CN108000831A - 一种钢网塑料复合管加工工艺 - Google Patents
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Abstract
本本发明涉及一种塑料管加工工艺，尤其涉及一种新型钢网塑料复合管加工工艺。一种新型钢网塑料复合管加工工艺，步骤包括分丝、包胶、挤出内层塑料层、挤出热熔胶、缠绕钢丝网层、挤出热熔胶层、挤出外层塑料层等。本发明由于同时采用轴向钢丝线与环向钢丝网结构，提高了管材的刚性强度，不易弯曲变形，更适用于架空安装使用工况。
Description
技术领域
本本发明涉及一种塑料管加工工艺，尤其涉及一种钢网塑料复合管加工工艺。
背景技术
钢塑复合压力管材广泛应用于市政埋地供水、建筑埋地生活给水、埋地消防给水、工业污水排放（压力管）、工业酸碱溶液与粉末或浆体输送。该复合管材种类，国内市场常见有钢骨架聚乙烯塑料复合管、钢丝网骨架塑料复合管两种管材。
现有的钢骨架塑料聚乙烯复合管（结构如专利号CN98119383.8，名称为“网状钢骨架—塑料复合管的网状钢骨架的制造方法和装置”中国发明专利所述）制作过程中，通常需要先将钢丝制作成网状钢骨架，网状钢骨架由管材轴向经线与环向纬线钢丝组成，然后再在钢骨架上进行挤塑成型，为了在挤塑过程中保证钢骨架的钢丝不变形、移位，钢骨架的经线与纬线的毎一个交叉接触点都需要预先进行焊接固定，生产速度太慢，效率低下。钢丝焊接处拉伸强度降低，降低了钢材的耐压强度。为了使钢骨架处于复合管管壁的中间，不会变形而太偏向于管壁的外侧或内侧，那么需要的对管壁加厚、采用更粗的钢丝制成钢骨架，这样大大增加了复合管的生产成本。由于钢丝与聚乙烯塑料两种材料无法自然粘合，使用过程中的热涨冷缩与管道内输送的流体压力的冲击，钢塑复合管易出现钢丝与塑料分层问题，导致流体从管材端口处渗漏爆管，因此在施工安装时，切断管材端口外露钢丝需再作加工注塑或焊接封口环，对管材端口进行密封处理，防止流体输送中的渗漏隐患。这种密封端口的安装施工工艺复杂耗时，限制了该种管材的使用范围。
为克服上述专利号CN98119383.8管材的缺点，国内又发明了钢丝网骨架塑料复合管（结构如专利号CN200420105205.8，名称为"用于制备金属丝增强复合塑料管的缠绕装置"中国实用新型专利所述）。制作过程中，先用塑料挤出机挤出管材内层塑料管，在冷却成型的内层塑料管的外壁缠绕正反方向交叉结构的钢丝网骨架，然后挤出专用热熔胶包覆所有钢丝网骨架，最后在管材外层再挤出一层塑料层，利用专用热熔胶粘接内外层塑料与钢丝网骨架层。此产品结构，有效避免因钢丝与塑料未粘接成一体的渗漏隐患，且钢丝缠绕在内层塑料管外壁，不受钢丝网骨架焊接生产速度限制，生产效率大大提高。由于该管材钢丝缠绕角度与管材轴向夹角为54度，能满足管材轴向与环向内压力的优化平衡。但是，相比上述专利号CN98119383.8管材钢丝经线与管材轴向平行，管材CN200420105205.8轴向方向与环向方向刚性强度都明显降低，不利于架空安装使用的工况要求，在架空安装时，易弯曲变形。
发明内容
本本发明的目的是为了解决现有技术性能的不足，提供了一种钢网塑料复合管加工工艺，能够同时具备强度高，又能避免两种材料复合分层的隐患，还能根据用户需求选择增加内层耐磨、防腐、抗菌、自润滑的功能层，为提高复合管钢丝线与热熔胶粘合强度，钢丝外表面作压花纹处理，轴向经线与环向纬线的钢丝交叉点无需焊接，提高了生产效率的加工工艺。
本发明的技术方案如下：一种钢网塑料复合管加工工艺，包括以下步骤。
一、使用塑料挤出机在多层共挤模具上挤出内层塑料层与功能层。
二、采用塑料管挤出加工用冷却水箱与冷却定径套，同时在模具芯棒通入冷却介质，将内层塑料层与功能层同时冷却定型。
三、使用塑料挤出机与包塑模具对钢丝线层的每根钢丝表面上包覆一层热熔胶层。
四、使用高频加热器对定位于内层塑料层表面的钢丝线层进行加热，并使用牵引机将加热后的钢丝线层与内层塑料层及功能层同步同速牵引行进，使钢丝线层粘接于内层塑料层的外壁上，且环绕一周均匀分布。
五、使用钢丝缠绕机将钢丝螺旋缠绕在内层塑料层外壁上的钢丝线层上，形成钢丝网层。
六、使用塑料挤出机再挤出一层热熔胶层层，使热熔胶层层包覆住钢丝网层。
七、使用烘箱对步骤六中包覆的那层热熔胶层进行加热，然后使用塑料挤出机挤出一层塑料再次包覆在热熔胶层外表面上，形成外层塑料层，对外层塑料层进行冷却处理后就制成了复合管。
八、使用切割机将制作好的复合管切割出一定长度的成品管材。
所述一种钢网塑料复合管，包括外层塑料层和内层塑料层，所述外层塑料层处于内层塑料层之外，所述外层塑料层和内层塑料层之间设置有一层热熔胶层，所述热熔胶层层中设置有钢丝网层和钢丝线层，所述钢丝线层沿复合管轴向方向呈圆形均匀分布，处于热熔胶层内靠近内层塑料层的位置，所述钢丝网层处于热熔胶层内靠近外层塑料层的位置，所述钢丝网层呈单向左旋或单向右旋或双向左旋与右旋方向方向螺旋缠绕在热熔胶层内，所述钢丝网层的钢丝与复合管轴线夹角为大于0度小于90度，所述钢丝线层和钢丝网层的外表面压有花纹，所述内层塑料层内侧壁上设置有功能层，所述钢丝线层每根钢丝与复合管轴心线的距离相等。
作为本发明的进一步技术方案，在步骤一之前，先将钢丝线层和钢丝网层的钢丝的外表面压制花纹。
作为本发明的进一步技术方案，所述步骤五中所述冷却定型采用内外模具同时冷却的方式，即对模具芯棒和模具外定型模具通入循环冷却介质冷却，且对模具芯棒的冷却采取分段独立循环冷却水的冷却方式，分段控制冷却温度，所述冷却介质为水或油或冷却气体，或者分段组合采用水、油和冷却气体。
本发明的有益效果如下。
1、本发明由于同时采用轴向钢丝线与环向钢丝网结构，提高了管材的刚性强度，不易弯曲变形，更适用于架空安装使用工况。
2、使用热熔胶包覆轴向钢丝与环向缠绕钢丝，解决了钢丝与塑料的分层问题，消除了管材端口渗漏爆管的隐患，避免了繁杂的封口处理工作。
3、钢丝外表面压花纹后，提高了钢网与塑料的长期粘合强度，有效避免复合管材长期使用中环境温度变化使管材热胀冷缩产生的钢塑分层。
4、内层增加特殊功能层，可实现管道使用需要的耐磨、防腐、抗菌、自润滑的功能。
5、轴向钢丝线与环向钢丝线使用热熔胶与塑料层粘合，钢丝交叉点无需焊接固定，生产速度大幅提高，降低生产成本。
、采用热熔胶粘接，无需焊接轴向与环向缠绕钢丝，避免钢丝焊接处拉抻强度降低，有效利用钢丝的拉伸强度性能。
附图说明
图1为钢网塑料复合管分层剖开展示结构示意图。
图2为钢网塑料复合管剖面示意图。
图中，外层塑料层1’、内层塑料层2’、钢丝网层3’、钢丝线层4’、热熔胶层5’、功能层6’。
具体实施方式
以下结合附图对本发明的优选实施例进行说明，应当理解，此处所描述的优选实施例仅用于说明和解释本发明，并不用于限定本发明。
实施例一。
一种钢网塑料复合管加工工艺，包括以下步骤。
一、使用塑料挤出机在多层共挤模具上挤出内层塑料层2’与功能层6’。
二、采用塑料管挤出加工用冷却水箱与冷却定径套，同时在模具芯棒通入冷却介质，将内层塑料层2’与功能层6’同时冷却定型。
三、使用塑料挤出机与包塑模具对钢丝线层4’的每根钢丝表面上包覆一层热熔胶层5’。
四、使用高频加热器对定位于内层塑料层2’表面的钢丝线层4’进行加热，并使用牵引机将加热后的钢丝线层4’与内层塑料层2’及功能层6’同步同速牵引行进，使钢丝线层4’粘接于内层塑料层2’的外壁上，且环绕一周均匀分布。
五、使用钢丝缠绕机将钢丝螺旋缠绕在内层塑料层2’外壁上的钢丝线层4’上，形成钢丝网层3’。
六、使用塑料挤出机再挤出一层热熔胶层5’层，使热熔胶层5’层包覆住钢丝网层3’。
七、使用烘箱对步骤六中包覆的那层热熔胶层5’进行加热，然后使用塑料挤出机挤出一层塑料再次包覆在热熔胶层5’外表面上，形成外层塑料层1’，对外层塑料层1’进行冷却处理后就制成了复合管。
八、使用切割机将制作好的复合管切割出一定长度的成品管材。
如图1和图2所示，所述一种钢网塑料复合管，包括外层塑料层1’和内层塑料层2’，所述外层塑料层1’处于内层塑料层2’之外，所述外层塑料层1’和内层塑料层2’之间设置有一层热熔胶层5’，所述热熔胶层5’层中设置有钢丝网层3’和钢丝线层4’，所述钢丝线层4’沿复合管轴向方向呈圆形均匀分布，处于热熔胶层5’内靠近内层塑料层2’的位置，所述钢丝网层3’ 处于热熔胶层 5’ 内靠近外层塑料层1’的位置，所述钢丝网层3’呈单向左旋或单向右旋或双向左旋与右旋方向方向螺旋缠绕在热熔胶层5’内，所述钢丝网层3’的钢丝与复合管轴线夹角为大于0度小于90度，所述钢丝线层4’和钢丝网层3’的外表面压有花纹，所述内层塑料层2’内侧壁上设置有功能层6’，所述钢丝线层4’每根钢丝与复合管轴心线的距离相等。
实施例二。
在步骤一之前，先将钢丝线层4’和钢丝网层3’的钢丝的外表面压制花纹。其他方案与实施例一相同。
实施例三。
作为本发明的进一步技术方案，所述步骤五中所述冷却定型采用内外模具同时冷却的方式，即对模具芯棒和模具外定型模具通入循环冷却介质冷却，且对模具芯棒的冷却采取分段独立循环冷却水的冷却方式，分段控制冷却温度，所述冷却介质为水或油或冷却气体，或者分段组合采用水、油和冷却气体。其他方案与实施例一相同。
最后应说明的是：以上所述仅为本发明的优选实施例而已，并不用于限制本发明，尽管参照前述实施例对本发明进行了详细的说明，对于本领域的技术人员来说，其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分技术特征进行等同替换。凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。
Claims (4)
1.一种钢网塑料复合管加工工艺，其特征在于，包括以下步骤：
一、使用塑料挤出机在多层共挤模具上挤出内层塑料层（2’）与功能层(6’)；
二、采用塑料管挤出加工用冷却水箱与冷却定径套，同时在模具芯棒通入冷却介质，将内层塑料层（2’）与功能层(6’)同时冷却定型；
三、使用塑料挤出机与包塑模具对钢丝线层（4’）的每根钢丝表面上包覆一层热熔胶层（5’）；
四、使用高频加热器对定位于内层塑料层（2’）表面的钢丝线层（4’）进行加热，并使用牵引机将加热后的钢丝线层（4’）与内层塑料层（2’）及功能层(6’)同步同速牵引行进，使钢丝线层（4’）粘接于内层塑料层（2’）的外壁上，且环绕一周均匀分布；
五、使用钢丝缠绕机将钢丝螺旋缠绕在内层塑料层（2’）外壁上的钢丝线层（4’）上，形成钢丝网层（3’）；
六、使用塑料挤出机再挤出一层热熔胶层（5’）层，使热熔胶层（5’）层包覆住钢丝网层（3’）；
七、使用烘箱对步骤六中包覆的那层热熔胶层（5’）进行加热，然后使用塑料挤出机挤出一层塑料再次包覆在热熔胶层（5’）外表面上，形成外层塑料层（1’），对外层塑料层（1’）进行冷却处理后就制成了复合管；
八、使用切割机将制作好的复合管切割出一定长度的成品管材。
2.根据权利要求1所述的一种钢网塑料复合管加工工艺，其特征在于：所述一种新型钢网塑料复合管，包括外层塑料层(1’)和内层塑料层(2’)，所述外层塑料层(1’)处于内层塑料层(2’)之外，所述外层塑料层（1’）和内层塑料层(2’)之间设置有一层热熔胶层(5’)，所述热熔胶层(5’)层中设置有钢丝网层(3’)和钢丝线层（4’），所述钢丝线层（4’）沿复合管轴向方向呈圆形均匀分布，处于热熔胶层(5’)内靠近内层塑料层(2’)的位置，所述钢丝网层(3’) 处于热熔胶层 (5’) 内靠近外层塑料层(1’)的位置，所述钢丝网层(3’)呈单向左旋或单向右旋或双向左旋与右旋方向方向螺旋缠绕在热熔胶层（5’）内，所述钢丝网层（3’）的钢丝与复合管轴线夹角为大于0度小于90度，所述钢丝线层（4’）和钢丝网层（3’）的外表面压有花纹，所述内层塑料层（2’）内侧壁上设置有功能层（6’），所述钢丝线层（4’）每根钢丝与复合管轴心线的距离相等。
3.根据权利要求1所述的一种钢网塑料复合管加工工艺，其特征在于：在步骤一之前，先将钢丝线层（4’）和钢丝网层（3’）的钢丝的外表面压制花纹。
4.根据权利要求1所述的一种钢网塑料复合管加工工艺，其特征在于：所述步骤二中所述冷却定型采用内外模具同时冷却的方式，即对模具芯棒和模具外定型模具通入循环冷却介质冷却，且对模具芯棒的冷却采取分段独立循环冷却介质的冷却方式，分段控制冷却温度，所述冷却介质为水或油或冷却气体，或者分段组合采用水、油和冷却气体。
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Application publication date: 20180508 |