CN111300910A - 一种连续纤维增强复合材料管的生产工艺 - Google Patents
一种连续纤维增强复合材料管的生产工艺 Download PDFInfo
- Publication number
- CN111300910A CN111300910A CN202010247901.6A CN202010247901A CN111300910A CN 111300910 A CN111300910 A CN 111300910A CN 202010247901 A CN202010247901 A CN 202010247901A CN 111300910 A CN111300910 A CN 111300910A
- Authority
- CN
- China
- Prior art keywords
- layer
- winding
- wound
- functional
- reinforcing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000000463 material Substances 0.000 title claims abstract description 43
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 30
- 239000003733 fiber-reinforced composite Substances 0.000 title claims abstract description 19
- 239000010410 layer Substances 0.000 claims abstract description 200
- 238000004804 winding Methods 0.000 claims abstract description 97
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 42
- 239000002346 layers by function Substances 0.000 claims abstract description 26
- 238000000034 method Methods 0.000 claims abstract description 20
- 238000002955 isolation Methods 0.000 claims abstract description 16
- 239000002184 metal Substances 0.000 claims description 19
- 238000001125 extrusion Methods 0.000 claims description 18
- 230000008569 process Effects 0.000 claims description 18
- 239000011241 protective layer Substances 0.000 claims description 16
- 238000005299 abrasion Methods 0.000 claims description 10
- 238000000465 moulding Methods 0.000 claims description 10
- 229920000642 polymer Polymers 0.000 claims description 10
- 238000001816 cooling Methods 0.000 claims description 7
- 229910052755 nonmetal Inorganic materials 0.000 claims description 7
- 238000003825 pressing Methods 0.000 claims description 6
- 229920001169 thermoplastic Polymers 0.000 claims description 6
- 239000004416 thermosoftening plastic Substances 0.000 claims description 6
- 238000003754 machining Methods 0.000 claims description 5
- 238000007493 shaping process Methods 0.000 claims description 4
- 238000009730 filament winding Methods 0.000 claims description 3
- 229920000728 polyester Polymers 0.000 claims description 3
- 238000004513 sizing Methods 0.000 claims description 3
- 230000002829 reductive effect Effects 0.000 abstract description 6
- 230000002787 reinforcement Effects 0.000 abstract description 5
- 238000011068 loading method Methods 0.000 abstract description 2
- 239000002994 raw material Substances 0.000 abstract description 2
- 238000007789 sealing Methods 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 239000002131 composite material Substances 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000006073 displacement reaction Methods 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 239000012815 thermoplastic material Substances 0.000 description 2
- 229920002748 Basalt fiber Polymers 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
- 229920003235 aromatic polyamide Polymers 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000005253 cladding Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000000670 limiting effect Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000003204 osmotic effect Effects 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 230000000452 restraining effect Effects 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
Images
Classifications
-
- 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 non-planar shape
- B32B1/08—Tubular products
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/56—Winding and joining, e.g. winding spirally
- B29C53/58—Winding and joining, e.g. winding spirally helically
- B29C53/581—Winding and joining, e.g. winding spirally helically using sheets or strips consisting principally of plastics material
- B29C53/582—Winding and joining, e.g. winding spirally helically using sheets or strips consisting principally of plastics material comprising reinforcements, e.g. wires, threads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/56—Winding and joining, e.g. winding spirally
- B29C53/58—Winding and joining, e.g. winding spirally helically
- B29C53/60—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/56—Winding and joining, e.g. winding spirally
- B29C53/58—Winding and joining, e.g. winding spirally helically
- B29C53/78—Winding and joining, e.g. winding spirally helically using profiled sheets or strips
- B29C53/785—Winding and joining, e.g. winding spirally helically using profiled sheets or strips with reinforcements
-
- 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
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
-
- 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
- B32B15/00—Layered products comprising a layer of metal
- B32B15/18—Layered products comprising a layer of metal comprising iron or steel
-
- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
-
- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
- B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
-
- 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
- B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
-
- 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
- B32B5/02—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 structural features of a fibrous or filamentary layer
-
- 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
- B32B5/02—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 structural features of a fibrous or filamentary layer
- B32B5/08—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 structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2023/00—Tubular articles
- B29L2023/22—Tubes or pipes, i.e. rigid
-
- 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
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0276—Polyester fibres
- B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
-
- 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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/548—Creep
-
- 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
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Rigid Pipes And Flexible Pipes (AREA)
Abstract
本发明公开了一种连续纤维增强复合材料管的生产工艺,其工艺步骤包括内管成型,辅助层缠绕覆盖,增强层缠绕,功能层缠绕,防磨层成型,轴向抗拉层缠绕,功能隔离层缠绕和外保护层成型。相对于现连续纤维增强复合材料管的生产工艺,本申请通过工业长丝缠绕内管,加强了内管抗蠕变和抗内压能力。低压力时,减少了增强层的缠绕层数。降低增强层缠绕时对角度公差和间隙要求。加强了压力管道在生产中的可控性。降低了产品原材料成本。加强了管材轴向载荷能力,一般可用于海洋管道、跨接管线和其他动态和非动态环境下的压力管道。
Description
技术领域
本发明涉及石油、气、水等流体介质长距离和短距离输送的压力管道领域,尤其涉及一种连续纤维增强复合材料管的生产工艺。
背景技术
连续增强连续纤维增强复合材料管是一种新型高性能的复合管道,从机构上看,其包括由聚合物组成的内衬密封层、协助和防止内衬密封层在压力作用下发生蠕变和渗透的工业长丝层、缠绕于工业长丝外表面的压力增强层、便于满足工业化和连续生产所设计的用于降低外保护层在加工时对温度敏感,降低塑料在加工过程中存在的冷热收缩差异性的功能层,他缠绕于增强层外表面、和防止增强材料与抗拉材料产生相互摩擦的包覆层以及用于管材轴向抗拉,防止管材在动态环境中轴向受损的抗拉层、功能层和包覆在管材外部起保护管材作用的外保护层。连续纤维增强柔性复合管的传统制作工艺如下:
首先,是有热塑性材料挤出成型内衬层;
其次,采用带材缠绕机,按照设计角度将带材缠绕于内衬层外表面,为了达到完全覆盖的目的,所缠绕的带材分别为两两方向相同且后一层带材须完全将前一层带材缠绕预留的缝隙覆盖,前两层缠绕的带材与后两层缠绕的带材互为反向。周而复始进行缠绕,以达到压力需求。最后是热塑性材料挤出外管进行包覆。内衬层与增强层之间、增强层与增强层之间、增强层与外管之间粘结与否取决于产品执行标准和客户需求。
上述复合管道已运用于浅海、陆地油、气、水集输管线,高压注水管线,热洗管线的生产和制造。
然而,在实际生产过程中,为了达到带材(为了加强内管抗蠕变性能)对内管完全覆盖,带材与带材之间又需要预留一定的间隙(以达到柔性弯曲的目的),所以,其缠绕方式一般为两两同向。否则,较难避免缠绕带与缠绕带之间交叉点同孔现象。所以,增强带缠绕层基数一般四层的倍数。对于小口径、低压力管道来说,增强层过剩,浪费了许多材料,成本相对较高;该工艺管道由于轴向抗拉载荷有限,所以,一般用于静态环境或埋地管线,对于动态环境,特别是海洋动态环境,该工艺管材受到较大限制,传统制作工艺管材对于角度要求较严,因为一次缠绕两层,对缠绕外径的增加较为明显,缠绕时所产生的应力较难平衡。实际生产操作中,控制难度加大。
由于缠绕的带材之间需要预留相应的间隙,以满足管材弯曲的需要,覆盖间隙的缠绕带在覆盖前一层缠绕带间隙时,必须考虑带材的合理宽度。否则,管材弯曲时,带材的位移就难保证将后一层缠绕带有效覆盖前一层缠绕带的间隙。管材的安全性就大大受到制造工艺限制。
发明内容
为解决上述技术问题,本发明设计了一种连续纤维增强复合材料管的生产工艺。
本发明采用如下技术方案:
一种连续纤维增强复合材料管的生产工艺,该连续纤维增强复合材料管包括内管、沿着平行于内管轴向的外表面上的缠绕的辅助层、缠绕在辅助层轴向外表面上的增强层、缠绕在轴向外表面的功能层、包覆于所述功能层外表面的防磨层、缠绕于防磨层外表面的轴向抗拉层、缠绕于轴向抗拉层外表面的功能隔离层和包覆于功能层外表面的外保护层;该连续纤维增强复合材料管的生产工艺步骤为:
S1:内管成型:对内管材质进行选型,选型后通过挤出成型设备热塑性挤压成型出内管;
S2:辅助层缠绕覆盖:通过丝缠绕设备将工业长丝均匀地以螺旋缠绕方式缠绕于内管的外表面形成辅助层,缠绕层数可以是一层或多层结构;
S3:增强层缠绕:通过带材缠绕设备将增强带均匀地螺旋缠绕于辅助层的外表面形成增强层,增强层的缠绕层为成双数的多层结构;
S4:功能层缠绕:通过带材缠绕设备将非金属带均匀地螺旋缠绕在增强层外表面形成功能层,螺旋缠绕的聚合物带材间相互压接;
S5:防磨层成型:选取防磨层材质,通过挤出成型设备挤出覆盖于功能层外表面,通过冷却定型和牵引完成加工成型,形成防磨层;
S6:轴向抗拉层缠绕:通过带材缠绕设备将金属带螺旋缠绕于防磨层外表面形成轴向抗拉层,轴向抗拉层的缠绕层为成双数的多层结构;
S7:功能隔离层缠绕:通过带材缠绕设备将非金属带均匀地螺旋缠绕在轴向抗拉层外表面形成功能隔离层,螺旋缠绕的聚合物带材间相互压接;
S8:外保护层成型:选取外保护层材质,通过挤出成型设备热塑性挤出覆盖于功能隔离层外表面,通过冷却定型和牵引完成加工成型,形成外保护层,完成整个连续纤维增强复合材料管的生产工艺。
作为优选,所述S2步骤中工业长丝采用柔性工业长丝。
作为优选,所述辅助层缠绕层数为多层,相邻缠绕层缠绕方向不同。
作为优选,所述步骤S3中,增强层的每一层增强带缠绕时,相邻缠绕的增强带间预留有一定的间隙。
作为优选,所述非金属带为聚酯带。
作为优选,所述S6步骤中的金属带为金属扁钢带,金属扁钢带的横切面为矩形结构。
作为优选,所述S6步骤中的金属带螺旋缠绕为小角度缠绕,缠绕角度小于45度。
作为优选,所述步骤S6中,轴向抗拉层的每一层金属带缠绕时,相邻缠绕的金属带间预留有一定的间隙。
作为优选,所述内管、辅助层、增强层、功能层、防磨层、轴向抗拉层、功能隔离层、外保护层间非粘结可滑移。
作为优选,所述S3和S6步骤中,成双数的多层结构,相邻层内增强带或金属带的缠绕角度相反。
本发明的有益效果是:相对于现连续纤维增强复合材料管的生产工艺,本申请通过工业长丝缠绕内管,加强了内管抗蠕变和抗内压能力。低压力时,减少了增强层的缠绕层数。降低增强层缠绕时对角度公差和间隙要求。加强了压力管道在生产中的可控性。降低了产品原材料成本。加强了管材轴向载荷能力,一般可用于海洋管道、跨接管线和其他动态和非动态环境下的压力管道。
附图说明
图1是本发明的一种结构示意图。
图2是图1的轴向剖面示意图。
图3是图1的径向断面示意图。
图4是本发明管道制造流程示意图。
图5是图4在实施生产过程中的制造流程图。
图中:1、内管,2、辅助层,3、增强层,4、功能层,5、防磨层,6、轴向抗拉层,7、功能隔离层,8、外保护层。
具体实施方式
下面通过具体实施例,并结合附图,对本发明的技术方案作进一步的具体描述:
实施例:如图1,图2,图3和图4所示,一种连续纤维增强复合材料管的生产工艺,该连续纤维增强复合材料管包括内管1、沿着平行于内管轴向的外表面上的缠绕的辅助层2、缠绕在辅助层轴向外表面上的增强层3、缠绕在轴向外表面的功能层4、包覆于所述功能层外表面的防磨层5、缠绕于防磨层外表面的轴向抗拉层6、缠绕于轴向抗拉层外表面的功能隔离层7和包覆于功能层外表面的外保护层8;该连续纤维增强复合材料管的生产工艺步骤为:
S1:内管成型:对内管材质进行选型,选型后通过挤出成型设备热塑性挤压成型出内管;
S2:辅助层缠绕覆盖:通过丝缠绕设备将工业长丝均匀地以螺旋缠绕方式缠绕于内管的外表面形成辅助层,缠绕层数可以是一层或多层结构;
S3:增强层缠绕:通过带材缠绕设备将增强带均匀地螺旋缠绕于辅助层的外表面形成增强层,增强层的缠绕层为成双数的多层结构;
S4:功能层缠绕:通过带材缠绕设备将非金属带均匀地螺旋缠绕在增强层外表面形成功能层,螺旋缠绕的聚合物带材间相互压接;
S5:防磨层成型:选取防磨层材质,通过挤出成型设备挤出覆盖于功能层外表面,通过冷却定型和牵引完成加工成型,形成防磨层;
S6:轴向抗拉层缠绕:通过带材缠绕设备将金属带螺旋缠绕于防磨层外表面形成轴向抗拉层,轴向抗拉层的缠绕层为成双数的多层结构;
S7:功能隔离层缠绕:通过带材缠绕设备将非金属带均匀地螺旋缠绕在轴向抗拉层外表面形成功能隔离层,螺旋缠绕的聚合物带材间相互压接;
S8:外保护层成型:选取外保护层材质,通过挤出成型设备热塑性挤出覆盖于功能隔离层外表面,通过冷却定型和牵引完成加工成型,形成外保护层,完成整个连续纤维增强复合材料管的生产工艺。
内管作为的密封层结构,作为来自管体内部对流体进行密封和管材所承受压力的专递作用,同时还具备一定的环刚度。可以根据工况(如管材输送介质、使用温度等)或客户要求对内管材质进行选型。在本申请的实施方式中,所述的内管可以是一种或多种混合的可塑性聚合物及其聚合物的添加剂。
辅助层根据客户要求、工况环境、输送介质、产品载荷等需求,材料可以是涤纶工业长丝、芳纶长丝、玻璃纤维长丝、玄武岩纤维长丝或其他材料的工业长丝。
辅助层的主要功能为增加内管抗蠕变能力,防止内管在压力作用下通过间隙进行穿刺或渗透,提高内管抗压变能力和增加内管的可挠度。
辅助层缠绕密度和缠绕螺距可以根据工艺设计而定,缠绕层数由内管的抗蠕变能力而定,辅助层为双层结构,包括第一辅助层2-1和第二辅助层2-2,第一辅助层和第二辅助层的缠绕方向互为反向。
增强层根据客户要求、工况环境、输送介质、产品载荷等需求,可以有不同的选择。一般而言,所述增强层的材料可以为钢带、具有一定强度的包装带或打包带以及其他金属或非金属带材。
增强层其主要功能是增强管道抗内压能力,是作为压力管道抗压主体存在,同时由于采用螺旋缠绕方式,具备一定的柔性和形成管状结构后的环刚度抵抗外压。
增强层的缠绕层数为四层结构,包括第一增强层3-1、第二增强层3-2、第三增强层3-3和第四增强层3-4。相邻增强层间增强带的缠绕方向相反。
增强层具体的缠绕层数,通过增强层强度,根据管道载荷能力、水底稳性、环刚度等因素确定。
功能层的主要功能是方便外保护层在加工过程中便于真空抽取而起到一定的密封性能,防止外保护层在加工过程中受加工温度影响,遇冷收缩不均等,以及限制最后一层增强带位移等。
防磨层主要是通过特殊的挤出成型设备,通过挤压将包覆材料按照工艺要求厚度及厚度公差挤出覆盖于功能层外表面,通过冷却定型和牵引完成加工,其主要功能是约束增强层,保护增强层,防止增强层与抗拉层之间的摩擦。
轴向抗拉层材质一般为金属扁钢带,其断面为矩形结构。
轴向抗拉层是小角度螺旋缠绕于功能隔离层外表面。
轴向抗拉层为两层,包括第一轴向抗拉层6-1和第二轴向抗拉层6-2。相邻增强层间金属带的缠绕方向相反。
功能隔离层缠绕材料,存在形式与功能层相同。
外保护层是通过挤压成型的可塑性聚合物,通过挤压完全密封和覆盖于功能层外表面,使管材轴向完全密封,使管体免受运输、受施工、安装、工作状态时的损坏。
请参见图4所示,在本申请的一种实施方式中,步骤S1所述的内管是通过挤压成型而成;步骤S2是通过螺旋缠绕方式成型;步骤S3是通过螺旋缠绕方式成型;步骤S4是通过螺旋缠绕的方式成型;步骤S5是通过挤压成型的方式成型;步骤S6是通过螺旋缠绕的方式成型;步骤S7是通过螺旋缠绕的方式成型;步骤S8是通过挤压成型的方式成型。
其参见图5所示,在本申请实施方式中,实施步骤过程中的质量控制。
本申请中技术相较于现有技术,是制造压力管道的重大技术创新,特别是对于压力管道和高压力管道具有相当的技术优势。本申请中增强层S3缠绕,可以采用相应宽度的带材进行缠绕,不限于有限的宽度和每一层的根数,只是带材宽度与每一层缠绕的带材根数需要一定的匹配。互为反旋缠绕的带材不需要考虑每一层缠绕带之间缝隙的覆盖问题。缠绕带的间隙受管道压力和弯曲半径限制。本申请中所制造的压力管道,其制造用的设备成本低,操作简单,有效解决了内管抗蠕变能力,提高了内管对增强层缠绕间隙的渗透压。从而降低了增强层缠绕对压力的最低需求。同时满足浅海海洋管道需求,为深海海洋管道奠定潜在基础。
需要说明的是,以上步骤仅用于理解本申请的制造方法,并不意味着每一个步骤必须严格遵循,所属技术领域人员不经过创造性劳动所作的任何更改或改进,仍包括在本申请所揭示的范围内。
Claims (10)
1.一种连续纤维增强复合材料管的生产工艺,其特征是,该连续纤维增强复合材料管包括内管、沿着平行于内管轴向的外表面上的缠绕的辅助层、缠绕在辅助层轴向外表面上的增强层、缠绕在轴向外表面的功能层、包覆于所述功能层外表面的防磨层、缠绕于防磨层外表面的轴向抗拉层、缠绕于轴向抗拉层外表面的功能隔离层和包覆于功能层外表面的外保护层;该连续纤维增强复合材料管的生产工艺步骤为:
S1:内管成型:对内管材质进行选型,选型后通过挤出成型设备热塑性挤压成型出内管;
S2:辅助层缠绕覆盖:通过丝缠绕设备将工业长丝均匀地以螺旋缠绕方式缠绕于内管的外表面形成辅助层,缠绕层数可以是一层或多层结构;
S3:增强层缠绕:通过带材缠绕设备将增强带均匀地螺旋缠绕于辅助层的外表面形成增强层,增强层的缠绕层为成双数的多层结构;
S4:功能层缠绕:通过带材缠绕设备将非金属带均匀地螺旋缠绕在增强层外表面形成功能层,螺旋缠绕的聚合物带材间相互压接;
S5:防磨层成型:选取防磨层材质,通过挤出成型设备挤出覆盖于功能层外表面,通过冷却定型和牵引完成加工成型,形成防磨层;
S6:轴向抗拉层缠绕:通过带材缠绕设备将金属带螺旋缠绕于防磨层外表面形成轴向抗拉层,轴向抗拉层的缠绕层为成双数的多层结构;
S7:功能隔离层缠绕:通过带材缠绕设备将非金属带均匀地螺旋缠绕在轴向抗拉层外表面形成功能隔离层,螺旋缠绕的聚合物带材间相互压接;
S8:外保护层成型:选取外保护层材质,通过挤出成型设备热塑性挤出覆盖于功能隔离层外表面,通过冷却定型和牵引完成加工成型,形成外保护层,完成整个连续纤维增强复合材料管的生产工艺。
2.根据权利要求1所述的一种连续纤维增强复合材料管的生产工艺,其特征是,所述S2步骤中工业长丝采用柔性工业长丝。
3.根据权利要求1所述的一种连续纤维增强复合材料管的生产工艺,其特征是,所述辅助层缠绕层数为多层,相邻缠绕层缠绕方向不同。
4.根据权利要求1所述的一种连续纤维增强复合材料管的生产工艺,其特征是,所述步骤S3中,增强层的每一层增强带缠绕时,相邻缠绕的增强带间预留有一定的间隙。
5.根据权利要求1所述的一种连续纤维增强复合材料管的生产工艺,其特征是,所述非金属带为聚酯带。
6.根据权利要求1所述的一种连续纤维增强复合材料管的生产工艺,其特征是,所述S6步骤中的金属带为金属扁钢带,金属扁钢带的横切面为矩形结构。
7.根据权利要求1所述的一种连续纤维增强复合材料管的生产工艺,其特征是,所述S6步骤中的金属带螺旋缠绕为小角度缠绕,缠绕角度小于45度。
8.根据权利要求1所述的一种连续纤维增强复合材料管的生产工艺,其特征是,所述步骤S6中,轴向抗拉层的每一层金属带缠绕时,相邻缠绕的金属带间预留有一定的间隙。
9.根据权利要求1所述的一种连续纤维增强复合材料管的生产工艺,其特征是,所述内管、辅助层、增强层、功能层、防磨层、轴向抗拉层、功能隔离层、外保护层间非粘结可滑移。
10.根据权利要求1所述的一种连续纤维增强复合材料管的生产工艺,其特征是,所述S3和S6步骤中,成双数的多层结构,相邻层内增强带或金属带的缠绕角度相反。
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN202010247901.6A CN111300910A (zh) | 2020-04-01 | 2020-04-01 | 一种连续纤维增强复合材料管的生产工艺 |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN202010247901.6A CN111300910A (zh) | 2020-04-01 | 2020-04-01 | 一种连续纤维增强复合材料管的生产工艺 |
Publications (1)
Publication Number | Publication Date |
---|---|
CN111300910A true CN111300910A (zh) | 2020-06-19 |
Family
ID=71151667
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CN202010247901.6A Pending CN111300910A (zh) | 2020-04-01 | 2020-04-01 | 一种连续纤维增强复合材料管的生产工艺 |
Country Status (1)
Country | Link |
---|---|
CN (1) | CN111300910A (zh) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN114132012A (zh) * | 2021-12-08 | 2022-03-04 | 苏州正乙丙纳米环保科技有限公司 | 一种环保材料芯材模块化拼装管道及其制造方法 |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN107956934A (zh) * | 2017-12-11 | 2018-04-24 | 嘉兴萨博思海洋工程设备制造有限公司 | 一种钢带缠绕连续增强非粘结柔性复合管 |
CN207584207U (zh) * | 2017-12-11 | 2018-07-06 | 嘉兴萨博思海洋工程设备制造有限公司 | 一种钢带缠绕连续增强非粘结柔性复合管 |
CN108644492A (zh) * | 2018-05-03 | 2018-10-12 | 宁波欧佩亚海洋工程装备有限公司 | 一种耐超低温钢带增强热塑性复合管 |
CN108758118A (zh) * | 2018-08-13 | 2018-11-06 | 宁波欧佩亚海洋工程装备有限公司 | 一种深海柔性复合管 |
CN108930846A (zh) * | 2018-09-28 | 2018-12-04 | 杭州智海人工智能有限公司 | 一种金属带缠绕连续增强热塑性塑料复合管 |
-
2020
- 2020-04-01 CN CN202010247901.6A patent/CN111300910A/zh active Pending
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN107956934A (zh) * | 2017-12-11 | 2018-04-24 | 嘉兴萨博思海洋工程设备制造有限公司 | 一种钢带缠绕连续增强非粘结柔性复合管 |
CN207584207U (zh) * | 2017-12-11 | 2018-07-06 | 嘉兴萨博思海洋工程设备制造有限公司 | 一种钢带缠绕连续增强非粘结柔性复合管 |
CN108644492A (zh) * | 2018-05-03 | 2018-10-12 | 宁波欧佩亚海洋工程装备有限公司 | 一种耐超低温钢带增强热塑性复合管 |
CN108758118A (zh) * | 2018-08-13 | 2018-11-06 | 宁波欧佩亚海洋工程装备有限公司 | 一种深海柔性复合管 |
CN108930846A (zh) * | 2018-09-28 | 2018-12-04 | 杭州智海人工智能有限公司 | 一种金属带缠绕连续增强热塑性塑料复合管 |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN114132012A (zh) * | 2021-12-08 | 2022-03-04 | 苏州正乙丙纳米环保科技有限公司 | 一种环保材料芯材模块化拼装管道及其制造方法 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US5730188A (en) | Flexible conduit | |
US6053213A (en) | Flexible pipe for great depths | |
US6415825B1 (en) | Flexible conduit with high inertia hoop | |
US8967205B2 (en) | Anti-extrusion layer with non-interlocked gap controlled hoop strength layer | |
US6691743B2 (en) | Flexible pipe with wire or strip winding for maintaining armours | |
US6401760B2 (en) | Subsea flexible pipe of long length and modular structure | |
US8714204B2 (en) | Free venting pipe and method of manufacture | |
CN108930846B (zh) | 一种金属带缠绕连续增强热塑性塑料复合管 | |
CA2458225C (en) | Flat textile tape for forming one layer of a flexible pipe for hydrocarbon transport and pipe thus formed | |
US6966344B2 (en) | Device for limiting the lateral buckling of armouring plies of a flexible pipe | |
AU5167799A (en) | Resistant flexible pipe comprising sealing sheath with limited creep | |
US7124780B2 (en) | Flexible tubular fluid-transfer conduit | |
JP2001505281A (ja) | 巻き取り可能な複合管 | |
CN101529144A (zh) | 加固型软管 | |
US8656961B2 (en) | Composite flexible pipe and method of manufacture | |
CN111300910A (zh) | 一种连续纤维增强复合材料管的生产工艺 | |
US20060144456A1 (en) | Umbilical for offshore/reduction of hydrocarbons | |
CN111844678A (zh) | 一种复合材料非粘接柔性管、制备方法和应用 | |
CN105508807A (zh) | 一种非开挖穿插用热塑性增强复合管及加工方法 | |
CN215334935U (zh) | 一种耐高温非粘结挠性复合管线 | |
US20040035485A1 (en) | Method of binding polyphenylene sulfide with polyamide and products made thereof | |
CN221004135U (zh) | 一种可盘绕式铠装管线 | |
CN112901865A (zh) | 一种法兰连接的软管总成 | |
CN215258432U (zh) | 一种新型法兰连接的软管总成 | |
CN220727388U (zh) | 一种汽车耐压胶管 |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
PB01 | Publication | ||
PB01 | Publication | ||
SE01 | Entry into force of request for substantive examination | ||
SE01 | Entry into force of request for substantive examination | ||
RJ01 | Rejection of invention patent application after publication |
Application publication date: 20200619 |
|
RJ01 | Rejection of invention patent application after publication |