CN113002030A - 一种衬塑不锈钢水箱制造方法及水箱 - Google Patents

一种衬塑不锈钢水箱制造方法及水箱 Download PDF

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CN113002030A
CN113002030A CN202110173955.7A CN202110173955A CN113002030A CN 113002030 A CN113002030 A CN 113002030A CN 202110173955 A CN202110173955 A CN 202110173955A CN 113002030 A CN113002030 A CN 113002030A
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water tank
stainless steel
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刘清文
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Jilin Yangyang Stainless Steel Water Tank Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/12—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined and welding bar
    • 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
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/851—Bag or container making machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D15/00—Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, sections made of different materials
    • B65D15/02—Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, sections made of different materials of curved, or partially curved, cross-section, e.g. cans, drums
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D21/00—Nestable, stackable or joinable containers; Containers of variable capacity
    • B65D21/02—Containers specially shaped, or provided with fittings or attachments, to facilitate nesting, stacking, or joining together
    • B65D21/0201—Containers specially shaped, or provided with fittings or attachments, to facilitate nesting, stacking, or joining together stackable or joined together side-by-side
    • B65D21/0205—Containers specially shaped, or provided with fittings or attachments, to facilitate nesting, stacking, or joining together stackable or joined together side-by-side joined together by bonding, adhesive or the like
    • E—FIXED CONSTRUCTIONS
    • E03—WATER SUPPLY; SEWERAGE
    • E03B—INSTALLATIONS OR METHODS FOR OBTAINING, COLLECTING, OR DISTRIBUTING WATER
    • E03B11/00—Arrangements or adaptations of tanks for water supply
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C2045/14237—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity
    • E—FIXED CONSTRUCTIONS
    • E03—WATER SUPPLY; SEWERAGE
    • E03B—INSTALLATIONS OR METHODS FOR OBTAINING, COLLECTING, OR DISTRIBUTING WATER
    • E03B11/00—Arrangements or adaptations of tanks for water supply
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Abstract

一种衬塑不锈钢水箱制造方法，首先将不锈钢板通过冷压技术制作成外鼓内凹的板材，板材四边均为两个连续的45度外折弯翻边，并在外翻边上打连接孔；然后将不锈钢板放入模具中，再将塑料母体注入模具中，使不锈钢表面均匀受塑料包裹，冷却后连同不锈钢板一起出模，形成内层是塑料外层是不锈钢的复合水箱板；最后组装，利用外侧45度翻边实现水箱板的同一平面连接，利用内侧45度翻边实现水箱板的垂直连接，水箱内部水箱板之间采用塑料焊条焊接，水箱外部水箱板之间通过螺丝加固连接；同一平面的水箱板在连接后形成的十字形结合处钻孔，并通过拉筋穿孔加固。本发明方法省去氩弧焊接，避免污染节约资源；强度增加，经久耐用，提高寿命3倍以上。

Description

一种衬塑不锈钢水箱制造方法及水箱
技术领域
本发明属于日常生活用品技术领域，尤其是涉及一种衬塑不锈钢水箱制造方法及水箱。
背景技术
水箱大量使用在我们生活工作中，小至家庭生活用水，自来水改造，大至国家重点水利工程、消防工程、热力设备和工业生产中。然而，目前使用的各种材料的水箱不尽如人意，水箱生产技术存在着诸多安全隐患，卫生标准也严重落后，甚至已经威胁到人们饮水安全了。
现有的水箱有模压不锈钢水箱、塑料焊接水箱和玻璃钢水箱，其中，模压不锈钢水箱使用氩弧焊接技术。在焊接过程中，不锈钢水箱板和拉筋过火后会产生大量污染，使不锈钢中的镍元素严重流失，水中的氯离子超标对不锈钢的腐蚀也极其严重，造成局部生锈、腐烂、断裂，对水质造成危害，使水箱寿命缩短，造成资源浪费。同时，不锈钢材料局部贫铬引起的晶界腐蚀也是目前解决不了的世界难题。塑料焊接水箱是用塑料板材拼接的，安装中板面较大，运输不便、安装复杂，材料强度不足，容易产生断裂、涨箱等危害。玻璃钢水箱也广泛应用在生活中，其制作中会使用大量的皮条、玻璃胶、裸露螺丝、树脂等，会造成粉尘污染，对水质造成危害，常有炸裂，漏水等现象发生，材料重、寿命短、污染大、老化快。
发明内容
本发明的目的是提供一种新的复合材料的水箱的制造方法，不使用各种胶类等化学用品，解决现有不锈钢水箱制造工艺产生水箱生锈、污染水质的问题，从而进一步解决水箱寿命短、老化快的问题。
本发明的另一个目的是提供一种新的制造方法涉及的衬塑不锈钢水箱，解决目前各种现有水箱存在的腐蚀、污染、断裂、涨箱、短寿、资源浪费的问题，从而提供一种没有污染，节省资源，强度大，经久耐用，寿命长，便于安装运输的衬塑不锈钢水箱。
为实现上述目的，本发明提供一种衬塑不锈钢水箱制造方法，其特征在于包括下列步骤：
1、首先将不锈钢板通过冷压技术制作成外鼓内凹的板材，板材四边均为两个连续的45度外折弯翻边，并在外翻边上打连接孔；
2、然后将不锈钢板放入模具中，利用注塑机再将塑料母体注入模具中，使不锈钢表面均匀受塑料包裹，冷却后连同不锈钢板一起出模，形成内层是塑料外层是不锈钢的复合水箱板；
3、最后组装，利用外侧45度翻边实现水箱板的同一平面连接，利用内侧45度翻边实现水箱板的垂直面的连接，水箱内部水箱板之间采用塑料焊条焊接，水箱外部水箱板之间通过螺丝加固连接；同一平面的水箱板在连接后形成的十字形结合处钻孔，并通过拉筋穿孔加固。
一种衬塑不锈钢水箱，由水箱板连接构成，水箱板本体为外鼓内凹的形状，水箱板外层是不锈钢板，内层是塑料板，内层和外层复合成一体，水箱板四边均为两个连续的45度外折弯翻边，水箱外部通过水箱板外侧的翻边利用螺丝连接构成水箱的同一平面，通过内侧的翻边连接构成水箱相垂直的两个面，水箱内部水箱板之间为塑料焊条焊接。
优选地，水箱板平面连接的十字形结合处钻有焊接加固孔，通过拉筋穿过焊接加固孔焊接加固。
优选地，拉筋穿透水箱板留在水箱里面的部分外面包裹一层塑料，方便与里层塑料板焊接，伸出水箱板外面的部分是通丝，方便与外面的不锈钢板固定连接。
优选地，所述的水箱板外层不锈钢板厚度为0.3-2mm，内层塑料板厚度为8-9.7mm。
优选地，不锈钢板采用304/201/镀锌钢板。
优选地，内层塑料板采用聚丙烯PP/聚乙烯PE/PVc材料。
本发明方法由于使用不锈钢与塑料的复合材料，省去氩弧焊接的环节，采用聚丙烯PP/聚乙烯PE/PVc材料在内部焊接，外部用螺丝紧固，避免污染和材料变性所带来的危害，节约大量资源；不使用各种胶类化学用品，不会对水质造成污染；使用复合材料，强度大大增加，使水箱经久耐用，提高寿命3倍以上；内层塑料厚度大大超过外层不锈钢厚度，成本大大降低，同时增加整体强度；内部拉筋采用通丝整体附塑结构，简单方便，随意组合，外面螺丝紧固即可，模块化生产，便于运输，安装简便，节省人力物力。
附图说明
图1是水箱的正视图；
图2是水箱板的结构示意图；
图3是沿图2中A-A线的剖视图：
图4是图1中去掉拉筋挡板的十字形结合处的示意图；
图5是图4的反面即水箱内部十字形结合处示意图。
具体实施方式
参照图1-5，本发明具体实施方式中，水箱板外层是0.3-2mm的不锈钢板，采用304/201/镀锌钢板，内层是8-9.7mm塑料板，采用聚丙烯PP/聚乙烯PE/PVc材料，内层和外层复合成一体，既轻便成本又低。水箱板本体1为外鼓内凹的球面形状，水箱板四边均为两个连续的45度外折弯翻边。水箱内部水箱板之间采用塑料焊条7焊接，水箱外部水箱板之间通过螺丝紧固连接。根据尺寸要求，如果水箱比较大，那么需要将多个水箱板同一平面连接，这种同一平面连接是利用外侧45度翻边，水平连接长度达到尺寸要求后，需要连接垂直面的水箱板，此时垂直连接是利用内侧45度翻边，水箱内部由于是塑料板，所以采用塑料焊条7焊接，水箱外部板是不锈钢板，所以通过螺丝连接。这种连接方式克服了目前水箱使用橡胶皮条、玻璃胶作为堵漏方式的缺陷，无污染，不变形，科技环保，使用寿命延长。同一平面四块水箱板共同连接后形成十字形结合处，在十字形结合处钻孔6，拉筋从里面穿到外面来，留在水箱里面的部分外面包裹一层塑料，方便与里层塑料板焊接，伸出水箱板外面的部分是通丝，与外层的不锈钢板通过拉筋挡板11紧固连接。其它如排气口、进水口、出水口、溢流口、底部排污口以及液位管、爬梯、人孔等水箱正常应有的根据具体需求随意设置安装在相应部位，5是水箱板翻边上开的连接孔，用于穿螺丝紧固连接水箱板。
本发明水箱的制造方法：
1、先将不锈钢板制作成以下四种规格1060×1060/1060×560/1560×560/1060×1560，再用冷压技术压制成外径为；984×984/984×484/1484×484/984×1484的四种型材，并在边缘处打孔(100*10)。将不锈钢板放入事先备好的模具中，用注塑机将塑料母体注入模具中，使不锈钢表面均匀受塑料包裹，使其外边缘形成1000×1000、1000×500、1500×500、1000×1500的四种复合材料，冷却后连同不锈钢板一起出模，(也可使用改性PP材料，)使其大小一致，浑然一体，光滑无气泡，无断裂，上述钢管衬塑技术是公知技术，此处不再赘述。
2、按照已知的水箱规格进行配板、拉筋长度的选择以及各边缘挑选，水箱基础同玻璃钢的基础一样，板材的配比可根据水箱的大小、高度选配相应的不锈钢厚度板材，板材在压制过程中可调配不锈钢板材的厚度，安装直接用螺栓对接即可，不加橡胶皮条，可一次紧固成型，成型后在水箱内部进行塑料焊接，可使用塑料焊枪进行2联3联两次焊接，或使用塑料挤朔机进行一次性焊接，都能达到很好的焊接效果。水箱焊完后进行拉筋的安装，先在四块板的结合处按拉筋的粗细钻相同的眼孔，将拉筋上面包裹的塑料皮扒下一段，然后从里面伸出，外面配拉筋挡板，用螺丝紧固，没扒下塑料皮的部分留在水箱里面刚好卡在眼孔处。内部长短搭配进行水平连接，再用塑料焊条将各接口焊死，支撑也同样处理。上部钻孔支出，下部直接焊于底板上，使其拉支结合，永久坚固。最后按图纸要求安装法兰，可根据客户要求使用衬塑法兰，或直接焊接PP/PPR管头即可。最后检查各部位是否牢固，做到无漏点、无毛刺、无松动即可交工验收。
本发明板材的另一种具体实施方式是：
先将不锈钢板制作成大小同第一种实施方式一样的板块，然后按规格大小用模具直接压出1000×1000、1000×500、1500×500、1000×1500四种规格。二者胶粘，再用压机进行二次复合，达到使用标准。

Claims (7)

1.一种衬塑不锈钢水箱制造方法，其特征在于包括下列步骤：
(1)首先将不锈钢板通过冷压技术制作成外鼓内凹的板材，板材四边均为两个连续的45度外折弯翻边，并在外翻边上打连接孔；
(2)然后将不锈钢板放入模具中，利用注塑机再将塑料母体注入模具中，使不锈钢表面均匀受塑料包裹，冷却后连同不锈钢板一起出模，形成内层是塑料板外层是不锈钢板的复合水箱板；
(3)最后组装，利用外侧45度翻边实现水箱板的同一平面连接，利用内侧45度翻边实现水箱板的垂直面的连接，水箱内部水箱板之间采用塑料焊条焊接，水箱外部水箱板之间通过螺丝加固连接；同一平面的水箱板在连接后形成的十字形结合处钻孔，并通过拉筋穿孔加固。
2.根据权利要求1所述的一种衬塑不锈钢水箱制造方法，其特征在于：所述的不锈钢板厚度为0.3-2mm，塑料板厚度为8-9.7mm。
3.根据权利要求1所述的一种衬塑不锈钢水箱制造方法，其特征在于：所述的不锈钢板采用304/201/镀锌钢板。
4.根据权利要求1所述的一种衬塑不锈钢水箱制造方法，其特征在于：所述的塑料板材料为聚丙烯PP/聚乙烯PE/PVc材料。
5.一种衬塑不锈钢水箱，由水箱板连接构成，水箱板本体为外鼓内凹的形状，其特征在于：水箱板外层是不锈钢板，内层是塑料板，内层和外层复合成一体，水箱板四边均为两个连续的45度外折弯翻边，水箱外部通过水箱板外侧的翻边利用螺丝连接构成水箱的同一平面，通过内侧的翻边连接构成水箱相垂直的两个面，水箱内部水箱板之间为塑料焊条焊接。
6.根据权利要求5所述的一种衬塑不锈钢水箱，其特征在于：水箱板平面连接的十字形结合处钻有焊接加固孔，通过拉筋穿过焊接加固孔焊接加固。
7.根据权利要求6所述的一种衬塑不锈钢水箱，其特征在于：拉筋穿透水箱板留在水箱里面的部分外面包裹一层塑料，伸出水箱板外面的部分是通丝。
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