CN108329555A - 一种耐低温的铝塑复合管的加工方法 - Google Patents
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Abstract
本发明涉及管材加工技术领域，具体涉及一种耐低温的铝塑复合管的加工方法，包括：A1：聚乙烯内管挤出，真空定径成型，冷却干燥；A2：将热熔胶挤出包覆在聚乙烯内管外壁上；A3：铝带焊接成铝管，整圆；A4：将热熔胶挤出包覆在铝管外壁上，同时改性聚乙烯外管挤出；A5：将涂覆有热熔胶的聚乙烯内管、涂覆有热熔胶的铝管、改性聚乙烯外管一起进入共挤出模头的模腔中，完成共挤成型，即得所述的铝塑复合管；本发明提供的铝塑复合管，通过改进位于最外层的聚乙烯外管，聚乙烯与聚苯醚的共混改性，提高该铝塑复合管在低温下的适应性，提高其使用寿命，所述的铝塑复合管的加工方法，工艺简单，易于操作。
Description
技术领域
本发明涉及管材加工技术领域，具体涉及一种耐低温的铝塑复合管的加工方法。
背景技术
铝塑复合管是一种最早替代铸铁管的供水管，其基本结构由内而外依次为塑料、热熔胶、铝合金、热熔胶和塑料。传统的铝塑复合管是将聚乙烯、聚乙烯专用热熔胶与铝合金箔通过高温、高压基础成型并复合成一体的五层结构复合管材，最外层和里层是高密度聚乙烯(比重大于0.95g/cm3)，第二层是热熔胶，第三层是铝管，第四层也是一层热熔胶；该管材由于含有金属铝层，不仅可以增加耐压强度，还可以阻隔氧气、二氧化碳和水等从而避免了铸铁管的锈蚀风险，导热性好而减少热点集中，抗静电而屏蔽性好，并具有一定的阻燃效果，更重要的是，通过中间层金属铝的隔断，里层使用安全卫生无添加的聚乙烯塑料，外层中允许添加足以抵抗光、氧老化的稳定剂而不影响内层接触水的安全卫生性，确保了输水管路的安全可靠。
现有技术中，铝塑复合管的内、外层通常采用高密度聚乙烯，但是高密度聚乙烯中双键含量较多，且双键旁的α碳原子上的氢原子比叔碳原子上的氢原子更易氧化，因此高密度聚乙烯的耐老化性能较差，在高温高压下老化速度更快，而且高密度聚乙烯分子间作用力较小，因而大分子链间较易相互滑动，在不大的机械应力作用下，聚乙烯仍能进行缓慢的形变。铝塑复合管的低温承受能力较差，在低温下外层塑料容易出现脆断，导致外层塑料剥落，影响正常的使用。
发明内容
针对现有技术中的问题，本发明的目的在于提供一种耐低温的铝塑复合管的加工方法，提高铝塑复合管在低温下的适应性及使用寿命。
为了实现上述目的，本发明采用以下技术方案予以实现：一种耐低温的铝塑复合管的加工方法，包括以下步骤：
A1：聚乙烯内管挤出，真空定径成型，冷却干燥；
A2：将热熔胶挤出包覆在聚乙烯内管外壁上；
A3：铝带焊接成铝管，整圆；
A4：将热熔胶挤出包覆在铝管外壁上，同时改性聚乙烯外管挤出；
A5：将涂覆有热熔胶的聚乙烯内管、涂覆有热熔胶的铝管、改性聚乙烯外管一起进入共挤出模头的模腔中，完成共挤成型，即得所述的铝塑复合管；
所述的改性聚乙烯外管用料的加工工艺包括：将40～70重量份低密度聚乙烯、20～35重量份高密度聚乙烯、10～15重量份聚苯醚、0.1～0.8重量份相容剂、0.2～2重量份功能助剂置于高速混合机中搅拌均匀，下料至双螺杆挤出机中，经熔融混炼、挤出拉条、冷却切粒得到。
本发明中，通过高、低密度的聚乙烯与聚苯醚的共混改性，提高聚乙烯树脂在低温下的耐候性，改善其低温下的力学性能，达到满足低温铝塑复合管的使用要求，具体的，所述的聚苯醚可以列举出2,6-二甲基苯酚的聚合物，2,6-二甲基苯酚和2,3,6-三甲基苯酚的共聚物中的一种或一种以上的混合物，其特性粘度为0.2～0.6dl/g。
进一步的，所述的低密度聚乙烯与高密度聚乙烯质量比为1：(0.28～0.8)，采用高、低密度聚乙烯共存的塑料混合，在满足较高强度的同时兼顾其韧性。
进一步的，本发明中所述的相容剂为苯乙烯嵌段弹性体，通过苯乙烯嵌段弹性体将聚苯醚接枝到聚乙烯的分子链段上，显著的改善了聚乙烯树脂与聚苯醚的相容性。具体的，所述的相容剂可以列举出SBS、SEBS、SEBS-MAH。
根据本发明，为了实现铝塑复合管的一些特殊的功能，所述的改性聚乙烯外管用料中还含有功能助剂，具体的，所述的功能助剂包括紫外线吸收剂、抗氧剂、光稳定剂。
本发明所述的紫外线吸收剂为苯丙三唑类紫外线吸收剂，具体的，可以举出2-(2'-羟基-3'-异丁基-5'-叔丁基苯基)苯并三唑，或2-(2H-苯并三唑-2-基)-6-十二烷基-4-甲酚，或其组合。
所述的抗氧剂为四[3-(3’,5’,-二叔丁基-4’-羟基苯基)丙酸]季戊四醇酯、β-(4-羟基-3，5-二叔丁基苯基)丙酸正十八碳醇酯、4，4’-硫代双(6-叔丁基-3-甲基苯酚)、4，4’-硫代双(6-叔丁基间甲酚)、1，1，3-三(2-甲基-4-羟基-5-叔丁基苯基)丁烷2，6-二叔丁基苯酚、2，6-二叔丁基-4-甲基苯酚或4-羟甲基-2，6-二叔丁基苯酚，或其组合。
所述的光稳定剂为受阻胺类光稳定剂，具体的，可以举出聚(1-羟乙基-2,2,6,6-四甲基-4-羟基哌啶)丁二酸酯，聚﹛[6-[(1,1,3,3-四甲基丁基)-胺基]1,3,5-三嗪-2,4-二基][(2,2,6,6-四甲基哌啶基)-亚胺基]-1,6-己烷二基-(2,2,6,6-四甲基哌啶基)-亚胺基﹜(商品名称为CH944，由巴斯夫公司生产)，或双(1-辛氧基-2,2,6,6-四甲基哌啶基)癸二酸酯，或其中至少两种的组合。
根据本发明，本发明所述的步骤A1中，真空定径套的压力设为-0.04～0.07Mpa。
根据本发明，为了提高热熔胶与聚乙烯内管的接触面积，提高其粘附力，本发明所述的步骤A2中，向聚乙烯内管外壁上挤塑热熔胶前，对聚乙烯内管外壁进行打磨使其粗糙，如此，经过打磨的聚乙烯内管外壁上，粗糙度提高，表面积增大，提高了其与热熔胶的接触面积。
根据本发明，本发明所述的步骤A4中，改性聚乙烯外管的挤出温度为200～220℃，采用压缩比为2.3～2.5的低压缩螺杆。
本发明中，在所述的步骤A3中，铝带焊接成铝管后，沿所述铝管的长度方向切割出条状通孔，条状通孔沿铝管的周向间隔布置有4条、6条或8条，通过该条状通孔的设置，使得聚乙烯内管外壁上的热熔胶与铝管外壁上的热熔胶相连系成一整体，使得整体铝塑复合管成为一整体结构，降低了该铝塑复合管管层之间分离的概率；更为重要的是，通过该条状通孔的设置，在该铝塑复合管经历冷热交替出现膨胀的时候起到缓冲的作用，改善了铝塑复合管在冷热交替时的适应性，提高了铝塑复合管在低温下的使用寿命。
与现有技术相比，本发明提供的铝塑复合管，通过改进位于最外层的聚乙烯外管，聚乙烯与聚苯醚的共混改性，提高该铝塑复合管在低温下的适应性，提高其使用寿命，所述的铝塑复合管的加工方法，工艺简单，易于操作。
具体实施方式
为了使本发明实现的技术手段、创作特征、达成目的与功效易于明白了解，下面结合具体实施例，进一步阐明本发明。
实施例1
一种耐低温的铝塑复合管的加工方法：
A1：将聚乙烯塑料(购自中石化DMDA8920)下料至内管挤出机中挤出，在压力为-0.03Mpa的真空下定径成型，然后快速冷却干燥，所述挤出机的温度为220℃、挤出机的压缩比为2.4，该聚乙烯内管的管径为25mm，壁厚为4mm；
A2：对步骤A1中的聚乙烯内管外壁进行打磨使其粗糙，将热熔胶(丙烯酸热熔胶，购自北京科力粘合剂有限责任公司)挤出包覆在聚乙烯内管外壁上，热熔胶的成胶厚度为3mm；
A3：将铝带(牌号8011A，购自江苏易迈)焊接成铝管，整圆，使其管径为30mm；
A4：将热熔胶(丙烯酸热熔胶，购自北京科力粘合剂有限责任公司)挤出包覆在铝管外壁上，同时采用压缩比为2.4的低压缩螺杆将改性聚乙烯外管挤出，该热熔胶的成胶厚度为3mm，改性聚乙烯外管的挤出温度为210℃，所述改性聚乙烯外管的管径为33mm；
A5：将涂覆有热熔胶的聚乙烯内管、涂覆有热熔胶的铝管、改性聚乙烯外管一起进入共挤出模头的模腔中，完成共挤成型，即得所述的铝塑复合管；
所述的改性聚乙烯外管用料的加工工艺包括：将55重量份低密度聚乙烯(购自LG化学，MB9500)、28重量份高密度聚乙烯(购自LG化学，ME2500)、13重量份聚苯醚(购自沙伯基础(原GE)534)、0.5重量份相容剂SBS(购自LG化学LG501)、0.5重量份苯丙三唑类紫外光吸收剂(购自BASF UV-329)，0.3重量份受阻胺类光稳定剂聚﹛[6-[(1,1,3,3-四甲基丁基)-胺基]1,3,5-三嗪-2,4-二基][(2,2,6,6-四甲基哌啶基)-亚胺基]-1,6-己烷二基-(2,2,6,6-四甲基哌啶基)-亚胺基﹜(购自BASF CH944)、0.5重量份抗氧剂四[3-(3’,5’,-二叔丁基-4’-羟基苯基)丙酸]季戊四醇酯置于高速混合机中搅拌均匀，下料至双螺杆挤出机中，经熔融混炼、挤出拉条、冷却切粒得到。
实施例2
本实施例与实施例1的铝塑复合管的加工方法相同，不同的是，所述的改性聚乙烯外管用料配方为：
40重量份低密度聚乙烯(购自LG化学，MB9500)、20重量份高密度聚乙烯(购自LG化学，ME2500)、10重量份聚苯醚(购自沙伯基础(原GE)534)、0.1重量份相容剂SBS(购自LG化学LG501)、0.5重量份抗氧剂四[3-(3’,5’,-二叔丁基-4’-羟基苯基)丙酸]季戊四醇酯、0.4重量份苯丙三唑类紫外光吸收剂(购自BASF UV-329)，0.5重量份受阻胺类光稳定剂聚﹛[6-[(1,1,3,3-四甲基丁基)-胺基]1,3,5-三嗪-2,4-二基][(2,2,6,6-四甲基哌啶基)-亚胺基]-1,6-己烷二基-(2,2,6,6-四甲基哌啶基)-亚胺基﹜(购自BASF CH944)。
实施例3
本实施例与实施例1的铝塑复合管的加工方法相同，不同的是，所述的改性聚乙烯外管用料配方为：
70重量份低密度聚乙烯(购自LG化学，MB9500)、35重量份高密度聚乙烯(购自LG化学，ME2500)、15重量份聚苯醚(购自沙伯基础(原GE)534)、0.8重量份相容剂SBS(购自LG化学LG501)、0.5重量份抗氧剂四[3-(3’,5’,-二叔丁基-4’-羟基苯基)丙酸]季戊四醇酯、0.4重量份苯丙三唑类紫外光吸收剂(购自BASF UV-329)，0.5重量份受阻胺类光稳定剂聚﹛[6-[(1,1,3,3-四甲基丁基)-胺基]1,3,5-三嗪-2,4-二基][(2,2,6,6-四甲基哌啶基)-亚胺基]-1,6-己烷二基-(2,2,6,6-四甲基哌啶基)-亚胺基﹜(购自BASF CH944)。
实施例4
本实施例与实施例1的铝塑复合管的加工方法相同，不同的是，在步骤A3中，所述的铝带焊接成铝管后，沿所述的铝管的长度方向切割出条状通孔，该条状通孔的孔长小于铝管的管长，并沿铝管的周向间隔布置有4条。
性能测试：
采用下述测试方法对上述实施例中的铝塑复合管进行性能测试，并以日丰管B1-1216作为对照组。
1、采用高低温交变湿热试验箱(LRHS-1000B-LJS上海林频仪器股份有限公司)对上述实施例1-4及对照组的铝塑复合管进行高低温冲击处理，高温条件为60℃、90％RH，低温条件为-30℃，高低温驻留时间为1h，循环200次，然后再采用GB/T 6111-2003进行静液压强度的测试，试验温度为95℃，试验时间为165h，静液压应力为4.6Mpa，试验结果记录到表1中。
2、单独的对实施例1-4中的改性聚乙烯树脂与铝带(牌号8011A，购自江苏易迈)进行剥离强度的测试，测试方法按照GB/T2790-1995标准进行，并将测试结果记录到表1中。
表1：
由上述实验数据可以看出，本发明提供的铝塑复合管具有很好的低温适应性。
以上显示和描述了本发明的基本原理、主要特征和本发明的特点。本行业的技术人员应该了解，本发明不受上述实施例的限制，上述实施例和说明书中描述的只是说明本发明的原理，在不脱离本发明精神和范围的前提下，本发明还会有各种变化和改进，这些变化和改进都落入要求保护的本发明的范围内。本发明要求保护的范围由所附的权利要求书及其等效物界定。
Claims (7)
1.一种耐低温的铝塑复合管的加工方法，其特征在于：包括以下步骤：
A1：聚乙烯内管挤出，真空定径成型，冷却干燥；
A2：将热熔胶挤出包覆在聚乙烯内管外壁上；
A3：铝带焊接成铝管，整圆；
A4：将热熔胶挤出包覆在铝管外壁上，同时改性聚乙烯外管挤出；
A5：将涂覆有热熔胶的聚乙烯内管、涂覆有热熔胶的铝管、改性聚乙烯外管一起进入共挤出模头的模腔中，完成共挤成型，即得所述的铝塑复合管；
所述的改性聚乙烯外管用料的加工工艺包括：将40～70重量份低密度聚乙烯、20～35重量份高密度聚乙烯、10～15重量份聚苯醚、0.1～0.8重量份相容剂、0.2～2重量份功能助剂置于高速混合机中搅拌均匀，下料至双螺杆挤出机中，经熔融混炼、挤出拉条、冷却切粒得到。
2.根据权利要求1所述的耐低温的铝塑复合管的加工方法，其特征在于：所述的低密度聚乙烯与高密度聚乙烯质量比为1：(0.28～0.8)。
3.根据权利要求1所述的耐低温的铝塑复合管的加工方法，其特征在于：所述的相容剂为苯乙烯嵌段弹性体。
4.根据权利要求1所述的耐低温的铝塑复合管的加工方法，其特征在于：所述的功能助剂包括紫外线吸收剂、抗氧剂、光稳定剂。
5.根据权利要求1所述的耐低温的铝塑复合管的加工方法，其特征在于：步骤A1中，真空定径套的压力设为-0.04～0.07Mpa。
6.根据权利要求1所述的耐低温的铝塑复合管的加工方法，其特征在于：步骤A2中，向聚乙烯内管外壁上挤塑热熔胶前，对聚乙烯内管外壁进行打磨使其粗糙。
7.根据权利要求1所述的耐低温的铝塑复合管的加工方法，其特征在于：步骤A4中，改性聚乙烯外管的挤出温度为200～220℃，采用压缩比为2.3～2.5的低压缩螺杆。
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