CN110114605B - 可伸缩波纹软管及其制备方法 - Google Patents

可伸缩波纹软管及其制备方法 Download PDF

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CN110114605B
CN110114605B CN201780066666.9A CN201780066666A CN110114605B CN 110114605 B CN110114605 B CN 110114605B CN 201780066666 A CN201780066666 A CN 201780066666A CN 110114605 B CN110114605 B CN 110114605B
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CN110114605A (zh
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路易吉诺·卡内瓦
詹马可·卡内瓦
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Adega Srl Unipersonale
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Abstract

一种可伸缩波纹软管，其包括以弹性可伸长的第一聚合物材料制成的第一承压层(1)，缠绕在所述第一层(1)上的增强件(2)，以弹性可伸长的第二聚合物材料制成的稳定的第二层(3)，该稳定的第二层(3)覆盖在所述的增强件(2)上以限定具有所述第一层(1)的波纹单管体(4)，涂层第三层(5)设置在所述的第二层(3)上，用于覆盖所述的波纹单管体(4)。

Description

可伸缩波纹软管及其制备方法
技术领域
本发明一般应用于软管领域及聚合物材料加工方法，特别地，涉及一种增强型可伸缩波纹软管，其特别适用于园艺。本发明还涉及一种用于制造上述波纹软管的方法。
背景技术
已知有几种柔性可伸缩的软管适用于园艺，其特征在于，在压力下拉伸，然后在无压力的情况下，从收缩的静止状态移动到或多或少伸长的工作状态，这取决于其内部的流体压力。
US8479776和US8291941公开了一种硫化橡胶软管，其插入到纺织品护套中，所述的纺织品护套的长度为，静止状态下的软管长度的2-3倍。在加压水通过时，软管膨胀并伸长以填充所述纺织品护套。然而，由于连续使用，护套往往不会在软管上均匀地分布，因此，橡胶软管在某些部分会延伸到护套外。此外，所述护套会变脏并且很难进行清洁。
WO2015177664公开了一种类似于上述的软管，其中，该软管未使用纺织品护套，而是使用类似于用于保护电线的波纹护套。这种软管较难伸展，在压力下容易旋转并且容易在相对低的压力下爆裂。同样在这种情况下，外护套也会沾染很多污垢。
WO2016128940公开了一种覆盖有弹性非常好的护套的波纹半钢软管。这种波纹软管在压力下延伸，而外护套使外软管平滑，以促进排出流体后软管的返回。然而，这种软管难以伸展，耐压性差，并且如果压力接近爆破压力，软管会损坏并失去收缩的功能。
WO2016098063公开了一种具有高厚度内层的软管，该内层被拉长约100％，该软管用网加强并用纺织物螺旋缠绕，随后用薄塑料护套覆盖。在管线出口处，由于内层上的张力，该软管会缩短以匹配内层的原始长度。
该软管的特征在于，在3巴的标准压力下，伸长率降低。所述的外护套非常薄并且容易腐烂，损害加固件；此外，所述软管的外表面不平滑，当软管缩短时也会汇集污垢。最后但同样重要的，水的流速低，因为它被限制为保持高压来保持软管的伸长。
最后，根据已知技术的可伸缩园艺软管受限于易于破损，沾染污垢，低爆破压力，由于低流速水导致难以伸展，导致不适合在梯田和花园中灌溉的高压，因为高压容易将泥土从容器中冲散。
发明内容
本发明的目的是通过提供一种可伸缩的波纹软管来克服上述缺陷，所述波纹软管具有高效率和相对成本效益的特点。
一个特定的目的是，提供一种可伸缩的波纹软管，其具有高爆破压力(优选地，至少25巴)，以及相对高的伸长率(在3巴时至少伸长100％)。
另外一个目的是，提供一种伸缩的波纹软管，其具有有限的最大伸长率，它可以延伸到明显低于爆破压力的预定压力(例如，高达3巴的压力)，以便在爆破压力之前保持基本稳定。
还有另外一个目的，是提供一种可伸缩波纹软管，其不会在其外表面上积聚污垢颗粒。
另一个目的是，提供一种具有良好的水流速度的可伸缩软管。
另一个目的是，提供一种相对较薄的，轻的，占据较小空间的可伸缩软管。
这些目的，以及将在下文中变得更加明显的其他目的，是通过一种可伸缩波纹软管实现的，该软管包括以弹性可伸长的第一聚合物材料制成的第一承压层，缠绕在所述第一层上的增强件，由弹性可伸长的第二聚合物材料制成的稳定的第二层覆盖在所述增强件上，以限定具有所述第一层的单管体。
根据本发明的一个独特特征，所述的单管体是波纹状的，并且还设置有第三涂层，其布置在所述的第二层上并覆盖所述波纹状单管体。
由于这些特征的组合，软管的外表面是光滑的，以避免在其上收集污垢，并且由于内层的弹性和增强件，该软管也将更具有伸长性和更高的爆破强度。
根据本发明的另一方面，提供了一种用于制造波纹软管的方法。
附图的简要说明
根据对本发明的一种软管及方法的优选的但非排他性实施例的详细描述，本发明的进一步的特征和优点将变得更加明显，借助附图以非限制性示例的方式示出，其中：
图1是根据两个变型的处于制造顺序中的第一步的软管的主视图；
图2是处于制造顺序中的下一步的软管的主视图；
图3是处于静止状态的软管的剖视图；
图4是软管在加压水流入其中之后处于伸长状态的剖视图；
图5是根据本发明的用于制造软管的生产线的侧视图；
图6是图5所示的生产线的变型的侧视图；
图7是图5和图6所示的生产线的细节的侧视图。
实施本发明的最佳方式
参考附图，示出了根据本发明的软管的优选但非排他性的结构，通常用10表示，其将应用于诸如园艺之类的区域中(但不限于此)，尤其是在诸如露台，阳台和小花园等有限的空间条件中。
图1示出了软管10的实施例的制造顺序中的第一部分，其中，对第一弹性可伸长聚合物材料的第一薄层进行挤压，以制造第一内管层1(图1中的a部分)。
随后，根据已知的方法，提供由适当的聚合物材料制成的，并且可以是网状的(图1中的b部分)或编织(图1中的c部分)的织物增强件2，以提高当软管10被加压时的稳定性，提高其爆破压力。
随后，可以在增强件2上提供第二可伸长聚合物材料的第二薄层3，例如通过挤压，以使增强件2稳定，获得多层单管体4。
所获得的多层单管状主体4将经历适当的程序，其中之一将在下面描述，以便获得波纹构造。
例如，管体4的波纹可以可选地包括未示出的容纳元件的布置，该容纳元件可以是围绕稳定层3螺旋缠绕的螺旋状元件，或者也可以具有不同的形状，例如环形，假设为图2中可见的形状，其将迫使管状主体4径向膨胀并起皱。通过改变波曲度，可以改变软管10的最大伸长率。最后，在波纹管状体4上，由非常柔软并有弹性的塑料材料制成的管状涂层第三层5，将被施加并锚固到波纹脊6上。
涂层5的厚度将大于之前层的厚度，以有利于软管10的弹性返回，但要避免这样的第三层5本身产生波纹和污垢收集区域。
可以通过在波纹的外表面插入弹性线来增强弹性回复。
所述外涂层第三层5将适当地非常有弹性并柔软，以允许软管10在使用后恢复到正常尺寸。
整个过程，包括波纹步骤，优选地但非排他性地在生产线上进行。
因此，无论使用何种特定工艺，软管10最基本的形式将从内到外包括：
由弹性可伸展的第一聚合物材料制成的第一层1；
在第一内层上缠绕的网状的或编织的增强件2；
覆盖在增强件2上的由弹性可伸展的第二聚合物材料制成的稳定的第二层3；
其中，所述的三层1,2,3经过波纹步骤，以获得弹性的和波纹状管状体4；
涂层第三层5覆盖在波纹状管状体4上。
对于本发明而言，在有利于层1和3的波纹，并避免第三层5产生波纹所需的弹性特征的限度内，对多个层的材料的选择不是限制性的。
作为非限制性示例，所述第一和第二聚合物材料可选自弹性体和热塑性弹性体(TPE)。特别的，可以使用TPE-S，例如PP/SEBS,PP/EPDM或TPE-0，例如乙烯-辛烯共聚物。其他合适的弹性体材料可以是橡胶或乳胶。
所述管状体4可具有根据ASTM 02240(3")标准测量的位于30ShA和80ShA之间，优选地介于40ShA和60ShA之间的总肖氏A硬度。
例如，所述增强件2可选自，由聚酯，尼龙，PE，PP，PVA，芳纶，对芳酰胺，间位芳纶纤维，人造纤维制成的复丝材料。
图5示出了根据本发明的方法用于制造软管的系统的优选但非排他的实施例。
通常用100表示的系统，包括作为第一工位的主轴101，该主轴101支撑挤压的第一管状层1并使其前进，所述第一管状层1具有与主轴101的轴线的方向相同的平移运动以及围绕该主轴101的可能的旋转运动。
用于第一管状层1的第一挤压机102，具有已知的结构，因此未详细描述，其设置在主轴101的下游，其任务显然是将第一聚合物材料沉积在主轴101上，从而形成内部第一层1。
因此提供了第一双螺旋机103，其适于用一组或两组螺纹加强所述第一层1，并制造上述增强件2。
在示例性但非限制性的方式中，所述第一螺旋机103可以由两个旋转体组成，支撑两组纱线。这些旋转体可以以彼此不同的速度旋转，并且将从纱线中取出的增强件2沉积在剖面的第一层1上。
在第一螺旋机103的下游设置有第二螺旋机104，该第二螺旋机具有单组螺纹，用于根据下述方法设定第一层1的螺旋波纹的螺距。
第二螺旋机104可包括单组纱线卷轴和旋转体，所述旋转体以适当的速度旋转，以便沉积一根或多根紧密纱线，这将迫使第一管状层在纱线沉积附近起皱，波纹软管的该部分最靠近前进轴线。
在所述第二螺旋机104的下游设置有第二挤压机105，用于通过添加由弹性可伸长聚合物材料制成的第二管状层3，将增强件2固定在所述的第一内部软管层1上，所述第二管状层3将粘附到第一层1上，并包裹住织物增强件2。
在第二挤压机105的下游将紧接着设置有第一冷却容器106，以冷水的轻射流冷却增强后的第一层1，并允许主轴101促进波纹的形成。
此时，第三涂层5将通过第三挤压机107施加到波纹状单管体4上。
适当地，所述的单管体4在进入第三挤压机107的挤压头之前，必须在短时间内起皱。
所述的第三挤压机107将在波纹状单管体4的脊6上沉积第三弹性管状层5，该第三弹性管状体5的功能是用于保护波纹状的管体4，使其在内部没有流体压力的情况下保持压实形状，并使得可伸长软管10的外表面平滑。
第二冷却容器108将具有在将软管10从牵引装置109中拉出并从挤压生产线100中沉积出来之前，冷却软管10的功能。
如果优选在稍后阶段切割软管10，则可以用未示出的切割器完成生产线100，以将软管10切割成预定长度或卷的片段(尽管未示出)。
图6所示的实施例不同于前一实施例，因为所述的第二螺旋机104设置在第一冷却容器106的下游。
主轴101将具有通过沉积第一层1，增强件2以及稳定的第二层3，来制造波纹状软管4的功能。
随后，借助于第二螺旋机104，沉积非弹性线状塑料线圈，其将迫使第一层1的外表面的一部分保持粘附到主轴101上。
所述的塑料线圈可以与用于增强件2的材料相同，但也可以用单丝或其他塑料材料，甚至可以使用更硬的材料，例如金属材料线。
此外，螺旋可以嵌入或者不嵌入波纹状管体内。
以这种方式，通过改变第一内层1的速度和/或推进螺距，后者将被迫起皱，因为它将不能径向膨胀。
根据一种操作模式，主轴101上将设置有支撑轴110(如图7所示)，该支撑轴110延伸过所述生产线100的整个纵向，并且将引起内层1的前进。
这样的轴110将以已知的方式在外部适当地成形，以便在该轴110在第二螺旋机器104上游的部分和在第二螺旋机器104的下游部分之间产生不同的间距，该第二间距低于上游的间距，使得第一层1的第一聚合物材料将被迫以减少的进料前进。
因此，材料的积聚将导致在轴110的上游部分立即发生间距变化，然而，由于存在从第二螺旋机104施加的非弹性螺旋，所以不能产生第一层1的均匀径向膨胀。
因此，第一层1将仅在其不与塑料螺旋接触的区域处径向膨胀，从而产生波纹。
图8示出了根据优选实施例的主轴101的进一步细节，其中可以注意到，所述的支撑轴110包括中心管状元件111以及围绕中心元件111缠绕的外围柔性轴112，在第二螺旋机104的所述部分与第二螺旋机104的下游部分之间的通道处，螺旋路径具有可变间距。
根据本发明的软管及相关的制造方法可以进行多种修改和变化，所有这些修改和变化都落入所附权利要求中表达的发明构思内。所有细节可以由其他技术上等效的元件代替，并且材料可以根据需要而不同，而不脱离本发明的范围。

Claims (8)

1.一种用于园艺的可伸缩波纹软管，包括：
单管体(4)，所述单管体(4)包含：
由弹性可伸长的第一聚合物材料制成的承压的第一层(1)；
缠绕在所述第一层(1)上的增强件(2)，所述增强件(2)是网状的、编织的、或螺旋的；
覆盖在所述增强件(2)上的，由弹性可伸长的第二聚合物材料制成的稳定的第二层(3)；
其中，所述单管体(4)是波纹状的并具有多个脊(6)，进一步设置第三涂层(5)并设置在所述第二层(3)上，以覆盖波纹状的所述单管体(4)，所述第三涂层(5)与所述脊(6)牢固连接，并且所述第三涂层(5)的厚度大于波纹状的所述单管体(4)的厚度，以便在其膨胀或收缩后不会出现波纹，
其特征在于，所述单管体(4)通过如下方式被波纹成型：
以预定间距将非弹性螺纹状塑料线圈缠绕在稳定的所述第二层(3)上或者围绕稳定的所述第二层(3)缠绕。
2.根据权利要求1所述的软管，其特征在于，所述增强件(2)是由单个或两个第一纱线系列形成的。
3.一种用于制造可伸缩波纹软管(10)的方法包括以下步骤：
(a)以弹性可伸长的第一聚合物材料制造第一层(1)；
(b)在靠内的所述第一层(1)上缠绕增强件(2)；
(c)在所述增强件(2)上定位由弹性可伸长的第二聚合物材料制成的稳定的第二层(3)，以覆盖所述增强件(2)并限定具有所述第一层(1)的单管体(4)；
(d)在所述第二层(3)上施加第三涂层(5)，以覆盖所述单管体(4)；
(e)波纹成型所述单管体(4)；
其中，所述波纹成型步骤(e)包括步骤(e')：在所述稳定的第二层(3)上以预定间距施加非弹性线状塑料线圈。
4.根据权利要求3所述的方法，其特征在于，所述波纹成型步骤(e)在所述施加第三涂层(5)的步骤(d)的上游进行。
5.根据权利要求3所述的方法，其特征在于，制造所述第一层(1)的步骤(a)包括：步骤(a')，在靠近前进的主轴(101)的头部挤压所述的第一聚合物材料；以及步骤(a")，用具有预定速度和间距的平移或旋转-平移运动运送所述第一层(1)，所述运送由所述主轴(101)促进。
6.根据权利要求5所述的方法，其特征在于，所述波纹成型步骤(e)规定，所述第一层(1)纵向前进，并且所述第一层(1)的第一纵向部分具有第一螺距，在所述第一纵向部分下游的第二纵向部分具有小于第一螺距的第二螺距，以引起所述第一纵向部分的径向膨胀，所述第一纵向部分通过非弹性元件在径向上局部约束，产生波纹成型的脊(6)。
7.根据权利要求6所述的方法，其特征在于，所述的波纹成型步骤(e)包括至少所述第一层的冷却步骤(f)。
8.根据权利要求7所述的方法，其特征在于，所述的冷却步骤(f)在所述的，施加所述非弹性线状塑料线圈的步骤(e)的下游进行。
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