CN111674110A - 一种三层防爆管及其制备工艺 - Google Patents
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Abstract
本发明涉及管材产品领域,具体涉及一种三层防爆管的制备工艺,包括以下步骤:1)、分别取相应质量份配比组分的各原料放入混合机中混合;2)、将混合物分别置入挤出机挤出造粒,烘干后得到外管材料粒料、中层管材料粒料、内管材料粒料;3)、将内管材料混合物粒料置入成型装置内挤出成型制得PPR内管,冷却后在外表面施胶;4)、而后将中层管材料粒料经成型装置在所得PPR内管的基础上挤出得到陶塑中层管并将其与所得PPR内管粘接;5)、而后将外管材料粒料经成型装置在所得陶塑中层管的基础上挤出得到PPR外管,并与所得陶塑中层管粘接;6)、放置冷却后制得所述三层防爆管。本发明提供了一种生产物理性能佳的三层防爆管并公开了其制备工艺。
Description
技术领域
本发明涉及管材产品领域,具体涉及一种三层防爆管及其制备工艺。
背景技术
PPR,又叫无规共聚聚丙烯,其制品韧性好、强度高、加工性能优异,且具有无规共聚聚丙烯特有的高透明性优点,可广泛用于管材、片材、日用品、包装材料、家用电器部件以及各种薄膜的生产。用PPR制作的管材具有卫生无毒、节能环保、耐热、不结垢、不渗漏等优点;然而,PPR管材在0℃以下容易变脆,不仅给运输和施工带来了很大不便,而且容易出现一些不可察觉的损伤,最终可能会导致PPR管安装通水后爆裂,在一定程度上限制了PPR管材的应用;目前市场上的PPR材料抗冲击强度较低,传统的增韧改性方法虽可在一定程度上提高PPR材料的韧性,增强其抗冲击强度,但通常又会导致PPR材料的其他一些指标不符合新版国标要求,难以得到平衡。
发明内容
因此,本发明提供一种三层防爆管及其制备工艺,解决了现有的PPR管物理性能不佳导致使用寿命不长的问题。
为达到上述目的,本发明是通过以下技术方案实现的:
一种三层防爆管,包括由外向内依次设置的PPR外管、陶塑中层管以及PPR 内管,所述PPR外管含有以下质量份配比组分:无规共聚聚丙烯60-80份、环氧树脂25-35份、滑石粉5-10份、甲基异丁酮10-15份、茶梗粉15-20份、海藻纤维素10-15份、十溴二苯乙烷5-7份、氢氧化铝5-10份、交联剂3-6份和稳定剂2-6份;
所述PPR内管含有以下质量份配比组分:无规共聚聚丙烯60-90份、聚氨酯12-18份、稳定剂2-8份、抗菌剂6-13份、改性剂15-22份;
所述陶塑中层管含有以下质量份配比组分:尼龙树脂60-80份、陶瓷粉8-15 份、硅系耐磨改性剂4份、活性炭4份、己二酸12份、丁腈橡胶15-25份、氨丙基三乙氧基硅烷5-10份、丙烯腈-丁二烯-苯乙烯共聚物15份、活性氧化铝6 份、稳定剂3份、纳米竹纤维3份、硫酸钙晶须1份、钼酸铵5份、填料4份、增韧剂2份。
优选的,所述PPR外管的圆周外表面设置有两条以上沿所述PPR外管外表面等距离分布且的螺旋金属凸条。
优选的,所述PPR外管的外表面热压一外包覆层,所述螺旋金属凸条嵌设在所述外包覆层内,所述外包覆层为交联聚乙烯层。
优选的,所述PPR外管上开设有用于嵌置所述螺旋金属凸条的凹槽,所述凹槽的深度不大于所述PPR外管上的厚度的1/3,所述螺旋金属凸条嵌设在所述凹槽与所述外包覆层内。
优选的,所述螺旋金属凸条为圆柱条状结构,所述凹槽具有用于装入所述螺旋金属凸条的开口,所述外包覆层填充在所述开口内并将所述金属凸条整体包覆。
一种三层防爆管的制备工艺,包括以下步骤:
1)、分别取相应质量份配比组分的各原料放入混合机中混合,制得外管材料混合物、中层管材料混合物以及内管材料混合物;
2)、将所述外管材料混合物、中层管材料混合物以及内管材料混合物分别置入挤出机挤出造粒,烘干后得到外管材料粒料、中层管材料粒料、内管材料粒料;
3)、将所述内管材料混合物粒料置入成型装置内挤出成型制得PPR内管,冷却后在外表面施胶;
4)、而后将中层管材料粒料经成型装置在所得PPR内管的基础上挤出得到陶塑中层管并将其与所得PPR内管粘接;
5)、而后将外管材料粒料经成型装置在所得陶塑中层管的基础上挤出得到 PPR外管,并与所得陶塑中层管粘接;
6)、放置冷却后制得所述三层防爆管。
优选的,所述成型装置包括呈流水线依次设置的内管成型机构、第一冷却机构、第一施胶机构、中层管成型机构、第二冷却机构、第二施胶机构以及外管成型机构,所述内管成型机构、中层管成型机构以及外管成型机构均包括挤出机以及设于挤出机输出端的成型模具。
优选的,上述步骤3)的成型装置挤出的工作温度为160-220℃。
优选的,上述步骤5)的成型装置挤出的工作温度为220~250℃。
通过采用前述技术方案,本发明的有益效果是:。
附图说明
图1为本发明实施例的的工艺流程示意图;
图2为本发明实施例防爆管产品的立体结构示意图;
图3为本发明实施例的局部剖视结构示意图。
具体实施方式
以下将结合具体实施例来详细说明本发明的实施方式,借此对本发明如何应用技术手段来解决技术问题,并达成技术效果的实现过程能充分理解并据以实施。
实施例
参考图1,一种三层防爆管,包括由外向内依次设置的PPR外管1、陶塑中层管2以及PPR内管3,其制备工艺,包括以下步骤:
1)、分别取相应质量份配比组分的各原料放入混合机中混合,制得外管材料混合物、中层管材料混合物以及内管材料混合物;
2)、将所述外管材料混合物、中层管材料混合物以及内管材料混合物分别置入挤出机挤出造粒,烘干后得到外管材料粒料、中层管材料粒料、内管材料粒料;
3)、将所述内管材料混合物粒料置入成型装置内挤出成型制得PPR内管3,冷却后在外表面施胶,成型装置挤出的工作温度为160℃,此处可根据需求调整温度,在160-220℃内即可;
4)、而后将中层管材料粒料经成型装置在所得PPR内管3的基础上挤出得到陶塑中层管2并将其与所得PPR内管3粘接;
5)、而后将外管材料粒料经成型装置在所得陶塑中层管2的基础上挤出得到PPR外管1,并与所得陶塑中层管2外表面粘接,成型装置挤出的工作温度为 220℃,此处可根据需求调整温度,在220~250℃即可;
6)、放置冷却后制得所述三层防爆管。
具体的,所述成型装置包括呈流水线依次设置的内管成型机构、第一冷却机构、第一施胶机构、中层管成型机构、第二冷却机构、第二施胶机构以及外管成型机构,所述内管成型机构、中层管成型机构以及外管成型机构均包括挤出机以及设于挤出机输出端的成型模具,此处针对三层结构设置不同的成型机构,一是由于PPR外管、陶塑中层管以及PPR内管所实用的原材料并不相同,故在生产中具有不同的熔融温度、时间,能够更利于生产要素的调整;二是这种流水线设置的成型装置能够更符合现代化的生产需求,降低生产成本,提高生产效率;所述第一冷却机构、第二冷却机构、第一施胶机构、第二施胶机构为市场上所购得,可根据需求选择,在此不多做赘述。
由上述工艺制得的一种三层防爆管,包括由外向内依次设置的PPR外管1、陶塑中层管2以及PPR内管3,所述PPR外管1含有以下质量份配比组分:无规共聚聚丙烯60-80份、环氧树脂25-35份、滑石粉5-10份、甲基异丁酮10-15 份、茶梗粉15-20份、海藻纤维素10-15份、十溴二苯乙烷5-7份、氢氧化铝 5-10份、交联剂3-6份和稳定剂2-6份;外管原料选择根据本申请人的在先申请CN 110204814 A所示,具有如下优点:1、茶梗富含木纤维,茶梗嫩枝木纤维木栓化程度比较低,较为柔软,柔软的木性纤维可以形成多孔、富有剩余力场的强吸附性材料,与海藻纤维素共同作用,可以有效增加管材原料之间吸附性和牵延性,增加原料的附着力度,有效增强了PPR外管的抗压性,不易脆裂; 2、树脂原料中加入滑石粉、甲基异丁酮、茶梗粉、海藻纤维素、十溴二苯乙烷、氢氧化铝等,显著降低了复合管材遇低温、高温时易脆裂的问题,使管材内部气孔结构分布均匀,使其经久耐用,避免产品机械强度低;茶叶加工过程中有大量的茶梗剩余,利用率低;本发明将其添加进复合管材中,变废为宝,提高了其利用价值;
所述PPR内管3含有以下质量份配比组分:无规共聚聚丙烯60-90份、聚氨酯12-18份、稳定剂2-8份、抗菌剂6-13份、改性剂15-22份;内管原料选择根据本申请人的在先申请CN 110204833 A所示,具有如下优点:采用食品级引水管用的无规共聚聚丙烯为主要原料,其分子只有碳、氢元素,没有有害有毒的元素存在,再加上银离子溶液、乙基香草醛以及4-己酰基苯的共同抗菌作用,能有效杀灭水中的有害微生物,使得本发明管材非常适合于家庭生活供水使用;(2)、本发明采用高密度聚乙烯、纳米氧化硅以及硅酸盐作为改性剂,高密度聚乙烯能明显改善PPR管材的冲击强度,并且在低温下脆性强度也有所提高,纳米氧化硅在所限定含量范围内的加入对管材低温下的冲击强度具有提高作用,超过这一范围,这种提高作用会随着纳米氧化硅含量的增加而减小,当含量增加到一定程度时容易出现团聚现象,严重阻碍了应力的传递和微裂纹的扩展,导致管材的低温冲击强度下降;硅酸盐的加入不仅改善和提高了管材的韧性和冲击强度,还能大幅度降低管材的线型膨胀系数,满足工程使用需要; 3、产出的内管无染色剂的添加,为透明色,具有出色的环保卫生性;
所述陶塑中层管2含有以下质量份配比组分:尼龙树脂60-80份、陶瓷粉 8-15份、硅系耐磨改性剂4份、活性炭4份、己二酸12份、丁腈橡胶15-25份、氨丙基三乙氧基硅烷5-10份、丙烯腈-丁二烯-苯乙烯共聚物15份、活性氧化铝6份、稳定剂3份、纳米竹纤维3份、硫酸钙晶须1份、钼酸铵5份、填料4 份、增韧剂2份。陶塑中层管2则具有牢固的整体性,具有耐高压,耐高热的性能;
本实施例未对稳定剂、改性剂进行具体陈述,此为市场上所购得,本领域技术人员熟知且具有较多选择,能满足生产需求即可,在此不做多赘述。
在结构上,参考图2及图3,本实施例在所述PPR外管1的圆周外表面设置有两条沿所述PPR外管1外表面等距离分布且的螺旋金属凸条4,所述PPR外管 1的外表面热压一外包覆层5,所述螺旋金属凸条4嵌设在所述外包覆层5内,具体的,所述外包覆层5为交联聚乙烯层;采用设置两条的螺旋金属凸条4结构,螺旋金属凸条4能够在结构上针对PPR外管1进行有效的结构支撑,配合交联聚乙烯层结构的外覆层5也能对PPR外管1的表面进行有效保护,同时配合交联聚乙烯的特性,提高防爆管的稳定性,使其具有抗冲击、抗开裂、耐老化、耐腐蚀等一系列优点;
具体的,所述PPR外管1上开设有用于嵌置所述螺旋金属凸条4的凹槽11,所述螺旋金属凸条4嵌设在所述凹槽11与所述外包覆层5内。本实施例中,本实施例中,具体如图3所示,所述螺旋金属凸条4为圆柱条状结构,所述凹槽 11具有用于装入所述螺旋金属凸条4的开口111,所述外包覆层5填充在所述开口11内并将所述金属凸条4整体包覆。这种结构,外包覆层5在热压包覆时,能够将螺旋金属凸条4充分包裹,并且所述外包覆层5也在所述凹槽内与所述 PPR外管具有一定部分的粘接,使所述外包覆层5形成与所述开口111相适配的嵌入段51,能够保证所述外包覆层5与PPR外管1之间的连接结构稳定。
本实施例中,所述凹槽11的深度进行设计,深度为所述PPR外管1上的厚度的1/3,在保证PPR外管1结构强度的前提下,也保证了螺旋金属凸条4与 PPR外管1连接的紧致性。
上述热压包覆为本领域所常用的管道生产工艺,在此不多做赘述。
尽管结合优选实施方案具体展示和介绍了本发明,但所属领域的技术人员应该明白,在不脱离所附权利要求书所限定的本发明的精神和范围内,在形式上和细节上可以对本发明做出各种变化,均为本发明的保护范围。
Claims (9)
1.一种三层防爆管,其特征在于:包括由外向内依次设置的PPR外管、陶塑中层管以及PPR内管,所述PPR外管含有以下质量份配比组分:无规共聚聚丙烯60-80份、环氧树脂25-35份、滑石粉5-10份、甲基异丁酮10-15份、茶梗粉15-20份、海藻纤维素10-15份、十溴二苯乙烷5-7份、氢氧化铝5-10份、交联剂3-6份和稳定剂2-6份;
所述PPR内管含有以下质量份配比组分:无规共聚聚丙烯60-90份、聚氨酯12-18份、稳定剂2-8份、抗菌剂6-13份、改性剂15-22份;
所述陶塑中层管含有以下质量份配比组分:尼龙树脂60-80份、陶瓷粉8-15份、硅系耐磨改性剂4份、活性炭4份、己二酸12份、丁腈橡胶15-25份、氨丙基三乙氧基硅烷5-10份、丙烯腈-丁二烯-苯乙烯共聚物15份、活性氧化铝6份、稳定剂3份、纳米竹纤维3份、硫酸钙晶须1份、钼酸铵5份、填料4份、增韧剂2份。
2.根据权利要求1所述的三层防爆管,其特征在于:所述PPR外管的圆周外表面设置有两条以上沿所述PPR外管外表面等距离分布且的螺旋金属凸条。
3.根据权利要求2所述的三层防爆管,其特征在于:所述PPR外管的外表面热压一外包覆层,所述螺旋金属凸条嵌设在所述外包覆层内,所述外包覆层为交联聚乙烯层。
4.根据权利要求3所述的三层防爆管,其特征在于:所述PPR外管上开设有用于嵌置所述螺旋金属凸条的凹槽,所述凹槽的深度不大于所述PPR外管上的厚度的1/3,所述螺旋金属凸条嵌设在所述凹槽与所述外包覆层内。
5.根据权利要求4所述的三层防爆管,其特征在于:所述螺旋金属凸条为圆柱条状结构,所述凹槽具有用于装入所述螺旋金属凸条的开口,所述外包覆层填充在所述开口内并将所述金属凸条整体包覆。
6.一种根据权利要求1所述的三层防爆管的制备工艺,其特征在于,包括以下步骤:
1)、分别取相应质量份配比组分的各原料放入混合机中混合,制得外管材料混合物、中层管材料混合物以及内管材料混合物;
2)、将所述外管材料混合物、中层管材料混合物以及内管材料混合物分别置入挤出机挤出造粒,烘干后得到外管材料粒料、中层管材料粒料、内管材料粒料;
3)、将所述内管材料混合物粒料置入成型装置内挤出成型制得PPR内管,冷却后在外表面施胶;
4)、而后将中层管材料粒料经成型装置在所得PPR内管的基础上挤出得到陶塑中层管并将其与所得PPR内管粘接;
5)、而后将外管材料粒料经成型装置在所得陶塑中层管的基础上挤出并与所得陶塑中层管粘接;
6)、放置冷却后制得所述三层防爆管。
7.根据根据权利要求6所述的三层防爆管的制备工艺,其特征在于:所述成型装置包括呈流水线依次设置的内管成型机构、第一冷却机构、第一施胶机构、中层管成型机构、第二冷却机构、第二施胶机构以及外管成型机构,所述内管成型机构、中层管成型机构以及外管成型机构均包括挤出机以及设于挤出机输出端的成型模具。
8.根据根据权利要求6所述的三层防爆管的制备工艺,其特征在于:上述步骤3)的成型装置挤出的工作温度为160-220℃。
9.根据根据权利要求6所述的三层防爆管的制备工艺,其特征在于:上述步骤5)的成型装置挤出的工作温度为220~250℃。
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