CN1078941C - 共挤塑多层塑料管及其制造方法和设备 - Google Patents

共挤塑多层塑料管及其制造方法和设备 Download PDF

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Publication number
CN1078941C
CN1078941C CN96199007A CN96199007A CN1078941C CN 1078941 C CN1078941 C CN 1078941C CN 96199007 A CN96199007 A CN 96199007A CN 96199007 A CN96199007 A CN 96199007A CN 1078941 C CN1078941 C CN 1078941C
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Prior art keywords
middle level
tubing
pipe
outer tube
multilayer plastic
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Expired - Fee Related
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CN96199007A
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CN1204387A (zh
Inventor
J·加闻凯拉
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Uponor Innovation AG
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UPONOR INNOVATION AG
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a non-planar shape
    • B32B1/08—Tubular products
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/22—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/13—Articles with a cross-section varying in the longitudinal direction, e.g. corrugated pipes
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B29C48/3366—Multiple annular extrusion nozzles in coaxial arrangement, e.g. for making multi-layered tubular articles the components merging one by one down streams in the die using a die with concentric parts, e.g. rings, cylinders
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明涉及共挤塑多层塑料管材，这种管材包括内管(1)、外管(2)以及介于内、外管之间的中层(3)，该中层是由较内管软的材料制成。本发明还涉及一种在多层挤塑机中制造共挤塑多层管材的方法以及供制造共挤塑多层管材的设备。

Description

共挤塑多层塑料管及 其制造方法和设备
本发明涉及共挤塑多层塑料管材，该多层塑料管材包括被较软材料制的中层包围的一个或多个内管和围绕所述中层的外管，其中所述中层包围着一个或多个内管。优选的是，本发明的多层塑料管材包含一个内管。
包括一薄壁内管的上述类型的塑料管材是早就知道的。例如，这类管材已用作地下排水管、压送管及电缆槽。虽然它们的制造过程较常用单层管材要复杂，但是，对于性能相当的两类管材来说，由于多层管材的材料消耗较单层管材低，因而重量轻，所以多层管材的价格较常规管材稍低一些。然而，多层管材的用途，尤其在高纬地区是很受限制的。其主要原因是这类管材的机械性能较常规单层管材差。
一种常规三层地下排水管具有如下结构：该结构符合本技术领域出版的标准(管材外径为315毫米)。
-硬质PVC塑料内层，厚度为约1.4毫米，弹性模量为约2000兆帕，密度为约1400千克/米3。
-发泡PVC塑料中层，厚度为约9.4毫米，弹性模量为约800兆帕，泡沫密度为约800千克/米3。
-硬质PVC塑料外层，厚度为约1.4毫米，弹性模量为约2000兆帕。
这类管材的环劲度为约8.8千牛/米2，这一数值足可以用作地下管道。管材中各层的环劲度如下：内管(1)为约0.0167千牛/米2、中层(2)为约1.8千牛/米2。外管(3)单独为约0.0136千牛/米2。
环劲度的大小排列次序为：(2)、(1)和(3)。这是典型的市售发泡管材的主要结构，尽管发泡材料的弹性模量最低，但中层发泡材料的劲度最高且是主要的承受负载结构。内管通常是劲度为次高的结构。
如果对市售的三层发泡管材中的每一层进行称重试验，可观察到另一主要大小原则：实体层的重量与管材总重量之比总是低于45％，对于上述实例来说，内管重量为约1.9千克/米，中层重量为约7.4千克/米及外管重量为约2千克/米。因此，内管和外管的重量之和与总重量11.2千克/米的重量比为34％。
美国专利4364882公开了一种常用PVC发泡管材。该PVC发泡至密度为500千克/米3，事实上这一数据已经是常规技术能达到的最低值。通常，PVC泡沫塑料的发泡程度为57％，据上可得出其密度为800千克/米3；如果密度低于该数值，PVC泡沫塑料的强度性能就会下降。该专利公开了一种外径为315毫米，并具有以下结构的管材：内管厚度为1.25毫米，中层厚度为9毫米以及外管厚度为1.25毫米，因此该管材的总厚度为11.5毫米，以及管材总重量为7.63千克/米。由此可见，该公开的管材与有相当劲度的常规管材相比，重量轻29％。
还可计算出上述管材的下述特征：内管重量为1.61千克/米以及环劲度0.013千牛/米2；中层重量为4.32千克/米及环劲度为1.41千牛/米2；外管重量为1.72千克/米以及环劲度为0.011千牛/米2。由此可见，与外层和内层相比，发泡中层的环劲度是外层和内层的100倍以上，以及外层和内层加在一起的重量是总重量的44％。
上述实例表明，采用发泡塑料的优点是：节省了大量材料(即降低了成本)并使管材结构变轻。采用这种“质地较差”材料作为中层起连接作用是很合理的，因为这一层是最少受到诸如磨损和应力应变的机械应力的作用，也是最少受到诸如紫外辐射和种种杂质的物理和化学应力作用的。
另一方面，当中层材料的发泡程度增加或其密度下降时，发泡材料的性能会明显地降低。目前，所用达最高发泡程度的发泡材料的密度实际上已降为未发泡材料的一半。如果采用再高的发泡程度，该泡沫塑料的强度会有相当大的下降，已经认为，要用这类泡沫塑料制成质量上乘的管材是不可能的。虽然，解决该问题的先有技术，例如能将发泡保持在这样一种程度使得该发泡材料仍具有较好的机械强度性能，但总避免不了损坏向内管延伸这种情况的发生。而且，发泡中间层的采用也没有使成本如预期那样地明显下降。
本发明的目的是提供一种内管受到较先有技术方法更有效保护的共挤塑多层塑料管材，并同时降低管材的制造成本。
本发明的另一个目的是提供一种共挤塑多层塑料管材，该管材与相应的已知管材相比，具有较好的机械性能，如冲击强度和环劲度，并较单层管材及相应的已知多层管材的重量轻。
本发明还有一个目的是一种制造共挤塑多层塑料管材的方法，该管材包括被较软材料制的中层包围的一个或多个内管(中层的密度低于外管和内管)和一层围绕所述中层的外管，其中该中层包围着所述一个或多个内管。
本发明还有一个目的是提供一种制造共挤塑多层塑料管材的方法，所述方法能使制得的管材中的发泡塑料中层具有很低的密度，并且在所述方法中，塑料的发泡是以压缩空气现场发泡的。
本发明再有一个目的是提供一种制造根据本发明的共挤塑多层管材的设备。
根据本发明多层管材的基本特征是：最重要的部分，即内管在各种应力作用下不会破裂或变形。
目前，本发明的多层塑料管材能达到上述性能，其中中层聚合物的重量与塑料管材的总重量之比至多为55％。
根据本发明，结构的最重要部分(即内管)可用较软的外层(即更容易变形的层)来保护，由此，所有各层界面间的粘附力是尽可能小并是可调整的。因此，即使外管由于压缩变形成椭圆形，或甚至当管子铺设在地坑中因受到尖角物体(如石块)的冲击力而破裂时，内管仍能保持圆形不受破坏。
已意外地发现，上述粘附力对结构的耐久性，尤其对耐冲击应力有很大的影响。在先有技术中所述的这类三层管材，发泡的中间层(尽管是发泡结构)显然是太硬，并与外管和内管贴得太紧密，因此在受到冲击作用使外管发生龟裂时，在最坏的情况下龟裂会延伸到中间层甚至进一步延伸到内管。
因为本发明保证了层间粘合力小于产生龟裂所需的力，从而使本发明的管材避免了上述问题。粘附力或粘附能可通过标准剥离试验来测定，并可通过标准抗拉强度的测量数据，分析出发生龟裂所需力的大小。软的泡沫塑料中间层起着内管与外管间的减震作用，并使内管和外管保持分开，因此，外管经受明显的变形时，而内管可完全不发生变形。塑料管材经受的最典型的损坏形式是开裂、变形或甚至是铺设好的管线因挖掘机或某项建设工程所引起的破裂。
上述已知的具有一种发泡材料中间层的多层管材有许多缺点，最明显的缺点是冲击强度低。本发明者已经发现，这一缺点是由于不同层间的重量比不合理引起的。正如从对先有技术管材作上述分析中看到的，在先有技术方法中，外管和内管的壁厚、重量比以及环劲度与发泡的中间层相比是很低的，例如，外管和内管的重量与管材总重量的比例至多为44％。当有冲击力撞击外管时，冲击能几乎是完全直接作用在承载负荷的中间层表面上，该表面通常是一种较不易变形的高密度PVC泡沫塑料。因为PVC塑料是对缺口极敏感的，还因为泡沫塑料中的每个气泡形成应力中心，所以该管材的冲击强度是低的，尤其在气温低的情况下。
本发明利用中层对整个塑料管的重量比低于先有技术管材这一特征，从而使本发明的管材出乎意料地达到了很高的冲击强度。基于这一点，外管和中层对来自管外的冲击能量的吸收程度高于已知的管材，因而内管较已知的不易损坏。事实上，该中层较已知管材中的中层软。中层的弹性模量优选为内管弹性模量的25％以下，最优选为10％以下。
本发明的层间重量比也可以这种方式表示。内管和外管重量之和与管材总重量之比至少是总重量的45％，优选为60％-85％。
根据本发明特别优选的实施方案，通过降低中层泡沫塑料的密度(与已知管材相比)可达到上述重量比及所需的环劲度比，因此中层密度不高于500千克/米3，优选为50-500千克/米3，更优选为100-300千克/米3。这样的密度值可通过如提高中层泡沫塑料的发泡程度(与已知管材相比)，以使其发泡程度达到至少为50％，优选为70-95％，更优选为70-85％，即中层密度至多为相应的未发泡材料的50％，优选只是10％-30％来达到。已经意外地发现，尽管表观上这种中层材料具有中等程度的机械性能，但整个管材的机械性能比那些有高密发泡中层的常规多层管材好得多。此外，这种管材由于泡沫塑料的密度低得很多，因而，其重量远比相应的已知管材轻得多。
本发明具有上乘的机械性能可能是由于中层和外管构成了类似能吸收来自外部冲击能的缓冲垫，这种缓冲垫能将冲击能在未达到内管前吸收掉。
按照本发明的一个实施方案可得到特别好的机械性能，其中外管和内管是用取向和/或拉伸纤维增强的和/或通过如我们的共同待审的申请书PCT/EP 96/02801中所述的交联增强的，该申请内容已列入本文以供参考。短切纤维，如纤维长为0.5-10毫米的玻璃纤维习惯上是不用来增强挤塑管材的，这主要是因为：由于经挤塑操作，纤维会与管轴呈平行排列，因而纤维就不能发挥其本身的增强性能。这一点也适用于沿圆周方向上需要增强的压送管和排水管。某些技术，如旋转模芯和旋转喷嘴，由于管材表面层旋转运动产生剪切作用的影响，使得部分纤维处于圆周方向。基于这种技术所需的费用，这种纤维结构还没有在用作排水管道的热塑性管材中得以应用。通常，含纤维的母料的成本较常规聚乙烯高出3-4倍。由于提高强度性能并不能补偿较高的原料价格，因此添加纤维会提高管材的价格。
然而，已意外地发现，根据本发明添加纤维的成品已做到较常规管材更便宜。这是由于本发明管材中的主要承载层，即内管和外管中的纤维增强效果是很明显的。经济地使用纤维增强材料是基于这样的观点：增强材料只加在增劲效果最大的区域，即表层上，因此，所需用量较实心壁管材要少。其次，对管材的中间部分加入费用很大的增强材料在很大程度上会是无用的，因为如果该管材用作地下污水管或排水管，由于管材变位，其中间部分是不大会发生变形的。根据本发明管材的一种旋转制造方法已公开在我们的共同待审的申请FI 961822中，该公开内容已列入本文以供参考。
不是特别精心制造的常规PVC泡沫塑料管材也存在有关缺口敏感性方面的另一缺点。在装卸时管材的外表面常会被刮伤，装卸不小心可能造成PVC表面刮伤甚至达0.5毫米。当管子在垂直方向发生变形时如果这种刮伤发生在三点或九点钟方向上，则在缺口的端口会形成强烈的应力集中。如果PVC在机械加工上存在缺陷，就可能会引起龟裂缓慢扩展，在PVC压送管中出现的这种现象是为大家所非常熟悉的。这种现象对于埋在地下的排水管或污水管也是非常明显的。这一问题在常规的外管很薄的泡沫塑料管材中尤为严重。在试验中已经发现，常规薄壁高密泡沫PVC管材在苛刻的试验条件下甚至不足100小时就发生破裂，而实心壁PVC管材或本发明管材能够持续试验数千小时。为了弥补中层材料的不足，本发明管材可有较厚的外管，因而有助于避免发生上述破裂的危险。因为甚至在裂纹下有足量的承载材料，所以裂缝常常不会延伸至泡沫塑料层。
根据本发明，通过制造两层不同的外管以使层间粘附能低于破裂能，可特别有效地防止上述现象的发生。因此龟裂扩展会在这些层之间的接缝处中止，于是阻止了龟裂向第二层扩展。例如，如果多层管是由取向聚丙烯(PP)内管、轻质发泡PP或PE发泡材料中层和由两层构成的外管(即靠近中层的MDPE的薄实心层及PP的实心外层)所构成的话，则在PP外层可能产生的龟裂几乎不会扩展到MDPE层。例如通过控制挤塑工艺参数能使MDPE与PP之间的粘附力保持在足够低的水平。根据本发明的另一个实施方案，这一现象可被利用来选择中层泡沫塑料和外管的材料、密度和挤塑工艺参数。
当该管材用作地下排水管时，其内管会经受几种类型的应力。据计算，除化学应力外，在使用一百年期间，污水携带的颗粒对管壁的磨损可能为0.5毫米。一种更大的应力是由管道清洗操作所引起的。研究结果已经表明，机械清洗在管材表面引起的刮伤甚至可达0.7毫米深。另一方面，当以常规方法采用比机械清洗更缓和的水喷射法清洗时，如果所用的水压太高，可能会切入管壁。根据本发明的一个实施方案，内管是由橡胶状热塑性塑料或弹性体制的，因而有极好的耐切性能。虽然这后面的原因还没有完全得到解释，但本发明管材中内管是相当厚的，内管的另一侧是很软的泡沫塑料层，显然，厚的内管是不良的共振表面，因而较常规泡沫塑料管有高得多的耐水喷射的切割效应。
管材重量减轻带来的问题是：如果目的是为根据环劲度不变而节省大量材料，则会使高强度承载层的材料减少和强度降低。这问题在聚乙烯制的双壁波纹管中是最明显的。当管材内壁很薄时，管材的轴向劲度会很低并颇缺乏稳定性，甚至难以将该管子弄直。就这方面来说，可认为，与先前优级肋管制造成本相同的本发明管材的性能是极好的。轴向劲度随型面高度而明显地增加；在本实施方案中，因可经济地制得比以前高的型面，因此，该三层管材是一种刚性很高的构型。
在安装后的使用期间，轴向劲度不足问题也可能变得明显起来。几乎没有一种塑料管材具有这样的刚性结构：甚至当基础表面不平坦时仍能保持直的状态。然而，当管子上方局部加载时，不同种类的管材会有明显不同的特性。在轴向软质管材上局部加载会产生立即可见的变形，如凹坑。根据本发明的实施方案的管材具有令人惊奇的优良性能，局部加载引起的凹坑变形通常只在管材外表面和中层，而刚性较大的内管不容易变形。由于这样原因，例如，因为是局部变形，所以测试管材变形的管径测量仪必须是固定的，因此，在任何情况下，目的是检测平均变形。上述自然也适用于其它装置，如模具净化装置等。
上述现象对于管道铺设工艺是极重要的。常规的管材必须铺设在经筛选过的，已除去任何较大石块的砂基上，而本发明的管材，由于有牺牲性的外层，所以铺设时不需任何保护性材料。众所周知，铺设管道时用于开挖管沟和保护性材料的费用要占80％以上；因此，外管和中层的环劲度较内管低得多的本发明管材可大大地降低管线的总费用，这是显而易见的。一种保证外层挠曲大于内管的方法是不仅要仔细地选择管材的构型原理而且还要选择中层和外层的材料。换言之，除选择适当的环劲度外，还要能允许有一定的局部弯曲或压缩性。例如，外层采用较软的材料就能有局部压缩性。内层的压缩模量优选至少是外层与中层一起测定的模量的两倍。在本发明的一个实施方案中，其中内管的劲度大于其它层的劲度，因此外管在载荷下发生变形时，由于根据本发明结构，外管变成椭圆形的程度大于内管。这是本发明特别重要的特征，例如，用作电缆槽时尤为重要。
当管道铺在地下时，一般的塑料管材总要变形约1％-1.5％，至多3％。这种变形主要是由管道铺设后土壤的固结作用引起的。因此，对于300毫米的管子来说软保护层的理想厚度是9毫米。该保护层吸收这种变形后，内管就不会发生变形。换言之，该管壁应可被压缩4.5毫米。为了能实现这种压缩，管壁必须有充分的空间。例如对于50％发泡程度的泡沫塑料管材来说，为防止整个载荷移向内管，泡沫塑料的最小厚度应为9毫米。如果采用发泡程度为80％的泡沫塑料，则泡沫层塑料厚度约为5.6毫米时，在内管的外表面上就可达到与上相同的载荷水平，从本质上说，这是一种费用较低廉的解决变形的方法。然而，如果泡沫塑料层厚度为9毫米，但发泡程度为80％，即泡沫塑料很轻，承受冲击的适应性大为提高，这种结构有利于得到高的冲击强度。
根据本发明的一种方法，该方法包括在具有至少一根外管挤塑螺杆和一根中层挤塑螺杆的挤塑机上制造包括一个或多个内管的共挤塑多层管材，螺杆的作用是在塑料成形为管材前输送和塑化塑料材料。
这类方法已经公开，如在CA1205265和EP 0236645中已经公开了这类方法。在这些已知方法中，通过向塑料材料添加化学发泡剂使塑料材料发泡可有效地成型中层。这类化学发泡方法的缺点是不可能得到低密度的泡沫塑料，即制得的泡沫塑料的发泡程度通常低于50％。
本发明提供一种制造多层塑料管材的方法，所述方法能使制得的管材中的泡沫塑料中层具有很低的密度。该低密度泡沫塑料可经下述过程制得：在中层挤塑螺杆的塑化区，向已基本熔融的塑料材料注入加压气体，气体与塑性基料混合后，经挤压并挤入管材内层与外层间的间隙中。
气体通过围绕螺杆的料筒壁、向螺杆注入是最有利的，但在螺杆的端部与塑料材料相混合。根据本发明方法的一个优选实施方案，向塑料材料添加高达1％化学发泡剂，于是该发泡剂也作为泡孔的成核剂，从而增进了物理发泡作用。
下文将根据附图对本发明作更详细的说明，其中：
图1是包括一层内管的本发明多层塑料管材的纵剖面，
图2和图3是制造本发明多层塑料管材的设备的图解说明，
图4和图5是本发明多层管材的两个其它实施方案的图解说明。
图1所示的管材包括一层内管1、一层外管2和泡沫塑料中层3。
内管1是由如压送管品级的中密度聚乙烯(MDPE)或某些其它热塑性或热固性塑料制造的。对于内径为300毫米的常压管来说，中密度管材的密度一般为940千克/米3，壁厚为1-5毫米，优选为2-3毫米。用于护套压力管的材料一般是PVC、取向PE、交联PE(PEX)或PP。护套压力管的管壁可以是比较厚的，随要求管材承受的应力而定。基本要点是这类护套压力管能承受的应力应较通常的实心壁管的管材高。由于本发明较软的中间泡沫塑料层和外层，因而内管不会受到象外应力那样大的应力，而且这些外层和中层也增强了管材结构。因此，有可能达到这一基本要点。
外管2可由密度为约955千克/米3的高密度聚乙烯(HDPE)(如供吹塑用的)制造，壁厚基本上与内管壁厚相等。另一些外管材料是PVC、PP、MDPE，以及特别是PEX，这是因为PEX是高度耐龟裂扩展的。
中层3是由密度低于内管和外管的泡沫塑料，如聚乙烯(LDPE)制造的，其壁厚度一般为5-20毫米，优选为约10毫米。如果需要较好的隔离性能或需要更好的防护内管免受外界干扰的性能，需采用较厚的泡沫塑料层。用本发明制造方法能达到的最大泡沫塑料厚度接近于50毫米。采用交联的泡沫材料，其厚度的上限还可上移。
根据本发明，中层3与整个塑料管材的重量比至多为55％。该比例是依据中层聚合物的质量计算的，而诸如填料没有计及。如果中层该重量比只有15％-40％，则本发明的优点是尤为明显的。
用细小填料和/或纤维状添加剂，如矿物纤维或人造短纤维能容易地调整泡沫塑料中层的机械性能。似乎纤维能有效地增强泡沫塑料中层。例如，可向聚烯烃泡沫塑料添加如5-30％硅灰石来调整其抗压强度。
在本发明管材中，可通过降低中层泡沫塑料的密度(与已知管材相比)来达到中层3重量比的下降，从而改善管材的冲击强度。因此，中层泡沫塑料的密度至多为500千克/米3，优选只有100-300千克/米3是适当的。在试验中已发现，外管和内管是聚乙烯、而中层是聚乙烯泡沫塑料的管材，当中层的密度为约200千克/米3，相当于发泡程度约79％时，具有极高的冲击强度。一般地讲，中层的发泡程度至少为50％，优选为70-85％是适当的。没有添加剂或填料的中层用树脂的适宜弹性模量为100-500兆帕，优选为约300兆帕，(用ISO 178方法测定)。当中层用树脂发泡后，其弹性模量自然会有很大程度下降。根据本发明功能优良的管材中的泡沫塑料的模量可低至25兆帕。根据需要，使用填料可以提高泡沫塑料模量。考虑到管材冲击强度，泡沫塑料的平均密度优选为上述范围；密度是向层中心降低的。
在本发明的一个实施方案中，用弹性模量至多为500兆帕的橡胶状热塑性塑料或弹性体制造内管可改善内管1的耐割性。
当本发明管材是用作地下排水管道时，管材的外径与外管的厚度比优选至多为210，管材的内径与内管的厚度比至多为200。
尤其是内管1(但可能也包括外管2)是用填料或纤维增强材料增强的，和/或管材的原材料是取向的或交联的。如果内管和/或外管是由取向的热塑性材料制的，并包含如作为增强材料的、能按偏离管轴方向取向的玻璃短纤维的话，该管材就有很高的冲击强度。
优选的内管1是不着色的或是浅色的塑料，这样就能借助显象观察便于探查损坏情况。优选的外管2是对紫外光稳定的，通常被着成黑色，这样，该管能经得起户外贮存，碳黑也能提高外管的冲击强度。
可单独将外管2或将外管2与中层3一起加工成波纹状或肋状。
内管、外管及中层分别有各自的环劲度，环劲度随该层的壁厚度(即质量比)及弹性模量而不同。
对于护套压力管来说，优选的内管环劲度至少是等于、优选是泡沫塑料层环劲度的两倍至十倍。在用作护套污水管或排水管的情况下，内管的环劲度通常高于泡沫塑料层的环劲度。对于经济型地下污水管或排水管来说，内管的环劲度较低，一般为泡沫塑料层环劲度的1％-10％。在这种情况下，泡沫塑料层是管材结构中刚性最高的部分，而外层的劲度一般是各层中最低的。通常，在污水管用途中，各层的环劲度是0.0050-0.3000千牛/米2，刚性最高层优选为中层或内管。
在某些用途中，可将外层设计成刚性最高的层，以便获得特殊的性能。这种情况的实例是一种拥有软质PEX内管、泡沫塑料层和云母填充的聚烯烃外层的管材。该结构具有隔离性能以及轴向刚度。由于这种刚度，管材在地面上安装时能保持直的状态，而日常的薄壁塑料管在安装支架间易发生下垂现象。由于云母填充的聚烯烃的良好阻隔性能，而使这种组合具有其它的优点。
根据本发明的多层管材还有另一很有用的用途是用作压送管，这种压送管是由PEX为内管、薄泡沫塑料层以及包有塑料表皮的金属管所构成。在这种情况下，泡沫塑料层在PEX与金属如铝之间起着粘合作用。这种结构可允许内管的外径发生收缩或膨胀，而复合体的外径仍保持一定。
根据本发明的共挤塑多层管的优选总环劲度超过8千牛/米2，这一数值一般可满足多种用途的要求：能在压送管中承受压力波动的风险和在常压用途中承受污物载荷。在采用取向的、或其它高性能热塑性塑料管时，软质管道太柔软的问题会变得很明显。当管道通过流体介质应能承受高应力(高于12.5千牛/米2)时，环劲度为10巴(106牛/米2)的管材对于地下设施或真空度可能波动的管线来说是太低了。根据本发明，多层压送管的总劲度能容易地被调整到适当的水平。通过在管材中共挤塑一保护性泡沫塑料层和一外表层就能容易地将总的环劲度提高到足够的水平。例如，如果取向PVC管材的环劲度是4千牛/米2，增加薄泡沫塑料层能使环劲度提高到8千牛/米2，对于大多数地下设施来说，这是最低值，甚至还超过16千牛/米2，这对于不良的土壤类环境常是必须的。这类高劲度即使在“无砂”设施中也可能是有利的。
下表列出了本发明管材结构的一些实施例。全部实施例涉及的管材内径为300毫米，环劲度为8.8千牛/米2。这些实施例的泡沫塑料层都不含任何填料。
                  P       E  层厚度      重量     劲度   劲度    质量比％，
              千克/米3 兆帕   毫米    千克/米  千牛/米  次序   外管和内管
                                                                 的百分比PE管1NCPE 2467            955     800    4.30     3.93    0.1881    1泡沫塑料层Mobil HTA001 F       200     25     11.16    2.23    0.0900    2外管Mobil HTA001         949     920    1.54     1.53    0.0076    3
                                         7.69                     71.00％PE管2NCPE 2467            955     800    2.00     1.81    0.0194    2泡沫塑料层Mobil HTA001 F       200     25     13.60    2.70    0.1662    1外管Mobil HTA001         949     920    2.00     1.99    0.0166    3
                                         6.50                     58.46％PE管3NCPE 2467            955     800    1.54     1.39    0.0089    3泡沫塑料层Mobil HTA001 F       200     25     12.56    2.48    0.1334    2外管Mobil HTA001         949     920    4.30     4.26    0.1658    1
作为上述实施方案的一种替代，用其它易弯曲的和软的结构，如图4中所示的易弯曲的支撑肋12来部分代替或全部代替管材中层的泡沫塑料。肋的形状为角状S形并在管子的径向是易弯曲的。优选的支撑肋是薄塑料制的，它们可与管子纵轴平行或与管子径向平行配置，如图5所示，支撑肋之间的空间可以是空的或用泡沫塑料充填。
本发明的塑料管是按下述方法制造的。将塑料原料喂入挤塑机4中，该挤塑机包括供挤塑中层3的螺杆5、供挤塑内管1和外管2的一根或两根螺杆(未画出)。螺杆5将塑料材料输送到图中的右端到喷嘴6为止，塑料由喷嘴进入定位装置，即管的外侧C区域及管的内侧7的区域(图3)，在此处管子被冷却。当塑料沿螺杆向喷嘴移动时，塑料在A段塑化。内管可在现场共挤塑，或者尤其在两层或多层内管情况下，内管可先挤塑，然后通过一侧向模头，在侧向模头内与泡沫层和外管汇合使泡沫层与外管粘附在内管上。
根据本发明，加压气体如氮气或二氧化碳经通道9通过机筒8或经其它方法通过机筒导入塑化的热塑性塑料中。在高压下气体被吸收入塑料中。泡孔尺寸在混合段B中被细微化。在说明性的实施方案中，借助变窄的螺距在螺杆中形成混合段，但是，实际上也可采用在技术上众所周知的普通型混合几何形状的螺杆。最优选的是，塑化螺杆是如我们共同待审的专利申请FI 961822中提出的以同轴安装在供挤塑外层的锥形螺杆内。
向塑料材料添加约1％化学发泡剂，如偶氮二甲酰胺来提高塑性材料的发泡率。也可以向形成内管和外管以及可能还包括中层的塑料材料添加能够在与管轴方向成一角度的方向上排列的短纤维。一种替代短纤维的方法，(或者仍添加短纤维)，是可借助挤塑机使内管和/或外管塑料发生取向，其中，成型管材内表面的模芯和/或成型外表面的喷嘴是绕设备的中心轴旋转的。
图3展开了一种典型的三层挤塑的模具、喷嘴和定位系统。编号1a表示模具的外表面，它限定物料流向多层管的外管。以2a表示限定中层外表面的部件，3a表示隔开中层与内管的模套。编号4a表示限定内管内表面的模具内表面。区域(A)代表属于模具(热的)部件，区域(B)代表属于喷嘴(热的)的部件，及区域(C)代表属于定径装置(热的或冷的)的部件。如果(B)与(C)之间装有用于阻止区域(B)的过多热流流向区域(C)的绝热材料隔板，则区域(C)与(B)也可互相连接。
喷嘴或模头组件仅包括可与模具以丝扣旋接的喷嘴套Ib和也与模具以丝扣旋接的模芯4b。当模芯4b装有冷却水通道(未画出)时，才能制得质量最好的内管。此外，如在专利PCT/US90/03394所公开的，整个模具的模体可以旋转以使纤维取向。
定径装置包括一个设有许多抽真空用的缝隙1d的外定径套1C。内定径套4c也有对应的缝隙4d。附图中也展示出挤出的外管2，软质(泡沫塑料)层3和内管1。在定径装置中，挤塑管材沿定位在管内侧的模芯4a和4b及定位在管外侧的定径装置外筒1c滑动，而中层泡沫塑料正好占据内外管间可利用的空间。泡沫塑料引起的压力挤压贴在模芯和定径套上的内管和外管，从而使它们彼此保持接触。这种挤压作用可通过上面提及的抽真空部件产生负压作用而得以增强。
共挤塑多层管中的被低密度泡沫塑料包围的内管的定中通常是采用特殊的定心片来进行的。
根据本发明，管材定中可方便地通过下述方法来实现：对引出装置或挤塑机头与另一引出装置之间的管段施加张力至中层泡沫塑料充分冷却，这样能使内管定中的剪切强度从外层传递到内层。
在上文中，只以几个优选的实施方案对本发明作了说明。本发明细节可在所附权利要求书中规定的范围内加以变更，这一点对于本领域技术熟练人员来说是不言而喻的。

Claims (37)

1.一种共挤塑多层塑料管材，该管材包括被较内管软的材料制的中层(3)包围的一层或多层内管(1)和围绕所述中层的外管(2)，其中所述中层包围着一个或多个内管，这种管材的特征在于：所述中层树脂与该塑料管材总重量之比至多为55％。
2.根据权利要求1所述的共挤塑多层塑料管材，其特征在于内管和外管(1，2)合在一起的质量至少是该管材总质量的45％。
3.根据权利要求2所述的共挤塑多层塑料管材，其特征在于内管和外管(1，2)合在一起的质量是该管材总质量的60％-80％。
4.根据权利要求1或2的共挤塑多层塑料管材，其特征在于该多层塑料管包括一层内管(1)。
5.根据权利要求1的共挤塑多层塑料管材，其特征在于外管和/或内管(2，1)与中层(3)之间的粘附能低于破裂能。
6.根据权利要求1的共挤塑多层塑料管材，其特征在于外管和/或内管(2，1)包括至少两层，所述层之间的粘附能小于层的破裂能。
7.根据权利要求1的共挤塑多层塑料管材，其特征在于制造中层的树脂的表观弹性模量低于内管弹性模量，并且至多为500兆帕。
8.根据权利要求7的共挤塑多层塑料管材，其特征在于中层(3)的表观弹性模量至多为内管(1)弹性模量的25％。
9.根据权利要求8的共挤塑多层塑料管材，其特征在于中层(3)的表观弹性模量低于内管(1)弹性模量的10％。
10.根据权利要求1的共挤塑多层塑料管材，其特征在于内管(1)是由弹性模量至多为500兆帕的弹性体制成。
11.根据权利要求1的共挤塑多层塑料管材，其特征在于内层(1)的压缩模量至少是外层(2)与中层(3)一起测定的模量的两倍。
12.根据权利要求1的共挤塑多层塑料管材，其特征在于在多层管材中，外管或内管(2，1)具有最高环劲度。
13.根据权利要求10的共挤塑多层塑料管材，其特征在于外管(2)具有最高的环劲度，多层管材包括交联聚乙烯(PEX)内管(1)、泡沫塑料中层(3)和由厚度为0.2-0.6毫米包有塑料表皮的金属管所构成的外管(2)。
14.根据权利要求12的共挤塑多层塑料管材，其特征在于外管(2)具有最高环劲度，多层管材包括交联聚乙烯(PEX)内管(1)、泡沫塑料中层(3)和云母填充聚烯烃外管(2)。
15.根据权利要求12的共挤塑多层塑料管材，其特征在于内管(1)的环劲度至少是中层(3)或外管(2)环劲度的两倍。
16.根据权利要求15的共挤塑多层塑料管材，其特征在于所述多层管材的总环劲度高于8千牛/米2，内管(1)的环劲度低于6千牛/米2，以及所述多层管被用作压送管。
17.根据权利要求1的共挤塑多层塑料管材，其特征在于中层(3)具有最高环劲度。
18.根据权利要求17的共挤塑多层塑料管材，其特征在于内管(1)的环劲度至少是中层(3)的环劲度的2％。
19.根据权利要求1的共挤塑多层塑料管材，其特征在于中层(3)由泡沫塑料制成和该泡沫塑料的密度为50-500千克/米3。
20.根据权利要求19的共挤塑多层塑料管材，其特征在于中层(3)泡沫塑料的密度为100-300千克/米3。
21.根据权利要求1的共挤塑多层塑料管材，其特征在于中层(3)由泡沫塑料制成，且该泡沫塑料的发泡程度为50％-95％。
22.根据权利要求21的共挤塑多层塑料管材，其特征在于中层泡沫塑料的发泡程度为70％-85％。
23.根据权利要求1的共挤塑多层塑料管材，其特征在于管材的外径与外管的厚度比至多为210，而管材的内径与内管的厚度比至多为200。
24.根据权利要求1的共挤塑多层塑料管材，其特征在于外管和/或内管(2，1)包含能按偏离管轴方向取向的短纤维。
25.根据权利要求1的共挤塑多层塑料管材，其特征在于内管和外管(1，2)是由MDPE或HDPE制造或由交联MDPE或HDPE制造，以及中层(3)是由LDPE制造，任选用稳定的纤维或纤维状添加剂如矿物纤维增强。
26.根据权利要求25的共挤塑多层塑料管材，其特征在于所述多层管是用作地下排水管或污水管。
27.根据权利要求1的共挤塑多层塑料管材，其特征在于所述管材的中层(3)包括柔性支撑肋，该支撑肋之间空间可以是空的或充填有泡沫材料。
28.制造如权利要求1的共挤塑多层塑料管材的一种方法，所述方法包括在挤塑机(4)中制造所述多层管材，该挤塑机配置至少一根外层挤塑螺杆和一根输送及塑化塑料材料，然后将其挤塑成型为管材中层(3)的螺杆(5)，其特征在于加压气体是在中层(3)挤塑螺杆(5)的其中塑性材料已基本熔融的塑化段(A)中注入塑性材料中的，并与塑性材料相混合，然后挤入由内管(1)和外管(2)构成的空腔中。
29.根据权利要求28的方法，其特征在于在成型为内管和外管(1，2)的塑料材料中添加短纤维，在挤塑时，这些纤维按照与管材轴向成一角度的方向排列。
30.根据权利要求28的方法，其特征在于在成型为中层(3)的塑料材料中也添加增强短纤维和/或纤维状添加剂，如矿物纤维。
31.根据权利要求28的方法，其特征在于管材的内表面和外表面是定径的，且中层正好占据内管和外管(1，2)之间所限定的空间。
32.根据权利要求31的方法，其特征在于对定径表面施以负压以使所述表面与内管和外管保持接触。
33.根据权利要求28的方法，其特征在于通过一个引出装置或挤塑机头与另一引出装置之间的管段施加张力至中层泡沫塑料充分冷却，这样能使管材定中的剪切强度从外层传递到内层，从而达到内管按管材中层定中。
34.一种供制造共挤塑多层塑料管的设备，所述设备包括多层管挤塑机(4)和任选一台和多台常规挤塑机、模具以及定径装置(7)，其特征在于能同时定径多层管的外表面和内表面的定径装置(7)是紧靠模具的喷嘴(6)安装的，所以部分发泡是在定径装置(7)中进行的。
35.根据权利要求34的设备，其特征在于模具(区段1a、2a、3a和4a)与喷嘴(1b与4b之间)之间界面(A：B)上喷嘴孔的截面积小于喷嘴与定径装置界面(B：C)上整个管壁截面积。
36.根据权利要求34或35制造在外表面和/或内表面含纤维的多层管的设备，其特征在于一个或多个部件(1a、1b、2a、3a、4a、4b)相对于其它部件呈回转排列的。
37.根据权利要求34的设备，其特征在于供外管定径的表面呈波纹状。
CN96199007A 1995-12-12 1996-12-12 共挤塑多层塑料管及其制造方法和设备 Expired - Fee Related CN1078941C (zh)

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US6176269B1 (en) 2001-01-23
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