CN114619610A - 一种玻璃钢管件的生产工艺 - Google Patents
一种玻璃钢管件的生产工艺 Download PDFInfo
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Abstract
本发明公开了一种玻璃钢管件的生产工艺,涉及模压技术领域,解决玻璃钢管件生产过程的优化,保证玻璃钢管件的良好成型以及玻璃钢管件的优良性能的技术问题,包括步骤一,原材料准备工作;步骤二,SMC片材机组加工;步骤三,预浸料熟化增稠;步骤四,片材切割成块;步骤五,模压成型;步骤六,修整放置。本发明中的生产工艺,优化了原材料的配方和配比,能够良好的形成片材,并且根据模具的形状设计,生产抗拉强度大的玻璃钢管件;整个生产工艺连续化程度高,生产过程能够顺利进行,能够高效的生产出性能良好,形状一致的玻璃钢管件。
Description
技术领域
本发明涉及模压技术领域,更具体的是涉及一种玻璃钢管件的生产工艺。
背景技术
模压成型工艺是复合材料生产中最古老而又富有无限活力的一种成型方法。它是将一定量的预混料或预浸料加入金属对模内,经加热、加压固化成型的方法。
模压成型工艺的主要优点:①生产效率高,便于实现专业化和自动化生产;②产品尺寸精度高,重复性好;③表面光洁,无需二次修饰;④能一次成型结构复杂的制品;⑤因为批量生产,价格相对低廉。
模压料的品种有很多,可以是预浸物料、预混物料,也可以是坯料。当前所用的模压料品种主要有:预浸胶布、纤维预混料、BMC、DMC、HMC、SMC、XMC、TMC及ZMC等品种。
模压成型的不足之处在于模具制造复杂,投资较大,加上受压机限制,最适合于批量生产中小型复合材料制品。随着金属加工技术、压机制造水平及合成树脂工艺性能的不断改进和发展,压机吨位和台面尺寸不断增大,模压料的成型温度和压力也相对降低,使得模压成型制品的尺寸逐步向大型化发展,目前已能生产大型汽车部件、浴盆、整体卫生间组件等。
对于模压成型的生产厂家,针对客户需求问题进行新设计或者自身问题进行优改进,均需要考虑到产品的原料、工艺以及所用设备是否合适,那么针对这些方面进行研发或者改良,则会使得产品最终性能良好,进而质量优、成本低的产品。
发明内容
本发明的为了解决玻璃钢管件生产过程的优化,保证玻璃钢管件的良好成型以及玻璃钢管件的优良性能的技术问题,本发明提供一种玻璃钢管件的生产工艺。
本发明为了实现上述目的具体采用以下技术方案:
一种玻璃钢管件的生产工艺,其特征在于,包括如下步骤:
步骤一,原材料准备工作:
原材料包括树脂,低收缩剂,苯乙烯,固化剂TBPB,阻聚剂,细钙粉,脱模剂,钛白粉,玻璃纤维,氧化镁;
将其中的树脂,低收缩剂,苯乙烯,固化剂TBPB,阻聚剂,细钙粉,脱模剂,钛白粉按比例称重倒入混料釜,加热搅拌均匀形成为液态料;
步骤二,SMC片材机组加工:
S1,将液态料通过泵体打到SMC片材机组的混合器中,SMC片材机组自动定量添加增稠剂氧化镁至混合器中,搅拌均匀形成糊状料;
S2,糊状料流入SMC片材机组中覆有底膜的工作段,并将糊状料附在匀速行进的底膜上;涂覆有糊状料的底膜经过切纱机工作段,切纱机把玻璃纤维均匀切碎,形成絮状体洒下并落到糊状料上;
S3,通过SMC片材机组再覆一层糊状料到顶膜上,将附有糊状料的顶膜覆盖到附有玻璃纤维及糊状料的底膜上,再经过27道辊压浸润,使糊状料和玻璃纤维充分融合形成预浸料;
S4,预浸料位于顶膜和底膜之间的结构视为片材,并从SMC片材机组中出料,片材放入片材框中折叠并整体称重,然后将片材框密封处理;
步骤三,片材跟随片材框进入40℃的熟化室进行熟化增稠,24-48小时使得预浸料融合;
步骤四,将片材切割成块,每块片材的面积为模具面积的50%~70%;
步骤五,将片材去除顶膜和底膜后放入模具的腔体中,通过模压机合模成型,成型参数为加温到160±1℃,保温3小时,模内压力500吨,深压3分钟。
步骤六,将将模具打开,将成品取出进行修整边幅,最后放入成品货架。
涉及原料配比及成品组分的工艺内容,步骤一中的原材料包括树脂,低收缩剂,苯乙烯,固化剂TBPB,阻聚剂,细钙粉,脱模剂,钛白粉,玻璃纤维,氧化镁,其按比例称重的配比为:树脂210份,低收缩剂85份,苯乙烯2.5份,固化剂TBPB 3份,阻聚剂0.16份,细钙粉500份,脱模剂13份,钛白粉11份,玻璃纤维230份,氧化镁8.5份。
进一步,步骤二的S2中,所述玻璃纤维切碎成0.02毫米—0.05毫米的絮状体。
涉及成品成型的工艺内容,步骤五中的模具包括凹模1和凸模2,凹模用于盛放切割好的片材物料,并将成品外侧面成型,凸模向凹模合模,并将成品内侧面成型。
进一步,所述凹模为凹陷式方形模具,其四角处分别具有凹定位角,其中部具有半圆形的凹陷腔体,凹陷腔体表面具有纵横交错的成筋槽;凹陷腔体的上下两侧具有成翼槽,成翼槽的区域中还具有成孔槽;凹陷腔体的左右两侧具有溢出区。
进一步,所述凸模为凸起式方形模具,其四角处分别具有凸定位角,其中部具有一块呈半圆形凸起的圆弧凸块,圆弧凸块表面光滑,且中部沿着圆弧凸块的弧形面中间设置一条成隔挡槽;圆弧凸块的上下两侧分别具有对应成孔槽的成孔柱。
所述成品中的玻璃纤维含量为30%,其结构包括圆弧形主体,主体两侧的连接翼,连接翼上具有连接孔;圆弧形主体内壁光滑,并且沿着弧形面中间位隔挡,圆弧形主体外壁具有纵横交错的加强筋。
本发明的有益效果如下:
1、本发明中的生产工艺,优化了原材料的配方和配比,能够良好的形成片材,并且根据模具形状,生产抗拉强度大的玻璃钢管件;整个生产工艺连续化程度高,生产过程能够顺利进行,能够高效的生产出性能良好,形状一致的玻璃钢管件。
2、本发明的原材料中树脂、低收缩剂、苯乙烯、固化剂TBPB、阻聚剂、细钙粉、脱模剂、钛白粉,赋予液体料良好的流动性和粘附性,并且形成白色的成品色彩;采用氧化镁作为增稠剂,将液态料增稠形成糊状料,能够良好的融合玻璃纤维形成片材,玻璃纤维在糊状料中添加,使得最终成品的抗拉强度性能增强。
2、本发明中的模具的结构设计良好,能够将玻璃钢管件一体成型,并且成品出模具仅需要简单修整工序后即可形成结构一致、形状稳定、完整度高的玻璃钢管件。
3、本发明中生产出的玻璃钢管件产品,任意两两结合即可完成管道的对接连接,连接快捷、使用方便。
附图说明
图1是本发明中合模状态的示意图;
图2是图1中A-A截面示意图;
图3是本发明中凹模的结构示意;
图4是本发明中凸模的结构示意;
图5是本发明中成品的结构示意;
附图标记:1-凸模,2-凹模,3-成品,101-凹定位角,102-成孔槽,103-成翼槽,104-溢出侧,105-成筋槽,201-凸定位角,202-成孔柱,203-圆弧凸块,204-成隔挡槽,301-连接翼,302-连接孔,303-隔挡,304-加强筋。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚,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,所描述的实施例是本发明一部分实施例,而不是全部的实施例。通常在此处附图中描述和示出的本发明实施例的组件可以以各种不同的配置来布置和设计。
因此,以下对在附图中提供的本发明的实施例的详细描述并非旨在限制要求保护的本发明的范围,而是仅仅表示本发明的选定实施例。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。
实施例1
本实施例提供一种玻璃钢管件的生产工艺,具体包括如下步骤:
步骤一,原材料准备工作:
原材料中的部分物料按比例称重后倒入混料釜,加热搅拌均匀形成为液态料。
步骤二,SMC片材机组加工:
S1,将液态料通过泵体打到SMC片材机组的混合器中,SMC片材机组自动定量添加增稠剂至混合器中,搅拌均匀形成糊状料;
S2,糊状料流入SMC片材机组中覆有底膜的工作段,并将糊状料附在匀速行进的底膜上;涂覆有糊状料的底膜经过切纱机工作段,切纱机把玻璃纤维均匀切碎,形成絮状体洒下并落到糊状料上;
S3,通过SMC片材机组再覆一层糊状料到顶膜上,将附有糊状料的顶膜覆盖到附有玻璃纤维及糊状料的底膜上,再经过27道辊压浸润,使糊状料和玻璃纤维充分融合形成预浸料;
S4,预浸料位于顶膜和底膜之间的结构视为片材,并从SMC片材机组中出料,片材放入片材框中折叠并整体称重,然后将片材框密封处理,谨防混入杂质。
步骤三,熟化工序:片材跟随片材框进入40℃的熟化室进行熟化增稠,24-48小时使得预浸料融合。
步骤四,切割工序:将片材切割成块,每块片材的面积为模具面积的50%~70%。
步骤五,成型工序:将片材去除顶膜和底膜后放入模具的腔体中,通过模压机合模成型,成型参数为加温到160±1℃,保温3小时,模内压力500吨,深压3分钟。
步骤六,整修工序:将模具打开,将成品取出进行修整边幅,最后放入成品货架。
实施例2
在实施例1的基础上,结合原材料的选用和配比,以形成抗拉强度大的产品;本实施例提供一种玻璃钢管件的生产工艺,具体包括如下步骤:
步骤一,原材料准备工作:
原材料包括树脂,低收缩剂,苯乙烯,固化剂TBPB,阻聚剂,细钙粉,脱模剂,钛白粉,玻璃纤维,氧化镁;
按比例称重将树脂210份,低收缩剂85份,苯乙烯2.5份,固化剂TBPB 3份,阻聚剂0.16份,细钙粉500份,脱模剂13份,钛白粉11份倒入混料釜,加热搅拌均匀形成为液态料。
步骤二,SMC片材机组加工:
S1,将液态料通过泵体打到SMC片材机组的混合器中,SMC片材机组自动添加增稠剂氧化镁8.5份至混合器中,搅拌均匀形成糊状料。
S2,糊状料流入SMC片材机组中覆有底膜的工作段,并将糊状料附在匀速行进的底膜上;涂覆有糊状料的底膜经过切纱机工作段,切纱机把对应原材料中的230份玻璃纤维均匀切碎,形成絮状体洒下并落到糊状料上。
其中,玻璃纤维切碎成0.02毫米—0.05毫米的絮状体。
S3,通过SMC片材机组再覆一层糊状料到顶膜上,将附有糊状料的顶膜覆盖到附有玻璃纤维及糊状料的底膜上,再经过27道辊压浸润,使糊状料和玻璃纤维充分融合形成预浸料。
S4,预浸料位于顶膜和底膜之间的结构视为片材,并从SMC片材机组中出料,片材放入片材框中折叠并整体称重,然后将片材框密封处理,谨防混入杂质,同时防止苯乙烯挥发。
步骤三,片材跟随片材框进入40℃的熟化室进行熟化增稠,24-48小时使得预浸料融合。
步骤四,将片材切割成块,每块片材的面积为模具面积的50%~70%。
步骤五,将成块的片材去除顶膜和底膜后放入模具的腔体中,通过模压机合模成型,成型参数为加温到160±1℃,保温3小时,模内压力500吨,深压3分钟。
步骤六,将将模具打开,将成品取出进行修整边幅,最后放入成品货架。
最终得到的成品中的玻璃纤维含量为30%。
实施例3
在实施例1或2的基础上,作为影响成品形状的关键步骤,模具结构的设计对成型起到关键作用。
如图1和图2所示,步骤五中选用模具包括凹模1和凸模2,凹模用于盛放切割好的片材物料,并将成品外侧面成型,凸模向凹模合模,并将成品内侧面成型。
如图3所示,所述凹模1为凹陷式方形模具,其四角处分别具有凹定位角101,其中部具有半圆形的凹陷腔体,并且凹陷腔体表面具有纵横交错的成筋槽105,用于形成产品上的加强筋。
凹陷腔体的上下两侧具有成翼槽103,用于形成产品的连接翼;成翼槽103的区域中还具有若干成孔槽102,成孔槽102在单侧成翼槽103中均匀间隔设置三处。
凹陷腔体的左右两侧具有溢出区104,用于多余片材物料的溢出。
如图4所示,所述凸模2为凸起式方形模具,其四角处分别具有凸定位角201,其中部具有一块呈半圆形凸起的圆弧凸块203。
圆弧凸块203表面光滑,且中部沿着圆弧凸块203的弧形面中间设置一条成隔挡槽204。
圆弧凸块203的上下两侧分别具有用于形成连接孔的成孔柱202。
如图1所示,在合模成型时,凹定位角101与凸定位角201配合进行合模定位;圆弧凸块203进入到凹陷腔体中,形成成品的圆弧形主体以及隔挡303的结构;成翼槽103用于形成连接翼301的结构;成孔柱202进入成孔槽102中,形成连接孔302的结构。
如图5所示,通过模具成型的玻璃钢管件产品,包括圆弧形主体,主体两侧的连接翼301,连接翼301上具有连接孔302;圆弧形主体内壁光滑,并且沿着弧形面中间位隔挡303,圆弧形主体外壁具有纵横交错的加强筋304。
Claims (7)
1.一种玻璃钢管件的生产工艺,其特征在于,包括如下步骤:
步骤一,原材料准备工作:
原材料包括树脂,低收缩剂,苯乙烯,固化剂TBPB,阻聚剂,细钙粉,脱模剂,钛白粉,玻璃纤维,氧化镁;
将其中的树脂,低收缩剂,苯乙烯,固化剂TBPB,阻聚剂,细钙粉,脱模剂,钛白粉按比例称重倒入混料釜,加热搅拌均匀形成为液态料;
步骤二,SMC片材机组加工:
S1,将液态料通过泵体打到SMC片材机组的混合器中,SMC片材机组自动定量添加增稠剂氧化镁至混合器中,搅拌均匀形成糊状料;
S2,糊状料流入SMC片材机组中覆有底膜的工作段,并将糊状料附在匀速行进的底膜上;涂覆有糊状料的底膜经过切纱机工作段,切纱机把玻璃纤维均匀切碎,形成絮状体洒下并落到糊状料上;
S3,通过SMC片材机组再覆一层糊状料到顶膜上,将附有糊状料的顶膜覆盖到附有玻璃纤维及糊状料的底膜上,再经过27道辊压浸润,使糊状料和玻璃纤维充分融合形成预浸料;
S4,预浸料位于顶膜和底膜之间的结构视为片材,并从SMC片材机组中出料,片材放入片材框中折叠并整体称重,然后将片材框密封处理;
步骤三,片材跟随片材框进入40℃的熟化室进行熟化增稠,24-48小时使得预浸料融合;
步骤四,将片材切割成块,每块片材的面积为模具面积的50%~70%;
步骤五,将片材去除顶膜和底膜后放入模具的腔体中,通过模压机合模成型,成型参数为加温到160±1℃,保温3小时,模内压力500吨,深压3分钟。
步骤六,将将模具打开,将成品取出进行修整边幅,最后放入成品货架。
2.根据权利要求1所述的一种玻璃钢管件的生产工艺,其特征在于,步骤一中的原材料包括树脂,低收缩剂,苯乙烯,固化剂TBPB,阻聚剂,细钙粉,脱模剂,钛白粉,玻璃纤维,氧化镁,其按比例称重的配比为:树脂210份,低收缩剂85份,苯乙烯2.5份,固化剂TBPB 3份,阻聚剂0.16份,细钙粉500份,脱模剂13份,钛白粉11份,玻璃纤维230份,氧化镁8.5份。
3.根据权利要求1所述的一种玻璃钢管件的生产工艺,其特征在于,步骤二的S2中,所述玻璃纤维切碎成0.02毫米—0.05毫米的絮状体。
4.根据权利要求1所述的一种玻璃钢管件的生产工艺,其特征在于,步骤五中的模具包括凹模1和凸模2,凹模用于盛放切割好的片材物料,并将成品外侧面成型,凸模向凹模合模,并将成品内侧面成型。
5.根据权利要求4所述的一种玻璃钢管件的生产工艺,其特征在于,所述凹模为凹陷式方形模具,其四角处分别具有凹定位角,其中部具有半圆形的凹陷腔体,凹陷腔体表面具有纵横交错的成筋槽;凹陷腔体的上下两侧具有成翼槽,成翼槽的区域中还具有成孔槽;凹陷腔体的左右两侧具有溢出区。
6.根据权利要求4或5所述的一种玻璃钢管件的生产工艺,其特征在于,所述凸模为凸起式方形模具,其四角处分别具有凸定位角,其中部具有一块呈半圆形凸起的圆弧凸块,圆弧凸块表面光滑,且中部沿着圆弧凸块的弧形面中间设置一条成隔挡槽;圆弧凸块的上下两侧分别具有对应成孔槽的成孔柱。
7.根据权利要求1所述的一种玻璃钢管件的生产工艺,其特征在于,所述成品中的玻璃纤维含量为30%,其结构包括圆弧形主体,主体两侧的连接翼,连接翼上具有连接孔;圆弧形主体内壁光滑,并且沿着弧形面中间位隔挡,圆弧形主体外壁具有纵横交错的加强筋。
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Application publication date: 20220614 |