CN108162352A - 螺旋状层构造体及螺旋状层构造体的制造方法 - Google Patents

螺旋状层构造体及螺旋状层构造体的制造方法 Download PDF

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Publication number
CN108162352A
CN108162352A CN201711285882.0A CN201711285882A CN108162352A CN 108162352 A CN108162352 A CN 108162352A CN 201711285882 A CN201711285882 A CN 201711285882A CN 108162352 A CN108162352 A CN 108162352A
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China
Prior art keywords
core components
helical
high molecular
layer tectosome
molecular material
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CN201711285882.0A
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Inventor
近藤和夫
加藤和也
大江广行
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Change Into Industrial Co Ltd
Toyota Motor Corp
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Change Into Industrial Co Ltd
Toyota Motor Corp
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Publication of CN108162352A publication Critical patent/CN108162352A/zh
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Abstract

本发明的课题在于提供具有能够自由地变形为任意形状的挠性，并抑制生锈、腐蚀等的发生，经过长期间而维持耐久性，使用环境等不受限制的螺旋状层构造体及其制造方法。螺旋状层构造体具有：螺旋状芯部件，其由具有挠性的长条平板状的芯部件形成、由铁等金属材料的钢板形成；以及高分子包覆层，其由热固性弹性材料、热塑性弹性材料等高分子材料形成，将螺旋状芯部件包覆。螺旋状层构造体的制造方法具有：对挠性的芯部件进行输送的输送工序、供给具有流动性的高分子材料的供给工序、将芯部件由高分子材料包覆的包覆工序、将由高分子材料包覆的包覆中间体冷却的冷却工序、将包覆中间体扭转加工为螺旋状而形成螺旋状层构造体的螺旋形成工序。

Description

螺旋状层构造体及螺旋状层构造体的制造方法
技术领域
本发明涉及螺旋状层构造体及螺旋状层构造体的制造方法。更详细地说，涉及由至少大于或等于二层的层构造形成的螺旋状层构造体及螺旋状层构造体的制造方法。
背景技术
当前，制造具有螺旋状(spiral状或者扭转状)的构造的部件、产品等在各种用中途使用。例如，对方管、平板状的钢板(平板钢板)进行扭转加工而成的扭转方管、扭转钢板等作为用于在庭园、建筑物等进行设置的装饰用部件使用(参照专利文献1)。
并且，作为建造物、围墙等地基加强材料，使用所谓“螺旋桩”(参照专利文献2)。该螺旋桩在对平板钢板进行扭转加工而形成螺旋体后，切成预先规定的长度，实施了将插入至地中侧的一端设为桩形状的加工。通过扭转加工为螺旋状，从而能够增加与从规定方向施加的压力相对抗的强度。
另一方面，作为其他螺旋状的产品等，例如是将被输送物向规定方向输送的螺杆、利用螺旋状的形态而对气体、液体的流动进行调整的整流部件的一部分，或者充分发挥每单位体积的面积变大的特性而作为热交换部件的一部分使用。
专利文献1：日本专利第3023583号公报
专利文献2：日本特开2014－14837号公报
现有的螺旋状的产品等大多主要由金属材料构成，从加强等使用目的、用途等出发，需要维持该螺旋状的形态。即，即使在对产品等施加强应力的情况下，螺旋状的形态(特别是螺旋轴方向的形态)也不变化。换言之，缺乏挠性，不会自由地变形为任意形状。
因此，在除了加强等用途以外的作为整流部件、热交换部件的一部分使用的情况下，向复杂地弯曲而成的形状的管、配管等的设置变得困难等、搬运性差，有时成为作业花费时间等使作业效率降低的原因。
此外，关于上述螺旋状的产品等，仅对方管、平板钢板等进行扭转加工、或在直线状的金属棒通过焊接等安装螺旋状的叶片。因此，铁、不锈钢等金属材料在产品表面直接露出。其结果，直接暴露于外部空气等的螺旋状的产品等与大气中的氧、雨水等接触的机会变大，有可能发生由于长期间的使用而在产品表面生锈等或腐蚀等问题。
因此，具有在屋外等的使用受限等课题。另外，例如，即使在作为整流部件、热交换部件的一部分等使用的情况下，也有时无法在可能与强酸性、强碱性或者其他腐蚀性的气体、液体接触的环境下使用。其结果，虽然具有螺旋状的构造，但无法充分地发挥其特性，有时使用环境大幅地受限。
发明内容
因此，本发明就是鉴于上述情况而提出的，课题在于提供一种具有能够自由地变形为任意形状的挠性，并且对生锈、腐蚀等的发生进行抑制，经过长期间而维持耐久性，使用环境等不受限制的螺旋状层构造体及该螺旋状层构造体的制造方法。
根据本发明，提供一种解决了上述课题的螺旋状层构造体及螺旋状层构造体的制造方法。
[1]一种螺旋状层构造体，其具有：螺旋状芯部件，其由具有挠性的长条平板状的芯部件形成，将所述芯部件的长度方向作为螺旋轴而呈螺旋状；以及高分子包覆层，其由高分子材料形成，对所述螺旋状芯部件的全部面进行了包覆。
[2]关于在所述[1]中记载的螺旋状层构造体，所述螺旋状芯部件是由铁、不锈钢及铝中的任一个金属材料形成的钢板。
[3]关于在所述[1]或者[2]中记载的螺旋状层构造体，所述螺旋状芯部件具有至少一个狭缝部，该狭缝部是将所述芯部件的芯部件正面及芯部件背面之间贯通以及将所述芯部件的一部分切除而成的。
[4]关于在所述[1]～[3]中任一项记载的螺旋状层构造体，所述螺旋状芯部件或者所述芯部件的芯部件厚度为0.25mm～3.00mm的范围，所述螺旋状芯部件或者所述芯部件的芯部件宽度为3mm～150mm的范围。
[5]关于在所述[1]～[4]中任一项记载的螺旋状层构造体，所述高分子包覆层的层厚度为0.3mm～10mm的范围。
[6]关于在所述[1]～[5]中任一项记载的螺旋状层构造体，形成所述高分子包覆层的所述高分子材料为三元乙丙橡胶、苯乙烯丁二烯橡胶、丁腈橡胶、硅橡胶、丙烯酸橡胶及氢化丁腈橡胶的任一个热固性弹性材料。
[7]关于在所述[1]～[5]中任一项记载的螺旋状层构造体，形成所述高分子包覆层的所述高分子材料是烯烃类热塑性弹性体、苯乙烯类热塑性弹性体、聚氨酯类热塑性弹性体、动态交联热塑性弹性体、酰胺类热塑性弹性体及酯类热塑性弹性体的任一个热塑性弹性材料。
[8]关于在所述[1]～[7]中任一项记载的螺旋状层构造体，所述高分子包覆层的肖氏A硬度为35～95的范围。
[9]一种螺旋状层构造体的制造方法，其是所述[1]～[8]中任一项记载的螺旋状层构造体的制造方法，该螺旋状层构造体的制造方法具有：输送工序，将具有挠性的长条平板状的芯部件沿所述芯部件的长度方向输送；供给工序，将具有流动性的高分子材料向在所述芯部件的输送路径的中途设置的包覆区域供给；包覆工序，在所述包覆区域，使由所述供给工序供给的所述高分子材料和所述芯部件接触，将所述芯部件由所述高分子材料包覆；冷却工序，对由所述高分子材料包覆所述芯部件而得到的包覆中间体进行冷却；以及螺旋形成工序，将经过所述冷却工序后的所述包覆中间体的长度方向作为螺旋轴，将所述包覆中间体扭转加工为螺旋状，形成螺旋状层构造体。
[10]关于在所述[9]中记载的螺旋状层构造体的制造方法，还具有在所述冷却工序及所述螺旋形成工序之间实施的下述工序：中间体滞留工序，使经过所述冷却工序后的所述包覆中间体暂时地滞留在缓冲区域；以及扭转加工后切断工序，将经过所述螺旋形成工序后的切断前螺旋状层构造体切断为规定长度，所述螺旋形成工序将切断为规定长度前的所述包覆中间体扭转加工为螺旋状。
[11]关于在所述[9]中记载的螺旋状层构造体的制造方法，还具有在所述冷却工序及所述螺旋形成工序之间实施的扭转加工前切断工序，该扭转加工前切断工序将所述冷却工序后的所述包覆中间体切断为规定长度，所述螺旋形成工序将切断为规定长度后的所述包覆中间体扭转加工为螺旋状。
[12]关于在所述[9]～[11]中任一项记载的螺旋状层构造体的制造方法，通过所述供给工序供给的所述高分子材料是三元乙丙橡胶、苯乙烯丁二烯橡胶、丁腈橡胶、硅橡胶、丙烯酸橡胶及氢化丁腈橡胶的任一个热固性弹性材料，还具有在所述包覆工序及所述冷却工序之间实施的热硬化工序，该热硬化工序对所述包覆中间体进行加热，对将所述芯部件包覆的所述高分子材料进行热硬化处理。
[13]关于在所述[12]中记载的螺旋状层构造体的制造方法，所述供给工序通过30℃～120℃的范围的温度进行加热处理，供给具有流动性的所述高分子材料，所述热硬化工序通过150℃～250℃的范围的热硬化温度及120s～600s的热硬化时间进行热硬化处理。
[14]关于在所述[9]～[11]中任一项记载的螺旋状层构造体的制造方法，通过所述供给工序供给的所述高分子材料是烯烃类热塑性弹性体、苯乙烯类热塑性弹性体、聚氨酯类热塑性弹性体、动态交联热塑性弹性体、酰胺类热塑性弹性体及酯类热塑性弹性体的任一个热塑性弹性材料，所述供给工序通过150℃～270℃的范围的温度进行加热处理，供给具有流动性的所述高分子材料。
发明的效果
根据本发明的螺旋状层构造体，其由层构造构成，该层构造是通过高分子包覆层对由金属材料构成的芯部件的全部面进行包覆而成的，芯部件由具有挠性的材料形成。由此，能够设为针对应力可自由地变形的螺旋状层构造体，能够实现搬运性、作业效率的提高。
此外，通过高分子包覆层，螺旋状芯部件不会直接暴露于大气等，该高分子包覆层是由对螺旋状芯部件的全部面进行了包覆的热固性弹性材料(橡胶)、热塑性弹性材料(弹性体)等高分子材料构成的。由此，发挥优异的耐久性，可经受长期间的使用，不存在使用环境受到限制的担心。
根据本发明的螺旋状层构造体的制造方法，在将长条平板状的芯部件通过高分子材料包覆后，扭转加工为螺旋状，由此能够高效地制造可实现上述的优异效果的螺旋状层构造体。
附图说明
图1是示意地表示本实施方式的螺旋状层构造体的概略结构的斜视图。
图2是表示扭转加工前的包覆中间体的概略结构的俯视图。
图3是表示扭转加工前的包覆中间体的概略结构的、图2的A－A线剖视图。
图4是表示扭转加工前的芯部件的狭缝部的其他例结构的俯视图。
图5是表示扭转加工前的芯部件的狭缝部的其他例结构的俯视图。
图6是表示作为高分子材料而使用热固性弹性材料的本实施方式的螺旋状层构造体的制造方法的流程的一个例子的说明图。
图7是表示设置于包覆区域的包覆头的概略结构的示意剖视图。
标号的说明
1：螺旋状层构造体，1a：切断前螺旋状层构造体，2：螺旋状芯部件，2a、4a：芯部件正面，2b、4b：芯部件背面，4c：芯部件侧面，3：高分子包覆层，4：芯部件，5：包覆中间体，5a：一端，5b：另一端，6、6a、6b、6c：狭缝部，6d：冲裁部(狭缝部)，7：高分子材料，10：螺旋状层构造体的制造方法，11：辊体，12：供给装置，13：包覆头，14：覆盖件，15：热硬化装置，16：冷却槽，17：缓冲用辊，18a、18b：固定部，19：切断装置，B：缓冲区域，C：包覆区域，F：输送方向，H：层厚度，R：输送路径，S：扭转加工方向，T：芯部件厚度，X：螺旋轴，W：芯部件宽度，S1：输送工序，S2：供给工序，S3：包覆工序，S4：热硬化工序，S5：冷却工序，S6：中间体滞留工序，S7：螺旋形成工序，S8：扭转加工后切断工序。
具体实施方式
下面，一边参照附图，一边对本发明的螺旋状层构造体及螺旋状层构造体的制造方法的实施方式进行详细叙述。此外，本实施方式的螺旋状层构造体及螺旋状层构造体的制造方法并不限定于下面的实施方式，只要不脱离本发明的主旨，可以施加各种设计的变更、修正及改良等。
1.螺旋状层构造体
本发明的一个实施方式的螺旋状层构造体1如图1～5等所示，是由至少两个层构成的，该层构造体具有：螺旋状芯部件2，其呈螺旋状；以及高分子包覆层3，其是将该螺旋状芯部件2的全部面通过高分子材料7包覆而成的。此外，图1为了对螺旋状层构造体1的结构进行说明，示出将一端侧的一部分扭转加工为螺旋状之前的芯部件4露出的状态。图2及图3分别示出在扭转加工为螺旋状层构造体1之前的芯部件4的全部面设置有高分子包覆层3的包覆中间体5的结构。
关于螺旋状层构造体1的结构，如果更详细地说明，则螺旋状芯部件2由具有挠性的长条平板状或者长条薄板状的芯部件4形成，以规定的间距等，等间隔地扭转加工为螺旋状而构建出。
在这里，螺旋状芯部件2及构成螺旋状芯部件2的芯部件4主要使用由铁、不锈钢及铝等金属材料构成的平板状的钢板、轧制钢板。前述的芯部件4的长度方向与螺旋状芯部件2及螺旋状层构造体1的长度方向一致，与螺旋状层构造体1的螺旋轴X(参照图1中的双点划线)一致。
本实施方式的螺旋状层构造体1使用具有挠性、且平板状的轧制钢板等金属材料而形成有芯部件4，因此通过使用公知的扭转加工装置(未图示)，从而能够容易地扭转加工为螺旋状的形态。在这里，扭转加工装置是指下述装置，即，例如在将长条状的芯部件4的一端及另一端分别夹持而固定(卡住)后，仅使芯部件4的另一端侧沿规定方向旋转，由此按照与芯部件4的长度方向一致的螺旋轴X(参照图1)构建螺旋状的形态。此外，实际的扭转加工是在芯部件4包覆高分子材料7而形成高分子包覆层3后实施的(详细内容在后面记述)。
扭转加工后的螺旋状芯部件2是由金属材料的芯部件4形成的，因此只要不施加特别强的应力，就能够维持该螺旋状的形态。但是，螺旋状芯部件2及芯部件4具有下述程度的挠性，即，例如利用人手的力等向试图使螺旋轴X弯曲的方向施加应力，由此能够使该形状变形。
螺旋状芯部件2或者芯部件4(下面，简称为“螺旋状芯部件2等”)为了具有上述这样的挠性的性状，作为主原料而使用铁、不锈钢、铝等金属材料，且需要将该螺旋状芯部件2等的芯部件厚度T及芯部件宽度W设定在规定的范围。
即，螺旋状芯部件2等的芯部件厚度T(参照图3)在本发明的螺旋状层构造体1中，设定在0.25mm～3.0mm的范围。通过将芯部件厚度T设定在上述范围，从而能够维持扭转加工后的螺旋状的形态，且使施加了应力后的情况下的变形变得容易。
此外，螺旋状芯部件2等的芯部件宽度W(参照图2)在本发明的螺旋状层构造体1中，设定在3mm～150mm的范围。通过将芯部件宽度W设定在上述范围，从而同样地能够维持扭转加工后的螺旋状的形态，且使施加了应力的情况下的变形变得容易。
在这里，在芯部件厚度T比0.25mm薄的情况下，成为维持螺旋状层构造体1的螺旋状形态的基本骨架的螺旋状芯部件2不具有充分的强度。其结果，由于自重、高分子包覆层3的重量及重力等，有可能无法充分地维持螺旋状的形态。并且，在扭转加工为螺旋状时强度不足，因此有螺旋状芯部件2等断裂或者切断的担心。
另一方面，在芯部件厚度T比3.00mm厚的情况下，用于将芯部件4扭转加工为螺旋状的力(负荷)变大，扭转加工的作业性恶化的可能性高，且施加应力而使螺旋状的形态变形的力也需要变多。即，缺乏挠性。
并且，在使芯部件宽度W比3mm窄的情况下，螺旋状的形态变得过小，无法充分地发挥采用该方式的效果。另一方面，在使芯部件宽度W比150mm宽的情况下，缺乏挠性，有扭转加工性、向任意形状的变形性受损的担心。并且，由于芯部件4的包覆宽度变宽，因此用于形成将芯部件4包覆的高分子包覆层3的装置(包覆头13：参照图7)必然变大。其结果，用于该包覆头13的设备成本有可能增大。因此，芯部件厚度T及芯部件宽度W在本发明中设定在规定的范围。
本实施方式的螺旋状层构造体1的螺旋状芯部件2等如图1～3等所示，作为进一步的结构，具有多个狭缝部6，该狭缝部6是将螺旋状芯部件2等的芯部件正面2a、4a及芯部件背面2b、4b之间贯通、或者将螺旋状芯部件2等的一部分切除而成的。在这里，狭缝部6是将大致平板状的螺旋状芯部件2等的一部分去除而成的空隙，实际上是以扭转加工为螺旋状前的芯部件4的状态设置的。此外，狭缝部6的形状、布局，进而狭缝部6形成后的螺旋状芯部件2等的形态，并不特别受到限定。
例如，如图1～3所示，举出下述结构，即，在螺旋状芯部件2等的中央部分及两侧部分分别设置大致长方形状的多个狭缝部6a、6b，螺旋状芯部件2等的整体大致呈“井”型状。在这里，中央部分的狭缝部6a是将芯部件正面2a、4a及芯部件背面2b、4b之间贯通而形成的，两侧部分的一对狭缝部6b是将芯部件侧面4c一并切除而形成的。
还可以在螺旋状芯部件2等的两侧部分设置一对大致长方体形状的多个狭缝部6c，使得呈将螺旋状芯部件2等的中央部分残留为直线状的大致“鱼骨”形状(参照图4)。在该情况下，一对狭缝部6c是将芯部件侧面4c一并切除而形成的。
此外，狭缝部6能够在本说明书中广义地理解，例如包含将对芯部件正面2a、4a及芯部件背面2b、4b之间冲裁为孔形状后的多个冲裁部6d(所谓“冲孔”)以等间隔配置的结构(参照图5)。还可以是将上述的多个狭缝部6a、6b、6c、或者狭缝部6的一部分即冲裁部6d等进行各种组合而配置的结构。
此外，上述狭缝部6a等及冲裁部6d示出将芯部件正面2a、4a及芯部件背面2b、4b之间贯通的结构，但也可以不必进行贯通，而包含将芯部件正面2a等的一部分刨除得到的刨除部(未图示)。此外，狭缝部6能够通过使用冲制加工、激光加工等公知的金属加工技术而形成。
如上所述，螺旋状芯部件2等具有多个狭缝部6，由此能够进一步提高螺旋状芯部件2等的挠性。此外，根据该狭缝部6的形状、布局，能够实现挠性的程度的调整，能够构建可维持螺旋状的形态、且通过应力而适当地变形的螺旋状层构造体1。由此，能够提高在复杂形状的场所设置时的作业性。
并且，螺旋状芯部件2等具有上述狭缝部6，由此能够将高分子包覆层3(详细内容在后面记述)之间的贴合性、粘接性等变得牢固。在使高分子材料7与具有狭缝部6的芯部件4的全部面接触，形成高分子包覆层3的情况下，高分子材料7的一部分填充至作为在芯部件4设置的空隙的狭缝部6(例如，参照图3等)。
由此，即使施加试图从螺旋状层构造体1仅将螺旋状芯部件2拔出的力，填充至狭缝部6的高分子包覆层3也对该动作进行限制。由此，螺旋状层构造体1能够稳定地维持螺旋状芯部件2及高分子包覆层3的二层的层构造。
另一方面，本实施方式的螺旋状层构造体1中的高分子包覆层3是使具有流动性的高分子材料7遍及螺旋状芯部件2等的全部面进行接触，通过热硬化或者冷却而形成的。由此，金属材料的螺旋状芯部件2等由高分子包覆层3完全覆盖，不会直接暴露于大气等。
此外，将螺旋状芯部件2包覆的高分子包覆层3，并不限定于图1及图3所示的一层，也可以由多个层构成。因此，本发明的螺旋状层构造体1具有由螺旋状芯部件2等及高分子包覆层3的至少二层构成的层构造，也可以呈更多层的多层构造。
高分子包覆层3使用具有弹性的高分子材料7(详细内容在后面记述)。因此，在将芯部件4扭转加工为螺旋状芯部件2的情况下，或者在向螺旋状层构造体1施加应力而变形的情况下，能够对应于各自的弯曲、加工而进行伸缩。因此，在高分子包覆层3的表面发生龟裂、裂痕等的担心减小。
在这里，高分子包覆层3的层厚度H从螺旋状芯部件2等的芯部件正面2a、4a、芯部件背面2b、4b及芯部件侧面(未图示)起设定在0.3mm～10mm的范围。如果层厚度H比0.3mm薄，则难以通过均一的层厚度H将芯部件4包覆，产生下述等问题，即，螺旋状芯部件2等的一部分直接暴露于外部空气等。
另一方面，在层厚度H比10mm厚的情况下，在将芯部件4扭转加工为螺旋状时、或者在将螺旋状层构造体1变形时，由于过厚的高分子包覆层3而妨碍加工、变形。并且，即使在扭转加工后，由弹性材料形成的高分子包覆层3所产生的复原力大，因此无法保持螺旋状的形态，有可能使间距、形态散乱。因此，高分子包覆层3的层厚度H规定在上述数值范围内。
在高分子包覆层3使用的高分子材料7，例如能够举出三元乙丙橡胶(EPDM)、苯乙烯丁二烯橡胶(SBR)、丁腈橡胶(NBR)、硅橡胶(VMQ)、丙烯酸橡胶(ACM)及氢化丁腈橡胶(HNBR)的任一个热固性弹性材料。特别优选三元乙丙橡胶的使用。
并且，作为高分子材料7，能够使用烯烃类热塑性弹性体(TPO)、苯乙烯类热塑性弹性体(TPE)、聚氨酯类热塑性弹性体(TPU)、动态交联热塑性弹性体(TPV)、酰胺类热塑性弹性体(TPA)及酯类热塑性弹性体(TPC)的任一个热塑性弹性材料。特别优选烯烃类热塑性弹性体、动态交联热塑性弹性体及苯乙烯类热塑性弹性体的使用。
如上所述，高分子包覆层3能够使用可针对应力而弹性变形的材料即作为热固性弹性材料的橡胶、作为热塑性弹性材料的弹性体等高分子材料7(在广义中为树脂材料)而形成。
并且，本实施方式的螺旋状层构造体1中的高分子包覆层3使用肖氏A硬度为35～95的范围的包覆层。在这里，肖氏A硬度是用于对橡胶(弹性体)的硬度进行测定的标准，通过将压片(压针)压入至被测定物的表面，使被测定物变形，从而对该变形量(或者压入深度)进行测定。
具体地说，基于JIS K6253，使用硬度计(弹簧式橡胶硬度计)进行测定。通过将肖氏A硬度设为35～95的范围，从而不损害扭转加工时的作业性、螺旋状层构造体1的变形性、且在高分子包覆层3不会发生裂痕等缺陷。
2.螺旋状层构造体的制造方法
本发明的第一实施方式的螺旋状层构造体的制造方法10(下面，简称为“制造方法10”)具有：输送工序S1，对芯部件4进行输送；供给工序S2，对高分子材料7进行供给；包覆工序S3，将芯部件4由高分子材料7包覆；热硬化工序S4，将包覆中间体5通过规定的热硬化温度进行加热，进行热硬化处理；冷却工序S5，对热硬化处理后的包覆中间体5进行冷却；中间体滞留工序S6，使冷却后的包覆中间体5暂时地滞留在缓冲区域B；螺旋形成工序S7，在将存放在缓冲区域B的包覆中间体5的一部分绕出后，扭转加工为螺旋状；以及扭转加工后切断工序S8，将扭转加工后的切断前螺旋状层构造体1a切断为规定长度。下面，对作为高分子材料而使用三元乙丙橡胶等热固性弹性材料的情况进行说明。
另外，本实施方式的制造方法10从将长条平板状的芯部件4抽出而沿长度方向输送的输送工序S1起至扭转加工为螺旋状的螺旋形成工序S7为止连续地实施。即，直至螺旋形成工序S7为止，芯部件4、包覆中间体5及切断前螺旋状层构造体1a(参照图6)是连接为一个的状态，在螺旋形成工序S7之后，切断为规定长度的螺旋状层构造体1。
关于制造方法10，如果更详细地说明，则由具有挠性的金属材料构成的长条平板状的芯部件4作为预先卷绕为辊状的辊体11而设置在绕出装置(未图示)，将芯部件4沿大致水平方向(图6中的纸面左右方向)抽出，由此沿输送方向F输送(输送工序S1)。
芯部件4的输送速度，换言之，从辊体11抽出的抽出速度没有特别限定，例如能够设定在2m/min～30m/min之间。由此，通过后面记述的包覆工序S3，能够使适量的高分子材料7与芯部件4接触，将芯部件4包覆，且能够使制造效率变得良好。
芯部件4能够使用已经叙述的铁等金属材料的钢板，例如举出以铁为主原料的芯部件厚度T：0.5mm及芯部件宽度W：25mm的冷轧钢板。另外，在芯部件4预先通过冲裁加工、激光加工等，以芯部件4的整体大致成为“井”型形状(参照图2)的方式设置有多个狭缝部6。
另一方面，由热固性弹性材料构成的高分子材料7通过预先规定的温度(例如，30℃～120℃)进行加热处理，调整为具有流动性的状态。在这里，在温度低于30℃的情况下，损害流动性，难以朝向芯部件4的输送路径R进行供给(喷出)。另一方面，在温度超过120℃的情况下，有导致作为热固性弹性材料的高分子材料7(橡胶)的硬化反应进行的担心。因此，用于使其具有流动性的高分子材料7的温度规定在上述数值范围内。
在高分子材料7中，除了上述的三元乙丙橡胶(EPDM)以外，能够混合其他成分。例如能够按照各自的配比添加碳、碳酸钙等填充剂、油分、硫化剂等各种材料。由此，能够对流动性、相对于芯部件4的附着性、高分子包覆层3的弹性进行调整。
被加热而具有流动性的状态下的高分子材料7，一边混炼一边从供给装置12以规定的压力向芯部件4的输送路径R供给(供给工序S2)。在这里，在设置于输送路径R的中途的包覆区域C，设置有与供给装置12连结的包覆头13。经过该包覆头13，从而芯部件4和高分子材料7进行接触。而且，从设置在包覆头13的覆盖件14一起挤出至包覆头13的外部。
由此，芯部件4和高分子材料7进行接触，遍及芯部件4的全部面而附着高分子材料7，将芯部件4包覆(包覆工序S3)。图7是表示包覆头13的概略结构的示意剖视图。通过对包覆头13的形状或者包覆头13的覆盖件14的形状进行变更，从而能够对高分子材料7从覆盖件14喷出的喷出量、可使用的芯部件4的芯部件宽度W进行变更。其结果，最终能够实现高分子包覆层3的层厚度H的调整。在本实施方式的制造方法10中，将芯部件4包覆，经过热硬化工序S4及冷却工序S5后的高分子包覆层3的层厚度H最终设定为1.0mm。
在芯部件4附着高分子材料7，该高分子材料7未硬化的状态下的包覆中间体5被输送至热硬化装置15，该热硬化装置15将硬化炉(未图示)内调整为比用于得到高分子材料7的流动性的温度更高温度的热硬化温度(热硬化工序S4)。在这里，热硬化温度设定在150℃～250℃的范围，并且将直至经过该热硬化装置15的硬化炉内为止所需的时间(热硬化时间)设定在120s～600s之间。
在本实施方式的制造方法10中使用的高分子材料7如上所述，以150℃～250℃之间的高温的热硬化温度进行热硬化处理，由此促进硬化反应。其结果，高分子材料7丧失流动性，构成为具有弹性的高分子包覆层3。经过热硬化工序S4后的包覆中间体5被输送至下一个工序的冷却工序S5，在冷媒(例如，水等)之中经过。由此，包覆中间体5的温度被冷却，完成具有弹性的高分子包覆层3的形成(冷却工序S5)。
经过冷却工序S5后的包覆中间体5被输送至实施下一个工序的中间体滞留工序S6的缓冲区域B，成为暂时地滞留的状态。在这里，在缓冲区域B如图6所示，将冷却工序S5后的包覆中间体5支撑于多个缓冲用辊17之间，由此赋予直至将包覆中间体5送出至螺旋形成工序S7为止的时滞，能够将包覆中间体5的移动时间确保得长。
此外，中间体滞留工序S6并不特别限定，如图6所示将多个缓冲辊交替地配置，增加用于经过缓冲区域B的时间即可。由此，在进行扭转加工前以包覆中间体5相连的状态滞留，因此能够确保用于螺旋形成工序S7的加工时间。其结果，能够连续地形成本发明的螺旋状层构造体1。
在缓冲区域B中的中间体滞留工序S6中，在缓冲区域B滞留的状态下的包覆中间体5此后以规定的长度拉出，输送至螺旋形成工序S7。在螺旋形成工序S7中，使用能够分别将包覆中间体5的下游侧的一端5a及上游侧的另一端5b夹持的固定部18a、18b而进行卡住。
然后，将一端5a卡住的固定部18a保持该状态，仅使将另一端5b卡住的固定部18b沿输送方向F绕设为螺旋轴X的轴进行旋转(参照图6中的扭转加工方向S)。
由此，能够将包覆中间体5扭转加工为螺旋状(螺旋形成工序S7)。其结果，得到由螺旋状芯部件2及高分子包覆层3的二层构成的层构造的切断前螺旋状层构造体1a。该状态下，在缓冲区域B滞留的包覆中间体5和切断前螺旋状层构造体1a相连。
在这里，通过扭转加工形成的螺旋状的间距并不特别受到限定，在本实施方式的制造方法10中，例如，能够设为150mm间隔。并且，通过使在下游侧的一端5a侧的附近设置的切断装置19工作，从而将缓冲区域B的包覆中间体5和进行了扭转加工的切断前螺旋状层构造体1a切断(扭转加工后切断工序S8)。由此，螺旋状层构造体1的制造完成。
如上述所示，第一实施方式的制造方法10通过根据芯部件4及高分子材料7而形成包覆中间体5，并且将热硬化处理、冷却处理及扭转加工处理连续地实施，最后进行切断，从而能够制造螺旋状层构造体1。由此，无需使各工序每次都停止，能够进行连续的制造，能够提高螺旋状层构造体1的制造效率。
在这里，本发明的螺旋状层构造体的制造方法并不限定于上述的本实施方式的制造方法10。即，在本实施方式的制造方法10中，示出在螺旋形成工序S7后实施扭转加工后切断工序S8，但并不限定于此，例如，也可以在冷却工序S5中实施将包覆中间体5切断为规定的长度的扭转加工前切断工序(未图示)。
在该情况下，针对切断后的包覆中间体5，实施使用上述装置的扭转加工(螺旋形成工序S7)。在该情况下，无需使包覆中间体5暂时地滞留的缓冲区域B及在缓冲区域B设置的多个缓冲用辊17等各种设备及结构，能够对设备成本的增大进行抑制，且将对螺旋状层构造体1进行制造的制造空间紧凑化。
此外，在扭转加工前将包覆中间体5切断为规定的长度，需要断开，因此图6所示的切断装置19需要设置在缓冲区域B(缓冲用辊17)和固定部18a之间。在切断为规定长度后，扭转加工前的包覆中间体5此后架设及固定在固定部18a及固定部18b之间，进行螺旋形成工序S7。
在这里，在本实施方式的制造方法10中，示出作为高分子材料7而使用热固性弹性材料即三元乙丙橡胶(EPDM)等的例子，但并不限定于此，也可以是使用热塑性弹性材料即热塑性苯乙烯类弹性体、动态交联热塑性弹性体等的螺旋状层构造体的制造方法。
在使用热塑性弹性材料的情况下，为了从供给装置12供给具有流动性的高分子材料7，需要在150℃～270℃的范围对高分子材料7的温度进行加热处理。如果温度低于150℃，则流动性降低，有可能无法进行良好的高分子材料7的供给及芯部件4的稳定的包覆。另一方面，在温度比270℃高的情况下，有热塑性弹性材料本身分解的担心。因此，需要设定在上述温度的数值范围内。
并且，在使用热塑性弹性材料的情况下，在本实施方式的制造方法10中，不需要在包覆工序S3后实施的热硬化工序S4。即，在热塑性弹性材料(弹性体)的情况下，无需进行诸如热固性弹性材料(橡胶)的热硬化处理，在将高分子材料7包覆于芯部件4后，直接输送至冷却槽16，能够进行冷却。
在冷却工序S5后，如上所述，可以使包覆中间体5暂时地滞留在缓冲区域B，在扭转加工为螺旋状后进行切断，或者在经过冷却工序S5后切断为规定长度，然后进行扭转加工为螺旋状。
如以上说明所述，根据本实施方式的制造方法10，使高分子材料7与长条平板状的芯部件4接触，在形成高分子包覆层3之后，实施扭转加工为螺旋状的螺旋形成工序S7。即，与使高分子材料7与将芯部件4形成为螺旋状的螺旋状芯部件2接触，形成高分子包覆层3的情况相比，作业性变得良好。
特别是，高分子包覆层3是使用具有弹性的高分子材料7而形成的，因此即使在形成高分子包覆层3后进行扭转加工，也不会在高分子包覆层3的表面等引入裂痕、龟裂等，能够良好地制造螺旋状层构造体1。
工业实用性
本发明的螺旋状层构造体除了现有的作为装饰用、地基加强材料使用以外，充分发挥螺旋状的形态及由高分子包覆层3实现的层构造，特别地，在要求作业效率、耐久性等的车辆搭载用的空调的配管内设置，能够作为对在配管内流通的冷风、暖风等流体进行整流的整流部件的一部分使用。或者，充分发挥每单位体积的表面积大的特点而能够作为热交换部件的一部分使用。

Claims (14)

1.一种螺旋状层构造体，其具有：
螺旋状芯部件，其由具有挠性的长条平板状的芯部件形成，将所述芯部件的长度方向作为螺旋轴而呈螺旋状；以及
高分子包覆层，其由高分子材料形成，对所述螺旋状芯部件的全部面进行了包覆。
2.根据权利要求1所述的螺旋状层构造体，其中，
所述螺旋状芯部件是由铁、不锈钢及铝中的任一个金属材料形成的钢板。
3.根据权利要求1或2所述的螺旋状层构造体，其中，
所述螺旋状芯部件具有至少一个狭缝部，该狭缝部是将所述芯部件的芯部件正面及芯部件背面之间贯通以及将所述芯部件的一部分切除而成的。
4.根据权利要求1至3中任一项所述的螺旋状层构造体，其中，
所述螺旋状芯部件或者所述芯部件的芯部件厚度为0.25mm～3.00mm的范围，
所述螺旋状芯部件或者所述芯部件的芯部件宽度为3mm～150mm的范围。
5.根据权利要求1至4中任一项所述的螺旋状层构造体，其中，
所述高分子包覆层的层厚度为0.3mm～10mm的范围。
6.根据权利要求1至5中任一项所述的螺旋状层构造体，其中，
形成所述高分子包覆层的所述高分子材料为三元乙丙橡胶、苯乙烯丁二烯橡胶、丁腈橡胶、硅橡胶、丙烯酸橡胶及氢化丁腈橡胶中的任一个热固性弹性材料。
7.根据权利要求1至5中任一项所述的螺旋状层构造体，其中，
形成所述高分子包覆层的所述高分子材料是烯烃类热塑性弹性体、苯乙烯类热塑性弹性体、聚氨酯类热塑性弹性体、动态交联热塑性弹性体、酰胺类热塑性弹性体及酯类热塑性弹性体中的任一个热塑性弹性材料。
8.根据权利要求1至7中任一项所述的螺旋状层构造体，其中，
所述高分子包覆层的肖氏A硬度为35～95的范围。
9.一种螺旋状层构造体的制造方法，其是权利要求1～8中任一项所述的螺旋状层构造体的制造方法，
在该螺旋状层构造体的制造方法中，具有下述工序：
输送工序，将具有挠性的长条平板状的芯部件沿所述芯部件的长度方向输送；
供给工序，将具有流动性的高分子材料向在所述芯部件的输送路径的中途设置的包覆区域供给；
包覆工序，在所述包覆区域，使由所述供给工序供给的所述高分子材料和所述芯部件接触，将所述芯部件由所述高分子材料包覆；
冷却工序，对由所述高分子材料包覆所述芯部件而得到的包覆中间体进行冷却；以及
螺旋形成工序，将经过所述冷却工序后的所述包覆中间体的长度方向作为螺旋轴，将所述包覆中间体扭转加工为螺旋状，形成螺旋状层构造体。
10.根据权利要求9所述的螺旋状层构造体的制造方法，其中，
还具有在所述冷却工序及所述螺旋形成工序之间实施的下述工序：
中间体滞留工序，使经过所述冷却工序后的所述包覆中间体暂时地滞留在缓冲区域；以及
扭转加工后切断工序，将经过所述螺旋形成工序后的切断前螺旋状层构造体切断为规定长度，
所述螺旋形成工序将切断为规定长度前的所述包覆中间体扭转加工为螺旋状。
11.根据权利要求9所述的螺旋状层构造体的制造方法，其中，
还具有在所述冷却工序及所述螺旋形成工序之间实施的扭转加工前切断工序，该扭转加工前切断工序将所述冷却工序后的所述包覆中间体切断为规定长度，
所述螺旋形成工序将切断为规定长度后的所述包覆中间体扭转加工为螺旋状。
12.根据权利要求9至11中任一项所述的螺旋状层构造体的制造方法，其中，
通过所述供给工序供给的所述高分子材料是三元乙丙橡胶、苯乙烯丁二烯橡胶、丁腈橡胶、硅橡胶、丙烯酸橡胶及氢化丁腈橡胶中的任一个热固性弹性材料，
还具有在所述包覆工序及所述冷却工序之间实施的热硬化工序，该热硬化工序对所述包覆中间体进行加热，对将所述芯部件包覆的所述高分子材料进行热硬化处理。
13.根据权利要求12所述的螺旋状层构造体的制造方法，其中，
所述供给工序通过30℃～120℃的范围的温度进行加热处理，供给具有流动性的所述高分子材料，
所述热硬化工序通过150℃～250℃的范围的热硬化温度及120s～600s的热硬化时间进行热硬化处理。
14.根据权利要求9至11中任一项所述的螺旋状层构造体的制造方法，其中，
通过所述供给工序供给的所述高分子材料是烯烃类热塑性弹性体、苯乙烯类热塑性弹性体、聚氨酯类热塑性弹性体、动态交联热塑性弹性体、酰胺类热塑性弹性体及酯类热塑性弹性体中的任一个热塑性弹性材料，
所述供给工序通过150℃～270℃的范围的温度进行加热处理，供给具有流动性的所述高分子材料。
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