CN105135090B - 一种双层复合软管及其制造方法 - Google Patents

一种双层复合软管及其制造方法 Download PDF

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CN105135090B
CN105135090B CN201510500128.9A CN201510500128A CN105135090B CN 105135090 B CN105135090 B CN 105135090B CN 201510500128 A CN201510500128 A CN 201510500128A CN 105135090 B CN105135090 B CN 105135090B
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layer
warp
pipe
shuttle
parallel
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CN105135090A (zh
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蔡宝祥
蔡卫丰
蔡利海
黄忠耀
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Institute Of Military New Energy Technology Institute Of Systems Engineering Academy Of Military Sciences
Nantong Beca Machinery Technology Co ltd
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Nantong Is Good Mechanical Science And Technology Ltd Doubly
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Priority to CN201510500128.9A priority Critical patent/CN105135090B/zh
Priority to US15/127,410 priority patent/US20180172186A1/en
Priority to EP15868375.5A priority patent/EP3232106A4/en
Priority to PCT/CN2015/095244 priority patent/WO2016091057A1/zh
Publication of CN105135090A publication Critical patent/CN105135090A/zh
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Publication of CN105135090B publication Critical patent/CN105135090B/zh
Priority to US16/524,122 priority patent/US11493153B2/en
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    • F16L11/04—Hoses, i.e. flexible pipes made of rubber or flexible plastics
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  • Mechanical Engineering (AREA)
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  • Rigid Pipes And Flexible Pipes (AREA)
  • Laminated Bodies (AREA)

Abstract

本发明涉及一种双层复合软管及其制造方法，包括中间层管坯、内表面复合胶体材料层、外表面复合胶体材料层；所述中间层管坯的结构为纬线接结的双层组织结构，所述双层组织结构包括内层、外层和接结纬线，所述内层包括内层经线、内层纬线，外层包括外层经线、外层纬线，接结纬线既与外层经线交织，又与内层经线交织，使内层和外层接结成一体。本发明织造的中间层管坯克服了传统双层套管中间层管坯的双层复合软管所存在的问题，具有柔软性好、交织点少、纱线强度损失小、扭转度小的优点，中间层管坯再通过专用的涂覆设备和专门的涂覆生产工艺就能直接生产出满足市场需要的大口径、高耐压、较柔软的双层复合软管，生产工艺简单，具有极高的实用价值及很好的生产推广性。

Description

一种双层复合软管及其制造方法
技术领域
本发明涉及管道技术领域，具体涉及一种双层复合软管及其制造方法。
背景技术
目前国内外生产的双层复合软管，其中间层管坯生产采用传统的编织方法编织出单层平纹或斜纹软管织物，然后利用一根中间层管坯外面再套一根中间层管坯的方法制成双层中间层管坯，内外层中间层管坯口径不一，该双层中间层管坯硬、内外层紧密度差，利用该中间层管坯生产出的复合软管剥离强度差、易脱落、表面粗糙、不耐高压、水流阻力大、耐磨性差，不适合市场需求。
发明内容
本发明的目的在于提供一种具有接结双层结构中间层管坯的双层复合软管及其制造方法，以解决双层套管中间层管坯的双层复合软管所存在的问题。
本发明是通过以下技术方案实现的：
第一方面，本发明提供了一种双层复合软管，其包括中间层管坯、内表面复合胶体材料层、外表面复合胶体材料层；所述中间层管坯的结构为纬线接结的双层组织结构，所述双层组织结构包括内层、外层和接结纬线，所述内层包括内层经线、内层纬线，外层包括外层经线、外层纬线，接结纬线既与外层经线交织，又与内层经线交织，使内层和外层接结成一体。
第二方面，本发明还提供了一种如前述的双层复合软管的制造方法，其包括下列步骤：
中间层管坯的织造：首先，根据单个完全循环组织的经线数、完全循环组织的循环个数确定中间层管坯中的经线总数量；然后，设定经线总数量，同时分别编织中间层管坯的内层和外层，并通过接结纬线与内层与外层交织，使内层和外层接结成一体，形成中间层管坯；
胶体复合：在所述中间层管坯的内外表面一次共挤涂覆胶料，或内表面涂覆粘合胶料，外表面涂覆粘合剂色浆双面成型。
作为优选方案，所述中间层管坯的编织结构为双层斜纹结构或双层平纹结构，中间层管坯中的经线总数量分别按如下方式确定：
当编织结构为双层斜纹接结时，编织结构由n个完全循环组织编织而成，每个完全循环组织的经线数量为6，所述中间层管坯中的经线总数量为6n+4。
当编织结构为双层平纹接结时，编织结构由n个完全循环组织编织而成，每个完全循环组织的经线数量为4，所述中间层管坯中的经线总数量为4n+2。
作为优选方案，所述一个完全循环组织，其采用如下编织方式：使用设定个数的梭子在编织机械上的同步圆周运动带动纬线，使所述纬线穿梭于已分层的经线之间进行编织，在同一个编织循环中与设定个数的分线盘配合分经，使梭子带动纬线穿过已分层的经线来完成把内层与外层织物连接起来，从而完成中间层管坯的编织。
作为优选方案，所述梭子，其个数为3。
作为优选方案，所述一个完全循环组织，其为双层斜纹接结时，编织方式具体如下：与第一个梭配合的分线盘依次有以下三个分经动作：一上一下一上三下、二下一上一下一上一下、一上三下一上一下，梭子带动纬线穿过已分层的经线来完成编织外层；与第二个梭配合的分线盘依次有以下三个分经动作：三上一下一上一下、一上一下三上一下、一上一下一上一下二上，梭子带动纬线穿过已分层的经线来完成编织内层；与第三个梭子配合的分线盘依次有以下三个分经动作：二上二下一上一下、一上一下二上二下、二下一上一下二上，第三个梭带动纬线穿过已分层的经线来完成把内层与外层织物连接起来，从而完成双层斜纹纬线接结软管中间层管坯的编织。
作为优选方案，所述一个完全循环组织，其为双层平纹接结时，编织方式具体如下：与第一个梭配合的特制分线盘依次有以下二个分经动作：一上三下、二下一上一下，梭子带动纬线穿过已分层的经线来完成编织外层；与第二个梭配合的分线盘依次有以下二个分经动作：三上一下、一上一下二上，梭子带动纬线穿过已分层的经线来完成编织内层；与第三个梭配合的分线盘依次有以下二个分经动作：二上二下、二下二上，第三个梭带动纬线穿过已分层的经线来完成把内层与外层织物连接起来，从而完成双层平纹纬线接结软管中间层管坯的编织。
作为优选方案，所述胶料为高分子弹性体胶料，所述粘合胶料为高分子弹性体粘合胶料，所述粘合剂色浆为高分子弹性体粘合剂色浆。
作为优选方案，所述胶料、粘合胶料的材料均为TPU，所述粘合剂色浆的材料为水性TPU。
本专利研发生产的高强度纤维双层接结复合软管，其中间层管坯是利用专门的编织机械在编织内外层的同时通过一纬线接结把相对独立的内外层编织组合成一个整体软管织物，使织物平整、柔软，生产出的复合软管承压能力大幅提高，彻底解决了大口径复合软管承压力低的难题，且水流阻力小。其成品耐磨性大大提高，外表保护层磨损后还有双层接结的中间层管坯外层来保护里层，而不至于衬里层泄露。即使在双层接结的中间层管坯外表面不涂覆任何保护层其高强度的外层同样起到保护内层的作用，所以本发明专利一种高强度纤维双层接结复合软管尤其适用于野外气、液介质的远距离输送，具有较为广泛的应用前景。
本发明的编织原理为：使用设定个数的梭子在编织机械上的同步圆周运动带动纬线，使所述纬线穿梭于已分层的经线之间进行编织，在同一个编织循环中与设定个数的分线盘配合分经，使梭子带动纬线穿过已分层的经线来完成把内层与外层织物连接起来，从而完成软管中间层管坯的编织。
该织造方法与双层套管中间层管坯的主要区别在于：
1、一个完全循环组织的经线数是单层管的一个完全循环组织的经线数的双倍，一个完全循环组织的纬线数是单层管的一个完全循环组织的纬线数的三倍；
2、如将已编入的接结纬线拆除，仍有两个完整的相对独立的内外织物层；
3、纬线数的增加可极大地提高中间层管坯的耐压力和耐磨性；
4、接结双层中间层管坯柔软，延伸及膨胀系数低，扭转度小。
本发明的有益效果是：
1、织造的中间层管坯克服了传统双层套管中间层管坯的双层复合软管所存在的问题；
2、纬线数的增加可极大地提高中间层管坯的耐压力和耐磨性；
3、具有使用寿命长，柔软性好、交织点少、纱线强度损失小、扭转度小的优点；
4、中间层管坯再通过专用的涂覆设备和专门的涂覆生产工艺就能直接生产出满足市场需要的大口径、高耐压、较柔软的双层复合软管，生产工艺简单，具有极高的实用价值及很好的生产推广性。
附图说明
通过阅读参照以下附图对非限制性实施例所作的详细描述，本发明的其它特征、目的和优点将会变得更明显：
图1为本发明结构示意图；
图2为接结双层斜纹接结结构中间层管坯的接结结构示意图；
图3为接结双层平纹接结结构中间层管坯的接结结构示意图；
图4为接结双层斜纹接结结构中间层管坯外层外表面实物图；
图5为接结双层斜纹接结结构中间层管坯外层内表面实物图；
图6为接结双层斜纹接结结构中间层管坯内层外表面实物图；
图7为接结双层斜纹接结结构中间层管坯内层内表面实物图；
图8为接结双层斜纹接结结构中间层管坯内外层整体实物图。
图中：1、中间层管坯；2、内表面复合胶体材料层；3、外表面复合胶体材料层；4、斜纹编织第一梭第二圈；5、斜纹编织第一梭第三圈；6、斜纹编织第一梭第一圈；7、斜纹编织第三梭第二圈；8、斜纹编织第三梭第三圈；9、斜纹编织第二梭第一圈；10、斜纹编织第三梭第一圈；11、斜纹编织第二梭第二圈；12、斜纹编织第二梭第三圈；a、经线；b、纬线；c、外层斜纹编织层；d、内外层接结纬线；e、内层斜纹编织层；A、C、D为斜纹编织第一梭上的纬线与外层经线形成的单层斜纹编织；F、G、I为第二梭上的纬线与内层经线形成的单层斜纹编织；B、E、H为第三梭上的纬线将内层、外层接结的连接体整体；13、平纹编织第一梭第二圈；14、平纹编织第一梭第一圈；15、平纹编织第二梭第一圈；16、平纹编织第二梭第二圈；17、平纹编织第三梭第二圈；18、平纹编织第三梭第一圈；19、20为平纹编织第一梭上的经线；21、22为平纹编织第二梭上的经线；J、L为第一梭上的纬线与外层经线形成的单层平纹编织；M、O为第二梭上的纬线与内层经线形成的单层平纹编织；K、N为第三梭上的纬线将内层、外层接结的连接体整体。
具体实施方式
下面结合具体实施例对本发明进行详细说明。以下实施例将有助于本领域的技术人员进一步理解本发明，但不以任何形式限制本发明。应当指出的是，对本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干变形和改进。这些都属于本发明的保护范围。
如图1所示，本发明提供了一种双层复合软管，包括中间层管坯1、内表面复合胶体材料层2、外表面复合胶体材料层3，其中：
当中间层管坯1的结构为双层斜纹组织结构时，六路经线为一个完全循环组织的经线数，双层斜纹织物包括内层；外层和独立接结纬线，独立接结纬线既与外层经线交织，又与内层经线交织，使内外层斜纹织物接结成一体；
当中间层管坯1的结构为双层平纹组织结构时，四路经线为一个完全循环组织的经线数，双层平纹织物包括内层，外层和独立接结纬线，内层包括内层经线，内层纬线，外层包括外层经线，外层纬线，独立接结纬线既与外层经线交织，又与内层经线交织，使内外层平纹织物接结成一体。
如图2所示，是中间层管坯1的一个完全循环组织结构示意图，完全循环组织为双层斜纹接结结构，图中：4为斜纹编织第一梭第二圈；5为斜纹编织第一梭第三圈；6为斜纹编织第一梭第一圈；7为斜纹编织第三梭第二圈；8为斜纹编织第三梭第三圈；9为斜纹编织第二梭第一圈；10为斜纹编织第三梭第一圈；11为斜纹编织第二梭第二圈；12为斜纹编织第二梭第三圈；a为经线；b为纬线；c为外层斜纹编织层；d为内外层接结纬线；e为内层斜纹编织层；A、C、D为第一梭上的纬线与外层经线形成的单层斜纹编织；F、G、I为第二梭上的纬线与内层经线形成的单层斜纹编织；B、E、H为第三个梭子上的纬线，将内、外层接结成整体。
如图3所示，是中间层管坯1的一个完全循环组织结构示意图，完全循环组织为双层平纹接结结构，图中：13、平纹编织第一梭第二圈；14、平纹编织第一梭第一圈；15、平纹编织第二梭第一圈；16、平纹编织第二梭第二圈；17、平纹编织第三梭第二圈；18、平纹编织第三梭第一圈；19、20为平纹编织第一梭上的经线；21、22为平纹编织第二梭上的经线；J、L为第一梭上的纬线与外层经线形成的单层平纹编织；M、O为第二梭上的纬线与内层经线形成的单层平纹编织；K、N为第三梭上的纬线，将内层、外层接结成整体。
本发明还涉及一种双层复合软管的制备方法，包括如下步骤：
中间层管坯的织造：首先，根据单个完全循环组织的经线数、完全循环组织的循环个数确定中间层管坯中的经线总数量；然后，设定经线总数量，同时分别编织中间层管坯的内层和外层，并用接结纬线与内层与外层交织，使内层和外层接结成一体，形成中间层管坯；
胶体复合：在所述中间层管坯的内外表面一次共挤涂覆胶料，或内表面涂覆粘合胶料，外表面涂覆粘合剂色浆双面成型。
优选的，所述中间层管坯的编织结构为双层斜纹结构或双层平纹结构，中间层管坯中的经线总数量分别按如下方式确定：
当编织结构为双层斜纹接结时，编织结构由n个完全循环组织编织而成，每个完全循环组织的经线数量为6，所述中间层管坯中的经线总数量为6n+4。即：对于双层斜纹接结编织，控制经线总数量（穿线总筘数）-4得到的差必须是6的倍数；
当编织结构为双层平纹接结时，编织结构由n个完全循环组织编织而成，每个完全循环组织的经线数量为4，所述中间层管坯中的经线总数量为4n+2。即：对于双层平纹接结编织，控制经线总数量（穿线总筘数）-2得到差必须是4的倍数，在一个编织循环中按规律排列；且每个经线单元（亦称一筘）中的经线根数可以是单数亦可以是双数。
所述一个完全循环组织，其采用如下编织方式：使用设定个数的梭子在编织机械上的同步圆周运动带动纬线，使所述纬线穿梭于已分层的经线之间进行编织，在同一个编织循环中与设定个数的分线盘配合分经，使梭子带动纬线穿过已分层的经线来完成把内层与外层织物连接起来，从而完成中间层管坯的编织。
所述一个完全循环组织，其为双层斜纹接结时，编织方式具体如下：与第一个梭配合的分线盘依次有以下三个分经动作：一上一下一上三下、二下一上一下一上一下、一上三下一上一下，梭子带动纬线穿过已分层的经线来完成编织外层；与第二个梭配合的分线盘依次有以下三个分经动作：三上一下一上一下、一上一下三上一下、一上一下一上一下二上，梭子带动纬线穿过已分层的经线来完成编织内层；与第三个梭子配合的分线盘依次有以下三个分经动作：二上二下一上一下、一上一下二上二下、二下一上一下二上，第三个梭带动纬线穿过已分层的经线来完成把内层与外层织物连接起来，从而完成双层斜纹纬线接结软管中间层管坯的编织。
所述一个完全循环组织，其为双层平纹接结时，编织方式具体如下：与第一个梭配合的分线盘依次有以下二个分经动作：一上三下、二下一上一下，梭子带动纬线穿过已分层的经线来完成编织外层；与第二个梭配合的分线盘依次有以下二个分经动作：三上一下、一上一下二上，梭子带动纬线穿过已分层的经线来完成编织内层；与第三个梭配合的分线盘依次有以下二个分经动作：二上二下、二下二上，第三个梭带动纬线穿过已分层的经线来完成把内层与外层织物连接起来，从而完成双层平纹纬线接结软管中间层管坯的编织。
所述经线和纬线的材料为任意一种高强纤维线。
作为优选方案，所述胶料为高分子弹性体胶料，所述粘合胶料为高分子弹性体粘合胶料，所述粘合剂色浆为高分子弹性体粘合剂色浆。
作为优选方案，所述胶料、粘合胶料的材料均为TPU，所述粘合剂色浆的材料为水性TPU。
如图4~7所示，分别是接结双层斜纹中间层管坯外层外表面实物图、接结双层斜纹中间层管坯外层内表面实物图、接结双层斜纹中间层管坯内层外表面实物图、接结双层斜纹中间层管坯内层内表面实物图。
如图8所示，是接结双层斜纹中间层管坯内外层整体实物图，是成型后的产品结构，其中，外层斜纹编织层c和内层斜纹编织层e之间由内外层接结纬线d连接。
下面是本发明的2个具体实施例，具体如下：
实施例1
本实施例是一种双层斜纹复合软管，其包括接结双层斜纹结构中间层管坯，中间层管坯的内、外表面复合胶体材料层，所述中间层管坯的结构为为接结纬接结的双层斜纹组织结构，六路经线为一个完全循环组织的经线数，双层斜纹织物包括内层、外层和独立接结纬线，独立接结纬线既与外层经线交织，又与内层经线交织，使内外层斜纹织物接结成一体。
本实施例中，双层复合软管的制造方法包括下列步骤：
步骤一、中间层管坯织造
本实施例中，一个完全循环组织的经线数为6，完全循环组织的循环个数为106，可计算得到中间层管坯中的经线总数量为640。
用第一梭单独织外层，第二梭单独织内层，第三梭织纬线接结，第三梭接结纬线既与外层经线交织，又与内层经线交织，使内外层接结成一体。
步骤二、胶体复合
在所述中间层管坯的内外表面一次共挤涂覆胶料，或内表面涂覆粘合胶料，外表面涂覆粘合剂色浆双面成型，所述胶料为高分子弹性体胶料，所述粘合胶料为高分子弹性体粘合胶料，所述粘合剂色浆为高分子弹性体粘合剂色浆，所述胶料、粘合胶料的材料均为TPU，所述粘合剂色浆的材料为水性TPU。
实施例2
本实施例是一种双层平纹复合软管，其包括接结双层平纹结构中间层管坯，中间层管坯的内、外表面复合胶体材料层、所述中间层管坯的结构为为接结纬接结的双层平纹组织结构，四路经线为一个完全循环组织的经线数，双层平纹织物包括内层、外层和独立接结纬线，内层包括内层经线、内层纬线，外层包括外层经线、外层纬线，独立接结纬线既与外层经线交织，又与内层经线交织，使内外层平纹织物接结成一体。
本实施例中，双层复合软管的制造方法，包括下列步骤：
步骤一、中间层管坯织造
本实施例中，一个完全循环组织的经线数为4，完全循环组织的循环个数为159，可计算得到中间层管坯中的经线总数量为638。
用第一梭单独织外层，第二梭单独织内层，第三梭织纬线接结，第三梭接结纬线既与外层经线交织，又与内层经线交织，使内外层接结成一体。
步骤二、胶体复合
在所述中间层管坯的内外表面一次共挤涂覆胶料，或内表面涂覆粘合胶料，外表面涂覆粘合剂色浆双面成型，所述胶料为高分子弹性体胶料，所述粘合胶料为高分子弹性体粘合胶料，所述粘合剂色浆为高分子弹性体粘合剂色浆，所述胶料、粘合胶料的材料均为TPU，所述粘合剂色浆的材料为水性TPU。
以上对本发明的具体实施例进行了描述。需要理解的是，本发明并不局限于上述特定实施方式，本领域技术人员可以在权利要求的范围内做出各种变形或修改，这并不影响本发明的实质内容。

Claims (8)

1.一种双层复合软管的制造方法，其特征在于：包括下列步骤：
中间层管坯的织造：首先，根据单个完全循环组织的经线数、完全循环组织的循环个数确定中间层管坯中的经线总数量；然后，设定经线总数量，同时分别编织中间层管坯的内层和外层，并通过接结纬线与内层与外层交织，使内层和外层接结成一体，形成中间层管坯；
胶体复合：在所述中间层管坯的内外表面一次共挤涂覆胶料，或内表面涂覆粘合胶料，外表面涂覆粘合剂色浆双面成型；
所述中间层管坯的编织结构为双层斜纹结构或双层平纹结构，分别按如下方式确定中间层管坯中的经线总数量：
当编织结构为双层斜纹接结时，编织结构由n个完全循环组织编织而成，每个完全循环组织的经线数量为6，所述中间层管坯中的经线总数量为6n+4；
当编织结构为双层平纹接结时，编织结构由n个完全循环组织编织而成，每个完全循环组织的经线数量为4，所述中间层管坯中的经线总数量为4n+2；
所述双层复合软管包括中间层管坯、内表面复合胶体材料层、外表面复合胶体材料层；所述中间层管坯的结构为纬线接结的双层组织结构，所述双层组织结构包括内层、外层和接结纬线，所述内层包括内层经线、内层纬线，外层包括外层经线、外层纬线，接结纬线既与外层经线交织，又与内层经线交织，使内层和外层接结成一体。
2.根据权利要求1所述的制造方法，其特征在于：所述一个完全循环组织，其采用如下方式编织：使用设定个数的梭子在编织机械上的同步圆周运动带动纬线，使所述纬线穿梭于已分层的经线之间进行编织，在同一个编织循环中与设定个数的分线盘配合分经，使梭子带动纬线穿过已分层的经线来完成把内层与外层织物连接起来，从而完成中间层管坯的编织。
3.根据权利要求2所述的制造方法，其特征在于，所述梭子，其个数为3。
4.根据权利要求3所述的制造方法，其特征在于：所述一个完全循环组织，其为双层斜纹接结时，编织方式具体如下：与第一个梭配合的分线盘依次有以下三个分经动作：一上一下一上三下、二下一上一下一上一下、一上三下一上一下，梭子带动纬线穿过已分层的经线来完成编织外层；与第二个梭配合的分线盘依次有以下三个分经动作：三上一下一上一下、一上一下三上一下、一上一下一上一下二上，梭子带动纬线穿过已分层的经线来完成编织内层；与第三个梭子配合的分线盘依次有以下三个分经动作：二上二下一上一下、一上一下二上二下、二下一上一下二上，第三个梭带动纬线穿过已分层的经线来完成把内层与外层织物连接起来，从而完成双层斜纹纬线接结软管中间层管坯的编织。
5.根据权利要求3所述的制造方法，其特征在于：所述一个完全循环组织，其为双层平纹接结时，编织方式具体如下：与第一个梭配合的特制分线盘依次有以下二个分经动作：
一上三下、二下一上一下，梭子带动纬线穿过已分层的经线来完成编织外层；与第二个梭配合的分线盘依次有以下二个分经动作：三上一下、一上一下二上，梭子带动纬线穿过已分层的经线来完成编织内层；与第三个梭配合的分线盘依次有以下二个分经动作：二上二下、二下二上，第三个梭带动纬线穿过已分层的经线来完成把内层与外层织物连接起来，从而完成双层平纹纬线接结软管中间层管坯的编织。
6.根据权利要求1～5中任意一项所述的制造方法，其特征在于：所述经线和纬线的材料为任意一种高强纤维线。
7.根据权利要求1所述的制造方法，其特征在于：所述胶料为高分子弹性体胶料，
所述粘合胶料为高分子弹性体粘合胶料，所述粘合剂色浆为高分子弹性体粘合剂色浆。
8.根据权利要求1或7所述的制造方法，其特征在于：所述胶料、粘合胶料的材料均为TPU，所述粘合剂色浆的材料为水性TPU。
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