CN112709869A - 一种耐磨钢丝网骨架复合管及制备工艺 - Google Patents
一种耐磨钢丝网骨架复合管及制备工艺 Download PDFInfo
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Abstract
本发明公开了一种耐磨钢丝网骨架复合管，包括外层管和芯层管，所述芯层管的内壁复合内耐磨层，所述芯层管的外壁依次复合增强层、结合层和外层管，并公开了该复合管的制备工艺，包括先共挤出内耐磨层和芯层管，定型后缠绕增强层，再涂覆结合层，最后复合上外层管；本发明通过原钢丝网骨架聚乙烯复合管内增加了专有的内耐磨层，各层逐次复合，基于本发明的结构和成型的工艺特点，使得本发明的复合管既能承受管内较大的压力又不怕管内介质的磨损和腐蚀，管材质量和使用可靠性大大提高，并且工艺流程简单，成本造价低，稳定性能高。
Description
技术领域
本发明涉及复合管道技术领域，特别涉及一种耐磨钢丝网骨架复合管及制备工艺。
背景技术
在高速发展的经济建设中，众多行业都有大量的粉状固体、液体及浆体状固液混合物需要通过管道输送，致使管道存在大量的磨损、腐蚀、结垢等问题。这是一个急待解决的问题。面对广大市场的需求，近年来已有一些耐磨管道应用到电力、冶金、煤炭、石油、化工、建材、等行业，并有高速发展的势态。
由于钢管的耐腐蚀性能和耐磨性能都较差，耐磨管道行业一直以来都在寻求新的化学管道以解决对耐磨性能的要求。近年来国内研发了多种材质的耐磨管道，如：合金钢管、合金双金属复合管、内衬陶瓷复合管、铸石复合管等，而发展最为迅速的是超高分子量聚乙烯(UHMWPE)管道，国外主要采用钢管内衬橡胶或聚氨酯弹性体(TPU)的办法来生产耐磨管，而交联橡胶或交联TPU与钢管表面的粘接强度必须依靠非常严格的材料选择和工艺要求来保证，导致其工艺流程较复杂，工艺要求较高，成本也较高，并且这种钢衬橡胶/TPU的耐磨管道在国内的应用过程中，常因质量不稳定而发生胶层与钢管脱层进而造成管道堵塞的问题，这一问题严重阻碍了衬胶钢管在国内的推广应用。
发明内容
本发明的主要目的在于提供一种耐磨钢丝网骨架复合管及制备工艺，可以有效解决背景技术中的问题。
为实现上述目的，本发明采取的技术方案为：一种耐磨钢丝网骨架复合管，包括外层管和芯层管，所述芯层管的内壁复合内耐磨层，所述芯层管的外壁依次复合增强层、结合层和外层管。
优选的，所述内耐磨层的材料为聚硅氧烷与超高分子量聚乙烯复合改性所制得的专用料。
优选的，所述外层管和芯层管均为PE管。
优选的，所述增强层为涂塑的钢丝网。
优选的，所述结合层为热熔胶层。
优选的，所述内耐磨层厚度为2-3mm。
一种耐磨钢丝网骨架复合管制备工艺，具体工艺步骤包括：
步骤一，把聚硅氧烷与超高分子量聚乙烯复合改性制得耐磨原料，备用；
步骤二，把HDPE原料和耐磨原料分别通过芯层管挤出机和内耐磨层挤出机挤出并通过共挤专用模具复合，经过芯层管真空定径以及冷却机组进行冷却定型，采用牵引机牵出；
步骤三，把涂塑高强度镀层钢丝经过钢丝缠绕机组缠绕在冷却定型后的芯层管外侧壁；
步骤四，对步骤三中缠绕钢丝后的芯层管外侧壁进行加热，把结合层原料经过结合层挤出机挤出，并通过结合层复合模具与芯层管外侧壁进行复合；
步骤五，外层PE原料经过外层挤出机挤出，经过外层复合模具与步骤四中复合结合层后的芯层进行复合，冷却成型；
步骤六，将步骤五中冷却成型后的复合管依次进行计米印字机计长、牵引切割、质检包装、入库。
与传统技术相比，本发明产生的有益效果是：本发明通过原钢丝网骨架聚乙烯复合管内增加了专有的内耐磨层，各层是逐次复合，即先共挤出耐磨材料层和芯层管，定型后缠绕上经涂塑的钢丝，再涂覆热熔胶，最后复合外层管，基于本发明的结构和成型的工艺特点，使得本发明的复合管既能承受管内较大的压力又不怕管内介质的磨损和腐蚀，管材质量和使用可靠性大大提高，并且工艺流程简单，成本造价低，稳定性能高。
附图说明
图1为本发明的整体结构示意图；
图2为本发明的摆动磨耗试验试验结果；
图3为本发明的浆体环管磨蚀试验结果。
图中：1、外层管；2、芯层管；3、内耐磨层；4、增强层；5、结合层。
具体实施方式
为使本发明实现的技术手段、创作特征、达成目的与功效易于明白了解，下面结合具体实施方式，进一步阐述本发明。
如图1所示，一种耐磨钢丝网骨架复合管，包括外层管1和芯层管2，所述芯层管2的内壁复合内耐磨层3，所述芯层管2的外壁依次复合增强层4、结合层5和外层管1，所述外层管1和芯层管2均为PE管，所述增强层4为涂塑的钢丝网，所述结合层5为热熔胶层。
所述内耐磨层3的材料为聚硅氧烷与超高分子量聚乙烯复合改性所制得的专用料，利用聚硅氧烷的疏水性和比表面能低的特点，以及UHMWPE的自润滑性和高强度对聚烯烃进行复合改性，制成的一种兼具优异抗磨耗性能和加工性能的耐磨管道专用料，该专用料的数据对比如下：
该专用料的项目指标对比如下：
| 项目 | 指标 | 典型值 |
| 密度，g/cm3 | 0.9±0.02 | 0.89 |
| 熔体指数(190℃、2.16kg)，g/10min | 0.5±0.2 | 0.6 |
| 拉伸强度，MPa | ≥20 | 22 |
| 断裂伸长率，％ | ≥600 | 1000 |
| 低温冲击脆化温度,℃ | ≤-40 | ≤-40 |
| 200℃氧化诱导期，min | ≥30 | ≥30 |
| 砂浆磨损率,％ | ≤0.5 | 0.27 |
耐磨层厚度设计采用如表1所示。
表1
耐磨性能试验
在耐磨性能试验中，本发明中的耐磨钢丝网骨架复合管产品代号为 GXCG-1101，以下试验统称为GXCG-1101。
1)砂浆磨耗试验：砂浆磨耗试验是根据QB/T 2668–2004《超高分子量聚乙烯管材》附录B“砂浆磨损率试验方法”，将不同材料制成相同尺寸的样片，置于砂浆中高速旋转磨擦，历时数小时后取出，测量样片的失重比例，得出不同材料在砂浆中磨耗率，在不同工矿条件下，结果不同，具体试验结果如表2。
表2
2)砂浆冲击磨耗：用砂浆泵将30％固含量的河砂砂浆以一定速度及一定角度向不同材料制成的试样表面喷射，测试经一定时间后试样的重量损失，具体试验结果如表3。
表3
3)摆动磨耗试验：将不同粒径的砂石按一定比例混配，装入1米长的试验管段中，加入一定量的水后将管端密封，夹持在摇摆机上，摇摆机按一定角度和速度往复摆动，使试验管段内的砂石来回磨损管壁。每经过10万次左右的磨损时更换一次砂石，称量管段的重量损失即为管子的磨损量，具体试验结果如图2。
4)浆体环管磨蚀试验：环管试验法的试验条件基本上模拟了工业管道输送的实际情况，试验系统是一个完整的环形管路，包括矿浆槽、矿浆泵、变频调速器、试验管段、流量计、调节阀门、浓度与速度标定装置、管道冷却系统等，磨蚀试验用铁精矿的平均密度为4722千克/米3；矿浆质量浓度为60％；矿浆流速为1.8—2.0米/秒。试验管道内径为50mm；环管总长为30m。每试验60小时换一次矿浆同时检测试验管段的耐蚀量，浆体温度控制在40℃以下，共试验600 小时，具体试验结果如图3。
为了更好的理解该耐磨材料的耐磨性能，选取了普通HDPE管，超高分子量聚乙烯UHMWPE管和GXCG-1101进行了SEM电镜观察，可以看到GXCG-1101比普通HDPE管，超高分子量聚乙烯UHMWPE管表面更光滑。
由上述试验结果表明，GXCG-1101相比较于传统管材既能承受管内较大的压力又不怕管内介质的磨损和腐蚀，使管材质量和使用可靠性大大提高。
实施例2
一种耐磨钢丝网骨架复合管制备工艺，具体工艺步骤包括：
步骤一，把聚硅氧烷与超高分子量聚乙烯复合改性制得耐磨原料，备用；
步骤二，把HDPE原料和耐磨原料分别通过芯层管挤出机和内耐磨层挤出机挤出并通过共挤专用模具复合，经过芯层管真空定径以及冷却机组进行冷却定型，采用牵引机牵出；
步骤三，把涂塑高强度镀层钢丝经过钢丝缠绕机组缠绕在冷却定型后的芯层管外侧壁；
步骤四，对步骤三中缠绕钢丝后的芯层管外侧壁进行加热，把结合层原料经过结合层挤出机挤出，并通过结合层复合模具与芯层管外侧壁进行复合；
步骤五，外层PE原料经过外层挤出机挤出，经过外层复合模具与步骤四中复合结合层后的芯层进行复合，冷却成型；
步骤六，将步骤五中冷却成型后的复合管依次进行计米印字机计长、牵引切割、质检包装、入库。
以上只通过说明的方式描述了本发明的某些示范性实施例，毋庸置疑，对于本领域的普通技术人员，在不偏离本发明的精神和范围的情况下，可以用各种不同的方式对所描述的实施例进行修正。因此，上述附图和描述在本质上是说明性的，不应理解为对本发明权利要求保护范围的限制。
Claims (7)
1.一种耐磨钢丝网骨架复合管，包括外层管和芯层管，其特征在于：所述芯层管的内壁复合内耐磨层，所述芯层管的外壁依次复合增强层、结合层和外层管。
2.根据权利要求1所述的一种耐磨钢丝网骨架复合管，其特征在于：所述内耐磨层的材料为聚硅氧烷与超高分子量聚乙烯复合改性所制得的专用料。
3.根据权利要求1所述的一种耐磨钢丝网骨架复合管，其特征在于：所述外层管和芯层管均为PE管。
4.根据权利要求1所述的一种耐磨钢丝网骨架复合管，其特征在于：所述增强层为涂塑的钢丝网。
5.根据权利要求1所述的一种耐磨钢丝网骨架复合管，其特征在于：所述结合层为热熔胶层。
6.根据权利要求1所述的一种耐磨钢丝网骨架复合管，其特征在于：所述内耐磨层厚度为2-3mm。
7.一种如权利要求1～6任意一项所述耐磨钢丝网骨架复合管制备工艺，其特征在于：具体工艺步骤如下：
步骤一，把聚硅氧烷与超高分子量聚乙烯复合改性制得耐磨原料，备用；
步骤二，把HDPE原料和耐磨原料分别通过芯层管挤出机和内耐磨层挤出机挤出并通过共挤专用模具复合，经过芯层管真空定径以及冷却机组进行冷却定型，采用牵引机牵出；
步骤三，把涂塑高强度镀层钢丝经过钢丝缠绕机组缠绕在冷却定型后的芯层管外侧壁；
步骤四，对步骤三中缠绕钢丝后的芯层管外侧壁进行加热，把结合层原料经过结合层挤出机挤出，并通过结合层复合模具与芯层管外侧壁进行复合；
步骤五，外层PE原料经过外层挤出机挤出，经过外层复合模具与步骤四中复合结合层后的芯层进行复合，冷却成型；
步骤六，将步骤五中冷却成型后的复合管依次进行计米印字机计长、牵引切割、质检包装、入库。
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