CN114714674B - 一种增强型三层波纹结构管材及其制备方法 - Google Patents
一种增强型三层波纹结构管材及其制备方法 Download PDFInfo
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Abstract
本发明涉及高分子复合材料领域,具体为一种增强型三层波纹结构管材及其制备方法。其包括由内至外经三层热熔复合的内层、中间层和外层,内层和中间层均为实壁结构,外层具有交替分布的波峰和波谷;外层采用聚丙烯共混改性复合材料制成,所述聚丙烯共混改性复合材料由以下重量份的原料组成:PPB8101,PPK8003,LLDPE7042,茂金属MPE,聚烯烃弹性体OBC,熔脂调节剂,增刚成核剂,硫酸钡;环保食品级改性纳米滑石粉,环保级碳黑,光热稳定剂,抗氧剂1010,抗氧剂168,光扩散剂。本发明能同时形成不同材料的内外壁组合,提供不同的内外壁产品性能要求,扩大管材适用范围。
Description
技术领域
本发明涉及高分子复合材料领域,特别是涉及一种增强型三层波纹结构管材及其制备方法。
背景技术
早期水网使用钢筋混凝土管和金属管。钢筋混凝土管内壁摩擦系数较大,在输送过程中阻力较大,使得输送效率降低,且施工安装时容易破损。金属水管易腐蚀,造价较高,后期维护费用较大,寿命短。塑料问世后,由于其杰出的性能,逐渐发展成可以满足市场管材的需要。鉴于PE管材的众多优点,逐步了取代了传统钢筋混凝土管和钢管;PE给水管材集环境保护、节能、卫生、密封性、防腐蚀、抗震等级等优势于一体,在管道行业具备不能代替性。
但PE给水管在应用中表现诸多的缺陷和问题:PE给水管材不能露天储放太久,经历一个高温天气暴晒后,品质变差、变质、变脆、性能降低,管材老化降低使用寿命;PE管材和管件如不是同一厂家供应,化学特性不一致,热熔焊接时熔接缝处粘接不牢固,容易漏水或者爆管;受温度影响大,热胀冷缩后内应力大毁坏管道;对接或承插热熔时焊接品质不高,PE给水管有对碰热熔对接和承插热熔对接两种对接方式。对碰熔接这种管材,接口热熔对接品质难以保证,在二次加压供水管路中受水压时高时低的摇摆不定危害,加之高低温热胀冷缩、地基沉降等原因,都很有可能产生管道爆裂现象;PE管材强度低,抗慢速裂纹增长能力差,在工地施工或者运输过程中,遇到坚硬石头、金属碰撞挤压易引起凹坑,裂纹扩张,直至穿孔爆管;内外壁壁厚不圆,特别是大口径管材,在焊接时需要对管材进行圆度加工,施工难;PE管材连接有热熔、电熔、和法兰等方式,在山区野外等非常不方便。
由于HDPE材料特性,使HDPE双壁波纹管的力学性能和使用范围受到了一定的局限,对于长距离输送和市政大口径PE给水管材,存在强度不够,抗慢速裂纹扩张、耐候耐老化性能差的问题。
发明内容
本发明目的是针对背景技术中存在的问题,提出一种增强型三层波纹结构管材及其制备方法,能同时形成不同材料的内外壁组合,提供不同的内外壁产品性能要求,扩大管材适用范围,管材具有承压能力强、抗冲击性能好、抗刮划性能好、拉伸强度好、韧性好、耐侯性好和耐老化性能好的特性。
一方面,本发明提出一种增强型三层波纹结构管材,包括由内至外经三层热熔复合的内层、中间层和外层,内层和中间层均为实壁结构,外层具有交替分布的波峰和波谷;
外层采用聚丙烯共混改性复合材料制成,所述聚丙烯共混改性复合材料由以下重量份的原料组成:18-30份PP B8101,18-30份PP K8003,5-7份LLDPE7042,10-20份茂金属MPE,3-5份聚烯烃弹性体OBC,0.2-0.4份熔脂调节剂,0.5-1份增刚成核剂,1-2份硫酸钡;20-30份环保食品级改性纳米滑石粉,2-3份环保级碳黑,0.3-0.5份光热稳定剂,0.3-0.5份抗氧剂1010,0.3-0.5份抗氧剂168,0.5-1份光扩散剂;
内层采用聚乙烯共混改性复合材料制成,所述聚乙烯共混改性复合材料由以下重量份的原料组成:55-72份HDPE100级延长049,5-7份LLDPE7042,10-15份茂金属MPE,6-9份聚烯烃弹性体OBC,1-2份环保级碳黑,0.5-1份光热稳定剂,1-2份硫酸钡,5-10份环保食品级改性纳米滑石粉,0.3-0.5份抗氧剂1010,0.3-0.5份抗氧剂168,0.5-1份光扩散剂;
中间层采用聚乙烯共混复合材料制成,所述聚乙烯共混复合材料由以下重量份的原料组成:40-50份LLDPE7042,25-30份聚烯烃弹性体OBC,25-30份聚烯烃弹性体EVA。
优选的,茂金属MPE为埃克森美孚3518CB;增刚成核剂为NA960;环保食品级改性纳米滑石粉为2500目以上,环保食品级改性纳米碳酸钙为3000目以上。
另一方面,本发明提出上述增强型三层波纹结构管材的制备方法,
A、聚丙烯共混改性复合材料的制备步骤如下:
S11、配置如下原料:18-30份PP B8101,18-30份PP K8003,5-7份LLDPE7042,10-20份茂金属MPE,3-5份聚烯烃弹性体OBC,0.2-0.4份熔脂调节剂,0.5-1份增刚成核剂,1-2份硫酸钡;20-30份环保食品级改性纳米滑石粉,2-3份环保级碳黑,0.3-0.5份光热稳定剂,0.3-0.5抗氧剂1010份,0.3-0.5份抗氧剂168,0.5-1份光扩散剂;
S12、包括如下两种制备方式:
第一种制备方式:将配置好的原料加入高速混合机中混合10-15分钟,制得混合物料,再加入到双螺杆挤出机组中进行熔融、塑化、混炼、挤出、造粒,最后冷却切粒,得到增强型三层波纹结构管材外层专用料,料筒温度分别为:190℃,200℃,220℃,220℃,220℃,口模温度为:220℃;
第二种制备方式:将配置好的原料加入密炼机中,利用密炼机进行混合、改性、熔融、塑化、混炼,再通过单螺杆挤出机组进行挤出、造粒,最后冷却切粒,得到增强型三层波纹结构管材外层专用料;
B、聚乙烯共混改性复合材料的制备步骤如下:
S21、配置如下原料:55-72份HDPE100级延长049,5-7份LLDPE7042,10-15份茂金属MPE,6-9份聚烯烃弹性体OBC,1-2份环保级碳黑,0.5-1份光热稳定剂,1-2份硫酸钡,5-10份环保食品级改性纳米滑石粉,0.3-0.5份抗氧剂1010,0.3-0.5份抗氧剂168,0.5-1份光扩散剂;
S22、包括如下两种制备方式:
第一种制备方式:将配置好的原料加入高速混合机中混合10-15分钟,制得混合物料,再加入到双螺杆挤出机组中进行熔融、塑化、混炼、挤出、造粒,最后冷却切粒,得到增强型三层波纹结构管材内层专用料,料筒温度分别为:165℃,180℃,190℃,190℃,190℃,口模温度为:190℃;
第二种制备方式:将配置好的原料加入密炼机中,利用密炼机进行混合、改性、熔融、塑化、混炼,再通过单螺杆挤出机组进行挤出、造粒,最后冷却切粒,得到增强型三层波纹结构管材内层专用料;
C、聚乙烯共混复合材料的制备步骤如下:
S31、配置如下原料:40-50份LLDPE7042,25-30份聚烯烃弹性体OBC,25-30份聚烯烃弹性体EVA;
S32、包括如下两种制备方式:
第一种制备方式:将配置好的原料加入高速混合机中混合10-15分钟,制得混合物料,再加入到双螺杆挤出机组中进行熔融、塑化、混炼、挤出、造粒,最后冷却切粒,得到增强型三层波纹结构管材中间粘合层专用料,料筒温度分别为:160℃,170℃,180℃,180℃,180℃,口模温度为:180℃;
第二种制备方式:将配置好的原料加入密炼机中,利用密炼机进行混合、改性、熔融、塑化、混炼,再通过单螺杆挤出机组进行挤出、造粒,最后冷却切粒,得到增强型三层波纹结构管材中间粘合层专用料。
优选的,采用一步法制得增强型三层波纹结构管材专用料,先用360度旋转的带加温装置的高混机对物料进行高混,使各种物料能达到高度均化;再通过双螺杆造粒机进行改性造粒,得到增强型三层波纹结构管材专用料。
优选的,将内层材料、外层材料和中间层材料分别加入内层挤出机、外层挤出机、中间层挤出机中挤出,物料通过挤出机单螺杆加热熔融塑化输送至三层共挤机头口模,管材内层和中间层通过内定径套抽真空再冷却定型,管材外层在内部空气压力和外部真空吸力的共同作用下和模块紧密接触成型,管材内层、中间层和外层均匀地熔合在一起;内层挤出各段温度:165℃,180℃,190℃,190℃,190℃;中间层挤出各段温度:160℃,170℃,180℃,180℃,180℃;外层挤出各段温度:190℃,200℃,220℃,220℃,220℃。
与现有技术相比,本发明具有如下有益的技术效果:
本发明中,增强型三层波纹结构管材,内、外壁采用不同质复合改性材料,来达到内外层不同功能的要求,外层要求更高刚性、高抗冲击、耐高低温、耐疲劳、耐候性等;内层要求更环保、更光滑、更有韧性等,通过中层粘合层把内外层完美熔合在一起,确保内外壁热熔复合后,管材内外壁永不分层。本发明用茂金属聚乙烯和聚烯烃弹性体OBC相容增韧剂和纳米无机材料复合增强增韧方法进行共混改性,提高了体系的相容性,刚韧平衡性、增强了体系材料的抗冲击性能、抗穿刺性能、拉伸、韧性、耐侯性、耐老化性能。
附图说明
图1为本发明实施例中增强型三层波纹结构管材的结构示意图;
图2为本发明实施例中增强型三层波纹结构管材的结构剖视图;
图3为图2中A处的结构放大图。
附图标记:1、内层;2、外层;3、中间层。
具体实施方式
如图1-3所示,本发明提出的一种增强型三层波纹结构管材,包括内层1、外层2和中间层3,外层2具有交替分布的波峰和波谷;中间层3连接在外层2的波谷内周面和内层1外周面之间。内层1和中间层3均为实壁层,中间层3间隔设置多个。介质在管道内部流通时起内部承压作用;外层结构主要起外部承压增强强度的作用,并有效降低了材料的成本。内层1、中间层3和外层2由内至外经三层热熔复合。管材具有承压能力强、抗冲击性能好、抗刮划性能好、拉伸强度好、韧性好、耐侯性好和耐老化性能好的特性。管材采用直壁结构和管件连接;采用专用的双层卡扣管件,其中外层为刚柔型改性PP复合材质制成,内层为弹性层与管材紧密连接并且有弹性密封闭水功能,双层卡扣管件上有卡扣自锁结构,能承受管材管件连接内部水压功能,采用柔性连接方式,此连接方式保证管材永不漏水和能承受内部水压,改变了以往给水管材采用热熔或者电熔的模式,利于野外无电无工具也能施工,防止因为需要专业的焊接设备和专业焊接人员带来的不便,并且此管材性能优良,成本低廉,大大节约工程造价成本。
实施例一
一种增强型三层波纹结构管材的制备方法:
外层2采用聚丙烯共混改性复合材料制成,聚丙烯共混改性复合材料由以下重量份的原料组成:30份PP B8101,30份PP K8003,5份LLDPE7042,10份茂金属MPE,3份聚烯烃弹性体OBC,0.4份熔脂调节剂,1份增刚成核剂,1份硫酸钡;20份环保食品级改性纳米滑石粉,2份环保级碳黑,0.5份光热稳定剂,0.5份抗氧剂1010,0.5份抗氧剂168,1份光扩散剂。
内层1采用聚乙烯共混改性复合材料制成,内层材料比外层材料的质量要好,外层的成本较低,节省成本,聚乙烯共混改性复合材料由以下重量份的原料组成:55份HDPE100级延长049,7份LLDPE7042,15份茂金属MPE,9份聚烯烃弹性体OBC,2份环保级碳黑,1份光热稳定剂,2份硫酸钡,10份环保食品级改性纳米滑石粉,0.5份抗氧剂1010,0.5份抗氧剂168,1份光扩散剂。
中间层3采用聚乙烯共混复合材料制成,聚乙烯共混复合材料由以下重量份的原料组成:40份LLDPE7042,30份聚烯烃弹性体OBC,30份聚烯烃弹性体EVA。
将外层2、中间层3和内层1所对应的配料分别加入高速混合机中混合10-15分钟,制得三种混合物料,每种混合物料再加入到双螺杆挤出机组中进行熔融、塑化、混炼、挤出、造粒,最后冷却切粒,得到增强型三层波纹结构管材外、中、内三层壁专用料,外层料筒温度分别为:190℃,200℃,220℃,220℃,220℃,口模温度为:220℃;中间层料筒温度分别为:160℃,170℃,180℃,180℃,180℃,口模温度为:180℃;内层料筒温度分别是:165℃,180℃,190℃,190℃,190℃,口模温度为:190℃;或者是利用密炼机进行混合、改性、熔融、塑化、混炼,再通过单螺杆挤出机组进行挤出、造粒,最后冷却切粒,得到增强型三层波纹结构管材专用料。
将内层材料、外层材料和中间层材料分别加入内层挤出机、外层挤出机、中间层挤出机中挤出,物料通过挤出机单螺杆加热熔融塑化输送至三层共挤机头口模,而管材内层和中间层是通过内定径套抽真空再冷却定型,管材外层在内部空气压力和外部真空吸力的共同作用下和模块紧密接触成型,管材内、中间层、外层均匀地熔合在一起,内层挤出各段温度::165℃,180℃,190℃,190℃,190℃,中间层挤出各段温度:160℃,170℃,180℃,180℃,180℃,外层挤出各段温度:190℃,200℃,220℃,220℃,220℃。
表1:实施例一制备的增强型三层波纹结构管材的物理力学性能
实施例二
一种增强型三层波纹结构管材的制备方法,本实施例与实施例一的区别在于:
外层2采用聚丙烯共混改性复合材料制成,聚丙烯共混改性复合材料由以下重量份的原料组成:18份PP B8101,18份PP K8003,7份LLDPE7042,20份茂金属MPE,5份聚烯烃弹性体OBC,0.2份熔脂调节剂,0.5份增刚成核剂,2份硫酸钡;30份环保食品级改性纳米滑石粉,3份环保级碳黑,0.3份光热稳定剂,0.3份抗氧剂1010,0.3份抗氧剂168,0.5份光扩散剂。
内层1采用聚乙烯共混改性复合材料制成,聚乙烯共混改性复合材料由以下重量份的原料组成:72份HDPE100级延长049,5份LLDPE7042,10份茂金属MPE,6份聚烯烃弹性体OBC,1份环保级碳黑,0.5份光热稳定剂,1份硫酸钡,5份环保食品级改性纳米滑石粉,0.3份抗氧剂1010,0.3份抗氧剂168,0.5份光扩散剂。
中间层3采用聚乙烯共混复合材料制成,聚乙烯共混复合材料由以下重量份的原料组成:50份LLDPE7042,25份聚烯烃弹性体OBC,25份聚烯烃弹性体EVA。
表2:实施例二制备的增强型三层波纹结构管材的物理力学性能
本发明中,增强型三层波纹结构管材,内、外壁采用不同质复合改性材料,来达到内外层不同功能的要求,外层要求更高刚性、高抗冲击、耐高低温、耐疲劳、耐候性等;内层要求更环保、更光滑、更有韧性等,通过中层粘合层把内外层完美熔合在一起,确保内外壁热熔复合后,管材内外壁永不分层。
本发明用茂金属聚乙烯和聚烯烃弹性体OBC相容增韧剂和纳米无机材料复合增强增韧方法进行共混改性,提高了体系的相容性,刚韧平衡性、增强了体系材料的抗冲击性能、抗穿刺性能、拉伸、韧性、耐侯性、耐老化性能。
上面结合附图对本发明的实施方式作了详细说明,但是本发明并不限于此,在所属技术领域的技术人员所具备的知识范围内,在不脱离本发明宗旨的前提下还可以作出各种变化。
Claims (5)
1.一种增强型三层波纹结构管材,其特征在于,包括由内至外经三层热熔复合的内层(1)、中间层(3)和外层(2),内层(1)和中间层(3)均为实壁结构,外层(2)具有交替分布的波峰和波谷;
外层(2)采用聚丙烯共混改性复合材料制成,所述聚丙烯共混改性复合材料由以下重量份的原料组成:18-30份PPB8101,18-30份PPK8003,5-7份LLDPE7042,10-20份茂金属MPE,3-5份聚烯烃弹性体OBC,0.2-0.4份熔脂调节剂,0.5-1份增刚成核剂,1-2份硫酸钡;20-30份环保食品级改性纳米滑石粉,2-3份环保级碳黑,0.3-0.5份光热稳定剂,0.3-0.5份抗氧剂1010,0.3-0.5份抗氧剂168,0.5-1份光扩散剂;
内层(1)采用聚乙烯共混改性复合材料制成,所述聚乙烯共混改性复合材料由以下重量份的原料组成:55-72份HDPE100级延长049,5-7份LLDPE7042,10-15份茂金属MPE,6-9份聚烯烃弹性体OBC,1-2份环保级碳黑,0.5-1份光热稳定剂,1-2份硫酸钡,5-10份环保食品级改性纳米滑石粉,0.3-0.5份抗氧剂1010,0.3-0.5份抗氧剂168,0.5-1份光扩散剂;
中间层(3)采用聚乙烯共混复合材料制成,所述聚乙烯共混复合材料由以下重量份的原料组成:40-50份LLDPE7042,25-30份聚烯烃弹性体OBC,25-30份聚烯烃弹性体EVA。
2.根据权利要求1所述的增强型三层波纹结构管材,其特征在于,茂金属MPE为埃克森美孚3518CB;增刚成核剂为NA960;环保食品级改性纳米滑石粉为2500目以上,环保食品级改性纳米碳酸钙为3000目以上。
3.一种根据权利要求1所述的增强型三层波纹结构管材的制备方法,其特征在于:
A、聚丙烯共混改性复合材料的制备步骤如下:
S11、配置如下原料:18-30份PPB8101,18-30份PPK8003,5-7份LLDPE7042,10-20份茂金属MPE,3-5份聚烯烃弹性体OBC,0.2-0.4份熔脂调节剂,0.5-1份增刚成核剂,1-2份硫酸钡;20-30份环保食品级改性纳米滑石粉,2-3份环保级碳黑,0.3-0.5份光热稳定剂,0.3-0.5抗氧剂1010份,0.3-0.5份抗氧剂168,0.5-1份光扩散剂;
S12、包括如下两种制备方式:
第一种制备方式:将配置好的原料加入高速混合机中混合10-15分钟,制得混合物料,再加入到双螺杆挤出机组中进行熔融、塑化、混炼、挤出、造粒,最后冷却切粒,得到增强型三层波纹结构管材外层专用料,料筒温度分别为:190℃,200℃,220℃,220℃,220℃,口模温度为:220℃;
第二种制备方式:将配置好的原料加入密炼机中,利用密炼机进行混合、改性、熔融、塑化、混炼,再通过单螺杆挤出机组进行挤出、造粒,最后冷却切粒,得到增强型三层波纹结构管材外层专用料;
B、聚乙烯共混改性复合材料的制备步骤如下:
S21、配置如下原料:55-72份HDPE100级延长049,5-7份LLDPE7042,10-15份茂金属MPE,6-9份聚烯烃弹性体OBC,1-2份环保级碳黑,0.5-1份光热稳定剂,1-2份硫酸钡,5-10份环保食品级改性纳米滑石粉,0.3-0.5份抗氧剂1010,0.3-0.5份抗氧剂168,0.5-1份光扩散剂;
S22、包括如下两种制备方式:
第一种制备方式:将配置好的原料加入高速混合机中混合10-15分钟,制得混合物料,再加入到双螺杆挤出机组中进行熔融、塑化、混炼、挤出、造粒,最后冷却切粒,得到增强型三层波纹结构管材内层专用料,料筒温度分别为:165℃,180℃,190℃,190℃,190℃,口模温度为:190℃;
第二种制备方式:将配置好的原料加入密炼机中,利用密炼机进行混合、改性、熔融、塑化、混炼,再通过单螺杆挤出机组进行挤出、造粒,最后冷却切粒,得到增强型三层波纹结构管材内层专用料;
C、聚乙烯共混复合材料的制备步骤如下:
S31、配置如下原料:40-50份LLDPE7042,25-30份聚烯烃弹性体OBC,25-30份聚烯烃弹性体EVA;
S32、包括如下两种制备方式:
第一种制备方式:将配置好的原料加入高速混合机中混合10-15分钟,制得混合物料,再加入到双螺杆挤出机组中进行熔融、塑化、混炼、挤出、造粒,最后冷却切粒,得到增强型三层波纹结构管材中间粘合层专用料,料筒温度分别为:160℃,170℃,180℃,180℃,180℃,口模温度为:180℃;
第二种制备方式:将配置好的原料加入密炼机中,利用密炼机进行混合、改性、熔融、塑化、混炼,再通过单螺杆挤出机组进行挤出、造粒,最后冷却切粒,得到增强型三层波纹结构管材中间粘合层专用料。
4.根据权利要求3所述的增强型三层波纹结构管材的制备方法,其特征在于,采用一步法制得增强型三层波纹结构管材专用料,先用360度旋转的带加温装置的高混机对物料进行高混,使各种物料能达到高度均化;再通过双螺杆造粒机进行改性造粒,得到增强型三层波纹结构管材专用料。
5.根据权利要求4所述的增强型三层波纹结构管材的制备方法,其特征在于,将内层材料、外层材料和中间层材料分别加入内层挤出机、外层挤出机、中间层挤出机中挤出,物料通过挤出机单螺杆加热熔融塑化输送至三层共挤机头口模,管材内层(1)和中间层(3)通过内定径套抽真空再冷却定型,管材外层(2)在内部空气压力和外部真空吸力的共同作用下和模块紧密接触成型,管材内层(1)、中间层(3)和外层(2)均匀地熔合在一起;内层(1)挤出各段温度:165℃,180℃,190℃,190℃,190℃;中间层(3)挤出各段温度:160℃,170℃,180℃,180℃,180℃;外层(2)挤出各段温度:190℃,200℃,220℃,220℃,220℃。
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