CN103527885A - 有网孔结构电热元件的塑料管道电熔连接件及其制备方法 - Google Patents

有网孔结构电热元件的塑料管道电熔连接件及其制备方法 Download PDF

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CN103527885A
CN103527885A CN201210232085.7A CN201210232085A CN103527885A CN 103527885 A CN103527885 A CN 103527885A CN 201210232085 A CN201210232085 A CN 201210232085A CN 103527885 A CN103527885 A CN 103527885A
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connecting piece
electric heating
heating element
mesh
resistance material
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CN103527885B (zh
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孙志强
邵信元
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NINGBO HENGYUAN PRECISION VALVES TECHNOLOGY CO., LTD.
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孙志强
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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
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/522—Joining tubular articles
    • B29C66/5221—Joining tubular articles for forming coaxial connections, i.e. the tubular articles to be joined forming a zero angle relative to each other
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L47/00—Connecting arrangements or other fittings specially adapted to be made of plastics or to be used with pipes made of plastics
    • F16L47/02—Welded joints; Adhesive joints
    • F16L47/03—Welded joints with an electrical resistance incorporated in the joint
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3404—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint
    • B29C65/3444—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint being a ribbon, band or strip
    • B29C65/3448—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint being a ribbon, band or strip said ribbon, band or strip being perforated
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3472—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint
    • B29C65/3476—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint being metallic
    • B29C65/348—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint being metallic with a polymer coating
    • 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
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • 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
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/522—Joining tubular articles
    • B29C66/5229—Joining tubular articles involving the use of a socket
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L43/00—Bends; Siphons
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L47/00—Connecting arrangements or other fittings specially adapted to be made of plastics or to be used with pipes made of plastics
    • F16L47/26—Connecting arrangements or other fittings specially adapted to be made of plastics or to be used with pipes made of plastics for branching pipes; for joining pipes to walls; Adaptors therefor
    • F16L47/32—Branch units, e.g. made in one piece, welded, riveted
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3404—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint
    • B29C65/342—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint comprising at least a single wire, e.g. in the form of a winding
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3468—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the means for supplying heat to said heated elements which remain in the join, e.g. special electrical connectors of windings
    • 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
    • B29C66/70—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
    • B29C66/71—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 composition of the plastics material of the parts to be joined

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  • Engineering & Computer Science (AREA)
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  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Branch Pipes, Bends, And The Like (AREA)
  • Manufacturing & Machinery (AREA)

Abstract

本发明公开了一种有网孔结构电热元件的塑料管道电熔连接件及其制备方法，该连接件内置圆筒状电热元件，其由沿电熔连接件内壁等间距布置，沿该筒壁呈连续的几字形排布的网孔结构的电阻材料条和同材料的塑料条构成。其制备方法包括以下步骤：1)制备网孔结构的电阻材料条；2)将步骤1)制备的网孔结构的电阻材料条表面固接同材料塑料条，将其卷成圆筒状电热元件；3)将步骤2)制备的圆筒状电热元件插入注塑模具中，按照常规的注塑成型工艺注塑获得成品。本发明连接件的电热元件结构稳定，其制备方法采用常规机械设备，并可制备多规格管道连接件，为特大口径的电熔连接件制造提供了技术平台，并能使连接件的焊接温度保持在所需温度，避免了短路和断路。

Description

有网孔结构电热元件的塑料管道电熔连接件及其制备方法
技术领域
本发明涉及一种电熔连接件及其制备方法，具体而言，本发明涉及一种有网孔结构电热元件的塑料管道电熔连接件及其制备方法。
背景技术
随着塑料管道的大量普及，由塑料管道连接件的缺陷引起的连接问题越来越突出，一直是制约管道施工的主要因素。塑料管道的连接方法按大类分为二种，第一种是胶水粘接，如PVC，PA，ABS等材料做成的管道，第二种就是热熔连接，如PE、PP、PE-RT等材料做成的管道。热熔连接又可分为以下三种方式：热熔对接、承插热熔连接、电熔连接，其中电熔连接由于具有不可替代的优越性能(特别是在钢丝网骨架管及PE燃气管道领域)而被市场全方位推崇。电熔连接为一种“热塑性塑料电熔连接件与管子间的接合。电熔连接件由嵌入在它和管子之间的接合面内的加热元件通过焦耳效应加热，使它们周围的材料熔化，从而使管子和管件表面熔在一起。”
九十年代开发的电熔连接件是按英国尤波诺公司制造工艺生产的，即市场上普遍使用的裸露丝电熔连接件。由于在使用中电热丝经常脱落、并丝而造成短路，在尺寸配合有偏差或椭圆度过大时，插入管件可造成断路，制造该种电熔连接件对操作工人的熟练程度要求相对较严，按该种生产工艺制造的废品率高。
为了避免上述缺陷，有厂家按韩国大莲精工的工艺着手开发了包塑电热丝的电熔连接件，就是将电热丝包塑成电线形状，再按要求绕制在注塑模型芯上注塑成型，冷却后脱模得到成品(见图1)。然而用这种包塑丝工艺生产的电熔连接件，虽然部分解决了裸露电热丝电熔连接件插入断线的缺陷，但由于在包塑时必须采用高温拉丝和低温水冷却，在电热线的表面形成了无法去除的氧化层，阻隔了管材与管件的熔化材料流动再结晶，所以一般采用此种工艺的电熔连接件的剥离强度无法与裸露电热丝电熔连接件相比。
基于前二种的工艺存在的缺陷以及劳动力成本的上升，部分厂家引入自动后布丝工艺和设备，在工艺上实现了自动化生产，增加了管道可配合尺寸的精度，但自动后布丝的方法需专用设备，而且价格昂贵，并且该方法由于仍然属于单线布丝的传统工艺，制备出的电热元件为单丝绕制，此种电热元件无论是隐蔽丝还是裸露丝，均可能产生熔接短路的后果。
综上所述，现有的电熔连接件由于均采用轴向布线(与管材插入的方向呈垂直角度的方向)，在通电焊接时，其温度可能高于保持塑料管道所需的温度且还会产生熔胀压力，使电热丝位移而造成短路，导致焊接失败甚至管件报废。此外，轴向布线的连接件与管道的配合不可能是同径配合，肯定存在一定间隙，插入管件可造成断路。因此，需要一种能避免上述温度过高、短路和断路的情况的、价格适中、制造成本低、质量稳定的电熔连接件。
发明内容
为了解决现有技术中采用轴向布线导致的连接时温度过高且易于短路，连接件和管道尺寸不配合而易于断路的问题，本发明提供了一种有网孔结构电热元件的塑料管道电熔连接件，所述的电熔连接件内置圆筒状电热元件，该圆筒状电热元件由沿电熔连接件内壁等间距布置的网孔结构的电阻材料条和与所述的电熔连接件材料相同的塑料条构成。所述的网孔结构的电阻材料条沿所述圆筒状电热元件的筒壁呈连续的几字形排布；所述的塑料条与所述的网孔结构的电阻材料条固接并且围成所述的圆筒状电热元件的内筒壁。
所述网孔结构的电阻材料条的总电阻必须符合所述有网孔结构电热元件的塑料管道电熔连接件的电流密度要求。电流密度是指表面负荷功率，一般电工学中的电流密度是指在同样截面的导线中通过的电流，由于导线的电阻不同，通过的电流大小不同，电阻越大，电流越小，功率越小，分配到表面的负载功率就越小，反之则表面的负载功率越大，材料表面发热点越集中，如轴向布线的电熔管件经常焊爆的现象就是电热丝短路后短时间表荷功率呈几何上升引发的后果，如果在焊接时间内材料表面发热不足以使与电热元件接触的塑料迅速分解碳化，其表面负荷功率符合塑料管道电熔连接件的电流密度要求。比如，根据PE材料的导热系数0.33W/m·K和材料密度0.92g/cm3计算，PE材料的熔化温度最高值为240℃，焊接电压为39.5V时(国标规定)，其表荷功率控制在1.5～2.2W·cm2为理想值，超过这个值就会分解PE材料的分子结构，仍至碳化。此外，所述电阻材料条可以由适合各规格塑料管道电熔连接件强度的合金电阻薄板材料制成，即所选用的电阻材料通电发热对管道的塑料材料熔化、冷却后得到的结晶体的拉伸强度应不小于同体积的电阻材料或管道的塑料材料的拉伸强度。所述结晶体的拉伸强度主要与电阻材料的电阻率有关，在输入额定电压后产生的表面负荷功率应能保证塑料分子结构不分解，这样的合金电阻薄板材料的电熔连接件强度符合塑料管道电熔连接件强度的要求。比如，上述PE材料在焊接电压为39.5V时，电阻率在常温下取值为0.90～1.28μΩ·m。所述合金电阻薄板材料包含铬和铼，铬的含量为15-24.5重量％，还可以包含铁或同时包含铁和铝，其中铝的含量为0.35重量％，该材料的使用温度为1100-1200℃，熔点为1400℃，密度为8.1-8.3g/cm3，20℃的电阻率为0.98-1.11μΩ·m，抗拉强度为750Mpa，延伸率为25％，反复弯曲次数>5，快速寿命为50h/℃。
本发明所采用的合金电阻薄板材料优选下表1中所示材料：
表1
Figure BDA00001855450100031
Figure BDA00001855450100041
本发明的有网孔结构电热元件的塑料管道电熔连接件中，所述网孔结构的电阻材料条中的孔可以是正方形，也可以是长方形或其他多边形，每个孔内任意不相邻顶点之间距离的平均值为所述电阻材料条厚度的5倍至10倍，其中构成每个网孔的边筋的宽度(即电阻材料条各边筋的宽度以及各网孔周边边筋的宽度)为所述电阻材料条厚度的1至3倍。所述有网孔结构电热元件的塑料管道电熔连接件与塑料管道的熔接面应不小于该塑料管道横截面中管材壁面积的2倍，在焊接带有钢骨架塑料管时，所述有网孔结构电热元件的塑料管道电熔连接件与塑料管道的熔接面应不小于该塑料管道横截面中管材壁面积的4倍。
本发明还提供了制备上述有网孔结构电热元件的塑料管道电熔连接件的方法，其包括以下步骤：
1)制备网孔结构的电阻材料条；
2)将步骤1)制备的网孔结构的电阻材料条表面固接与所制备的塑料管道电熔连接件材料相同的塑料条，将其卷成圆筒状电热元件；
3)将步骤2)制备的圆筒状电热元件插入到电熔连接件的注塑模具中，接入引出线和电极桩，按照常规的注塑成型工艺注塑即获得电熔连接件成品。
用上述方法可生产多种规格或型号的电熔连接件，例如直通、变径、弯头、三通、四通、法兰和管帽等。
所述的电熔连接件的制备方法，其特征在于，所述的步骤1)采用下列方法：
方法A：
A1-1)根据所述的电熔连接件的规格将电阻材料按焊接带所需宽度切成带状材料；
A1-2)将步骤A1-1)切成的带状材料根据所述的电熔连接件的焊接面积冲孔压制，制成孔网带，再将所制备的孔网带制成网孔结构的电阻材料条(通常将所述孔网带冲模落料而成)；
步骤1)也可以采用以下方法AA：
AA1-1)根据所述的电熔连接件的内径、电阻材料的收缩特性和所述的电熔连接件的熔接面积，将所述电阻材料切成沿所制备的网孔结构的电阻材料条的长度方向呈连续的几字形排布的电阻材料条；
AA1-2)在步骤AA1-1)切成的沿长度方向呈连续等间距的几字形排布的电阻材料条的中间冲孔，制成网孔结构的电阻材料条。
所述的步骤2)采用下列方法之一：
方法B：注塑成型电热元件
B2-1)设计相对应规格的注塑模并将注模塑造成型，所述注塑模能使步骤1)所制备的网孔结构的电阻材料条卷曲后放入其模具型腔；
B2-2)模具结构采用油缸抽插型芯，抽插型芯的端面应设有圆角，便于插入弯曲的电阻材料条，型芯直径与对应管件的内径等同，在模具上先用活动镶块/压块在电阻材料条的宽度中间压住，活动镶块/压块的宽度是电阻材料条宽度的二分之一，这样做的目的有两个，一是压紧电阻材料条，在注射塑料时电阻材料条不会受挤压变形，二是预留了注塑成品时的空间，使电阻材料条与成品内壁紧密相连，保证电熔连接件内孔的尺寸稳定，闭模注塑后在电阻材料条的外径形成塑料条，冷却脱模后成为圆筒状电热元件。
上述方法较适于Dn200以下规格连接件的批量生产，该方法成型快速，自动化程度高，劳动力成本低，所生产的连接件尺寸稳定。
方法C：网孔结构的电阻材料条与塑料薄条挤出后同步热压成型
C2-1)在步骤1)制备的网孔结构的电阻材料条上用塑料薄条挤出机连续热压与所连接的塑料管道材料相同的塑料条，热压即将网孔结构的电阻材料条放置在塑料薄条挤出的出口下面，塑料薄条挤出尚未冷却时用二个滾轮同时挤压电阻材料条和塑料薄条，使塑料薄条的部分材料嵌入网孔结构的电阻材料条的网孔，从而形成二种材料合成的一个整体，便于步骤C2-2)的操作；
C2-2)将在步骤C2-1)中形成的压上塑料条的网孔结构的电阻材料条切成所要配置规格电熔连接件的内径长度，在工装上卷成筒状，将其压上的塑条对焊后成为圆筒状的电热元件。
上述方法适用于批量生产Dn315以上Dn630以下的电熔连接件。
方法D：
D2-1)在步骤1)制备的网孔结构的电阻材料条上用超声波焊机将其与所连接的塑料管道材料相同的塑料条平焊；
D2-2)将在步骤D2-1)中形成的焊上塑料条的网孔结构的电阻材料条在与成品注塑模具同尺寸的工装上卷成筒状，将其焊上的塑条对焊后成为圆筒状的电热元件。
由上述制备有网孔结构电热元件的塑料管道电熔连接件的方法所得的与所连接的塑料管道材料相同的所述塑料条的厚度为所述电热元件电阻材料厚度的2至5倍，在二次注塑时，能保证电热元件的几字型单元不受注塑压力而变形。
本发明的有网孔结构电热元件的塑料管道电熔连接件具有以下优势：
1、网孔结构电热元件的结构比轴向布线的电热丝结构稳定，使得焊接时的输出功率恒定，即使发生输入电压波动也不可能短路(甚至在电熔连接件熔焊至外形变形时，其电阻值仍保持不变)，确保施工的顺利进行，杜绝事故隐患，保证管线的安全运行。
2、网孔结构电热元件适用于任何型号管道连接件的制造，包括中小规格甚至特大口径的电熔连接件，也使无法用单线绕丝制造的特大口径电熔连接件如Dn710、Dn800、Dn900、Dn1000、Dn1200、Dn1600等的制造提供了技术支撑，避免了由于大口径连接件和管道的尺寸配合椭圆度精度较差而导致的断路。
3、网孔结构的电热元件，在同样电阻值(功率)的前提下，增加了发热面积，降低了表荷功率(电流密度)，使电热元件传导温度保持在塑料所需200℃至240℃的温度范围内。
4、可预制电热元件的工艺为流水线作业提供了技术平台。
5、制备方法可以采用常规机械设备全工位实现自动化生产，采用流水线作业，降低制造成本，避免人为操作因素引发的质量不稳定。
6、与后布丝工艺相比，制备本发明的电熔连接件无需专用设备，进一步降低制造成本，选用国产常规机械设备(主要是冲床)即可满足工艺需要。
此外，本发明还具有便于施工、质量稳定可靠、使用寿命长、抗地基沉降性能优越、气密性好、综合成本低(与传统工艺相比，本发明的电熔连接件经工时计算可以节省50％劳动用工)、操作的劳动强度低等优势。
附图说明
图1-a为现有技术中包塑电热丝电熔连接件的局部剖视示意图，其中3表示包塑电热丝。
图1-b为现有技术中包塑电热丝电熔连接件的包塑电热丝的结构示意图，其中1表示与制造连接件同种材料的包皮，2表示电阻丝。
图1-c为现有技术中包塑电热丝电熔连接件的包塑电热丝的剖视图。
图2为本发明实施例1所制备的孔网带的示意图，其中4表示预留固定用折边脚子，5表示焊接带宽度。
图3为本发明实施例1所制备的网孔结构的电阻材料条的示意图。
图4为本发明实施例1所制备的热压塑料条的电阻材料条的示意图。
图5为本发明实施例1所制备的圆筒状电热元件的示意图。
图6为本发明实施例1所制备的塑料管道电熔连接件成品(直通)的示意图。
具体实施方式
下面结合实施例，进一步说明本发明。
实施例1
制备规格直通Dn200的塑料管道的电熔连接件，选择表1中牌号为GH140，厚度为1mm，电阻率为1.04的合金电阻薄板材料，该材料包含20％的铬(Cr)，0.35％的铝(Al)，其余为铁(Fe)和铼(Re)，具体实施工序如下：
1、按照Dn200的连接件的规格将上述材料按焊接带所需宽度切成宽为48mm的带状材料；
2、将带状材料以给进冲模的冲压工艺连续在该带上冲压5x5mm的棱形孔，构成每个网孔的边筋的宽度为2mm，并将所得孔网带按电熔连接件的内径周长减5mm冲模落料，Dn200电熔连接件的内径周长长度631.5-5=626.5mm，制成网孔结构的电阻材料条。所述有网孔结构电热元件的塑料管道电熔连接件与塑料管道的熔接面为Dn200塑料管道横截面中管材壁面积的2倍。所述网孔结构由相同形状的菱形网孔并排沿所得电热元件带的长度方向呈连续等间距的几字形排布而成，所述电阻材料条宽度方向上相邻菱形网孔的相交的两个边的呈角为103°。几字型的单元分割按电熔连接件的功率要求值分配，Dn200规格电阻值要求为0.95Ω至0.98Ω。48mm宽1mm厚的电阻材料带冲孔后的米电阻为0.08Ω/m，为了达到电阻值，几字型单元格应分为13mm宽的49个单元格，这样导体的长度就增加了3倍，导体截面减小了50％，按相关公式计算，每条的体积电阻为0.48Ω，二个电热元件为一组串连后电阻为0.96Ω，符合Dn200电熔连接件的功率要求；
3、设计注塑模具，所述注塑模能使上述步骤制备的网孔结构的电阻材料条卷曲后放入其模具型腔；
4、模具结构采用油缸抽插型芯，抽插型芯端面设有圆角，便于插入弯曲的电阻材料条，型芯直径与对应管件的内径等同，在模具闭模前上先用活动镶块在电阻材料条的宽度中间压住，活动镶块的宽度是电阻材料条宽度的二分之一，这样做的目的有两个，一是压紧电阻材料条，在注射塑料时电阻材料条不会受挤压变形，二是预留了注塑成品时的空间，使电阻材料条与成品内壁紧密相连，保证电熔连接件的内孔尺寸稳定。闭模后压紧预留的二次注塑用的部分，注塑后即成塑料壁厚为2至3mm的圆筒状电热元件；
5、将二个电热元件串连，并在二个元件的外端分别接上引出线和电极桩；
6、设计成品外形模，将组合的电热元件正确放入成品模，注塑、冷却脱模后即可。
实施例2
制备规格直通Dn630的塑料管道的电熔连接件，选择表1中牌号为Cr15Ni60，电阻率为1.1，厚度为1.5mm的合金电阻薄板，该材料包含15％的铬(Cr)，其余为铼(Re)，具体实施工序如下：
1、将以上指定的材料切成宽度为140mm电阻材料条；
2、继而在电阻材料条的中间冲孔，每个孔内任意不相邻顶点之间距离的平均值为8mm，构成每个网孔的边筋的宽度为2mm。所述有网孔结构电热元件的塑料管道电熔连接件与塑料管道的熔接面为Dn630塑料管道横截面中管材壁面积的2倍。所述网孔结构由相同形状的菱形网孔并排沿所得电热元件带的长度方向呈连续等间距的几字形排布而成，所述电阻材料条宽度方向上相邻菱形网孔的相交的两个边的呈角为103°。将带状电热元件条切成Dn630电熔连接件的内径周长，长度1979-8=1971mm，宽度为140mm的长方形条，几字型的单元分割按电熔连接件的功率要求分配，Dn630规格要求电阻为0.80Ω至0.84Ω。140mm宽1.5mm厚的电阻材料带冲孔后的米电阻为0.024Ω/m，为了达到电阻值，将几字型的单元格应分为42mm宽的47个单元格，这样导体的长度就增加了4倍，导体截面减小了47％，按相关公式计算，每条的体积电阻为0.41Ω，二个电热元件为一组，符合Dn630电熔连接件的功率要求；
3、在上述步骤制备的网孔结构的电阻材料条带上用塑料薄条挤出机连续复上与所连接的塑料管道材料相同的塑料条带；
4、将在步骤5中形成的压上塑料条带的网孔结构的电阻材料条带切成所要配置规格电熔连接件的内径长度，在工装上卷成筒状，将其压上的塑条对焊后成为圆筒状的电热元件；将二个电热元件串连，并在二个元件的外端分别接上引出线和电极桩；
5、设计成品外形模，将组合的电热元件正确放入成品模，注塑、冷却脱模后即可。

Claims (10)

1.一种有网孔结构电热元件的塑料管道电熔连接件，其特征在于：
所述的电熔连接件内置圆筒状电热元件，该圆筒状电热元件由沿电熔连接件内壁等间距布置的网孔结构的电阻材料条和与所述的电熔连接件材料相同的塑料条构成。
2.根据权利要求1所述的有网孔结构电热元件的塑料管道电熔连接件，其特征在于：
所述网孔结构的电阻材料条沿所述圆筒状电热元件的筒壁呈连续的几字形排布，所述塑料条与所述网孔结构的电阻材料条固接并且围成所述圆筒状电热元件的筒壁。
3.根据权利要求2所述的有网孔结构电热元件的塑料管道电熔连接件，其特征在于：
所述网孔结构的电阻材料条由包含铬和铼，或包含铬、铼和铁，或包含铬、铼、铁和铝的合金电阻薄板材料制成，其中铬的含量为15-24.5重量％，铝的含量为0.35重量％。
4.根据权利要求2所述的有网孔结构电热元件的塑料管道电熔连接件，其特征在于：
所述网孔结构的电阻材料条的使用温度为1100-1200℃，熔点为1400℃，密度为8.1-8.3g/cm3，20℃的电阻率为0.98-1.11μΩ·m，抗拉强度为750Mpa，延伸率为25％，反复弯曲次数>5，快速寿命为50h/℃。
5.根据权利要求1至4任一项所述的有网孔结构电热元件的塑料管道电熔连接件，其特征在于： 
所述网孔结构的电阻材料条中的网孔为正方形、长方形或其他多边形，每个网孔内任意不相邻顶点之间距离的平均值为所述电阻材料条厚度的5倍至10倍，构成每个网孔的边筋的宽度为所述电阻材料条厚度的1倍至3倍，所述的电熔连接件与塑料管道的熔接面不小于该塑料管道横截面中管材壁面积的2倍至4倍。
6.根据权利要求1至4任一项所述的有网孔结构电热元件的塑料管道电熔连接件，其特征在于：
所述的电熔连接件包括直通、变径、弯头、三通、四通、法兰和管帽。
7.一种制备如权利要求1至6任一项所述的有网孔结构电热元件的塑料管道电熔连接件的方法，其特征在于所述的方法包括以下步骤：
1)制备网孔结构的电阻材料条；
2)将步骤1)制备的网孔结构的电阻材料条表面固接与所制备的塑料管道电熔连接件材料相同的塑料条，将其卷成圆筒状电热元件；
3)将步骤2)制备的圆筒状电热元件插入到电熔连接件的注塑模具中，接入引出线和电极桩，按照常规的注塑成型工艺注塑即获得电熔连接件成品。
8.根据权利要求7所述的电熔连接件的制备方法，其特征在于，所述的步骤1)采用下列方法：
方法A：
A1-1)根据所述的电熔连接件的规格将电阻材料按焊接带所需宽度切成带状材料；
A1-2)将步骤A1-1)切成的带状材料根据所述的电熔连接件的焊接面积冲孔压制，制成孔网带，再将所制备的孔网带制成网孔结构的电阻材料条。
9.根据权利要求7所述的电熔连接件的制备方法，其特征在于所述的步骤 2)采用下列方法之一：
方法B：注塑成型电热元件
B2-1)设计对应规格的注塑模并将注模塑造成型，所述注塑模能使步骤1)所制备的网孔结构的电阻材料条卷曲后放入其模具型腔；
B2-2)模具结构采用油缸抽插型芯，抽插型芯的端面应设有圆角，所述型芯直径与对应管件的内径等同，在模具上先用活动镶块/压块在电阻材料条的宽度中间压住，所述活动镶块/压块的宽度是电阻材料条宽度的二分之一，闭模注塑后在电阻材料条的外径形成塑料条，冷却脱模后成为圆筒状电热元件。
方法C：电热元件塑料挤出后同步热压成型
C2-1)在步骤1)制备的网孔结构的电阻材料条上用塑料薄条挤出机连续热压与所连接的塑料管道材料相同的塑料条；
C2-2)将在步骤C2-1)中形成的压上塑料条带的网孔结构的电阻材料条带切成所要配置规格电熔连接件的内径长度，在工装上卷成筒状，将其压上的塑条对焊后成为圆筒状的电热元件；
方法D：电热元件超声波平焊塑条成型
D2-1)在步骤1)制备的网孔结构的电阻材料条上用超声波焊机将其与所连接的塑料管道材料相同的塑料条平焊；
D2-2)将在步骤D2-1)中形成的焊上塑料条的网孔结构的电阻材料条在与成品注塑模具同尺寸的工装上卷成筒状，将其焊上的塑条对焊后成为圆筒状的电热元件。
10.根据权利要求9所述的电熔连接件的制备方法，其特征在于：
与所连接的塑料管道材料相同的所述塑料条的厚度为所述电热元件电阻材料厚度的2倍至5倍。 
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