The plastic pipe electrofusion connecting piece that mesh-structured electric heating element is arranged
Technical field
The utility model relates to a kind of electrofusion connecting piece, and particularly, the utility model relates to a kind of plastic pipe electrofusion connecting piece that mesh-structured electric heating element is arranged.
Background technique
Along with a large amount of of plastic pipe popularize, more and more outstanding by the connectivity problem that the defective of style plastic pipe connector causes, be the principal element of restriction pipeline construction always.The connecting means of plastic pipe is divided into two kinds by large class, and the first is that glue is bonding, and such as PVC, PA, the pipeline that the materials such as ABS are made, the second are exactly that hot melt connects, the pipeline of making such as materials such as PE, PP, PE-RT.Hot melt connects the following three kinds of modes that can be divided into again: heat-melting butt-joint, socket hot-melting connect, electric smelting connects, and wherein electric smelting connects owing to have irreplaceable superior function (particularly in steel wire mesh frame pipe and PE gas pipeline field) by the comprehensive high praise in market.Electric smelting is connected to, and a kind of " the thermoplastic electrofusion connecting piece engages with pipe way.Electrofusion connecting piece is heated by joule effect by the heating element in the mating face that is embedded between it and the pipe, makes material fusing around their, thereby makes pipe and the pipe fitting surface is molten is in the same place.”
The electrofusion connecting piece of the nineties exploitation is by Britain You Bonuo company fabrication process, the exposed silk electrofusion connecting piece that namely generally uses on the market.Owing to electric heating wire in use often comes off, doubling causes short circuit, when dimensional fits has deviation or ovality excessive, the insertion pipe fitting can cause and open circuit, and it is relatively tight to operator's qualification requirement to make this kind electrofusion connecting piece, and the reject rate of making by this kind production technology is high.
For fear of defects, there is producer to start to develop the electrofusion connecting piece of plastic electric heating wire by the technique of the large lotus Seiko of Korea S, be exactly with the plastic one-tenth electric wire of electric heating wire shape, be wound on request molding and forming on the injection mould core again, the demoulding obtains finished product (seeing Fig. 1) after the cooling.Yet the electrofusion connecting piece with this plastic silk explained hereafter, although part has solved the defective that exposed electric heating wire electrofusion connecting piece inserts broken string, but owing to when plastic, must adopt high temperature wire drawing and low temperature water cooling, formed the oxide layer that to remove on the surface of electrically-heated-wire, intercepted the mobile recrystallization of molten material of tubing and pipe fitting, so generally adopt the peeling strength of the electrofusion connecting piece of this kind technique to compare with exposed electric heating wire electrofusion connecting piece.
The defective that exists based on the technique of the first two kind and the rising of labor cost, cloth silk technology and equipment after part producer introduces automatically, realized automatic production in technique, but increased the precision of pipeline fit dimension, but the method for cloth silk needs special device automatically, and expensive, and the method is owing to still belong to the tratitional technology of single line cloth silk, the electric heating element of preparing is the monofilament coiling, no matter this kind electric heating element is hidden silk or exposed silk, all may produce the consequence of welding short circuit.
In sum, existing electrofusion connecting piece is owing to all adopt axially wiring (direction of inserting with tubing is the direction of vertical angle), when the energising welding, its temperature may be higher than and keep the required temperature of plastic pipe and also can produce molten swelling pressure power, make the electric heating wire displacement and cause short circuit, cause welding failure even pipe fitting is scrapped.In addition, the link of axial wiring can not be to cooperate with the footpath with cooperating of pipeline, certainly has certain interval, and the insertion pipe fitting can cause and open circuit.Therefore, need a kind ofly to avoid that said temperature is too high, short circuit and situation about opening circuit, moderate cost, low cost of manufacture, stay-in-grade electrofusion connecting piece.
The model utility content
For solve available technology adopting axially wiring cause connection the time excess Temperature and be easy to short circuit, link and line size are mismatched and the problem that is easy to open circuit, the utility model provides a kind of plastic pipe electrofusion connecting piece that mesh-structured electric heating element is arranged, the built-in cylindric electric heating element of described electrofusion connecting piece, this cylindric electric heating element is made of with the plastic strip identical with described electrofusion connecting piece material the mesh-structured resistance material bar of equidistantly arranging along the electrofusion connecting piece inwall.Described mesh-structured resistance material bar is continuous several fonts along the barrel of described cylindric electric heating element and arranges; Described plastic strip and described mesh-structured resistance material bar are affixed and surround the inner tube wall of described cylindric electric heating element.
The all-in resistance of described mesh-structured resistance material bar must meet the described current density requirement that the plastic pipe electrofusion connecting piece of mesh-structured electric heating element is arranged.Current density refers to surface loading power, current density in the general electrotechnology refers to the electric current that passes through in the wire in same cross section, because the resistance of wire is different, the size of current of passing through is different, resistance is larger, electric current is less, power is less, the bearing power that is assigned to the surface is just less, otherwise then the bearing power on surface is larger, the material surface heat generating spot is more concentrated, as the electric melting pipe fittings of axial wiring often the quick-fried phenomenon of weldering be exactly after the electric heating wire short circuit short time table lotus power be the consequence that rises and cause for how much, if the material surface heating is not enough so that the plastics that contact with electric heating element decompose rapidly carbonization within weld interval, its surface loading power meets the current density requirement of plastic pipe electrofusion connecting piece.Such as, according to thermal conductivity 0.33W/mK and the density of material 0.92g/cm of PE material
3Calculate, the melting point peak of PE material is 240 ℃, and when weldingvoltage is 39.5V (GB regulation), its table lotus power is controlled at 1.5~2.2Wcm
2Be ideal value, surpass the structure of molecule that this value will decomposed P E material, still to carbonization.In addition, described resistance material bar can be made by the resistance alloys light sheet material that is fit to each specification plastic pipe electrofusion connecting piece intensity, and namely the tensile strength of the crystalline solid that obtains after to the plastic materials fusing of pipeline, cooling of selected resistance material heating power should be not less than the tensile strength with the plastic materials of the resistance material of volume or pipeline.The tensile strength of described crystalline solid is main relevant with the specific resistance of resistance material, the surface loading power that produces behind input rated voltage should be able to guarantee that the plastic molecules structure do not decompose, and the electrofusion connecting piece intensity of such resistance alloys light sheet material meets the requirement of plastic pipe electrofusion connecting piece intensity.Such as, above-mentioned PE material is when weldingvoltage is 39.5V, specific resistance at normal temperatures value is 0.90~1.28 μ Ω m.Described resistance alloys light sheet material comprises chromium and rhenium, and the content of chromium is the 15-24.5 % by weight, can also comprise iron or comprise simultaneously iron and aluminium, wherein the content of aluminium is 0.35 % by weight, the serviceability temperature of this material is 1100-1200 ℃, and fusing point is 1400 ℃, and density is 8.1-8.3g/cm
3, the specific resistance of 20 ° of C is 0.98-1.11 μ Ω m, tensile strength is 750Mpa, specific elongation is 25%, alternating bending frequency〉5, the life-span is 50h/ ° of C fast.
Material shown in the preferred following table 1 of the resistance alloys light sheet material that the utility model adopts:
Table 1
In the plastic pipe electrofusion connecting piece that mesh-structured electric heating element arranged of the present utility model, hole in the described mesh-structured resistance material bar can be square, also can be rectangular or other polygonals, in each hole arbitrarily between the nonadjacent vertices mean value of distance be 5 times to 10 times of described resistance material bar thickness, the width (being the width of each limit muscle of resistance material bar and the width of each mesh peripheral edge muscle) that wherein consists of the limit muscle of each mesh is 1 to 3 times of described resistance material bar thickness.The face of weld of the described plastic pipe electrofusion connecting piece that mesh-structured electric heating element arranged and plastic pipe should be not less than 2 times of tubing wall area in this plastic pipe cross section, in welding during with the steel frame-plastic pipe, the face of weld of the described plastic pipe electrofusion connecting piece that mesh-structured electric heating element arranged and plastic pipe should be not less than 4 times of tubing wall area in this plastic pipe cross section.
Of the present utility model have the preparation method of the plastic pipe electrofusion connecting piece of mesh-structured electric heating element may further comprise the steps:
1) the mesh-structured resistance material bar of preparation;
2) with step 1) affixed with the prepared identical plastic strip of plastic pipe electrofusion connecting piece material in mesh-structured resistance material bar surface of preparation, it is rolled into cylindric electric heating element;
3) with step 2) the cylindric electric heating element of preparation is inserted in the injection mould of electrofusion connecting piece, and access lighting outlet and electrode stake namely obtain the electrofusion connecting piece finished product according to the injection molding process injection moulding of routine.
But with the electrofusion connecting piece of said method production plurality of specifications or model, such as straight-through, reducing, elbow, threeway, four-way, flange and pipe cap etc.
The preparation method of described electrofusion connecting piece is characterized in that, described step 1) adopt following method:
Method A:
A1-1) be with required width to be cut into strip material by welding resistance material according to the specification of described electrofusion connecting piece;
A1-2) with steps A 1-1) strip material that is cut into is according to the bonding area punching compacting of described electrofusion connecting piece, make the hole pattern band, more prepared hole pattern band is made mesh-structured resistance material bar (usually described hole pattern band punch die blanking being formed);
Step 1) also can adopt following methods AA:
AA1-1) according to the internal diameter of described electrofusion connecting piece, the shrinkage character of resistance material and the welding area of described electrofusion connecting piece, described resistance material is cut into along the length direction of prepared mesh-structured resistance material bar is the resistance material bar that continuous several fonts are arranged;
AA1-2) at steps A A1-1) the middle punching that is along its length continuously the resistance material bar that equally spaced several fonts arrange of being cut into, make mesh-structured resistance material bar.
Described step 2) adopt one of following method:
Method B: molding and forming electric heating element
B2-1) injection mould of the corresponding specification of design and plastic injection caused type, described injection mould can make step 1) put into its mold cavity after the prepared mesh-structured resistance material crimped;
B2-2) mould structure adopts oil cylinder to pull and push core, the end face that pulls and pushes core should be provided with fillet, be convenient to insert crooked resistance material bar, the core diameter is equal to the internal diameter of corresponding pipe fitting, on mould, push down in the middle of the width of resistance material bar with loose plug/briquetting first, the width of loose plug/briquetting is 1/2nd of resistance material bar width, the purpose of doing like this has two, the one, compress the resistance material bar, the resistance material bar can extrusion when injection of plastic, the 2nd, reserved the space when injection-molded finished, the resistance material bar is closely linked to each other with the finished product inwall, guarantee the dimensionally stable of electrofusion connecting piece endoporus, the external diameter at the resistance material bar after the mold closing injection moulding forms plastic strip, becomes cylindric electric heating element after the cooling and demolding.
Said method is suitable for the batch production of the following specification link of Dn200, and the method moulding is quick, and automaticity is high, and labor cost is low, the link dimensionally stable of producing.
Method C: thin of mesh-structured resistance material bar and plastics are extruded rear hot-forming synchronously
C2-1) in step 1) the mesh-structured resistance material bar of preparation is with thin extruder continuous hot-press of plastics plastic strip identical with the plastic pipe material that connects, hot pressing is about to mesh-structured resistance material bar and is placed on below thin outlet of extruding of plastics, thin of plastics are extruded when not yet cooling off with Er Roll wheel simultaneously thin of pinched resistor material rod and plastics, make the part material of thin of plastics embed the mesh of mesh-structured resistance material bar, thereby form a synthetic integral body of two kinds of materials, be convenient to step C2-2) operation;
C2-2) will be at step C2-1) in the mesh-structured resistance material bar that presses plastic strip that forms be cut into the interior electrical path length that will dispose the specification electrofusion connecting piece, be rolled into tubular in frock, its bar of moulding that presses is become electric heating element cylindraceous to postwelding.
Said method is applicable to produce in batches the following electrofusion connecting piece of the above Dn630 of Dn315.
Method D:
D2-1) in step 1) on the mesh-structured resistance material bar of preparation with the supersonic welder plastic strip downhand welding that it is identical with the plastic pipe material that connects;
D2-2) will be at step D2-1) in the mesh-structured resistance material bar of the plastic strip of burn-oning that forms being rolled into tubular with the unidimensional frock of finished product injection mould, its bar of moulding of burn-oning is become electric heating element cylindraceous to postwelding.
Be 2 to 5 times of described electric heating element resistance material thickness by the thickness of the identical described plastic strip of the plastic pipe material method gained and that connect of the above-mentioned plastic pipe electrofusion connecting piece that is prepared with mesh-structured electric heating element, when quadric injection mould, several fonts unit that can guarantee electric heating element is not subjected to injection pressure and is out of shape.
Of the present utility model have the plastic pipe electrofusion connecting piece of mesh-structured electric heating element to have following advantage:
1, the structure of mesh-structured electric heating element is more stable than the heating wire structure of axially wiring, so that the output power in when welding is constant, also can not short circuit even input voltage fluctuation occurs (even in electrofusion connecting piece melting welding during to shape deformation, its resistance value still remains unchanged), that guarantees to construct carries out smoothly, stop accident potential, guarantee the safe operation of pipeline.
2, mesh-structured electric heating element is applicable to the manufacturing of any model pipe joint, the electrofusion connecting piece that comprises middle small dimension even super-large diameter, also making to provide technical support with the manufacturing of the super-large diameter electrofusion connecting piece of single line wrapping wire manufacturing such as Dn710, Dn800, Dn900, Dn1000, Dn1200, Dn1600 etc., has avoided relatively poor the opening circuit of causing of dimensional fits ovality precision owing to heavy caliber link and pipeline.
3, mesh-structured electric heating element under the prerequisite of same resistance value (power), has increased heating area, has reduced table lotus power (current density), and electric heating element conduction temperature is remained in the temperature range of required 200C to the 240 ° of C of plastics.
Prepare method of the present utility model and have following advantage:
1, technique that can prefabricated electric heating element provides technology platform for pipelining.
2, the preparation method can adopt conventional mechanical equipment full work station to realize automatic production, adopts pipelining, reduces manufacture cost, and the quality of avoiding the manual operation factor to cause is unstable.
3, compare with rear cloth silk technique, prepare electrofusion connecting piece of the present utility model and need not special device, further reduce manufacture cost, select domestic conventional mechanical equipment (mainly being punch press) can satisfy arts demand.
In addition, the utility model also has the advantages such as constructability, steady quality are reliable, long service life, anti-foundation settlement superior performance, tightness is good, overall cost is low (compare with tratitional technology, electrofusion connecting piece of the present utility model can be saved 50% labor through man-hour calculation), the labor intensity of operation is low.
Description of drawings
Fig. 1-a is the partial schematic sectional view of plastic electric heating wire electrofusion connecting piece in the prior art, wherein the plastic electric heating wire of 3 expressions.
Fig. 1-b is the structural representation of the plastic electric heating wire of plastic electric heating wire electrofusion connecting piece in the prior art, wherein 1 expression and the foreskin of making the link same material, 2 expression resistance wires.
Fig. 1-c is the sectional view of the plastic electric heating wire of plastic electric heating wire electrofusion connecting piece in the prior art.
Fig. 2 is the schematic representation of the prepared hole pattern band of the utility model embodiment 1, and wherein the fixing flanging bottom sediment of use is reserved in 4 expressions, and bandwidth are welded in 5 expressions.
Fig. 3 is the schematic representation of the prepared mesh-structured resistance material bar of the utility model embodiment 1.
Fig. 4 is the schematic representation of the resistance material bar of the prepared hot compression molding material strip of the utility model embodiment 1.
Fig. 5 is the schematic representation of the prepared cylindric electric heating element of the utility model embodiment 1.
Fig. 6 is the schematic representation of the prepared plastic pipe electrofusion connecting piece finished product (leading directly to) of the utility model embodiment 1.
Embodiment
Below in conjunction with embodiment, further specify the utility model.
Embodiment 1
The electrofusion connecting piece of the plastic pipe of the straight-through Dn200 of preparation specification, the trade mark is GH140 in the option table 1, thickness is 1mm, specific resistance is 1.04 resistance alloys light sheet material, this material comprises 20% chromium (Cr), 0.35% aluminium (A1), all the other are iron (Fe) and rhenium (Re), the implementation operation is as follows:
1, the specification according to the link of Dn200 is cut into wide the be strip material of 48mm by welding with required width with above-mentioned material;
2, with strip material with the stamping process that feeds punch die continuously this with on the prismatic hole of punching press 5x5mm, the width that consists of the limit muscle of each mesh is 2mm, and gained hole pattern band subtracted 5mm punch die blanking by the internal diameter girth of electrofusion connecting piece, the internal diameter perimeter length 631.5-5=626.5mm of Dn200 electrofusion connecting piece makes mesh-structured resistance material bar.The face of weld of the described plastic pipe electrofusion connecting piece that mesh-structured electric heating element arranged and plastic pipe is 2 times of tubing wall area in the Dn200 plastic pipe cross section.Describedly mesh-structuredly be continuously equally spaced several fonts along the length direction of gained electric heating element band side by side by identical shaped diamond-shaped meshes and arrange and form, the angle that is on two limits of intersecting of adjacent diamond-shaped meshes is 103 ° on the described resistance material bar width direction.The power requirements value distribution by electrofusion connecting piece is cut apart in the unit of several fonts, and it is 0.95 Ω to 0.98 Ω that Dn200 specification resistance value requires.Rice resistance after the thick resistance material band punching of the wide 1mm of 48mm is 0.08 Ω/m, in order to reach resistance value, a few font cells should be divided into 49 wide cells of 13mm, the length of conductor has just increased by 3 times like this, cross-sectional area of conductor has reduced 50%, calculates by correlation formula, and every volume resistance is 0.48 Ω, two electric heating elements are that resistance is 0.96 Ω behind one group of series winding, meet the power requirements of Dn200 electrofusion connecting piece;
3, design injection mould is put into its mold cavity after the mesh-structured resistance material crimped that described injection mould can make above-mentioned steps prepare;
4, mould structure adopts oil cylinder to pull and push core, pull and push the core end face and be provided with fillet, be convenient to insert crooked resistance material bar, the core diameter is equal to the internal diameter of corresponding pipe fitting, push down in the middle of the width of resistance material bar with loose plug first in that the mould mold closing is front upper, the width of loose plug is 1/2nd of resistance material bar width, the purpose of doing like this has two, the one, compress the resistance material bar, the resistance material bar can extrusion when injection of plastic, the 2nd, reserved the space when injection-molded finished, the resistance material bar is closely linked to each other with the finished product inwall, guarantee the endoporus dimensionally stable of electrofusion connecting piece.The part that the quadric injection mould of compress reserving behind the mold closing is used, after the injection moulding the plastics wall thickness be 2 to 3mm cylindric electric heating element;
5, connect respectively lighting outlet and electrode stake with two electric heating element series windings, and in the outer end of two elements;
6, design finished product epimorph is correctly put into Finished die with the electric heating element of combination, gets final product after injection moulding, the cooling and demolding.
Through above-mentioned steps, form the electrofusion connecting piece of the plastic pipe of the straight-through Dn200 of specification, the trade mark is GH140 in the option table 1, thickness is 1mm, specific resistance is 1.04 resistance alloys light sheet material, and wherein mesh-structured is the prismatic hole of 5x5mm, and the width that consists of the limit muscle of each mesh is 2mm, the face of weld of this electrofusion connecting piece and plastic pipe is 2 times of tubing wall area in the Dn200 plastic pipe cross section, and its plastics wall thickness is 2 to 3mm.
Embodiment 2
The electrofusion connecting piece of the plastic pipe of the straight-through Dn630 of preparation specification, the trade mark is Cr15Ni60 in the option table 1, specific resistance is 1.1, thickness is the resistance alloys thin plate of 1.5mm, this material comprises 15% chromium (Cr), and all the other are rhenium (Re), and the implementation operation is as follows:
1, the material of above appointment being cut into width is 140mm resistance material bar;
2, then in the middle punching of resistance material bar, in each hole arbitrarily between the nonadjacent vertices mean value of distance be 8mm, the width that consists of the limit muscle of each mesh is 2mm.The face of weld of the described plastic pipe electrofusion connecting piece that mesh-structured electric heating element arranged and plastic pipe is 2 times of tubing wall area in the Dn630 plastic pipe cross section.Describedly mesh-structuredly be continuously equally spaced several fonts along the length direction of gained electric heating element band side by side by identical shaped diamond-shaped meshes and arrange and form, the angle that is on two limits of intersecting of adjacent diamond-shaped meshes is 103 ° on the described resistance material bar width direction.Banded electric heating element bar is cut into the internal diameter girth of Dn630 electrofusion connecting piece, length 1979-8=1971mm, width is the rectangular bars of 140mm, and the power requirements that the unit of several fonts is cut apart by electrofusion connecting piece distributes, and Dn630 specification requirement resistance is 0.80 Ω to 0.84 Ω.Rice resistance after the thick resistance material band punching of the wide 1.5mm of 140mm is 0.024 Ω/m, in order to reach resistance value, the cell of several fonts should be divided into 47 wide cells of 42mm, the length of conductor has just increased by 4 times like this, cross-sectional area of conductor has reduced 47%, calculates by correlation formula, and every volume resistance is 0.41 Ω, two electric heating elements are one group, meet the power requirements of Dn630 electrofusion connecting piece;
3, the mesh-structured resistance material band of above-mentioned steps preparation with plastics thin extruder answer continuously the plastic strip identical with the plastic pipe material that connects;
The mesh-structured resistance material band that presses plastic strip that 4, will form in step 5 is cut into the interior electrical path length that will dispose the specification electrofusion connecting piece, is rolled into tubular in frock, and its bar of moulding that presses is become electric heating element cylindraceous to postwelding; Two electric heating elements are contacted, and connect respectively lighting outlet and electrode stake in the outer end of two elements;
5, design finished product epimorph is correctly put into Finished die with the electric heating element of combination, gets final product after injection moulding, the cooling and demolding.
Through above-mentioned steps, form the electrofusion connecting piece of the plastic pipe of the straight-through Dn630 of specification, the trade mark is Cr15Ni60 in the option table 1, thickness is 1.5mm, specific resistance is 1.1 resistance alloys light sheet material, in each mesh-structured hole wherein arbitrarily between the nonadjacent vertices mean value of distance be 8mm, the width that consists of the limit muscle of each mesh is 2mm, the face of weld of this electrofusion connecting piece and plastic pipe is 2 times of tubing wall area in the Dn200 plastic pipe cross section.