CN1142055C - 大面积高抗拉地网,其制造方法和装置及其应用 - Google Patents

大面积高抗拉地网,其制造方法和装置及其应用 Download PDF

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CN1142055C
CN1142055C CNB001046667A CN00104666A CN1142055C CN 1142055 C CN1142055 C CN 1142055C CN B001046667 A CNB001046667 A CN B001046667A CN 00104666 A CN00104666 A CN 00104666A CN 1142055 C CN1142055 C CN 1142055C
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sticking plaster
high tensile
earth mat
vibration
tensile strength
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CN1282660A (zh
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G��ϣ��̹
G·希尔坦
V·马勒
ά
S·普里维克
W·尤勒曼
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Novi & Co GmbH
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/69—General aspects of joining filaments 
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
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    • B29C55/04—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique
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    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/843—Machines for making separate joints at the same time in different planes; Machines for making separate joints at the same time mounted in parallel or in series
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/9512—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools by controlling their vibration frequency
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • E—FIXED CONSTRUCTIONS
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    • E—FIXED CONSTRUCTIONS
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Abstract

兹提出一种大面积高抗拉地网，制造它的方法和装置及作为排流网和钢筋网及栅栏的应用。用交叉的、可在交叉区通过焊接彼此连接在一起的热塑性塑料棒连续制造大面积地网的该方法，其特征是，采用单层的均质分子定向高抗拉塑料棒并将大量依次排列的交叉区以循环作业形式采用振动焊接技术同时焊在一起。其中，采用一种新发明的振动焊接装置，其特征是，它具有至少一个振动-摆动装置而同时可焊接至少100个交叉区，最好多至500个交叉区。

Description

大面积高抗拉地网，其制造方法和 装置及其应用
本发明涉及一种大面积高抗拉地网，它的制造方法和装置及作为排流网和钢筋网的应用。
这种形式的地网，例如被用于公路及铁轨建造加固，用于地基加固，坡面稳固及存放密封系统的固定。
自70年代以来，Netlon公司的被称之为Tensar地网在世界范围内的不同应用领域获得应用。
在制造这类地网时，将聚乙烯或聚丙烯挤出带以均匀间隔冲孔。在加热情况下，使该带材或按英国专利文献2 073 090沿纵向(单轴线)或按英国专利文献2 035 191沿纵向和横向(双轴线)伸展。通过这种伸展方式，使聚合物分子沿伸展方向从任意排列状态进入定向排列状态，这种方法提高了地网的抗拉强度和刚性。这类地网的一种拓展形式已由美国专利US-PS 4 168 385(Mercer)公开。不过，该地网的问题是，网格点不能完全和网格点之间的横挡一样被拉长，因此，这样伸展的网格，在某些方向的单位平方米重量强度不十分令人满意。
为改善强度与平方米重量的关系，在德国专利DE-PS 41 37 310(Akzo)中描述了一种制造地网的方法，其中，首先制造具有两层不同熔融范围的聚合物的带条然后将其拉伸(分子定向双组分条带)。然后，条带这样交叉排列，即具有较低熔融范围的条带侧彼此相邻。然后对形成的排列组织施加这样的温度，即它高于具有较低熔融范围的聚合物的熔融范围，但低于具有较高熔融范围的聚合物的熔融范围。由此，相邻列带条的交叉位借助较低熔融范围的聚合物被焊在一起。
英国专利申请2 314 802(Mercer)提出了另一种近似的方法，在其关于已有技术的引言中提出，由Sjgnode公司用分子定向聚酯带制造的地网覆盖在具有较低熔融温度的塑料一侧上(双组分带)。该双组分聚酯带这样彼此交叉重叠，即低熔点侧彼此叠在一起。交叉区接下来被焊接。
该地网的缺点是，由低熔点聚合物组分形成的交叉区的结合强度不令人满意。
为避免这种缺点，上述的英国专利申请2 314 802(1996.7.2申请并在1998.1.14公开)提出了一种方法，其中，虽然也采用分子定向双组分条带加工，但所不同的是，在每个网格横挡的沿机器方向都增加一个下双组分条带和一个上组分条带，因此，两条带的较低熔点侧在横条放入后全面积彼此重叠。然后，每个下双组分条带在横条带封入情况下借助火焰焊接或热空气焊接与上双组分条带彼此连在一起。
用这种方法虽然能提高交叉区的结合强度，但其缺点是，从材料方面看需要两种不同的聚合物，以便制造双组分带材而形成每个横挡组分分别需要两种双组分带材。
本发明的目的因此在于提供一种大面积高抗拉地网，它由单层均质分子定向的高抗拉的、没有附加涂层的棒通过一如下方式焊接制成，即一方面达到了塑料棒的焊接交叉区内的另人满意的结合强度，而没有对分子定向，即塑料棒在交叉区的抗拉强度产生本质影响，另一方面确保了经济的生产速度。
上述目的通过采用单层的均匀分子定向的高抗拉塑料棒和通过应用振动-焊接技术来达到，其中，交叉的单层均匀分子定向的高抗拉塑料棒的大量一个接一个并排设置的交叉区在相同条件下以相同压力以流水作业形式彼此同时连接在一起。
振动-焊接技术包括摩擦-焊接方法，在该方法中，彼此叠在一起的塑料棒交叉区不是通过外界导入热量而是通过摩擦能直接转换为热能而塑化。在此，塑料棒在其交叉区以这样的频率和振幅摆动，即表面变软并以这种方式在高压下焊接。因此，振动-焊接的主要特征是，为形成摩擦而反复运动，因此，融化热仅仅在棒表面产生，而分子定向仅仅在塑料棒表面失去。此外这种方法具有加热和冷却时间短的优点，因为加热仅仅在表面发生，由此短的循环时间变得可能，这使得所希望的经济生产速度成为可能，亦即，本发明的总宽度例如5m、塑料棒从棒中心到棒中心的间隔约为3cm的大面积地网可以每分钟至少2.5m的速度制造。
起先人们认为这是不可能的，因为人们接受的是，在约1.5N/mm2的预期表面压力和例如12mm的塑料棒宽度下，对于3cm网格和约5000个要焊接的交叉区而言产生约1,000,000N的力，这不可能发生可控的焊接。此外人们认为，以60Hz至300Hz摆动和同时要焊接的交叉区如此大的数量会损坏机器部件。
不过另人惊奇地发现，在焊接台相当重的设置下，上述力可达到并因此可以同时焊接例如500至8000个交叉区。
为此，本发明新的震动-焊接装置是最重要的，它配备有大面积铺设的摆动板和相应的底部结构和相应的控制系统和压力系统以及棒输送机构。依次安装多个这样的新振动-焊接装置并使其同时在相同压力条件下以相同振幅和频率摆动。在此，振幅和频率这样控制，即振幅在0.5mm至2.5mm，最好在1mm至2mm范围内，而频率在60至300HZ，最好是150至180HZ范围内。
因为利用本发明的振动-焊接装置可按照交叉区间隔和棒宽分别焊接100至500个交叉区(这在过去是不可思议的)，因此，按照本发明可制造任意宽度，最好是3至6m宽度的大面积地网，在此，要依次安装相应数量的本发明的振动-焊接装置。
沿纵向，即机械方向输送的棒(后面称为纵棒)的输送，最好以相同间隔彼此平行地进行。垂直于纵向送入的棒(后面成为横棒)的敷设最好与纵向成直角敷设在纵棒上，其中，纵棒和横棒最好形成正方形或被或多或少拉长的长方形网格空间，当然，横棒也可与平行伸展的纵棒交叉撑45°至90°角度。
纵棒之间的间隔及横棒之间的间隔可任意选择，它们从棒的侧边到侧边测量最好在10mm至100mm范围内，尤其在20mm至80mm范围之间。
在本发明的大面积地网制造时，可将如此多的塑料棒沿机械方向和相应多的塑料棒沿横向排列，即使地网的总宽度为3m至6m，最好是5m，而其总长度为25m至100m，最好是50m至100m。
本发明所采用的塑料棒或者是有其边长最好为2.0mm至6.0mm，尤其是2.5mm.至4.5mm的正方形截面或者其宽度最好为5mm至40mm，尤其是10mm，12mm或16mm，而其厚度最好为0.4mm至2.5mm，尤其是1.0mm至1.5mm的长方形截面。
按照特别的实施形式，纵棒采用比横棒更宽和/或更厚的塑料棒。
优先采用的热塑性塑料有聚酯(PES)，如聚对苯二酸乙二醇酯(PET)，聚烯烃，如高密度聚乙烯(PEHD)或聚丙烯(PP)，聚酰胺(PA)，如PA6和PA66，芳酰胺及聚乙烯醇(PVA)。
尤其采用聚对苯二酸乙二醇酯(PET)或聚丙烯(PP)作为热塑性塑料。为确保尽可能高的抗拉强度，PP的拉伸比最大应为1∶15，优选1∶9至1∶13。对于PET，最大拉伸比为1∶10，最好是1∶6至1∶8是合适的。对此，在最大拉力下的伸长为5％至20％。
塑料棒的强度最好在300N/mm2和800N/mm2之间，可是柔性的或刚性的。
因为钢筋网与地基之间的相互作用基于地基与网之间的摩擦力作用，网棒的上侧或下侧最好设有可提高对地基摩擦力/接触力的造型/压花。
可能的压花为例如具有0.05mm至0.5mm压花深度的菱形结构。压花深度应为塑料棒厚度的0.5％至30％之间。例如，当塑料棒厚度为1.5mm时，每侧的压花深度为0.15mm。
其它可能的压花例如有：
·纵槽
·横槽
·蜂窝状结构
·带钉菱形结构
·粒结、钉等
·由上述压花组成的复合体。
此外参照下面的例子对本发明进一步说明，但不仅限于此。
高抗拉塑料棒借助一个具有自动熔融筛网的水平结构形式的挤出机挤压。
塑料棒借助多个拉伸支架，热空气管道及喷射管道并随着棒转向被高抗拉拉伸，期间分子发生定向。
被挤压和拉伸的塑料棒借助缠绕机被缠到线盘上，例如直到15,000连续米。
为了将高抗拉塑料棒再加工成宽度最好为3.0m至6.0m，尤其5.0m的大面积地网，将制好的线盘放在线盘框架上。该线盘容纳体最好具有制动装置，以确保线盘可控放线。在加工宽度为5.0m，从塑料棒中心到塑料棒中心间隔为30mm，而塑料棒宽度为10mm情况下，必须有167个容纳体。
如已谈到的，也可选择在10mm至100mm范围内的其它间隔，因为如对于排流网而言，其间隔最好减小直到约10mm，甚至更小，以确保排流结构的压力稳定的排流状态。
同样如已经谈到的，所有沿纵向敷设的塑料棒最好彼此平行输送。
沿纵向(机器方向)伸展的塑料棒(纵棒)借助一个抽拉组件被抽拉。在该抽拉组件内有一个用来在换棍时将纵棒分开的横截断系统和一个自动将新纵棒与旧纵棒的剩余部分接在一起的连接装置。最好采用超声焊接装置或振动-焊接装置连接。
借助气动制动装置确保每个塑料棒受控进入牵拉组件。该牵拉组件这样设计，即在后续的焊接过程中确保每个塑料棒的连续拉力。
垂直于纵棒伸展的塑料棒(横棒)借助一个铺设头铺设。可同时铺设最好至多50个横塑料棒。铺设头这样设计，即在纵棒从上面经过时可最好沿两个方向铺设至多50个横棒。
每个制动器确保在敷设期间每个横棒的拉力相同。
铺好的横棒通过履带的传送或牵拉被输送到将形成网格交叉区的焊接单元。该履带由一个下面位置固定的双链和两个可水平移动的双链组成。为确保两个双链之间足够的使横棒压紧的压力，在下链轨道下方设有一个压力软管，它将上履带链压在上履带链上。
同步的裁断装置将被压紧的横棒在送入焊接装置之前裁断。
振动焊接装置例如由10个依次排列的振动-摆动装置组成，它们分别带有与摆动框成一体的大摆动板，驱动振荡器，振幅控制板和摆动限界装置。每个振动-摆动装置的尺寸例如为475mm×720mm，因此，所有10个振动-摆动装置在一个工作程序内可实现例如约4000至约8000个单点焊接。该焊接过程最好在60和300Hz，尤其在150和180Hz范围之间和在至多2mm的振幅下进行。
10个振动-摆动装置分别具有一个整套的机械框，10个相应的底部工具位于10个焊接台上，它们在焊接时借助4个液压汽缸被提升。在焊接工具范围用分离齿送入塑料棒。
制得的大面积地网在焊接过程之后借助一个主牵拉组件被送到一个例如用于无纺布，织物，针织品或薄膜的涂覆区，以便在紧接地网制造之后的工作程序制造用作塑料排流网或分割网及钢筋网的、由筛网和无纺布组成的复合产品。一侧或两侧的涂覆可借助热隔条，热空气，粘接剂等进行。复合产品在涂覆之后被送到裁断及缠绕单元。
本发明涂覆有薄膜的地网尤其适合用作防潮物品，卡车及临时屋顶的盖布。
本发明的地网除前面所谈到的主要应用领域外，还可以用于制作围栏，例如作为森林保护围栏，圈住动物的围栏或用于制作工地保护围栏，雪崩防护栏或岩石崩塌防护栏。

Claims (25)

1.用交叉的、可在交叉区通过焊接彼此连接在一起的热塑性塑料棒连续制造大面积地网的方法，其特征是，采用单层的均质分子定向高抗拉塑料棒并将大量依次排列的交叉区以循环作业形式采用振动焊接技术同时焊在一起。
2.按照权利要求1所述的方法，其特征是，同时焊接500至8000个交叉区。
3.按照权利要求1或2所述的方法，其特征是，使多个振动焊接装置在相同压力下，以相同振幅和频率同时摆动，其中，振幅在0.5mm至2.5mm范围之间，而频率在60至300Hz之间。
4.按照权利要求3所述的方法，其特征是，所述振幅在1mm至2mm之间和所述频率在150至180Hz之间。
5.按照权利要求1或2所述的方法，其特征是，可这样摆放交叉塑料棒，即垂直于机器方向伸展的塑料棒与彼此平行于机器方向伸展的塑料棒相交45°至90°的角度。
6.按照权利要求1或2所述的方法，其特征是，将塑料棒这样排列，即它们彼此，也就是从侧边到侧边相互间具有10至100mm的间隔。
7.按照权利要求6所述的方法，其特征是，所述间隔是20mm至80mm。
8.按照权利要求1或2所述的方法，其特征是，沿机器方向设置这样多的塑料棒，沿与之垂直的方向设置相应多的塑料棒，即使地网总宽度为3m至6m，而其总长度为25m至500m。
9.按照权利要求8所述的方法，其特征是，所述地网总宽度为5m和总长度是50m至100m。
10.按照权利要求1或2所述的方法，其特征是，采用具有300至800N/mm2抗拉强度的塑料棒。
11.按照权利要求1或2所述的方法，其特征是，采用具有边长为2mm至6mm的正方形截面的塑料棒，或采用具有其宽度为5mm至40mm，其厚度为0.4mm至2.5mm的矩形截面的塑料棒。
12.按照权利要求11所述的方法，其特征是，采用其宽度为10mm、12mm或16mm和其厚度为1.0mm至1.5mm的矩形截面的塑料棒。
13.按照权利要求1或2所述的方法，其特征是，采用其上侧和/或下侧带有压花的塑料棒。
14.按照权利要求13所述的方法，其特征是，所采用的塑料棒在上侧或下侧具有相对于塑料棒厚度的0.5至30％的压花深度。
15.按照权利要求14所述的方法，其特征是，所述压花为菱形结构。
16.按照权利要求1或2所述的方法，其特征是，作为纵棒，采用比沿横向采用的塑料棒更宽和/或更厚的塑料棒。
17.按照权利要求1或2所述的方法，其特征是，所采用的塑料棒由聚对苯二酸乙二醇酯(PET)或聚丙烯(PP)组成。
18.按照权利要求1或2所述的方法，其特征是，在制成的大面积地网的一侧或两侧上借助热隔条，热空气或粘接剂，无纺布，织物，针织品或薄膜而另加覆盖层。
19.大面积高抗拉地网，由交叉的热塑性单层均质的分子定向高抗拉塑料棒组成，塑料棒在交叉点处借助振动-焊接技术被焊在一起。
20.按照权利要求19所述的大面积高抗拉地网，其特征是，它们按照上述权利要求1至18之任一项的方法制造。
21.用交叉的高抗拉塑料棒制造大面积高抗拉地网的振动-焊接装置，其特征是，该装置具有至少一个振动-摆动装置，它可同时焊接至少100个交叉区和最高至500个交叉区。
22.按照权利要求21所述的用交叉的高抗拉塑料棒制造大面积高抗拉地网的振动-焊接装置，其特征是，10个振动-摆动装置彼此相邻设置，它们借助相应的控制装置以相同振幅和相同频率在压力作用下被同时摆动，以便在压力作用下同时焊接最高至8000个交叉区。
23.按照权利要求19或20所述的大面积高抗拉地网在土建工程中作为排流网或钢筋网的应用。
24.按照权利要求19或20所述的大面积地网作为栅栏件的应用。
25.按照权利要求19或20所述的大面积地网作为盖布的应用，其中所述地网的单侧或双侧涂覆薄膜。
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