CN110332383A - 一种复合软管及制备方法 - Google Patents
一种复合软管及制备方法 Download PDFInfo
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Abstract
一种复合软管,包括内层、纤维增强层、涂覆层、钢丝加箍层和涂覆阻燃层,所述纤维增强层和钢丝加箍层从内向外依次包裹于所述内层外,纤维增强层和钢丝加箍层之间设置涂覆层,钢丝加箍层外设置涂覆阻燃层。基于塑料管的优势,用特殊工艺生产出一种新型的复合管材,赋予管材柔韧性与刚性,更好的适应使用环境。
Description
技术领域
本发明涉及复合管材,具体涉及一种复合软管及制备方法。
背景技术
随着经济的发展,需要使用特种管材的场所变得多样化,对材料的性能指标有了更加严格和多样的要求,比如耐腐蚀性、拉伸强度、抗静电性、阻燃性,抗挠曲性,耐高低压性,严酷环境适应性能等指标均有严格的要求。不断的提高管材的性能,是经济和社会发展的迫切需求。
传统的管材材料多存在阻燃性差、化学稳定性差、抗静电性能弱、力学性能差、使用寿命短等问题,给实际使用带来很多不便,甚至威胁到人们的生命财产安全。因此,急需改变原有管材生产工艺,改进材料性能,以适应特种管材市场多样的需求。随着人性化理念的普及,及现代环保要求,设计一种适应各个性能的特种复合管材是非常必要的。
塑料钢丝管生产线主要是由挤出机,钢丝绕簧机,淋水槽,牵引机等机械组成。绕簧均匀一致,连续生产时间较长。长度都可以随着现实情况的要求任意设定。
塑料钢丝管材料强度高,具有良好的耐腐蚀性、耐磨蚀性和抗老化性,使用寿命长。在高压真空下能保持原状。
塑料钢丝管具有良好的耐热性和抗热变形的能力。可在70℃温度下连续作业和120℃温度下间歇作业的状况下正常使用不损坏。
塑料钢丝软管根据用途可以分为工业级(专门输送工业用水,输油,污水,粉料、化工原料等)和无毒级(食品厂输送果汁,奶汁,食用水,酒厂输送白酒、啤酒,等),风力发电、吸排水、油、化学品等液体及固体颗粒、粉状物料。
钢丝管主要是耐负压,钢丝管耐正压能力不强,虽然可以在钢丝管基础上外加纤维增强线或增强布,但耐正压能力提高不多,况且钢丝管厚度有一定的限制,当纤维增强层与涂覆层结合不牢时,抗正压能力更弱。
塑料纤维增强软管是现代工业设备中的一种软管,近几年这种软管使用范围越来越广泛,而且发展非常迅速。
塑料纤维增强软管具有自重轻、耐腐蚀、耐压强度高、卫生安全、水流阻力小、节约能源等优点。外观非常漂亮、色彩亮丽。用户可以根据自身需要进行不同种类以及不同颜色外观的选择。安装简便、快捷。使用寿命长。但是现有的塑料纤维增强软管虽耐正压加强了,但没有耐负压能力,也没有抗扭曲能力。
发明内容
鉴于以上情形,为了解决上述技术存在的问题,本发明基于塑料管的优势,用特殊工艺生产出一种新型的复合管材,赋予管材柔韧性与刚性,更好的适应使用环境。
一种复合软管,包括内层、纤维增强层、涂覆层、钢丝加箍层和涂覆阻燃层,所述纤维增强层和钢丝加箍层从内向外依次包裹于所述内层外,纤维增强层和钢丝加箍层之间设置涂覆层,钢丝加箍层外设置涂覆阻燃层。
根据本申请的一种复合软管,所述内层为橡胶材料或PVC树脂制成的软管。
根据本申请的一种复合软管,所述纤维增强层为涤纶纤维线或者涤纶纤维布。
根据本申请的一种复合软管,所述钢丝加箍层为镀锌钢丝或者不锈钢钢丝。
根据本申请的一种复合软管,所述内层、纤维增强层、涂覆层、钢丝加箍层和涂覆阻燃层之间设有胶黏剂增加各层之间的结合度。
根据本申请的一种复合软管及制备方法,其生产工艺在于,首先通过纤维管挤出机号机挤出内管即所述内层,经过冷却水槽定型,由号牵引机送入纤维编织机,编织涤纶纤维,得到纤维增强层;然后经加热装置后进入纤维管挤出机号机涂覆第二层即所述涂覆层,进冷却水槽定型;再由号牵引机送入钢丝加箍机,均匀缠绕加箍层即所述钢丝加箍层;由加热装置加热后进入外层涂覆挤出机号挤出机涂覆最外层即所述涂覆阻燃层;最后经冷却水槽冷却定型,进行后续处理。
在采取本发明提出的技术后,根据本发明实施例的复合软管,具有以下有益效果。
1)在纤维增强管生产基础上融合钢丝管生产工艺,把钢丝均匀的缠绕在纤维增强管外表,形成箍状,是用钢丝来加固纤维管的新技术。以往的技术是在钢丝管基础上融入纤维管技术,来提高钢丝管的耐正压能力,耐正压靠的是纤维增强线(布)的粗细,效果并不理想。本发明是在纤维管基础上融入钢丝管技术,各种材料不变,就可以提高耐正压,耐负压,抗扭曲的能力。
2)针对塑料及橡胶挤出行业,结合纤维增强管与钢丝管生产技术,赋予管材刚性与柔韧性的同时,最大限度的提高产品的各项性能。在纤维增强管基础上外加钢丝作为加固层,更好的发挥出钢丝管与线管的特性,耐正负压更强,更大的抗扭曲性,更小的弯曲半径。作为橡胶管的替代产品使用。
附图说明
图1为根据本申请的一种复合软管结构示意图;
图2为根据本申请的一种复合软管生产工艺流程图。
具体实施方式
下面将参照附图对本发明的各个优选的实施方式进行描述。提供以下参照附图的描述,以帮助对由权利要求及其等价物所限定的本发明的示例实施方式的理解。其包括帮助理解的各种具体细节,但它们只能被看作是示例性的。因此,本领域技术人员将认识到,可对这里描述的实施方式进行各种改变和修改,而不脱离本发明的范围和精神。而且,为了使说明书更加清楚简洁,将省略对本领域熟知功能和构造的详细描述。
如图1和图2所示,一种复合软管,包括内层1、纤维增强层2、涂覆层3、钢丝加箍层4和涂覆阻燃层5,所述纤维增强层2和钢丝加箍层4从内向外依次包裹于所述内层1外,纤维增强层2和钢丝加箍层4之间设置涂覆层3,钢丝加箍层4外设置涂覆阻燃层5。
所述内层1为橡胶材料或PVC树脂制成的软管。
所述纤维增强层2为涤纶纤维线或者涤纶纤维布。
所述钢丝加箍层4为镀锌钢丝或者不锈钢钢丝。
所述内层1、纤维增强层2、涂覆层3、钢丝加箍层4和涂覆阻燃层5之间设有胶黏剂增加各层之间的结合度。
其生产工艺在于,首先通过纤维管挤出机1号机挤出内管即所述内层1,经过冷却水槽定型,由1号牵引机送入纤维编织机,编织涤纶纤维,得到纤维增强层2;然后经加热装置后进入纤维管挤出机2号机涂覆第二层即所述涂覆层3,进冷却水槽定型;再由2号牵引机送入钢丝加箍机,均匀缠绕加箍层即所述钢丝加箍层4;由加热装置加热后进入外层涂覆挤出机3号挤出机涂覆最外层即所述涂覆阻燃层5;最后经冷却水槽冷却定型,进行后续处理。
根据本申请的一种复合软管,所用原料为塑料及橡胶,如PVC,tpu,pe,尼龙等。橡胶材料主要用作内层。纤维增强可采用涤纶纤维线(布),钢丝加箍层可用镀锌钢丝或不锈钢钢丝。各层之间可以使用胶黏剂增加结合度。
PVC树脂的分子量(聚合度)和制品的物理机械性能有关,分子量越高,制品的拉伸强度、冲击强度、弹性模量越高;本发明通过将PVC树脂的聚合度控制在2000-2500,可以使得制品具有较高的强度。
增塑剂是由偏苯三酸三辛酯和其他增塑剂以重量比1:1-1.5组成的混合物。两种增塑剂均为环保增塑剂,可以降低PVC分子链间的作用力,使PVC塑料的玻璃化温度、流动温度与所含微晶的熔点均降低,增塑剂可提高树脂的可塑性,使制品柔软、耐低温性能好;当两种增塑剂以重量比1:1-1.5复配使用时,可以提高制品的柔软性和耐低温性能。
热稳定剂为是由主体稳定剂、辅助稳定剂和助剂以重量比18-39:3-7:1组成的混合物。通过将主体稳定剂、辅助稳定剂和助剂以重量比18-39:3-7:1混合制得热稳定剂,其热稳定效果好,使材料在加工过程中有很好的分散性、相容性和加工流动性,使材料热稳定性优良。
本发明采用石蜡作为外润滑剂,能降低PVC熔体与模具、机筒的摩擦;采用硬脂酸作为内润滑剂,能降低PVC熔体的分子间摩擦;两种润滑剂混合使用可以使材料在加工过程中改善材料的流动性和制品的脱模性。
TPU具有卓越的高张力、高拉力、强韧和耐老化的特性,是一种成熟的环保材料。目前,TPU已广泛应用于医疗卫生、电子电器、工业及体育等方面,其具有其它塑料材料所无法比拟的强度高、韧性好、耐磨、耐寒、耐油、耐水、耐老化、耐气候等特性,同时他具有高防水性透湿性、防风、防寒、抗菌、防霉、保暖、抗紫外线以及能量释放等许多优异的功能。
HDPE树脂
性质:本色、圆柱状或扁圆状颗粒,颗粒光洁,粒子的尺寸在任意方向上应为2mm~5mm,无机械杂质,具热塑性。粉料为本白色粉末,合格品允许有微黄色。常温下不溶于一般溶剂,但在脂肪烃、芳香烃和卤代烃中长时间接触时能溶胀,在70℃以上时稍溶于甲苯、醋酸中。在空气中加热和受日光影响发生氧化作用。能耐大多数酸碱的侵蚀。吸水性小,在低温时仍能保持柔软性,电绝缘性高。
纤维增强软管是现代工业设备中的一种软管,近几年这种软管使用范围越来越广泛,而且发展非常迅速。
具有自重轻、耐腐蚀、耐压强度高、卫生安全、水流阻力小、节约能源等优点。外观非常漂亮、色彩亮丽。安装简便、快捷。使用寿命长。
涤纶纤维是一种品质优良的合成纤维,用以制得的线强力高,在各类线中仅次于尼龙线,居第二位,而且湿态时不会降低强度。它的缩水率很小,经过适当定型后收缩小于1%,因此能始终保持平挺美观,无皱缩。耐磨性仅次于锦纶。回潮率低,有良好的耐高温、耐低温、耐光性和耐水性。所以,涤纶线是使用极为广泛的品种。
塑料钢丝管生产线主要是由挤出机,钢丝绕簧机,淋水槽,牵引机等机械组成。绕簧均匀一致,连续生产时间较长。长度都可以随着现实情况的要求任意设定。
塑料钢丝管材料强度高,具有良好的耐腐蚀性、耐磨蚀性和抗老化性,使用寿命长。在高压真空下能保持原状。
镀锌钢丝表面平滑、光洁、没有裂纹地、节、起刺、伤痕和锈蚀,镀锌层均匀、附着力强、耐腐蚀力持久,韧性和弹性极好。抗拉强度应在900Mpa-2200Mpa之间(丝径Φ0.2mm-Φ4.4mm)。扭转次数(Φ0.5mm)在20次以上,反复弯曲应在13次以上。
热镀的锌层厚度为250g/m。大大提高了钢丝的抗腐蚀能力
不锈钢丝又称不锈钢线,用不锈钢为原材料制作的各类不同规格和型号的丝质产品,原产地美国、荷兰、日本,截面一般呈圆形或扁形。常见的耐腐蚀性好、性价比高的不锈钢丝是304和316的不锈钢丝。
根据本申请的一种复合软管,整体生产工艺在于,纤维管挤出机1号机挤出内管,经过冷却水槽定型,由1号牵引机送入纤维编织机,编织涤纶纤维;经加热装置后进入纤维管挤出机2号机涂覆第二层,进冷却水槽定型;由2号牵引机送入钢丝加箍机,均匀缠绕加箍层;由加热装置加热后进入外层涂覆挤出机3号挤出机涂覆最外层;最后经冷却水槽冷却定型,经3号牵引机进入裁断装置,盘管收卷。
根据本申请的一种复合软管,在纤维增强管生产基础上融合钢丝管生产工艺,把钢丝均匀的缠绕在纤维增强管外表,形成箍状,是用钢丝来加固纤维管的新技术。以往的技术是在钢丝管基础上融入纤维管技术,来提高钢丝管的耐正压能力,耐正压靠的是纤维增强线(布)的粗细,效果并不理想。本发明是在纤维管基础上融入钢丝管技术,各种材料不变,就可以提高耐正压,耐负压,抗扭曲的能力。
根据本申请的一种复合软管,针对塑料及橡胶挤出行业,结合纤维增强管与钢丝管生产技术,赋予管材刚性与柔韧性的同时,最大限度的提高产品的各项性能。在纤维增强管基础上外加钢丝作为加固层,更好的发挥出钢丝管与线管的特性,耐正负压更强,更大的抗扭曲性,更小的弯曲半径。作为橡胶管的替代产品使用。
以上对本发明进行了详细介绍,本文中应用了具体个例对本发明的原理及实施方式进行了阐述,以上实施例的说明只是用于帮助理解本发明的方法及其核心思想;同时,对于本领域的一般技术人员,依据本发明的思想,在具体实施方式及应用范围上均会有改变之处,综上所述,本说明书内容不应理解为对本发明的限制。
通过以上的实施方式的描述,本领域的技术人员可以清楚地了解到本发明可实施。当然,以上所列的情况仅为示例,本发明并不仅限于此。本领域的技术人员应该理解,根据本发明技术方案的其他变形或简化,都可以适当地应用于本发明,并且应该包括在本发明的范围内。
Claims (6)
1.一种复合软管,其特征在于,包括内层(1)、纤维增强层(2)、涂覆层(3)、钢丝加箍层(4)和涂覆阻燃层(5),所述纤维增强层(2)和钢丝加箍层(4)从内向外依次包裹于所述内层(1)外,纤维增强层(2)和钢丝加箍层(4)之间设置涂覆层(3),钢丝加箍层(4)外设置涂覆阻燃层(5)。
2.根据权利要求1所述的一种复合软管,其特征在于,所述内层(1)为橡胶材料或PVC树脂制成的软管。
3.根据权利要求1所述的一种复合软管,其特征在于,所述纤维增强层(2)为涤纶纤维线或者涤纶纤维布。
4.根据权利要求1所述的一种复合软管,其特征在于,所述钢丝加箍层(4)为镀锌钢丝或者不锈钢钢丝。
5.根据权利要求1所述的一种复合软管,其特征在于,所述内层(1)、纤维增强层(2)、涂覆层(3)、钢丝加箍层(4)和涂覆阻燃层(5)之间设有胶黏剂增加各层之间的结合度。
6.根据权利要求1至5中任一项所述的一种复合软管制备方法,其生产工艺在于,首先通过纤维管挤出机(1)号机挤出内管即所述内层(1),经过冷却水槽定型,由(1)号牵引机送入纤维编织机,编织涤纶纤维,得到纤维增强层(2);然后经加热装置后进入纤维管挤出机(2)号机涂覆第二层即所述涂覆层(3),进冷却水槽定型;再由(2)号牵引机送入钢丝加箍机,均匀缠绕加箍层即所述钢丝加箍层(4);由加热装置加热后进入外层涂覆挤出机(3)号挤出机涂覆最外层即所述涂覆阻燃层(5);最后经冷却水槽冷却定型,进行后续处理。
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