CN109958824A - 一种连续纤维增强热塑性复合管道 - Google Patents

一种连续纤维增强热塑性复合管道 Download PDF

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CN109958824A
CN109958824A CN201711420190.2A CN201711420190A CN109958824A CN 109958824 A CN109958824 A CN 109958824A CN 201711420190 A CN201711420190 A CN 201711420190A CN 109958824 A CN109958824 A CN 109958824A
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李芳凯
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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 general shape other than plane
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
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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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
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    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L57/00—Protection of pipes or objects of similar shape against external or internal damage or wear
    • F16L57/02—Protection of pipes or objects of similar shape against external or internal damage or wear against cracking or buckling
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L57/00—Protection of pipes or objects of similar shape against external or internal damage or wear
    • F16L57/04—Protection of pipes or objects of similar shape against external or internal damage or wear against fire or other external sources of extreme heat
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L9/00—Rigid pipes
    • F16L9/14—Compound tubes, i.e. made of materials not wholly covered by any one of the preceding groups
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • 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
    • B32B2597/00—Tubular articles, e.g. hoses, pipes

Abstract

本发明公开了一种连续纤维增强热塑性复合管道,属于双层管技术领域。这种复合管道可以设计成至少三层结构,且每一层中都以热塑性树脂为其基体,以不同含量的连续纤维或其织物为其增强材料,连续纤维或其织物以纵向方式、缠绕方式和编织方式铺设。这种复合管道可以改善和提高抗冲击、耐老化、耐温性、耐候性等性能,使这种复合管道的每层结构材料利用与性能得到最佳优化,不仅可以节约大量的材料,而且具有更加优异的力学性能与化学性能。

Description

一种连续纤维增强热塑性复合管道
技术领域
本发明涉及一种以连续纤维为增强材料，以热塑性树脂为基本体的复合管道，属于双层管技术领域。
背景技术
目前采用纤维增强的热塑性复合管道主要有玻璃纤维增强聚氯乙烯塑料管(GFPVC)、柔性热塑性增强塑料复合管(RTP)、塑铝管和塑钢管。玻璃纤维增强聚氯乙烯塑料管(GFPVC)是在聚氯乙烯树脂中加入一定量的短切玻璃纤维或者是用连续玻璃纤维预浸聚氯乙烯树脂，切成料粒后在挤压机上挤压成型。柔性热塑性增强塑料复合管(RTP)的内层和外层都是高密度聚乙烯(HDPE)，中间层是芳纶纤维增强层；生产工艺是先挤压内层高密度聚乙烯(HDPE)管，然后在其表面正反交错缠绕芳纶纤维增强带，最后挤压高密度聚乙烯(HDPE)外保护层。塑铝管和塑钢管的中间层是铝管或者钢管(如申请号为01114155.7的中国发明专利申请所公开的高强度玻璃钢复合管)，内外挤压一层热塑性塑料。《塑料科技》2007年4月版杂志发表了一篇名为“连续纤维增强热塑性复合材料的制备与成型”的文章，论述了连续纤维增强热塑性塑料片材的制备工艺以及连续纤维增强热塑性塑料制件的成型工艺，并论述了国内连续纤维增强热塑性塑料制品生产工艺的进展
以上这些增强热塑性压力管道都是在其中间加增强材料形成增强结构层，内外层都是纯塑性树脂层，个别会在中间层加入少量增强短纤维。
发明内容
本发明的目的是将连续纤维增强材料加入到复合管道的各个结构层面中，使产品的设计更灵活、性能更优越、用料最省，达到连续一次性制造出热塑性压力管道。
本发明所公开的一种连续纤维增强型热塑性复合管道包括内衬层、外表面层及增强层，内衬层与外表面层之间包含至少一层增强层。内衬层、外表面层及增强层均是以热塑性树脂为基体，以连续纤维或其织物为增强材料；内衬层与外表面层的连续纤维或其织物含量为40—50％、树脂含量为50—60％；增强层的连续纤维或其织物含量为60—70％、树脂含量为30—40％。热塑性树脂是聚乙烯、聚丙烯或聚酰胺。连续纤维是玻璃纤维、碳纤维、硼纤维、玄武岩纤维或芳纶纤维。每层结构中的连续纤维或其织物以纵向、缠绕或编织方式铺设。
复合管道的增强层可以包含内侧增强层和外侧增强层两层；内侧增强层以缠绕或编织方式铺设连续纤维或其织物，用聚乙烯树脂浸渍构成内侧增强层的基体；外侧增强层以纵向方式铺设连续纤维或其织物，用聚乙烯树脂浸渍构成外侧增强层的基体；优选方式下，内侧增强层和外侧增强层的树脂含量为35％、纤维含量为65％。复合管道的内衬层以纵向铺设或以编织铺设连续纤维或其织物，用热塑性树脂浸渍构成内衬层的基体；内衬层的树脂含量为60％、纤维含量为40％。复合管道的外表面层以编织方式铺设连续纤维或其织物，用聚乙烯树脂浸渍构成外表面层的基体；外表面层的树脂含量为55％、纤维含量为45％。
复合管道的增强层包含内侧增强层、中间增强层和外侧增强层三层；内侧增强层以缠绕方式铺设连续纤维或其织物，用热塑性树脂浸渍构成内侧增强层的基体；中间增强层以纵向方式铺设连续纤维或其织物，用热塑性树脂浸渍构成中间增强层的基体；外侧增强层以缠绕方式铺设连续纤维或其织物，用热塑性树脂浸渍构成外侧增强层的基体；优选方式下，内侧增强层、中间增强层和外侧增强层的树脂含量为35％、纤维含量为65％。内衬层以纵向铺设或以编织铺设连续纤维或其织物，用热塑性树脂浸渍构成内衬层的基体；内衬层的树脂含量为65％、纤维含量为35％。外表面层以编织方式铺设连续纤维或其织物，用聚乙烯树脂浸渍构成外表面层的基体；外表面层的树脂含量为55％、纤维含量为45％。
本发明所公开的复合管道是以热塑性树脂为基体，其中热塑性树脂主要包括聚乙烯、聚丙烯、聚酰胺等。热塑性主聚物树脂及其纤维制品，连续增强纤维主要是玻璃纤维、碳纤维、硼纤维、玄武岩纤维、芳纶纤维等。这种连续纤维增强的热塑性压力管根据管径的大小及使用压力等级的高低可以设计成至少三层或更多层结构，且每一层中都有不同纤维含量的连续纤维或其织物进行增强。每层结构中的连续纤维或其织物以纵向、缠绕或编织方式铺设。
特别是在内衬层与外表面层中加入一定量的连续增强纤维，可以改善和提高其抗冲击、耐老化、耐温性、耐候性等性能，从而使制品获得最佳性能，同时还可以根据制品的规格与使用性能的要求，更加方便灵活对产品结构进行设计，这样就可以使这种多层结构的连续纤维增强型热塑性复合管道的每层结构材料利用与性能得到最佳优化，不仅可以节约大量的材料，而且又比其他纤维增强型热塑性复合管道具有更加优异的力学性能与化学性能。
因此可以概括地说，这种连续纤维增强型热塑性复合管道其特征就在于热塑性压力管每层结构中都由连续纤维或其织物进行增强，其中内衬层与外表层为富树脂，连续纤维或连续纤维织物含量为40—50％、树脂含量为50—60％；中间增强层连续纤维或连续纤维织物含量为60—70％、树脂含量为30—40％。上述含量值能够保证压力管的强度最优
具体实施方
第一个实施例
本发明的四层热塑性树脂塑料压力管道是由连续纤维或连续纤维织物作为增强材料浸入热塑性树脂制造成型的，构成管壁的每层结构都由连续纤维或其织物进行增强。
第一层为内衬层，由连续纤维纵向铺设或者编织铺设，由热塑性树脂浸渍成内衬层。如采用密度为600Tex或2400Tex无碱玻璃纤维，采用HDPE-80高密度聚乙烯树脂，采用挤拉成型技术制备第一层内衬层，这层结构中树脂含量为60％、纤维含量为40％。第二层、第三层为连续纤维增强结构层，第二层为内增强层，第三层为外增强层；其中第二层为连续纤维缠绕或织布缠绕，第三层为连续纤维纵向铺设；两层都使用HDPE-80高密度聚乙烯树脂浸渍，同时构成增强结构层，其中树脂含量为35％、纤维含量为65％。如采用密度为2400Tex玻璃纤维纱团，采用芳纶纤维纱布(100g/m2、宽100mm)进行缠绕，然后通过加热、冷却定型模具成型增强结构层，树脂的浸渍在加热模具中采用RTM技术实现的。第四层为外表面层，由连续纤维编织铺设而成，采用HDPE-80高密度聚乙烯树脂，其中树脂含量为55％、纤维含量为45％。如采用120支密度为600Tex无碱玻璃纤维纱，利用编织机在增强结构层外面铺设一层增强纤维，然后浸入模具加热浸渍上热塑性树脂，并经冷却定型成型
以上各层的设计壁厚分别为：第一层1mm，第二层2mm，第三层1mm，第四层1mm，构成总壁厚度为5mm的纤维增强型热塑性复合管，以内径为62mm管为例，其工作压力可达到10MPa，爆破压力可达到15MPa，与普通同规格HDPE高密度聚乙烯树脂管相比，工作压力可提高至少8倍以上。
第二个实施例
复合管道为五层结构，从内到外分别为：第一层为内衬层，这层结构中树脂含量为60％、纤维含量为40％；第二层为内侧增强层，该层连续纤维或连续纤维织物以缠绕方式铺设，其中树脂含量为35％、纤维含量为65％；第三层为中间增强层，该层连续纤维以纵向铺设，其中树脂含量为35％、纤维含量为65％；第四层为为外侧增强层，该层连续纤维或连续纤维织物以缠绕方式铺设，其中树脂含量为35％、纤维含量为65％；第五层为外表面层，其中树脂含量为55％、纤维含量为45％。
设计壁厚为7mm，其中内衬层厚度为1mm，内侧增强厚度为2mm，中间增强层厚度为1mm，外侧增强层厚度为2mm，外表面层厚度为1mm。以内径为62mm为例，其工作压力可达到20MPa，爆破压力可达到40MPa。
第三个实施例
复合管道为六层结构，从内到外分别为：第一层为内衬层，这层结构中树脂含量为60％、纤维含量为40％。第二层为第一增强层，该层连续纤维或连续纤维织物以缠绕方式铺设，其中树脂含量为35％、纤维含量为65％；第三层为第二增强层，该层连续纤维以纵向铺设，其中树脂含量为35％、纤维含量为65％；第四层为第三增强层，该层连续纤维或连续纤维织物以缠绕方式铺设，其中树脂含量为35％、纤维含量为65％；第五层为第第四增强层，其中树脂含量为35％、纤维含量为65％。第六层为外表面层，其中树脂含量为55％、纤维含量为45％
设计壁厚为8mm，其中内衬层厚度为1mm，第一增强厚度为2mm，第二增强层厚度为1mm，第三增强层厚度为1mm，第四增强层厚度为2mm，外表面层厚度为1mm。以内径为62mm为例，其工作压力可达到25MPa，爆破压力可达到45MPa。
以上所述，仅为本发明较佳的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明披露的技术范围内，根据本发明的技术方案及其发明构思加以等同替换或改变，都应涵盖在本发明的保护范围之内。

Claims (4)

1.一种连续纤维增强热塑性复合管道，包括内衬层、外表面层及增强 层；内衬层与外表面层之间包含至少一层增强层；其特征在于：内衬层、外表面层、增强层均是以热塑性树脂为基体，以连续纤维或其织物为增强材料；内衬层与外表面层的连续纤维或其织物含量为40—50％、树脂含量为50—60％；增强层的连续纤维或其织物含量为60—70％、树脂含量为30—40％。
2.根据权利要求1所述的连续纤维增强热塑性复合管道，其特征在于：所 述热塑性树脂是聚乙烯、聚丙烯或聚酰胺。
3.根据权利要求1所述的连续纤维增强热塑性复合管道，其特征在于：所述连续纤维是玻璃纤维、碳纤维、硼纤维、玄武岩纤维或芳纶纤维。
4.根据权利要求1至3任一所述的连续纤维增强热塑性复合管道，其特征在于：所述每层结构中的连续纤维或其织物以纵向、缠绕或编织方式铺设。
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