DE102013100719B4 - Plastic composite pipes with process and device for continuous production - Google Patents

Abstract

Process for the continuous production of plastic composite pipes with fiber composite material, with the following steps: a) Extruding a weldable, thermoplastic plastic strip (2) of a predetermined width and feeding this strip to a forming station (4) in an inlet level, which is relative to the axis of the pipe to be produced runs at a distance of the radius of a core pipe (5) of the pipe to be produced, the tape (2) being guided with an adjustable inlet angle; b) bending the tape (2), which is aligned with respect to the inlet angle, so that the tape (2) is supported by a inner support tube results in a helix with the pipe diameter of the core pipe (5) as the outer diameter of the helix with a narrow gap (2a) between adjacent tape windings and the resulting core pipe (5) grows out of the forming station (4) and extends helically along the pipe axis from the forming station ( 4) moved; c) closing the gap gaps (2a) between adjacent types of tape windings by welding the tape windings and forming the core tube (5), which grows and rotates along the tube axis; d) winding impregnated fabric tape (60) onto the circumference of the growing, rotating core tube (5) when the tube is melted on the surface and on the surface fused and impregnated fabric tape (60) for the purpose of welding the fabric tape (60) to the pipe; e) repeating step d) if several layers of fabric tape (60) are to be used to form the pipe wall; f) if desired, apply a protective coating (15) over the outer surface of the manufactured pipe.

Description

Field of invention

The invention relates to a method and a device for the continuous production of plastic composite pipes with fiber composite material, in particular with stepless diameter adjustment, as well as to the plastic composite pipe itself.

Background of the invention

With WO 2008/066768 A1 It is known to manufacture plastic composite pipes discontinuously by winding plastic profiles, including those with fiber material, onto a driven mandrel and welding them. This known method only enables the production of pipes of predetermined dimensions in terms of nominal diameter and length on a specific production facility.

Out DE 695 09 832 T2 (equals to EP 0 693 650 B1 ) it is known to wind an injection-molded hollow body made of thermoplastic material on the outside with a bundle of soaked, continuous reinforcing fibers and to reinforce the inside with axially parallel, dispersed reinforcing fibers.

Out EP 0 109 413 B1 a machine for the production of helically wound pipe is known, in which a plastic strip is fed to a roller ring in the form of a cage with a number of rollers and is wound there with overlapping edges. A composite roller works with a pressure member to bring the tape edges into locking engagement with one another at the point of overlap. This continuous process does not produce a plastic composite pipe with a fiber composite material.

It is known to manufacture plastic composite pipes discontinuously by winding fiber material onto a core with a simultaneous supply of plastic material. This known method only enables the production of pipes of predetermined dimensions in terms of nominal diameter and length on a specific production facility.

General description of the invention

The invention is based on the object of creating a method and a device for the continuous production of plastic composite pipes. Furthermore, pipes of different diameters should be able to be produced with one and the same production plant, i. H. the pipe diameter should be changeable in a diameter range.

The object set is achieved on the basis of the features of the independent claims and is configured and further developed by the further features of the dependent claims.

In detail, the method provides for the extrusion of a thermoplastic plastic strip of a predetermined width and feeding of this strip in an inlet plane at a radius distance from the pipe to be produced and with an adjustable inlet angle relative to the axis of the pipe to be produced. The strip, which is aligned with regard to the inlet angle, is curved in a forming station so that the strip results in a helix whose diameter corresponds to the diameter of a core tube. Remaining gaps between adjacent turns of the helix are welded, i.e. H. the narrow gaps between the band edges are closed, for example by means of extrusion welding, whereby a core tube is formed that grows along the tube axis and rotates in the process. In the further course, the pipe is supported from below and is preferably driven to rotate at the same time. Impregnated fabric tape, preferably in several layers, is wound onto the circumference of the increasingly longer core tube, with both the surface of the core tube and the impregnated fabric tape being melted. As a result, the fabric tape is welded to the core tube. If desired, a protective coating can also be applied over the outer surface of the manufactured pipe.

In order to avoid defects in the pipe produced, the impregnated fabric tape surface is monitored for air inclusions and with a good bond between the reinforcement in the fabric tape. The infrared emission of the fabric tape surface is controlled by image analysis.

The diameter of the pipes produced can be continuously adjusted. For this purpose, before feeding the thermoplastic plastic strip, its inlet level is adjusted to the desired one The diameter of the pipe to be produced is adjusted and the inlet angle is adjusted to the pitch of the helix.

Further details of the invention emerge from the following description of exemplary embodiments and the appended claims.

Figure list

• 1 eine Gesamtanlage zur Herstellung von Kunststoff-Verbundrohren in schematischer Darstellung,
• 2 eine perspektivische Ansicht von Teilen der Gesamtanlage mit gestaffelten Auftragsstationen
• 3 eine Band-Zuführeinrichtung,
• 4 eine Formstation,
• 5 eine Bandkrümmungsvorrichtung,
• 6 einen Teil einer Vorrichtung zur Stabilisierung der Rohrkrümmung eines in Entstehung begriffenen Rohres,
• 7 einen Gurtantrieb,
• 8 eine Imprägniervorrichtung von Fasergewebe,
• 9 eine Laminatstation, und
• 10 ein Kunststoffrohr, im Entstehen begriffen.

Show it:

• 1 a complete system for the production of plastic composite pipes in a schematic representation,
• 2 a perspective view of parts of the overall system with staggered application stations
• 3 a tape feeder,
• 4th a forming station,
• 5 a belt curling device,
• 6th part of a device for stabilizing the pipe curvature of a pipe being formed,
• 7th a belt drive,
• 8th an impregnation device for fiber fabric,
• 9 a laminate station, and
• 10 a plastic pipe, in the making.

Detailed description of the invention

In the 1 The overall system outlined includes an extruder 1 for the production of a thermoplastic plastic tape 2 , a tape feeder 3 of the plastic belt to a forming station 4th , from which a core tube 5 grows out by means of laminate application devices 8th with impregnated fabric tape 60 ( 10 ) is wound to form a continuous string of tubing. The fabric tape 60 is in a plant 6th ( 8th ) and a laminate feeder 7th to the core tube 5 or the pipe string produced. The tubing string can be placed in a protective cover applicator 9 with a protective cover 15th ( 10 ) on the outer surface. The pipe produced in this way is in a station 10 Cut to commercial length and the pipe ends checked for faultlessness and the cut pipes over a roller conveyor 11 discharged.

2 shows details of the plant, partly opposite 1 modified form. The core tube 5 is in the forming station 4th formed of the thermoplastic plastic tape 2 ( 10 ) via the tape feeder 3 is fed. To the forming station 4th counts a belt curler 20th ( 4th and 5 ), which is the thermoplastic plastic tape 2 curves helically to form a helix (see 10 ), so that the narrow sides or edges of adjacent tape windings are close to each other and the gap gap 2a is narrow between adjacent tape edges. The tape edges are welded together, which is shown in 4th by means of a welding extruder 12th takes place, its nozzle 13th to the gap 2a can be oriented between adjacent tape windings and a weld bead to close the gap 2a gives away. In this way, the core tube is created from the strip coil 5 , which because of constant growth moves along the pipe axis and rotates in the process. Several belt drives are used to support the pipe being created 50 ( 7th ) are used, which form a rotating and supporting device for the pipe during its manufacture.

Any laminate applicator 8th includes a laminate guide and a pressure roller (similar to the roller table 32 the 3 ) to the impregnated fabric tape 60 on the core tube 5 to apply. In detail, this is done with the help of laminate stations 81 , 82 , 83 via laminate feed stations 71 , 72 , 73 brought to the circumference of the pipe being created and by means of the laminate application devices 8th pressed there. Further pressing takes place via belt drives 50 as well as via pairs of supporting rollers 55 ( 7th ).

3 shows the tape feeder 3 who have favourited the tape 2 to the forming station 4th brings up. If different diameter of the core tube 5 are to be produced, the feed point of the plastic tape must 2 to the circumference of the core tube 5 be changeable. For this purpose the band Feeding device 3 adjustable in height and as a trolley 35 on tracks 36 movable. The tape feeder 3 includes a base plate 30th , the carrier of a height-adjustable, drivable pair of rollers 31 and a roller table 32 is around a vertical pivot axis 30a relative to the car 35 is pivotable to the inlet angle of the plastic tape 2 to the axis of the core tube 5 to be able to adjust. The base plate 30th can still have a cutting unit 33 wear as shown. The tape feeder 3 also has a pulley 34 on to from the tape extruder 1 supplied tape 2 on the correct feed plane tangential to the core tube 5 to steer. Lifting spindles can be used to adjust the height. The conveying speed of the pair of drivable rollers 31 is on the peripheral speed of the core tube 5 adjustable.

4th shows the forming station 4th in connection with the tape feed device 3 and the extruder 12th . The thermoplastic plastic tape 2 becomes tangential to the resulting core tube 5 and brought up at an inlet angle relative to the pipe axis which corresponds to the pitch angle of the helical coil with the diameter of the core pipe 5 corresponds to. The plastic tape 2 has a width that corresponds to the pitch of the helix. See also 10 . That way are the gaps 2a between adjacent turns of the helix small and can with the welding extruder 12th can be easily closed. Its outlet nozzle 13th can be guided very close to the gap at 2a between two adjacent turns of the helical coil in order to deliver a weld bead into the gap and to close it.

5 Figure 10 shows the front of the belt curler 20th , the back of which is in 4th can be seen on a reduced scale and the one height-adjustable roller station with a driven pair of rollers 21 , 22nd and with a non-driven curling roller 23 represents. The curling roller 23 is relative to the pair of rollers 21 , 22nd adjustable so that the surface of the curving roller and the gap between the roller pair 21 , 22nd in the intended curvature of the pipe wall of the core pipe 5 lie. The gap between the pair of rollers 21 , 22nd is on the thickness of the plastic tape 2 adjustable.

The forming station 4th ( 4th ) also includes a roller cage 40 , on which several rolling stands 41 around the circumference of the developing core tube 5 are attached around. How best to look 6th can be seen, contain the rolling frames 41 a guide roller 42 and two rows of guide rollers 43 , 44 . The leadership roles 43 , 44 sit on axes 45 , 46 that are over curved girders 47 are connected to each other. The curvature of the curved beams 47 is the wall curvature of the resulting core tube 5 adapted and is selected accordingly for each new diameter of the pipe.

Tests carried out have shown that core tubes 5 with diameters in the range from 500 to 1400 mm can be produced without an inner support tube.

7th shows one of the belt drives 50 . Every belt drive 50 includes a tenter frame 51 for tensioning a belt 52 that can be driven in a rotating manner. The stenter frame 51 is about a spindle 53 height adjustable. The belt drive 50 is from a rack 54 surrounded which adjustable pinch rollers 55 carries that on the perimeter of the nascent pipe 5 be brought to the cause. In this way, the supplied impregnated fabric tape 60 be pressed against the pipe in the process of being formed.

8th shows schematically the production of the impregnated fiber fabric (fabric tape) 60 , which is also known as a laminate. Glass fabric 61 is from a spool of glass fabric 62 a pair of calenders 63 , 64 fed which the impregnation material 65 into the glass fabric 61 press in. The impregnation material 65 , mostly hot thermoplastic of the type like the tape 2 , is on both sides of the glass fabric 61 of extruders 66 , 67 fed. The calenders 63 , 64 are heated to ensure the safe impregnation of the glass fabric 61 to ensure with liquid thermoplastic. An optical testing device 68 with connected measuring electronics is on the fabric tape produced 60 directed to monitor their surface quality. The impregnated fabric tape 60 can have a deduction device 69 directly to the laminate feeder 7th be fed to the resulting tube with the impregnated fabric tape 60 to wrap. To continuously impregnated fabric tape 60 To be able to deliver, a material magazine with glass fabric spools can be used 62 be provided from which the glass fabric 61 is deducted. When a coil runs out, the glass fabric becomes 61 a new spool to the end of the glass fabric 61 sewn to the old bobbin.

Laminate production can also take place in stock, ie the hot, impregnated fabric belt leaving the calender 60 is cooled by air and on supply spools 80 wound up for the laminate stations 81 , 82 , 83 to be available as 2 combined with 9 shows. The pipe production plant is fed with turnstiles 84 , which are the supply spools 80 store (see 9 ). The impregnated tape 60 is via a deduction device 85 deducted and over a Overlock sewing machine 86 the respective laminate feed device 71 , 72 or 73 fed. The overlock sewing machine 86 makes it possible to use fabric tapes from the supply reels 80 to be joined by sewing to form a continuous strip of impregnated fabric 60 to create. In the respective laminate feed devices there are heating devices for melting the surface of the laminates in order to ensure a secure bond with the pipe to be produced. An image surveillance system monitors the melting of the laminate and the correct connection to the pipe.

The laminate feeders 71 , 72 , 73 correspond in their construction to the tape feeder 3 and therefore do not need to be described in more detail.

The plastic composite pipes are manufactured as follows:

With the extruder 1 becomes a thermoplastic plastic tape 2 predetermined width generated and the tape feeder 3 passed that the tape 2 the belt curler 20th feeds. The feed takes place in an inlet plane at a radius distance from the axis of the pipe to be produced and with an inlet angle to the axis that corresponds to the angle of inclination of the screw thread from which the core tube is formed 5 builds up. The shaping into a helix with a tube diameter takes place in the band bending device 20th ( 4th , 5 ). Gaps remain between the individual turns of the helix 2a having a weld bead from the extruder 12th be replenished. This creates a core tube 5 that moves in a helical manner while cooling down from the rolling stands 41 the forming station 4th shaped, ie calibrated to size and shape. The weld beads are also rolled flush with the surface of the core tube.

Next is the core tube 5 with impregnated fabric tape 60 , the so-called laminate. In order to be able to do this, the pipe being manufactured is supported at several points along the length of the pipe and driven to rotate, so that the pipe being formed continues to move helically. Impregnated fabric tape 60 , which is applied to the circumference of the pipe being created, is wound up in a helical manner and thereby strengthens the pipe wall (see 10 ). The impregnated fabric tape 60 can be applied in several layers in staggered stations, as in 2 shown. Care must be taken to ensure that the fabric tape is connected to the resulting pipe without waves and air bubbles. Therefore, the surfaces of the impregnated fabric tape and the pipe that is being formed are melted and the melted surfaces are checked for their quality. The check is carried out on the basis of the infrared emission of the fabric tape and the pipe surface, which is image-wise analyzed by suitable image processing software and monitored for defects. At the same time, the heating power for melting the impregnated fabric tapes is regulated by a process control. It should be noted that in the final inspection station 10 the welding of the laminates to the pipe is checked for possible air inclusions or a lack of bonding between the laminate and the pipe using another image analysis system.

The pipe is propelled by the regulated belt drives 50 who finally put the laminated pipe in the coating station 9 convey in. There can be a protective cover 15th ( 10 ) to be applied to the emerging pipe made of the same thermoplastic material as that of the pipe. The order can be provided with a color.

After the pipe wall has hardened, commercial piece lengths can be cut off from the pipe by means of a rotating saw and removed from the production line by roller transport.

Example: Pipes with a nominal diameter between 500 and 1400 mm are produced for a pressure range between zero and 40 bar. Laminate plastic tapes with a thickness in the range of 5 to 10 mm with glass fiber, plastic fiber, e.g. aramid fiber, or natural fiber, as well as thermoplastic materials with good impregnation properties, as are customary for pipes and fittings when used under pressure, are used. In coordination with the nominal pressure range, the number of laminate layers was 1 to 15th as well as the wall thickness of the liner 5 to 10 mm. The width of the laminate was 0.2 to 1.0 m.

The following table provides an overview of the pipes produced. Nominal size DN 500 600 700 800 Pressure area bar 0-40 0-40 0-40 0-40 Outside diameter pipe wall thickness coating / liner mm 500 630 710 800 Thick plastic tape Width plastic tape mm 5-10 5-10 5-10 5-10 Coating / liner / laminate m 0.2-1.0 0.2-1.0 0.2-1.0 0.2-1.0 Number of laminate layers 1-15 1-15 1-15 1-15 Nominal size DN 900 1000 1200 1400 Pressure area bar 0-40 0-40 0-40 0-40 Outside diameter pipe wall thickness coating / liner mm 900 1000 1200 1400 Thick plastic tape Width plastic tape mm 5-10 5-10 5-10 5-10 Coating / liner / laminate m 0.2-1.0 0.2-1.0 0.2-1.0 0.2-1.0 Number of laminate layers 1-15 1-15 1-15 1-15

It is evident to the person skilled in the art that the embodiments described above are to be understood as examples, and that the invention is not limited to them, but can be varied in many ways without departing from the scope of protection of the claims. Furthermore, it can be seen that the features, regardless of whether they are disclosed in the description, the claims, the figures or otherwise, also individually define essential components of the invention, even if they are described together with other features.

Claims (15)

Process for the continuous production of plastic composite pipes with fiber composite material, with the following steps: a) Extrusion of a weldable, thermoplastic plastic band (2) of a predetermined width and feeding this band to a forming station (4) in an inlet plane which runs relative to the axis of the pipe to be produced at a distance of the radius of a core pipe (5) of the pipe to be produced, wherein the tape (2) is guided with an adjustable inlet angle; b) bending the strip (2), which is aligned with regard to the inlet angle, so that the strip (2), without being supported by an inner support tube, results in a helix with the tube diameter of the core tube (5) as the outside diameter of the helix with a narrow gap (2a) between adjacent band windings the resulting core tube (5) grows out of the forming station (4) and moves helically along the tube axis from the forming station (4); c) closing the gap gaps (2a) between adjacent tape windings by welding the tape windings and forming the core tube (5) which grows and rotates along the tube axis; d) winding impregnated fabric tape (60) onto the circumference of the growing, rotating core tube (5) with a superficially melted pipe and superficially melted and impregnated fabric tape (60) for the purpose of welding the fabric tape (60) to the pipe; e) repeating step d) if several layers of fabric tape (60) are to be used to form the pipe wall; f) if desired, applying a protective coating (15) over the outer surface of the pipe being manufactured. Procedure according to Claim 1 , wherein in step d) the full-area melting of the impregnated fabric tape surface and the surface of the pipe being formed is controlled via infrared emission and image analysis. Procedure according to Claim 1 or 2 , the inlet plane and the inlet angle of the thermoplastic plastic strip (2) being set as a function of the width of the strip (2) and the diameter of the pipe to be produced before step a). Apparatus for the continuous production of wound thermoplastic pipes made of fiber composite material, comprising: - an extruder (1) for supplying a weldable, thermoplastic strip (2) of predetermined width; - A tape feed device (3) for feeding the thermoplastic tape (2) in an inlet plane at a radius distance from the axis of the pipe to be produced and with an aligned inlet angle to the pipe axis which corresponds to the pitch angle of a helix formed by the tape (2) in the pipe wall ; - A forming station (4) with a band-bending device (20) of the thermoplastic band (2) to form a helical screw without support from an inner support tube, the pipe wall of a core pipe (5) being formed after welding adjacent band windings, which extends helically along the pipe axis the forming station (4) moved away; - A welding device for welding the gap gaps (2a) between adjacent tape windings to complete the core tube (5); - rotating and supporting devices for the moving away core tube (5) and for the tube to be produced, - a system (6) for producing impregnated fabric tape (60); - A laminate feed device (7) for feeding the impregnated fabric tape (60) to the circumference of the advancing pipe to be produced; - Heating devices for melting the surfaces of the supplied fabric tape (60) and of the pipe to be produced; and - at least one application device (8) of the impregnated and fused fabric tape (60) onto the rotating and moving, fused tube in order to wrap it with fabric tape (60). Device according to Claim 4 wherein the heating devices of the surfaces of the fabric tape (60) and the tube are assigned a testing device which controls the quality of the surface melting via infrared emission and image analysis. Device according to Claim 4 or 5 , comprising a protective cover applicator (9) for applying a protective cover (15) to the outer surface of the pipe to be manufactured. Device according to one of the Claims 4 to 6th , Containing a cutting device for cutting off commercially available piece lengths from the continuously produced pipe. Device according to one of the Claims 4 to 7th , wherein the feed devices (3; 7) of the thermoplastic plastic band (2) and the fabric band (60) each comprise a movable, height-adjustable roller table (32), the conveying direction of which can be adjusted at the desired angle of inflow to the axis of the pipe to be produced. Device according to Claim 8 , the feed device (3) of the thermoplastic plastic tape (2) having a height-adjustable deflection roller (34) which is connected downstream of the extruder (1) for delivery of the thermoplastic tape (2) and which directs the tape (2) to the feed level. Device according to one of the Claims 4 to 9 wherein the band bending device (20) of the thermoplastic band (2) comprises a height-adjustable roller station with a driven pair of rollers (21, 22) which is used to adjust the pipe wall curvature and is adjustable in its position. Device according to one of the Claims 4 to 10 wherein the forming station (4) has a roll cage (40) with a plurality of roll frames (41) which can be adapted to the wall curvature of the pipe to be produced and which each comprise a guide roll (42) and rows of guide rolls (43, 44). Device according to one of the Claims 4 to 11 wherein the rotating and supporting devices for the pipe to be produced comprise a plurality of belt drives (50) which are arranged along the pipe to be produced and which support and rotate it from below. Device according to one of the Claims 4 to 12th , wherein the plant (6) for the production of impregnated fabric tape (60) comprises two extruders (66, 67) for feeding liquid thermoplastic from both sides onto a glass fabric (61) and two calenders (63, 64) which the liquid thermoplastic press with the glass fabric (61). Device according to Claim 13 wherein an intermediate store of impregnated fabric tape (60) temporarily stored on reels (80) is provided, from which the at least one application device (8) of the impregnated fabric tape (60) is fed. Plastic composite pipe, producible by a method according to at least one of Claims 1 - 3 , and comprising - a core tube (5) as the innermost plastic layer, which has a helical structure with a coiled thermoplastic tape (2) and a welded gap (2a), - one or more layers of helically wound, continuously impregnated thermoplastic fabric tape (60) in thermal welded connection with the core tube (5) and with each other, the fabric tape (60) having a fiber fabric which is impregnated with thermoplastic material so that a laminate is formed, the surface of the core pipe (5) with the surface of the fabric tape (60 ) is welded, and - with or without a protective coating (15) on the outside of the composite pipe.

Images