和重量,使得这些系统不能在现有的居住环境或工业建筑上安装。
另一种减少温度膨胀的方法是降低Ce,一个选择是加强管子。加强的聚丙烯管子的Ce主要由该加强材料的线性热膨胀系数决定。对应的加强材料的选择取决于管子所需的物理机械、经济、美学和卫生条件。
例如,用铝箔加强的塑料管用于供热和供水系统。该铝箔靠近管子表面设置,然后再涂覆塑料层,从而防止铝箔的机械损坏,并使得产品的外表美观。这种管子的线性热膨胀系数Ce要比规格为PN10、PN16、PN20、没有加强的聚丙烯管低5倍,为0.03mm/m.T(gr)。另外,铝箔作为保护屏障,能防止氧气从环境扩散到所输送的介质中。
不过,聚丙烯管的铝加强层使得用该管的供水和供热系统的安装复杂。在安装前,这些管子必须在安装的地点进行剥皮,除去铝箔,因为安装塑料的、特别是聚丙烯管和由相同材料制成的配件,需要通过熔接完成。如果在铝箔加强管中,通过加深使得铝箔层进一步离开表面(如,Dizayn Oxy Plus管通过这种方式完成),然后,在安装供水和供热系统时,剥去上层就不是必须的,但是必须剥去管子末端的铝。即,在所有的情况下,安装时,必须对用铝箔加强的管子进行清除。
而且,需要剥皮的加强铝管在生产过程中也需要将胶水层用于聚丙烯上,以固定管内的铝,从而熔接铝箔的接缝处。这些操作也使得加强的聚丙烯管的生产技术复杂,从而增加了产品的缺陷的可能性。
本发明的技术效果由管子的结构实现,其中安装和生产技术,以及基于此的供水和供热系统得到简化,并且获得所需的物理机械参数,如机械寿命、抗氧气扩散能力和管子的线性热膨胀系数。根据政府标准P 52134-2003(DIN 8077,16968),提供了符合标准和标准尺寸的聚丙烯配件。
通过挤制加工型的管子获得上述效果,该挤制加工型的管子用于供水和供热系统,由三层组成,其中内层和外层由聚丙烯构成,而中间层由聚丙烯的组合物组成,该组合物中不少于一种添加剂,从而稳定管子的线性热膨胀,该组合物是纤维的形式,比例如下:稳定线性热膨胀的添加剂的质量百分比为15-29%,剩下的是聚丙烯;中间层的厚度占管子的厚度0.4-0.86。
管子中间层的聚丙烯是必须的。这是因为,一方面,其为填充剂(类似于建筑混凝土中的钢筋),并允许纤维展开,和中间层中的单一加强结构形成材料时结合纤维中的添加剂,该层性能稳定;另一方面,其使得管子中所有的三层间形成稳定的结合。
管子线性热膨胀系数的重复性和稳定性在其生产和应用中是重要的。因为管子用铝箔加强而获得的系数使得管子在应用时具有满意的特征,技术问题必须在本发明中得到解决,和没有用加强层的管子的安装相比,本发明加强的聚丙烯管及其加强层不会使得系统的安装过程复杂。但同时,以这种方式加强的管子的线性热膨胀系数的值必须和用铝箔加强的管子的该系数的值接近。图1显示的是聚丙烯管(K3)、用铝带加强的管子(K1)和用纤维加强的管子(K2)的线性膨胀曲线。
具体型号的添加剂的选择取决于其线性热膨胀系数,因为其决定了管子中间层的Ce,并最终决定管子的Ce。除了目前的已知物质,热膨胀系数Ce最低的有玻璃纤维(Ce=0.003mm/m.T(C,gr))和玄武岩纤维(Ce=0.004mm/m.T(C,gr))。相应的,用玻璃纤维或玄武岩纤维或它们的混合物作为添加剂稳定管子和其中间层的线性热膨胀是合适的。鉴于此,和不用添加剂的聚丙烯管子的安装相比,中间层由该种添加剂和聚丙烯组成的管子的安装不需要更多的步骤。
用于供水和供热系统的管子的尺寸由政府标准制定(政府标准P52134-2003“适于供水和供热系统的热塑性塑料制成的压力管和它们的连接件的一般技术要求”)。尺寸的标准化,包括管子的厚度,导致需要解决稳定添加剂含量最优化的问题,以及管子中间层的厚度和其内层、外层厚度的比例的问题。
管子的内层和外层不必含有玻璃纤维或玄武岩纤维,理由如下:
对于内层,需要提供必要的卫生安全(玻璃纤维或玄武岩纤维用供应的水浸渍除外)、化学稳定性、抗撕裂,其必须确保供热和供水系统指定的使用寿命。例如,根据政府标准P 52134-2003,在温度20℃、PN对应的压力的情况下,管子的寿命是50年;以及
对于外层,要确保不会破坏中间层,并能提供足够的韧性熔接聚丙烯管和聚丙烯配件。
图2显示的是用纤维加强的用于供水和供热系统的管子的三层剖面图,图中:
1-管子;
2-管子内层;
3-管子中间层;
4-管子外层。
管子的各种参数定义如下:
ΔX-管壁的厚度;
α-管1的内径
β-管1的直径(或DN)
γ-内层2的厚度
δ-中间层3的厚度
ε-外层4的厚度
从对管子匀称和重复性的要求来看,特别是不同管径的线性膨胀,其符合:
δ/(γ+ε)=const=K
根据政府标准P 52134-2003:
β/ΔX=SDR,对于PN 25,SDR=5;PN20,SDR=6;PN10,SDR=7.4,等等。
定义ΔX=δ+γ+ε,
即δ==ΔX x K/(1+K)=β/SDR x K/(1+K)=DN/SDR x K/(1+K)
下面定义内层γ厚度的限制条件。
根据可得到的聚丙烯的测试数据,水和沙子的混合物对聚丙烯的磨损在1000个测试周期中小于0.2mm。而且,在50年内,脱落物质的磨损不能超过0.5mm。管子椭圆度的误差可以是0.5mm。内层得到的最小的厚度是0.9mm。接受内层为1mm是得当的。该厚度适于不同直径和PN的管子。
现在定义厚度ε的限制条件。
以DN20、PN20的管子作为一具体实例。
对于DN20、PN20的管子,管壁总厚度为3.4+0.6mm。配件内径D1为19mm。相应的,外层的厚度必须不小于0.5mm。根据政府标准52134-2003,管子DN20的最大直径为20.3mm。其表明,外层的厚度必须不小于0.65mm。考虑到配件和管子的轴对准误差值(接近3度),有必要要求外层的厚度误差达到0.5mm(管座熔接带的长度乘以sin3°)。
考虑到上述所说,DN20、PN20的管子的外层的最小厚度为1.15mm。
采用这种方法,我们将管子的外层厚度定义为20mm至160mm之间(表2的政府标准P 52134和表3的“管子末端和配件承口的尺寸”)。
中间层的最大厚度为:
ε=0.28x DN+0.6,γ=1;
δ=ΔX-(0.028x DN+0.6-1=ΔX-0.028x DN-1.6=
DN/SDR-0.028x DN-1.6=DN(1/SDR-0.028)-1.6
因此,常数δ/(γ+ε)=const=K,稳定的玻璃纤维含量百分比是有效的:
δ=ΔX x K/(1+K)=β/SDR x K/(1+K)=DN/SDR x K/(1+K)。
用中间层最大厚度得到方程式
δ=DN(1/SDR-0.28)-1.6或(δ+1.6)/ΔX=1-0.028xSDR,变量δ/(γ+ε)和玻璃纤维、玄武岩纤维或它们的混合物的含量的变化是有效的。
定义δ/ΔX的范围。对于SDR=5,是最吸引消费者的,δ/ΔX=0.4,SDR=0,则δ/ΔX=0.86;δ/ΔX的范围为0.4-0.86。SDR=7.4和更大时,δ/ΔX的范围如上所述。
通过挤压制成型的方法制成的管子中的加强纤维和聚丙烯的比例取决于多种因素。该比例有上限,因为混合物必须通过挤压机。另一方面,混合物的量必须具有所需的线性热膨胀系数值。
图3和4显示的是管子的线性热膨胀系数的曲线,其中中间层含有聚丙烯和纤维的混合物,纤维可以是玄武岩或玻璃纤维,δ/ΔX=0.5。
图4中的相关性分析显示,功能曲线上反映的第二衍生物标志的改变发生在对应混合物中玻璃纤维的含量约为20%的点。进一步降低线性膨胀系数受制于大量的玻璃纤维含量。同时,由于这些层中聚丙烯分子的结合,中间层、内层和外层之间的结合可能仅仅是技术性的。这种结合的寿命和中间层表面S上的聚丙烯的表面呈比例:
S=S1-k x S2,
其中S1是中间层和外层或内层的结合表面,
S2是结合面上玻璃纤维的表面,
K是中间层和外层或内层的结合寿命系数,即中间层的聚丙烯和其它层的聚丙烯的结合寿命。
为了获得这种情况下这些层之间结合的最大寿命,解决这个问题的方法必须确保满足下述条件:全部管子的寿命必须能保持在最长的水平,也就是说,有必要考虑中间层中含量为15-30%的玻璃纤维,即图4中显示第二衍生物附近的点显示值为零。玻璃纤维的含量为这些值(15-27%)时,有可能获得线性热膨胀系数的范围为0.03-0.05mm/mT(gr.C)。
类似的,图3中相关性分析显示,功能曲线上反映的第二衍生物标志的改变发生在对应混合物中玄武岩纤维的含量约为23%的点。玄武岩纤维的含量为16%-29%时,线性热膨胀系数的范围为0.03-0.05mm/mT(gr.C)。
相应的,一方面,可以通过改变中间层中稳定添加剂的含量百分比获得三层管子所需的线性热膨胀系数;另一方面,也可以通过改变管子中间层(完全由聚丙烯和添加剂制成)和管子外层和内存的厚度比获得三层管子所需的线性热膨胀系数。
通过调换图4中坐标轴δ/ΔX和中间层中稳定线性热膨胀的添加剂的百分比含量,获得层厚和玻璃纤维含量的变化与线管子性热膨胀系数的关系曲线:图5(玻璃纤维作为稳定管子线性热膨胀系数的添加剂)和图6(玄武岩纤维作为稳定管子线性热膨胀系数的添加剂)。
从图5和图6拟等势曲线可知,管子线性热膨胀系数区域在所需的范围Ce=0.03-0.05mm/mxK(gr)内,并通过数值范围为0.4-0.86的δ/ΔX、中间层中稳定管子热膨胀系数的添加剂玻璃纤维的质量百分比范围为13%-30%和添加剂玄武岩纤维的质量百分比范围15%-33%进行限制(如上所述)。
因此,排除极限值,如SDR=0,优选考虑范围内的数值,可以认为玻璃纤维能用作稳定添加剂,在中间层中优选的质量百分比范围为15-27%,剩下的为聚丙烯。对于玄武岩纤维,在中间层中优选的质量百分比范围为18-29%,剩下的为聚丙烯。将玄武岩纤维和玻璃纤维的混合物用作稳定添加剂时,在中间层中优选的质量百分比范围为15-29%,剩下的为聚丙烯。
为了扩展供水和供热系统的运用范围,其以防止氧气从外围环境扩散到聚丙烯管子内的聚丙烯管为基础进行安装,这些管子用含有不少于一层的防扩散层的物理机械性能改性的聚丙烯制成,如通过PP-R聚丙烯和乙烯-乙烯醇的相互作用进行改性。
用于供水和供热系统的聚丙烯是PP-R(3型),即丙烯和乙烯的无规、共混共聚物。当处理管子的聚丙烯层表面,或以纤维方式稳定管子线性膨胀的添加剂和聚丙烯的混合物组成的层、并用于挤压获得管子的任何层或加热状态时,乙烯-乙烯醇和聚丙烯(PP-R)中的聚乙烯反应。由此,一层的密度超过了聚丙烯的密度,晶格中原子的间距也小于丙烯中的原子间距。由于这些性能,管子中任一层的表面形成的阻挡层防止了氧气的扩散。
Claims (6)
1.一种用于供水和供热系统的多层塑料管,其通过挤压制成,不少于三层,其中的一层由聚丙烯和不少于一种的纤维形式的稳定线性热膨胀的添加剂组成的混合物制成,该添加剂的质量百分比为15-29%,剩下的是丙烯,相应的另外两层,即由聚丙烯制成的内层和外层和由聚丙烯和至少一种稳定线性热膨胀的添加剂组成混合物制成的一层的厚度,及外层(ε)、中间层(δ)和内层(γ)的厚度比例δ/(γ+ε)的范围为0.4-0.86。
2.权利要求1所述的用于供水和供热系统的多层塑料管,其中由聚丙烯制成的内层和外层和由聚丙烯和一种稳定线性热膨胀的添加剂组成混合物制成的一层中使用一种添加剂,该添加剂选自玻璃纤维,其质量百分比为15-27%,剩下的是聚丙烯。
3.权利要求1所述的用于供水和供热系统的多层塑料管,其中由聚丙烯制成的内层和外层和由聚丙烯和一种稳定线性热膨胀的添加剂组成混合物制成的一层中使用一种添加剂,该添加剂选自玄武岩纤维,其质量百分比为18-29%,剩下的是聚丙烯。
4.权利要求1所述的用于供水和供热系统的多层塑料管,其中由聚丙烯制成的内层和外层和由聚丙烯和一种稳定线性热膨胀的添加剂组成混合物制成的一层中使用两种添加剂,该两种添加剂选自玻璃纤维和玄武岩纤维,其合并的质量百分比为15-29%,剩下的是聚丙烯。
5.权利要求1所述的用于供水和供热系统的多层塑料管,其中进一步包括不少于一层的防扩散层。
6.权利要求5所述的用于供水和供热系统的多层塑料管,其中的防扩散层通过已经制成的层中的聚丙烯、或者是稳定线性热膨胀添加剂混合物制成的层中的聚丙烯与乙烯-乙烯醇的相互作用形成。
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