CN103057115B - 超高分子量聚乙烯膜片带热熔焊接管材的方法及其焊接机 - Google Patents

超高分子量聚乙烯膜片带热熔焊接管材的方法及其焊接机 Download PDF

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CN103057115B
CN103057115B CN201310047604.7A CN201310047604A CN103057115B CN 103057115 B CN103057115 B CN 103057115B CN 201310047604 A CN201310047604 A CN 201310047604A CN 103057115 B CN103057115 B CN 103057115B
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tubing
molecular weight
weight polyethylene
high molecular
welded bands
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CN103057115A (zh
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刘阜东
牟其善
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Shunfang Pipes Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/03—After-treatments in the joint area
    • B29C66/038—Covering the joint by a coating material
    • B29C66/0384—Covering the joint by a coating material the coating material being in tape, strip or band form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • B29C65/10—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
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    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
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    • B29C66/522—Joining tubular articles
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    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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Abstract

本发明提供了一种超高分子量聚乙烯膜片带热熔焊接管材的方法及其焊接机，包括下述步骤：①将待连接的管材或普通管材的接头处磨成斜面；②将两个管材接头对正后焊丝填平V型槽；③采用角磨机使焊缝的表面与管材外表面位于同一平面内；④将焊接机套在管材外周；⑤取单面的膜片焊接带一端牵引至管材焊接缝处，使滚轮压紧膜片焊接带一端。⑥打开焊接机上的热风枪；⑦转动焊接机，使焊接机沿管材外周接缝处转动。所述焊接机包括支架，支架上设置采用超高分子量聚乙烯制成的膜片焊接带，膜片焊接带的一端通过异形固定架贴在焊缝处，异形固定架一端固定热风枪。本发明能够快速牢固焊接超高分子量聚乙烯膜片管材接头及普通聚乙烯管材接头。

Description

超高分子量聚乙烯膜片带热熔焊接管材的方法及其焊接机
技术领域
 本发明涉及超高分子量聚乙烯膜片管材及普通聚乙烯管材接头焊接方法及热熔焊接机，是一种超高分子量聚乙烯膜片带热熔焊接管材的方法及其焊接机。
背景技术
由于申请人研制的超高分子量聚乙烯膜片具有极高的强度，同时具有较高的弹性模量、较好的耐高温及耐腐蚀性能等许多优点，具有广泛的应用价值。利用超高分子量聚乙烯膜片可以螺旋缠绕加热加压制成管材，在相同承压条件下，其壁厚可降至PE100管的1/5-1/3左右，大幅降低生产成本。但是，由于这种超高分子量聚乙烯膜片制成的管材的焊接方法不能采用现有技术中任一种焊接机，同时由于聚乙烯等塑料管材的连接始终是影响塑料管道使用的瓶颈之一，因此，如何在保证质量的前提下，能够快速牢固焊接超高分子量聚乙烯膜片管材接头及普通聚乙烯管材接头，是本领域技术人员需要研究的重要课题之一。
发明内容
本发明的目的是提供一种超高分子量聚乙烯膜片带热熔焊接管材的方法及其焊接机，它能够快速牢固焊接超高分子量聚乙烯膜片管材接头及普通聚乙烯管材接头，使管材接头焊接处的强度大于管材本体的强度。
本发明为实现上述目的，通过以下技术方案实现：超高分子量聚乙烯膜片带管材接头热熔焊接方法，包括下述步骤：
①将待连接的超高分子量聚乙烯膜片管材或普通聚乙烯管材的接头处磨成45°斜面；
②将两个管材接头对正后形成V型，用焊枪将聚乙烯焊丝沿V型槽焊接一周，热熔后的焊丝填平V型槽；
③采用角磨机将焊缝打磨平整，使焊缝的表面与管材外表面位于同一平面内；
④将超高分子量聚乙烯膜片带热熔焊接机套在管材外周，使步骤③焊接磨平后的管材接头位于焊接机的中间部位；
⑤取单面热覆粘结层的膜片焊接带一端牵引至管材焊接缝处，使覆粘结层的表面接触管材，将其不覆粘结层的一端打磨成楔形，使之紧贴管材连接处。调节焊接机上的滚轮和压轮的松紧度，使滚轮压紧膜片焊接带一端。
⑥打开焊接机上的热风枪，热风枪的出风口为扁平的喇叭形，出口的宽度与膜片带的宽度一致，对膜片焊接带粘结层面加热，同时对管材表面进行活化处理，热风枪喷出的热风温度控制在380℃-420℃，热风枪将膜片焊接带与焊缝贴合的内表面加热至240℃-280℃；
⑦转动焊接机，使焊接机沿管材外周接缝处转动。转动速度为0.3米/分钟- 0.6米/分钟，焊接机转动的同时,将内表面粘结层热熔后的膜片焊接带通过滚轮将其压贴在管材的焊缝处,压轮再对贴合在焊缝处的膜片焊接带外表面加压,使膜片焊接带与管材接头焊缝及管材外表面紧密熔合。
超高分子量聚乙烯膜片带热熔焊接管材的焊接机，包括支架，支架上设置采用超高分子量聚乙烯制成的膜片焊接带，膜片焊接带的一端通过异形固定架贴在焊缝处，异形固定架一端固定热风枪，热风枪位于膜片焊接带上端，异形固定架安装热风枪的一端外壁上安装可调架，可调架上安装滚轮，异形固定架水平方向一侧与连杆固定，异形固定架水平方向另一侧与丝杆连接，丝杆外周壁上设置压紧弹簧，丝杆一端固定压轮架，压轮架上安装压轮，异形固定架绕管材外周转动时，滚轮及压轮均与管材外壁上热熔的膜片焊接带相触。异形固定架由至少4个平面板呈不同角度相互连接构成弓形。异形固定架由平面板及弧面板相互连接构成敞口圆状。异形固定架由曲面板构成敞口圆状。异形固定架由第一直板、第一斜板、平面板、第二斜板及第二直板依次相互连接构成，可调架安装在第二直板或第二斜板上。膜片焊接带的宽度是待焊管材壁厚的10-17倍，膜片焊接带的厚度为2-4.5毫米，长度为待焊管材周长的3-5倍。可调架上安装的滚轮为两个，两个滚轮上下排列，滚轮的宽度大于膜片焊接带的宽度。
本发明提供的超高分子量聚乙烯膜片带热熔焊接管材的方法及其焊接机，能牢固地将超高分子量聚乙烯膜片管材或普通聚乙烯管材连接起来，管材接头外周的焊接材料与管材的基材属于同分子结构，粘合力强，冷却后焊缝处的强度大于管材本体强度。本发明焊接方法中先将管材接头边沿磨成45°角，再初焊V型槽，之后再大面积热熔焊接的方法，使管材在使用寿命期限内，管材的接头处不出现裂缝等任何质量问题，经检测：管材的接头处的强度大于管材本身的强度，有效提高了超高分子量聚乙烯膜片管材及普通聚乙烯管材的工程质量和使用寿命。本发明提供的超高分子量聚乙烯膜片带热熔焊接机，是专用于超高分子量聚乙烯膜片管材及普通聚乙烯管材的两管连接处，它能够快速、连续焊接，不需要管材转动，只需焊接机绕管材周壁行走即可，能够适用于焊接各种口径的管材，特别是解决了大型管材焊接时的耗电、耗人力、需要较多支撑部件的繁琐操作，节省能源，降低了生产成本，能够使膜片焊接带大面积热熔在管材接头处，使管材接头处的安全性大大提高，经过破坏性检测表明，用本发明所述的超高分子量聚乙烯膜片带热熔焊接机焊接的管材接头处的强度大于管材本身的强度。
附图说明
附图1是本发明超高分子量聚乙烯膜片带热熔焊接管材的焊接机的结构示意图；附图2是附图1的A向结构示意图；附图3是附图2的B-B剖视结构示意图，为超高分子量聚乙烯膜片管材接头焊接后的结构示意图。
具体实施方式
本发明提供的超高分子量聚乙烯膜片带热熔焊接管材的方法，包括下述步骤：
①将待连接的超高分子量聚乙烯膜片管材或普通聚乙烯管材的接头处磨成45°斜面；
②将两个管材接头对正后形成V型，用焊枪将聚乙烯焊丝沿V型槽焊接一周，热熔后的焊丝填平V型槽；
③采用角磨机将焊缝打磨平整，使焊缝的表面与管材外表面位于同一平面内；
④将超高分子量聚乙烯膜片带热熔焊接机套在管材外周，使步骤③焊接磨平后的管材接头位于焊接机的中间部位；
⑤取单面热覆粘结层的膜片焊接带一端牵引至管材焊接缝处，使覆粘结层的表面接触管材，将其不覆粘结层的一端打磨成楔形，使之紧贴管材连接处。调节焊接机上的滚轮和压轮的松紧度，使滚轮压紧膜片焊接带一端。
⑥打开焊接机上的热风枪，热风枪的出风口为扁平的喇叭形，出口的宽度与膜片带的宽度一致，对膜片焊接带粘结层面加热，同时对管材表面进行活化处理，热风枪喷出的热风温度控制在380℃-420℃，热风枪将膜片焊接带与焊缝贴合的内表面加热至240℃-280℃；
⑦转动焊接机，使焊接机沿管材外周接缝处转动。转动速度为0.3米/分钟- 0.6米/分钟，视膜片焊接带表面粘结层的熔化程度而定，既要保证膜片焊接带牢固地粘结到管材接缝处，又要防止管材接缝和膜片焊接带局部受热过度导致收缩变形或表面烧损。焊接机转动的同时,将内表面粘结层热熔后的膜片焊接带通过滚轮将其压贴在管材的焊缝处,压轮再对贴合在焊缝处的膜片焊接带外表面加压,使膜片焊接带与管材接头焊缝及管材外表面紧密熔合。
本发明焊接方法中使用的膜片焊接带为长条状，其宽度是待焊管材壁厚的8-16倍，膜片焊接带11的厚度为2-4.5毫米，膜片焊接带11的长度为待焊管材周长的3-5倍，膜片焊接带11的纵向抗拉强度大于150 MPa，断裂伸长率大于60%，横向拉伸强度大于35 MPa，断裂伸长率大于100%。本发明使用的膜片焊接带11的内表面上热覆一层线性低密度聚乙烯薄膜，该薄膜的熔点较膜片焊接带11的熔点低，流动性好，利于与待焊接头的管材的热熔焊接，本发明限定的膜片焊接带11的长度、宽度和厚度保证了管材接头焊缝处的强度，特别是在高压试验中，焊缝处不出现开裂等任何质量问题。
本发明所述的焊接方法中使用的热熔焊接机是本发明的独特设计，其结构如附图1、附图2所示，该焊接机有一支架，支架上设置采用超高分子量聚乙烯制成的膜片焊接带11，膜片焊接带11的一端通过异形固定架贴在焊缝处，异形固定架一端固定热风枪10，热风枪10位于膜片焊接带11上端，异形固定架安装热风枪的一端外壁上安装可调架9，可调架9上安装滚轮2，异形固定架水平方向一侧与连杆14固定，异形固定架水平方向另一侧与丝杆5连接，丝杆5外周壁上设置压紧弹簧6，丝杆5一端固定压轮架19，压轮架19上安装压轮8，异形固定架绕管材外周转动时，滚轮2及压轮8均与管材外壁上热熔的膜片焊接带11相触。
所述异形固定架有多种结构形状，优选的结构有以下几种：异形固定架由至少4个平面板呈不同角度相互连接构成弓形，4个平面中有一个底平面板，底平面板两端分别连接两个相同结构并与底平面板形成相同角度的侧平面板，该角度为45°-65°，两个侧平面板中的一个侧平面板的一端与垂直平面板连接。垂直平面板上安装丝杆5、压轮架19及压紧弹簧6调节等结构，另一个侧平面板的一端与可调架9连接，这种结构便于带动焊接机沿不同口径的管材转动，并可提高生产效率。
异形固定架由平面板及弧面板相互连接构成敞口圆状，该结构的平面板设计在底部，底部的平面板两端分别连接弧面板，其中一个弧面板与丝杆5固定，丝杆5上安装压轮架19及压紧弹簧6等结构，另一个弧面板上安装可调架9，这种结构的优点在于：制造成本低的前提下，可进一步提高生产效率，并可适用多个口径的管材。
异形固定架由曲面板构成敞口圆状，这种结构的优点在于制造成本低，安装方便。
异形固定架的另一优选结构是，它由第一直板22、第一斜板24、平面板3、第二斜板25及第二直板26依次相互连接构成，可调架9安装在第二直板26或第二斜板25上，如图1所示，第一直板22下端与第一斜板24上端连接，第一斜板24下端与平面板3一端连接，平面板3另一端与第二斜板25下端连接，第二斜板25上端与第二直板26下端连接，第一直板22与丝杆5固定。
焊接机支架上的膜片焊接带11为长条状，其宽度是待焊管材壁厚的10-17倍，膜片焊接带11的厚度为2-4.5毫米，膜片焊接带11长度为待焊管材周长的3-5倍，这种膜片焊接带11的结构形状实现了接头处的大面积热熔，并进一步保证了该接头处的强度、硬度及弹性等各种技术性能与管材基体的性能相同。
本发明所述超高分子量聚乙烯膜片带热熔焊接管材的焊接机上安装的可调架9上安装的滚轮2为两个，两个滚轮2上下排列，滚轮2的宽度大于膜片焊接带11的宽度，可进一步增加滚轮2的压合力度，并进一步增强了膜片焊接带11与管材的粘接强度。
图中：1把手 2滚轮 3直面板 4手轮  5丝杆  6压紧弹簧 7第一螺母  8压轮 9可调架 10热风枪 11膜片焊接带 12第一管材 13第二管材 14连杆 15调节槽 16第一支架 17第二滚轮 18连接板 19固定板 20固定杆 21挡板 22第一直板 23第二螺母 24第一斜板 25第二斜板 26第二直板 27焊丝。

Claims (9)

1.超高分子量聚乙烯膜片带热熔焊接管材的方法，其特征在于：包括下述步骤：
①将待连接的超高分子量聚乙烯膜片管材或普通聚乙烯管材的接头处磨成45°斜面；
②将两个管材接头对正后形成V型，用焊枪将聚乙烯焊丝沿V型槽焊接一周，热熔后的焊丝填平V型槽；
③采用角磨机将焊缝打磨平整，使焊缝的表面与管材外表面位于同一平面内；
④将超高分子量聚乙烯膜片带热熔焊接机套在管材外周，使步骤③焊接磨平后的管材接头位于焊接机的中间部位；
⑤取单面热覆粘结层的膜片焊接带一端牵引至管材焊接缝处，使覆粘结层的表面接触管材，将其不覆粘结层的一端打磨成楔形，使之紧贴管材连接处；调节焊接机上的滚轮和压轮的松紧度，使滚轮压紧膜片焊接带一端；
⑥打开焊接机上的热风枪，热风枪的出风口为扁平的喇叭形，出口的宽度与膜片带的宽度一致，对膜片焊接带粘结层面加热，同时对管材表面进行活化处理，热风枪喷出的热风温度控制在380℃-420℃，热风枪将膜片焊接带与焊缝贴合的内表面加热至240℃-280℃；
⑦转动焊接机，使焊接机沿管材外周接缝处转动；转动速度为0.3米/分钟- 0.6米/分钟，焊接机转动的同时,将内表面粘结层热熔后的膜片焊接带通过滚轮将其压贴在管材的焊缝处,压轮再对贴合在焊缝处的膜片焊接带外表面加压,使膜片焊接带与管材接头焊缝及管材外表面紧密熔合；膜片焊接带的内表面热覆线性低密度聚乙烯层作为粘结层。
2.根据权利要求1所述的超高分子量聚乙烯膜片带热熔焊接管材的方法，其特征在于：膜片焊接带为长条状，膜片焊接带的宽度是待焊管材壁厚的8-16倍，膜片焊接带（11）的厚度为2-4.5毫米，长度为待焊管材周长的3-5倍。
3.超高分子量聚乙烯膜片带热熔焊接管材的焊接机，其特征在于：包括支架，支架上设置采用超高分子量聚乙烯制成的膜片焊接带（11），膜片焊接带（11）的一端通过异形固定架贴在焊缝处，异形固定架一端固定热风枪（10），热风枪（10）位于膜片焊接带（11）上端，异形固定架安装热风枪的一端外壁上安装可调架（9），可调架（9）上安装滚轮（2），异形固定架水平方向一侧与连杆（14）固定，异形固定架水平方向另一侧与丝杆（5）连接，丝杆（5）外周壁上设置压紧弹簧（6），丝杆（5）一端固定压轮架（19），压轮架（19）上安装压轮（8），异形固定架绕管材外周转动时，滚轮（2）及压轮（8）均与管材外壁上内表面粘结层热熔的膜片焊接带（11）外表面相接触。
4.根据权利要求3所述的超高分子量聚乙烯膜片带热熔焊接管材的焊接机，其特征在于：异形固定架由至少4个平面板呈不同角度相互连接构成弓形。
5.根据权利要求3所述的超高分子量聚乙烯膜片带热熔焊接管材的焊接机，其特征在于：异形固定架由平面板及弧面板相互连接构成敞口圆状。
6.根据权利要求3所述的超高分子量聚乙烯膜片带热熔焊接管材的焊接机，其特征在于：异形固定架由曲面板构成敞口圆状。
7.根据权利要求3所述的超高分子量聚乙烯膜片带热熔焊接管材的焊接机，其特征在于：异形固定架由第一直板（22）、第一斜板（24）、平面板（3）、第二斜板（25）及第二直板（26）依次相互连接构成，可调架（9）安装在第二直板（26）或第二斜板（25）上。
8.根据权利要求3所述的超高分子量聚乙烯膜片带热熔焊接管材的焊接机，其特征在于：膜片焊接带（11）的宽度是待焊管材壁厚的8-16倍，膜片焊接带（11）的厚度为2-4.5毫米，长度为待焊管材周长的3-5倍。
9.根据权利要求3所述的超高分子量聚乙烯膜片带热熔焊接管材的焊接机，其特征在于：可调架（9）上安装的滚轮（2）为两个，两个滚轮（2）上下排列，滚轮（2）的宽度大于膜片焊接带（11）的宽度。
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