CN110985771A - 一种玄武岩纤维增强复合管 - Google Patents

一种玄武岩纤维增强复合管 Download PDF

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CN110985771A
CN110985771A CN201911369755.8A CN201911369755A CN110985771A CN 110985771 A CN110985771 A CN 110985771A CN 201911369755 A CN201911369755 A CN 201911369755A CN 110985771 A CN110985771 A CN 110985771A
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basalt fiber
steel wire
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汪昕
吴智深
刘霞
陈兴芬
蒋丽娟
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Hengshui Ruixian New Material Technology Co ltd
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    • 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
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Abstract

本发明提供了一种玄武岩纤维增强塑料复合管，包括内层，中间层和外层，内层和外层均为高密度聚乙烯，中间层为由按设计角度交叉间隔缠绕的连续玄武岩纤维粗纱或玄武岩纤维粗纱‑钢丝复合体作为增强骨架，纤维粗纱与钢丝通过粘结树脂牢固粘结形成复合体。该复合管通过采用玄武岩纤维粗纱/玄武岩纤维粗纱‑钢丝复合体与管道内层外表面和管道外层内表面直接粘结，选用单根直径7‑13μm玄武岩纤维，拉伸强度为2500‑3000MPa，弹性模量为85‑95GPa及缠绕角度为50‑60度的结构，与现有技术相比，实现了本发明的复合管具有强度高，刚度大，耐高温，抗冻融，易于切割，便于安装，使用寿命长等优点。

Description

一种玄武岩纤维增强复合管
技术领域
本发明属于纤维增强复合材料领域，特别涉及一种玄武岩纤维增强复合管。
背景技术
钢丝网骨架增强塑料复合管是以高强度钢丝左右螺旋缠绕成型的网状骨架为增强体，用高密度聚乙烯(High Density Polyethylene，HDPE)为基体，并用专用粘结树脂将钢丝网骨架与内外层高密度聚乙烯紧密地连接在一起，经连续挤出成型的新型复合管道，在石油化工、水利电力、市政燃气等工程领取得了广泛应用。
钢丝网骨架增强塑料复合管中的钢材和HDPE的线膨胀系数相差16倍(钢材的线膨胀系数为1.2×10-5/℃；HDPE为20×10-5/℃)，因而在环境温度变化时，两种材料在管道纵向产生反向的纵向应力；此外钢丝表面光滑，同时进行了防锈处理，如涂覆防锈涂层，表面涂层使钢丝与专用粘结树脂粘结力降低，钢丝骨架在管道中容易发生脱粘、滑移，严重影响钢丝-粘结树脂界面质量，造成复合管整体性能差，甚至发生局部屈曲失稳等问题。同时工程实践中发现，在土壤、污水和海水等恶劣条件下，由于界面在抗湿热方面是薄弱环节，环境中的水分子由于毛细作用进入钢丝-树脂粘结界面中，长时间作用使钢丝腐蚀，界面发生破坏；此外，管道切割端封边处理不良，接口处钢丝外漏，环境中的水或管道内的水/气直接腐蚀管道内层钢丝，给复合管的长期耐压性能，严重影响管道的使用寿命。
发明内容
为解决上述技术问题，本发明采用的技术方案是：一种玄武岩纤维增强复合管，由内到外依次包括内层，中间层和外层，所述内层为高密度聚乙烯，所述中间层由连续玄武岩纤维粗纱或玄武岩纤维粗纱-钢丝复合体按设计角度交叉间隔缠绕形成，所述外层为高密度聚乙烯。
进一步，所述连续玄武岩纤维粗纱缠绕于复合管内外层之间，玄武岩纤维粗纱与管道内层外表面和管道外层内表面直接粘结。
进一步，连续玄武岩纤维粗纱缠绕于复合管内层、外层之间，玄武岩纤维粗纱与管道内层外表面和管道外层内表面直接粘结。
进一步，连续玄武岩纤维粗纱-钢丝复合体缠绕于复合管内层、外层之间，复合体与管道内层外表面和管道外层直接粘结。
进一步，所述连续玄武岩纤维粗纱-钢丝复合体中玄武岩纤维粗纱均匀分布于钢丝周围，粗纱与钢丝通过粘结树脂粘结，粗纱轴线与钢丝轴线平行，所述粘结树脂为环氧树脂或聚乙烯树脂。
进一步，玄武岩纤维粗纱单根纤维直径7-13μm，拉伸强度为2500-3000MPa，弹性模量为85-95GPa；高密度聚乙烯弹性模量为700-800MPa。
进一步，玄武岩纤维粗纱细度为150tex-2400tex，耐温性能为-260℃～600℃。
进一步，玄武岩纤维粗纱蠕变率为3％～5％，蠕变断裂应力为54％fu，fu为极限强度。
进一步，所述玄武岩纤维粗纱或玄武岩纤维粗纱-钢丝复合体的缠绕角度为50-60度。
进一步，玄武岩纤维粗纱在管道截面的体积分数比为0.5％-10％。
有益效果：玄武岩纤维增强复合管采用玄武岩纤维粗纱/玄武岩纤维粗纱-钢丝复合体与管道内层外表面和管道外层内表面直接粘结，与钢丝网骨架增强复合管相比，本发明提出的复合管耐腐蚀，粘结性能优异，且管道易于施工。
玄武岩纤维粗纱纤维直径小(7-13μm)，比表面积大，管道整体性能好。同时，交叉缠绕的玄武岩纤维粗纱/玄武岩纤维粗纱-钢丝复合体形成网状结构，与HDPE相互粘结，紧密约束，应力集中小，有效抑制了管道开裂，限制了管道在温度作用下的变形。
与HDPE相比，玄武岩纤维粗纱拉伸强度高，且钢丝和玄武岩纤维粗纱弹性模量均较高(分别是HDPE的240倍和120倍)，作为增强骨架，承担了复合管内压产生的管壁拉应力，很大程度上提高了复合管的承载能力及在外压作用下管道的抗弯能承载力。
玄武岩纤维对温度的敏感性较小，同时纤维的工作温度范围大(-260℃～600℃)，提高了复合管在严酷环境中的适应性。
附图说明
图1为本发明玄武岩纤维增强复合管示意图。
图2为本发明玄武岩纤维粗纱增强复合管示意图。
图3为本发明玄武岩纤维粗纱-钢丝复合体增强复合管示意图。
图4为本发明玄武岩纤维增强复合管效果图。
附图中：1-内层；2-中间层；3-外层；4-玄武岩纤维粗纱；5-钢丝；6-玄武岩纤维粗纱复合体中的玄武岩纤维粗纱。
具体实施方式
下面对本发明附图结合实施例作出进一步说明。
本发明采用连续玄武岩纤维粗纱或玄武岩纤维粗纱-钢丝复合体作为中间的骨架层具有如下的优势：
(1)连续玄武岩纤维粗纱缠绕于复合管内外层之间，玄武岩纤维粗纱与管道内层外表面和管道外层内表面直接粘结。
与现有的钢丝网骨架增强复合管相比，后者工艺复杂：钢丝缠绕采用双层螺旋缠绕，内层钢丝为涂塑钢丝，外层为裸丝。内层钢丝涂塑处理采用专用胶料筒涂塑，涂塑机温度180-230℃，胶层厚度0.10-0.25mm；为保证内层涂塑钢丝与芯管粘合，在缠绕中定位不产生偏移，烘箱需预热芯管层，温度控制在(90±10℃)。
相比较下，本发明的玄武岩纤维粗纱增强复合管工艺简单，连续玄武岩纤维粗纱与内外层高密度聚乙烯具有良好的粘结性能，不需涂塑及预热处理工艺。此外，取消钢丝网骨架的玄武岩纤维增强复合管易于切割，且切割端部处理简易，施工方便。
(2)连续玄武岩纤维粗纱-钢丝复合体中玄武岩纤维粗纱均匀分布于钢丝周围，粗纱与钢丝通过粘结树脂粘结，粗纱轴线与钢丝轴线平行。钢丝弹性模量高，可有效提高复合管的抗压强度和抗冲击性能。玄武岩纤维直径小，与复合管内外层具有优异的粘结性能，均匀分布于钢丝周围，避免了钢丝与管道内外层粘结力不足的问题；同时玄武岩纤维耐腐蚀，可保护钢丝在土壤、污水和海水等恶劣条件下发生锈蚀。
同时，玄武岩纤维粗纱与钢丝通过热塑性树脂粘结，其粘结树脂可为环氧树脂或聚乙烯树脂。
(3)玄武岩纤维粗纱单根纤维直径7-13μm，拉伸强度为2500-3000MPa，弹性模量为85-95GPa。单根纤维直径仅为钢丝的7/1000～13/1000，比表面积大，较大的比表面积增大了与复合管内外层的粘结面，因而界面粘结性能好，玄武岩纤维粗纱增强复合管具有较好的整体性。玄武岩纤维粗纱/玄武岩纤维粗纱-钢丝复合体交叉缠绕形成网状结构，较小直径的纤维与HDPE两种材料相互粘结，紧密约束，且应力集中小，有效地抑制了管道开裂。
(4)玄武岩纤维弹性模量为85-95GPa，高密度聚乙烯的弹性模量为700-800MPa，前者是后者的120左右，玄武岩纤维粗纱-钢丝复合体弹性模量为195-200GPa，是高密度聚乙烯的240倍左右，因此复合管内压产生的管壁拉应力主要由玄武岩纤维/玄武岩纤维粗纱-钢丝复合体承担，因而很大程度上提高了复合管的承载能力。
(5)玄武岩纤维粗纱蠕变率为3％～5％，蠕变断裂应力为54％fu(fu为极限强度)。HDPE是典型的粘弹性材料，在荷载的长期作用下，材料的粘弹性引起结构的应力重分布，产生应力松弛或蠕变，在较高的应力作用下会发生脆性断裂，或者引起结构的蠕变失稳。玄武岩纤维的蠕变率低，且蠕变断裂应力高，利用玄武岩纤维粗纱/玄武岩纤维粗纱-钢丝复合体作为增强骨架，可以提高复合管的许用应力及承压能力。
(6)玄武岩纤维粗纱细度为150tex-2400tex，耐温性能为-260℃～600℃。玄武岩纤维粗纱细度的选择需根据增强复合管的力学性能进行合理设计；玄武岩纤维热膨胀系数为6～8×10-5/℃，对温度的敏感性较小，同时纤维的工作温度范围大，在严酷环境中玄武岩纤维粗纱/玄武岩纤维粗纱-钢丝复合体的适应性更强。
(7)玄武岩纤维粗纱/玄武岩纤维粗纱-钢丝复合体的缠绕角度为50-60°。当缠绕角度<50°时，玄武岩纤维粗纱/玄武岩纤维粗纱-钢丝复合体对复合管的轴向增强作用减弱，无法限制管道在正常施工及使用过程中因温度变化产生的轴向变形；当缠绕角度>60°时，玄武岩纤维粗纱/玄武岩纤维粗纱-钢丝复合体对复合管的环向加强作用减弱，由于玄武岩纤维粗纱/玄武岩纤维粗纱-钢丝复合体承担了大部分管道内流体对管壁产生拉应力，因此随着缠绕角的增大，复合管整体承载能力得不到充分发挥。
(8)玄武岩纤维粗纱在管道截面的体积分数比为5％-10％，保证了玄武岩纤维粗纱承担复合管中80％以上的内压。同时复合管在土压力(外压)作用下，管基支承角按2α＝90°进行强度计算时，在管壁顶点和底点内侧将产生最大的弯曲应力，玄武岩纤维粗纱很大程度上提高了复合管在外压作用下对弯曲的承载力。优选地，玄武岩纤维粗纱-钢丝复合体中粗纱在管道截面的分数比为0.5％-1％，保证玄武岩纤维粗纱-钢丝骨架承担了60％以上的内压。进一步地，本发明中设置玄武岩纤维粗纱在管道截面的体积分数比为0.5％-10％。
实施例1
如图2所示，玄武岩纤维粗纱增强复合管由内层1、中间层2和外层3组成。内层芯管采用高密度聚乙烯High Density Polyethylene，也可简称为HDPE，通过挤出工艺挤出成型，芯管外径464mm，内层管壁厚8mm，形成的内层管外径480mm。中间层根据内层管外径进行玄武岩纤维粗纱交叉双层缠绕。玄武岩纤维粗纱环向缠绕在内层1的外表面，粗纱与外表面的高密度聚乙烯HDPE相互粘结。
玄武岩纤维直径12μm，拉伸强度2600MPa，弹性模量92GPa，粗纱细度为1200tex，缠绕角为55°，粗纱体积含量为6％，最终形成厚度为2mm的中间层。芯管与中间层玄武岩纤维粗纱缠绕复合后，进行外层挤出复合，外层HDPE首先填充在玄武岩纤维粗纱形成的网眼，形成致密的骨架层；其次，HDPE形成外层管壁，管壁厚度外管直径控制为500mm。复合管冷却后进行切割封口，并进行检验。
采用玄武岩纤维粗纱增强的复合管，生产工艺简单，粘结性能优异，且管道易于切割，施工方便。
实施例2
如图3所示，玄武岩纤维粗纱-钢丝复合体增强复合管由内层1、中间层2和外层3组成。内层芯管采用高密度聚乙烯High Density Polyethylene，也可简称为HDPE，通过挤出工艺挤出成型，芯管外径468mm，内层管壁厚7.5mm，形成的内层管外径483mm。中间层根据内层管外径进行玄武岩纤维粗纱-钢丝复合体交叉双层缠绕。玄武岩纤维直径10μm，拉伸强度2500MPa，弹性模量88GPa，粗纱细度为150tex；钢丝直径1mm，拉伸强度1450MPa，杨氏模量210GPa；玄武岩纤维粗纱均匀包裹在钢丝圆周，粗纱的纵轴与钢丝纵轴平行，粗纱与钢丝通过环氧树脂粘结形成玄武岩纤维粗纱-钢丝复合体。玄武岩纤维粗纱-钢丝复合体环向缠绕在内层1的外表面，粗纱与外表面的HDPE相互粘结。缠绕角为57°，玄武岩纤维粗纱-钢丝复合体在管道截面的体积含量为1％，最终形成厚度为1mm的中间层。芯管与中间层玄武岩纤维粗纱-钢丝复合体缠绕复合后，进行外层挤出复合，外层HDPE首先填充在玄武岩纤维粗纱-钢丝复合体形成的网眼中，形成致密的骨架层；其次，HDPE形成外层管壁，管壁厚度外管直径控制为500mm。复合管冷却后进行切割封口，并进行检验。
采用玄武岩纤维粗纱-钢丝复合体增强的复合管，粘结性能优异，且管道壁厚薄，强度高，刚度大。
以上所述实施例仅表达了本发明的几种实施方式，其描述较为具体和详细，但并不能因此而理解为对发明专利范围的限制。应当指出的是，对于本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干变形和改进，这些都属于本发明的保护范围。因此，本发明专利的保护范围应以所附权利要求为准。

Claims (9)

1.一种玄武岩纤维增复合管，其特征在于：由内到外包括内层(1)，中间层(2)和外层(3)，其中所述内层(1)为高密度聚乙烯基体，所述中间层(2)为骨架层，所述外层(3)为高密度聚乙烯；骨架层由连续玄武岩纤维粗纱或玄武岩纤维粗纱-钢丝复合体按一定角度交叉缠绕形成。
2.根据权利要求1所述的玄武岩纤维增强复合管，其特征在于：连续玄武岩纤维粗纱缠绕于复合管内层(1)、外层(3)之间，玄武岩纤维粗纱与管道内层(1)外表面和管道外层(3)内表面直接粘结。
3.根据权利要求1所述的玄武岩纤维增强复合管，其特征在于：连续玄武岩纤维粗纱-钢丝复合体缠绕于复合管内层(1)、外层(3)之间，复合层与管道内层(1)外表面和管道外层(3)直接粘结。
4.根据权利要求3所述的玄武岩纤维增强复合管，其特征在于：所述连续玄武岩纤维粗纱-钢丝复合体中玄武岩纤维粗纱均匀分布于钢丝周围，粗纱与钢丝通过粘结树脂粘结，粗纱轴线与钢丝轴线平行，所述粘结树脂为环氧树脂或聚乙烯树脂。
5.根据权利要求2或3所述的玄武岩纤维增强复合管，其特征在于：玄武岩纤维粗纱单根纤维直径7-13μm，拉伸强度为2500-3000MPa，弹性模量为85-95GPa；高密度聚乙烯弹性模量为700-800MPa。
6.根据权利要求2或3所述的玄武岩纤维增强复合管，其特征在于：玄武岩纤维粗纱细度为150tex-2400tex，耐温性能为-260℃～600℃。
7.根据权利要求2或3所述的玄武岩纤维增强复合管，其特征在于：玄武岩纤维粗纱蠕变率为3％～5％，蠕变断裂应力为54％fu，fu为极限强度。
8.根据权利要求1所述的玄武岩纤维增强复合管，其特征在于：所述玄武岩纤维粗纱或玄武岩纤维粗纱-钢丝复合体的缠绕角度为50-60度。
9.根据权利要求1所述的玄武岩纤维增强复合管，其特征在于：玄武岩纤维粗纱在管道截面的体积分数比为0.5％-10％。
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