CN111578004A - 一种纤维增强隔热复合软管及其制造方法 - Google Patents
一种纤维增强隔热复合软管及其制造方法 Download PDFInfo
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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
- B32B5/18—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 features of a layer of foamed material
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- 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
- F16L59/00—Thermal insulation in general
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- F16L59/028—Composition or method of fixing a thermally insulating material
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Abstract
本发明属于复合软管技术领域,具体涉及一种纤维增强隔热复合软管及其制造方法。所述纤维增强隔热复合软管,包括增强层,所述增强层包括内衬层和通过热熔方式复合在所述内衬层外表面的带坯,所述带坯外表面依次设置有热熔胶膜层和隔热层;所述隔热层的材料为微胶囊发泡材料。采用一次成型共挤工艺制造而成。有益效果:本发明的纤维增强隔热复合软管在保持材质轻质、柔软的同时,具有较高的强度和良好的保温保冷效果,采用一体成型法,简便高效。
Description
技术领域
本发明属于复合软管技术领域,具体涉及一种纤维增强隔热复合软管及其制造方法。
背景技术
纤维增强复合软管是一种常用的流体和气体输送管道,具有柔性、耐压、输送线路灵活的特点,特别适用于消防水带、农用水带、油气输送等应用领域。相较于硬质管道,复合软管具有质轻、可折叠、可收卷、安装使用方便等特点,广泛应用于应急抢险、油气输送等用途。
作为一种流体传输的管道,不同的地域或领域,其应用环境各不相同,比如我国北方冬天气温会达到零下40℃,我国南方夏天温度又会达到零上40℃,有的介质比如热力蒸汽要求保热,有的输送介质比如液化天然气要求保冷,因此很多应用场合有隔绝或大幅降低输送介质与周围环境热交换的需求,而普通的复合软管难以达到很好的保温保冷效果。因此隔热的复合软管除了能满足常规流体传输的耐压、柔性等要求外,也能满足传输介质的保温保冷要求。
本发明的纤维增强隔热复合软管,采用微胶囊发泡高分子隔热层,通过多层复合技术,在保持材料轻质、柔软的同时,具有比较好的强度和良好的保温效果。
发明内容
为了解决现有技术中存在软管不能同时具有良好的强度和保温保冷性能的缺陷,本发明在于提供一种纤维增强隔热复合软管及其制造方法。本发明的纤维增强隔热复合软管在保持材质轻质、柔软的同时,具有较高的强度和良好的保温保冷效果,采用一体成型的制备工艺,简便高效。
本发明是通过如下技术方案实现的:
一种纤维增强隔热复合软管,包括增强层,所述增强层包括内衬层和通过热熔方式复合在所述内衬层外表面的带坯,所述带坯外表面依次设置有热熔胶膜层和隔热层;所述隔热层的材料为微胶囊发泡材料。
隔热层采用微胶囊发泡材料进行发泡,形成尺寸均匀的气泡,形成闭孔结构,过程易控,而且形成的隔热层的表面比较光滑,有利于保留隔热层材料的强度和提高与带坯的粘结性,提高软管的使用寿命。
优选地,所述内衬层所用材料为乙丙橡胶、丁腈橡胶、天然橡胶和热塑性弹性体中的一种或多种的共混物。
优选地,所述带坯所用材料为高强纤维,所述高强纤维为涤纶纤维、尼龙纤维和芳纶纤维中的一种或多种的混纺物,所述带坯通过圆织机将经线和纬线编制而成。采用高强纤维材料的带坯,能够提高软管的强度。
优选地,所述热熔胶膜层所用材料为聚氨酯、尼龙、聚酯、EVA和EEA中的一种或多种或它们的改性材料。
优选地,所述热熔胶膜层的厚度为60-80μm,所述隔热层的厚度为2-12mm,优选为4-7mm。
本发明还在于提供一种所述的纤维增强隔热复合软管的制造方法,采用一次成型法,具体包括如下步骤:
(1)制作增强层:将高强纤维进行混编,分别制成经线和纬线,然后通过圆织机将经线和纬线编织成所述带坯,然后将所述内衬层所用的材料经挤出机挤出内衬软管,所述内衬软管通过热熔方式复合在所述带坯的内壁,得到增强层;
(2)隔热层材料预混:将高分子基体材料100份、微胶囊发泡剂0.5-3份、分散剂0.1-1份和气泡稳定剂0.5-1份,经预混进行混合后,加入第二单螺杆挤出机中,备用;
(3)复合成型:将步骤(1)得到的增强层穿过环形口模(7),同时从第一单螺杆挤出机中挤出热熔胶覆与所述带坯外表面,形成热熔胶膜层,从第二单螺杆挤出机中挤出隔热材料覆与所述热熔胶膜层的外表面,形成隔热层,得到软管;
(4)定型、包装:经口模(7)出来的软管经过冷水定型、收卷包装,即得纤维增强隔热复合软管。
优选地,步骤(2)中所述高分子基体材料为TUP、PE和软质PVC中的一种或多种或它们的改性材料;
所述微胶囊发泡剂是以热塑性高分子材料为壳体,内含液状碳氢化合物的微珠,所述微胶囊发泡剂的粒径为5-50μm,膨胀温度为100-220℃;
所述分散剂为两亲性化合物,所述两亲性化合物为离子型表面活性剂、非离子型表面活性剂和两性表面活性剂中的一种或多种的复配物;
所述气泡稳定剂为烷基磺酸盐、乙氧基脂肪酸和聚硅氧烷-聚氧化烷共聚物中的一种或多种的混合物。
优选地,步骤(3)中穿过环形口模(7)的增强层内充入空气,以保持增强层内的压力为0.2-1.0bar。本发明制备的复合软管,由于软管是连续的软体材料,采用常规的芯模很难在软管上复合其他的膜层,而本发明采用在增强层内充入空气以维持复合软管成型,无需使用芯模。
优选地,所述第一单螺杆挤出机设置如下:加料段165℃,压缩段172℃,计量段182℃,模头180℃,螺杆转速35rpm;
所述第二单螺杆挤出机)设置如下:加料段165℃,压缩段172℃,计量段175-180℃,模头170-175℃,螺杆转速45rpm。
相对于现有技术,本发明具有以下有益效果:
(1)本发明的隔热层采用微胶囊发泡剂,在发泡的过程中,形成尺寸均匀的气泡,具有闭孔结构,过程比较容易控制,且形成的隔热层表面比较光滑,有利于保留材料的强度和提高与带坯的粘结性,使其牢固结合,不易分离脱落;为相对于现有技术中的管材采用填充保温材料(如玻璃微珠等)的手段,需要高的填充量才可以起到保温保冷效果,必然会导致管材的柔性大幅度降低,而本发明采用微胶囊发泡材料就避免了由于填充带来的柔性降低的问题。
(2)本发明的隔热层材料配方中采用两亲性化合物作为分散剂,有利于协助微胶囊发泡剂均匀分散在高分子基体材料中,使得形成的气泡均匀分散;同时,添加的气泡稳定剂能够防止气泡合并、坍塌;可见,微胶囊发泡剂、分散剂和气泡稳定剂的协同作用,使制备的隔热层材料具有优良的保温保冷效果。
(3)本发明采用一次成型的熔融共挤工艺,使得制备的隔热复合软管具有完整的结构,各层之间结合牢固,不容易分离脱落。相对于现有技术中采用缠绕保温带或增强层的两步法的技术手段,首先缠绕的过程不易操作,其次,缠绕成型的产品隔热层和增强层是分离的,在使用过程中容易松散脱落,影响使用和保温效果,而本发明的一次成型法避免了操作复杂、松散脱落、保温欠佳的问题,简便高效、保温保冷效果更优异。
附图说明
图1为本发明隔热复合软管的剖面结构示意图;
图2为本发明隔热复合软管的制造工艺示意图;
图中:1-内衬层;2-带坯;3-热熔胶膜层;4-隔热层;5-第一单螺杆挤出机;6-第二单螺杆挤出机;7-口模。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。以下对至少一个示例性实施例的描述实际上仅仅是说明性的,决不作为对本发明及其应用或使用的任何限制。基于本发明中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
除非另外具体说明,否则在这些实施例中阐述的数值不限制本发明的范围。对于相关领域普通技术人员已知的技术、方法可能不作详细讨论,但在适当情况下,所述技术、方法应当被视为说明书的一部分。在这里示出和讨论的所有示例中,任何具体值应被解释为仅仅是示例性的,而不是作为限制。因此,示例性实施例的其它示例可以具有不同的值。
此外,需要说明的是,使用“第一”、“第二”等词语来限定单螺杆挤出机,仅仅是为了便于对不同覆膜的挤出机的区别,如没有另行声明,上述词语并没有特殊含义,因此不能理解为对本发明保护范围的限制。
实施例1
如图1所示,一种纤维增强隔热复合软管,包括增强层,其特征在于,所述增强层包括内衬层1和通过热熔方式复合在所述内衬层1外表面的带坯2,所述带坯2外表面依次设置有热熔胶膜层3和隔热层4;所述隔热层4的材料为微胶囊发泡材料;
所述内衬层1所用材料为热塑性弹性体;
所述带坯2所用材料为1000D高强涤纶纤维,所述带坯2通过圆织机将经线和纬线编制而成内径50mm的圆形带坯;
所述热熔胶膜层3所用材料为聚氨酯,膜层厚度为80μm,所述隔热层4的厚度为8mm。
如图2所示,一种纤维增强隔热复合软管的制造方法,采用一次成型法,具体包括如下步骤:
(1)制作增强层:将1000D高强涤纶纤维进行混编,分别制成经线和纬线,然后通过圆织机将经线和纬线编织成内径50mm的带坯2,然后将所述内衬层1所用的材料聚氨酯经挤出机挤出内衬软管,所述内衬软管通过热熔方式复合在所述带坯2的内壁,得到增强层;
(2)隔热层材料预混:将硬度为HA86的TPU(高分子基体材料)100份、粒径为20-30μm的微胶囊发泡剂(松本F-100)2份、分散剂(壬基酚聚氧乙烯醚)0.2份和气泡稳定剂0.5份,经预混进行混合后,加入第二单螺杆挤出机6中,备用;
(3)复合成型:将步骤(1)得到的增强层穿过环形口模7,增强层内充入空气,以保持增强层内的压力为0.5bar,同时从第一单螺杆挤出机5中挤出热熔胶覆与所述带坯2外表面,形成热熔胶膜层3,从第二单螺杆挤出机6中挤出隔热材料覆与所述热熔胶膜层3的外表面,形成隔热层4,得到软管;
(4)定型、包装:经口模7出来的软管经过冷水定型、收卷包装,即得纤维增强隔热复合软管。
所述第一单螺杆挤出机5设置如下:加料段165℃,压缩段172℃,计量段182℃,模头180℃,螺杆转速35rpm;
所述第二单螺杆挤出机6设置如下:加料段165℃,压缩段172℃,计量段175℃,模头170℃,螺杆转速45rpm。
实施例2
如图1所示,一种纤维增强隔热复合软管,包括增强层,其特征在于,所述增强层包括内衬层1和通过热熔方式复合在所述内衬层1外表面的带坯2,所述带坯2外表面依次设置有热熔胶膜层3和隔热层4;所述隔热层4的材料为微胶囊发泡材料;
所述内衬层1所用材料为丁腈橡胶;
所述带坯2所用材料为1000D高强涤纶纤维,所述带坯2通过圆织机将经线和纬线编制而成内径50mm的圆形带坯;
所述热熔胶膜层3所用材料为聚氨酯,膜层厚度为60μm,所述隔热层4的厚度为4mm。
如图2所示,一种纤维增强隔热复合软管的制造方法,采用一次成型法,具体包括如下步骤:
(1)制作增强层:将1000D高强涤纶纤维进行混编,分别制成经线和纬线,然后通过圆织机将经线和纬线编织成内径50mm的带坯2,然后将所述内衬层1所用的材料聚氨酯经挤出机挤出内衬软管,所述内衬软管通过热熔方式复合在所述带坯2的内壁,得到增强层;
(2)隔热层材料预混:将硬度为HA86的TPU(高分子基体材料)100份、粒径为100μm的微胶囊发泡剂(松本F-100)2份、分散剂(壬基酚聚氧乙烯醚)0.2份和气泡稳定剂0.5份,经预混进行混合后,加入第二单螺杆挤出机6中,备用;
(3)复合成型:将步骤(1)得到的增强层穿过环形口模7,增强层内充入空气,以保持增强层内的压力为1.0bar,同时从第一单螺杆挤出机5中挤出热熔胶覆与所述带坯2外表面,形成热熔胶膜层3,从第二单螺杆挤出机6中挤出隔热材料覆与所述热熔胶膜层3的外表面,形成隔热层4,得到软管;
(4)定型、包装:经口模7出来的软管经过冷水定型、收卷包装,即得纤维增强隔热复合软管。
所述第一单螺杆挤出机5设置如下:加料段165℃,压缩段172℃,计量段182℃,模头180℃,螺杆转速35rpm;
所述第二单螺杆挤出机6设置如下:加料段165℃,压缩段172℃,计量段180℃,模头175℃,螺杆转速45rpm。
实施例1~2制备的纤维增强隔热复合软管具有高强度的同时,还具有良好的保温保冷效果。
以上所述的具体实施例,对本发明的目的、技术方案和有益效果进行了进一步详细说明,所应理解的是,以上所述仅为本发明的具体实施例而已,并不用于限制本发明,凡在本发明的精神和原则之内,所做的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (10)
1.一种纤维增强隔热复合软管,包括增强层,其特征在于,所述增强层包括内衬层(1)和通过热熔方式复合在所述内衬层(1)外表面的带坯(2),所述带坯(2)外表面依次设置有热熔胶膜层(3)和隔热层(4);所述隔热层(4)的材料为微胶囊发泡材料。
2.根据权利要求1所述的一种纤维增强隔热复合软管,其特征在于,所述内衬层(1)所用材料为乙丙橡胶、丁腈橡胶、天然橡胶和热塑性弹性体中的一种或多种的共混物。
3.根据权利要求1所述的一种纤维增强隔热复合软管,其特征在于,所述带坯(2)所用材料为高强纤维,所述高强纤维为涤纶纤维、尼龙纤维和芳纶纤维中的一种或多种的混纺物,所述带坯(2)通过圆织机将经线和纬线编制而成。
4.根据权利要求1所述的一种纤维增强隔热复合软管,其特征在于,所述热熔胶膜层(3)所用材料为聚氨酯、尼龙、聚酯、EVA和EEA中的一种或多种或它们的改性材料。
5.根据权利要求1所述的一种纤维增强隔热复合软管,其特征在于,所述热熔胶膜层(3)的厚度为60-80μm,所述隔热层(4)的厚度为2-12mm。
6.根据权利要求5所述的一种纤维增强隔热复合软管,其特征在于,所述隔热层(4)的厚度为4-7mm。
7.一种权利要求1~6任一项所述的纤维增强隔热复合软管的制造方法,其特征在于,采用一次成型法,具体包括如下步骤:
(1)制作增强层:将高强纤维进行混编,分别制成经线和纬线,然后通过圆织机将经线和纬线编织成所述带坯(2),然后将所述内衬层(1)所用的材料经挤出机挤出内衬软管,所述内衬软管通过热熔方式复合在所述带坯(2)的内壁,得到增强层;
(2)隔热层材料预混:将高分子基体材料100份、微胶囊发泡剂0.5-3份、分散剂0.1-1份和气泡稳定剂0.5-1份,经预混进行混合后,加入第二单螺杆挤出机(6)中,备用;
(3)复合成型:将步骤(1)得到的增强层穿过环形口模(7),同时从第一单螺杆挤出机(5)中挤出热熔胶覆与所述带坯(2)外表面,形成热熔胶膜层(3),从第二单螺杆挤出机(6)中挤出隔热材料覆与所述热熔胶膜层(3)的外表面,形成隔热层(4),得到软管;
(4)定型、包装:经口模(7)出来的软管经过冷水冷却定型、收卷包装,即得纤维增强隔热复合软管。
8.根据权利要求7所述的一种纤维增强隔热复合软管的制造方法,其特征在于,步骤(2)中所述高分子基体材料为TUP、PE和软质PVC中的一种或多种或它们的改性材料;
所述微胶囊发泡剂是以热塑性高分子材料为壳体,内含液状碳氢化合物的微珠,所述微胶囊发泡剂的粒径为5-50μm,膨胀温度为100-220℃;
所述分散剂为两亲性化合物,所述两亲性化合物为离子型表面活性剂、非离子型表面活性剂和两性表面活性剂中的一种或多种的复配物;
所述气泡稳定剂为烷基磺酸盐、乙氧基脂肪酸和聚硅氧烷-聚氧化烷共聚物中的一种或多种的混合物。
9.根据权利要求7所述的一种纤维增强隔热复合软管的制造方法,其特征在于,步骤(3)中穿过环形口模(7)的增强层内充入空气,以保持增强层内的压力为0.2-1.0bar。
10.根据权利要求7所述的一种纤维增强隔热复合软管的制造方法,其特征在于,所述第一单螺杆挤出机(5)设置如下:加料段165℃,压缩段172℃,计量段182℃,模头180℃,螺杆转速35rpm;
所述第二单螺杆挤出机(6)设置如下:加料段165℃,压缩段172℃,计量段175-180℃,模头170-175℃,螺杆转速45rpm。
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Application publication date: 20200825 |