JP2010162749A - 管ライニング材の製造方法 - Google Patents

管ライニング材の製造方法 Download PDF

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Publication number
JP2010162749A
JP2010162749A JP2009006213A JP2009006213A JP2010162749A JP 2010162749 A JP2010162749 A JP 2010162749A JP 2009006213 A JP2009006213 A JP 2009006213A JP 2009006213 A JP2009006213 A JP 2009006213A JP 2010162749 A JP2010162749 A JP 2010162749A
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JP
Japan
Prior art keywords
tube
tubular resin
absorbent material
resin absorbent
heater
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
JP2009006213A
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English (en)
Inventor
Takao Kamiyama
隆夫 神山
Koji Kaneda
光司 金田
Kenji Fujii
謙治 藤井
Masao Ueno
雅央 上野
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KAZU CHEMICAL KK
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KAZU CHEMICAL KK
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Filing date
Publication date
Application filed by KAZU CHEMICAL KK filed Critical KAZU CHEMICAL KK
Priority to JP2009006213A priority Critical patent/JP2010162749A/ja
Priority to KR1020090129769A priority patent/KR20100084117A/ko
Priority to TW099100382A priority patent/TW201036802A/zh
Priority to US12/657,145 priority patent/US20100175818A1/en
Priority to CN201010004418A priority patent/CN101780716A/zh
Publication of JP2010162749A publication Critical patent/JP2010162749A/ja
Pending legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/522—Joining tubular articles
    • B29C66/5227—Joining tubular articles for forming multi-tubular articles by longitudinally joining elementary tubular articles wall-to-wall (e.g. joining the wall of a first tubular article to the wall of a second tubular article) or for forming multilayer tubular articles
    • B29C66/52271—Joining tubular articles for forming multi-tubular articles by longitudinally joining elementary tubular articles wall-to-wall (e.g. joining the wall of a first tubular article to the wall of a second tubular article) or for forming multilayer tubular articles one tubular article being placed inside the other
    • B29C66/52272—Joining tubular articles for forming multi-tubular articles by longitudinally joining elementary tubular articles wall-to-wall (e.g. joining the wall of a first tubular article to the wall of a second tubular article) or for forming multilayer tubular articles one tubular article being placed inside the other concentrically, e.g. for forming multilayer tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/26—Lining or sheathing of internal surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/24—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools characterised by the means for heating the tool
    • B29C65/30—Electrical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/63—Internally supporting the article during joining
    • B29C66/634—Internally supporting the article during joining using an inflatable core
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—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
    • B29C66/72—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 structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/826—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps without using a separate pressure application tool, e.g. the own weight of the parts to be joined
    • B29C66/8266—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps without using a separate pressure application tool, e.g. the own weight of the parts to be joined using fluid pressure directly acting on the parts to be joined
    • B29C66/82661—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps without using a separate pressure application tool, e.g. the own weight of the parts to be joined using fluid pressure directly acting on the parts to be joined by means of vacuum
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L55/00—Devices or appurtenances for use in, or in connection with, pipes or pipe systems
    • F16L55/16—Devices for covering leaks in pipes or hoses, e.g. hose-menders
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L55/00—Devices or appurtenances for use in, or in connection with, pipes or pipe systems
    • F16L55/16—Devices for covering leaks in pipes or hoses, e.g. hose-menders
    • F16L55/162—Devices for covering leaks in pipes or hoses, e.g. hose-menders from inside the pipe
    • F16L55/165—Devices for covering leaks in pipes or hoses, e.g. hose-menders from inside the pipe a pipe or flexible liner being inserted in the damaged section
    • F16L55/1652—Devices for covering leaks in pipes or hoses, e.g. hose-menders from inside the pipe a pipe or flexible liner being inserted in the damaged section the flexible liner being pulled into the damaged section
    • F16L55/1654—Devices for covering leaks in pipes or hoses, e.g. hose-menders from inside the pipe a pipe or flexible liner being inserted in the damaged section the flexible liner being pulled into the damaged section and being inflated
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L55/00—Devices or appurtenances for use in, or in connection with, pipes or pipe systems
    • F16L55/16—Devices for covering leaks in pipes or hoses, e.g. hose-menders
    • F16L55/162—Devices for covering leaks in pipes or hoses, e.g. hose-menders from inside the pipe
    • F16L55/165—Devices for covering leaks in pipes or hoses, e.g. hose-menders from inside the pipe a pipe or flexible liner being inserted in the damaged section
    • F16L55/1656—Devices for covering leaks in pipes or hoses, e.g. hose-menders from inside the pipe a pipe or flexible liner being inserted in the damaged section materials for flexible liners
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/34—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/006—Using vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—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
    • B29C66/71—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 composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—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
    • B29C66/72—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 structure of the material of the parts to be joined
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—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
    • B29C66/72—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 structure of the material of the parts to be joined
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70—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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—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
    • B29C66/73—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
    • 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
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Abstract

【課題】チューブを管状樹脂吸収材に均一にしかも効率的に熱溶着し、簡単な方法で高品質の管ライニング材を製造する。
【解決手段】管状樹脂吸収材１０をチューブ１１内に挿入して円柱状に膨張させチューブ内周面に密着させる。円柱状に膨張したチューブと管状樹脂吸収材の外周面にヒーター２０を密着して巻回し、ヒーターに通電することによりチューブと管状樹脂吸収材を加熱し、チューブを管状樹脂吸収材に熱溶着する。このような構成では、チューブと管状樹脂吸収材を移動させる機構が不必要になるとともに、加熱むらを発生させることなく、チューブを管状樹脂吸収材に均一に熱溶着させることができ、高品質の管ライニング材を製造することが可能になる。
【選択図】図２

Description

本発明は、老朽化した既設管をライニングするための管ライニング材の製造方法に関する。
地中に埋設された下水道管、上水道管などの既設管が老朽化した場合に、既設管を掘り出すことなく補修するための管路ライニング工法が実施されている。この工法では、熱硬化性樹脂を含浸させた管状樹脂吸収材からなる管ライニング材が既設管に反転或いは引き込みにより挿入され、空気圧などで膨張されて既設管の内周面に圧接された状態に保持される。この状態で管ライニング材が加熱されて管状樹脂吸収材に含浸されていた熱硬化性樹脂が硬化され既設管がライニングされる（例えば、特許文献１、２など）。
管ライニング材の樹脂吸収材は、柔軟なフェルトなどからなり、その外周面（管ライニング材が反転される場合には、内周面となる）には、気密性の高いプラスチックフィルムからなる柔軟なチューブが熱溶着されてコーティング層が形成される。このチューブは、管状樹脂吸収材に含浸される硬化性樹脂を保護し樹脂が外部に接触するのを防止している。また、管ライニング材が反転して管路に挿入された場合には、熱溶着されたチューブが内周面となって、その後のライニング過程で管ライニング材が圧縮空気で膨張される場合に、管状樹脂吸収材に含浸される樹脂が直接圧縮空気に当たるのを、あるいは該樹脂が蒸気や温水などの熱媒で加熱される場合、直接熱媒が樹脂に当たるのを防止している。
特開２００６−１３０８９９号公報 特開２００７−１２５７０３号公報
管ライニング材の樹脂吸収材の外周面にチューブを熱溶着する場合、従来では、管状樹脂吸収材をチューブ内で膨張させてその内周面に密着させ、これを軸方向に延びるヒーターを設けた円柱状の加熱炉内に搬入している。加熱炉内に搬入されたチューブと管状樹脂吸収材は、加熱炉内を出口に向け移動され、その移動中に外周から加熱されて、チューブが管状樹脂吸収材に熱溶着される。
このような方法では、チューブと管状樹脂吸収材を加熱炉内で移動させる機構が必要になると共に、円柱状に膨張したチューブと管状樹脂吸収材の中心軸と加熱炉の中心軸を合わせて、チューブと管状樹脂吸収材を移動させないと、ヒーターのチューブと管状樹脂吸収材に対する距離が上部と下部で異なるために、加熱むらが発生し、チューブは管状樹脂吸収材に均一に熱溶着されなくなる。熱溶着が不十分であると、管状樹脂吸収材に含浸された樹脂の硬化も良好でなくなり、信頼性のあるライニングが困難になるという欠点がある。
また、チューブと管状樹脂吸収材の先端が加熱炉に搬入されたときに、加熱炉の全長にわたって延びるヒーター全体に通電する必要があるので、また、チューブと管状樹脂吸収材の後端が加熱炉の出口を通過するまで、ヒーターに給電を継続する必要があるので、無駄な加熱、電力消費が発生する、という欠点がある。
本発明は、このような問題点を解決するためになされたものであり、チューブを管状樹脂吸収材に均一にしかも効率的に熱溶着し、簡単な方法で高品質の管ライニング材を製造することが可能な管ライニング材の製造方法を提供することを課題とする。
上記課題を解決する本発明は、
管状樹脂吸収材の外周面に気密性のプラスチックフィルムからなるチューブを熱溶着し、該管状樹脂吸収材に硬化性樹脂を含浸して管ライニング材を製造する管ライニング材の製造方法であって、
管状樹脂吸収材をチューブ内に挿入して円柱状に膨張させてチューブ内周面に密着させ、
円柱状に膨張した管状樹脂吸収材を被覆するチューブの外周面にヒーターを密着して巻回し、
ヒーターに通電することによりチューブと管状樹脂吸収材を加熱し、チューブを管状樹脂吸収材に熱溶着することを特徴とする。
本発明では、円柱状に膨張した管状樹脂吸収材を被覆するチューブの外周面にヒーターを密着して巻回し、ヒーターに通電することによりチューブと管状樹脂吸収材を加熱し、チューブを管状樹脂吸収材に熱溶着するようにしているので、チューブと管状樹脂吸収材を移動させる機構が不必要になるとともに、加熱むらを発生させることなく、チューブを管状樹脂吸収材に均一に熱溶着させることができ、高品質の管ライニング材を製造することができる。
また、本発明では、ヒーターはチューブの外周面に密着して巻回されるので、無駄なくチューブと管状樹脂吸収材を加熱することができ、少ない電力で効率的にチューブを管状樹脂吸収材に熱溶着することができる。
チューブに管状樹脂吸収材を挿入して管状樹脂吸収材を膨張させたときの管ライニング材を示す斜視図である。 （ａ）はヒーターを巻回したチューブと管状樹脂吸収材を示す斜視図、（ｂ）は複数のヒーターを巻回したチューブと管状樹脂吸収材を示す斜視図である。 ヒーターの電熱線の接続を示す配線図である。
以下、図を参照して本発明の実施例を説明する。ここでは、既設管として下水道管をライニングするための管ライニング材の製造方法を説明する。しかしながら、本発明は、これだけでなく、上水道管、農業用水管などの管ライニング材の製造方法にも適用できるものである。
図１は既設管を補修あるいは更生する管ライニング材の製造過程を示している。管ライニング材１は、柔軟な管状樹脂吸収材１０の外周面をポリエチレン、ポリプロピレン、ナイロン、又は塩化ビニール等の気密性の高いプラスチックフィルムからなる柔軟なチューブ１１で被覆してなる柔軟な管状ライニング材である。
管状樹脂吸収材１０は、ポリアミド、ポリエステル、ポリプロピレンなどのプラスチック繊維を用いた不織布、織布、あるいはマット；あるいはガラス繊維を用いた織布、あるいはマット；あるいは上記プラスチック繊維とガラス繊維を組み合わせた不織布、織布、あるいはマットからなり、管状樹脂吸収材１０には、不飽和ポリエステル樹脂、ビニルエステル樹脂、又はエポキシ樹脂などの液状の未硬化の熱硬化性樹脂が含浸される。
このような管ライニング材を製造するには、管状樹脂吸収材１０をチューブ１１内に挿入し、また管状樹脂吸収材１０内に一端（図１で右側）が閉じた管状のインライナー１２を挿入し、管状樹脂吸収材１０をチューブ１１とインライナー１２間で保持する。
管状樹脂吸収材１０とチューブ１１に穴をあけ真空ホース１３を取り付け、管状樹脂吸収材１０を真空引きするとともに、インライナー１２の開放端（図１で左側）から圧縮空気を供給すると、チューブ１１、管状樹脂吸収材１０、並びにインライナー１２は、最初はそれぞれ扁平な形になっているが、図１に示したように、共に円柱形状に膨張し、管状樹脂吸収材１０は、チューブ１１とインライナー１２で挟持された状態でチューブ１１の内周面に密着する。チューブ１１、管状樹脂吸収材１０、インライナー１２が共に円柱形状に膨張させるために、円柱形状になったときのチューブ１１の内径と管状樹脂吸収材１０の外径がほぼ一致するように、また管状樹脂吸収材１０の内径とインライナー１２の外径がほぼ一致するようにしておく。
なお、図１では、真空ホース１３は一箇所しか設けられていないが、効率的に管状樹脂吸収材を真空引きするために、通常管ライニング材の長さに応じて複数箇所に真空ホースが取り付けられる。
続いて、図２（ａ）に示したように、チューブ１１、管状樹脂吸収材１０、インライナー１２を膨張させた状態にしておき、円柱状に膨張した管状樹脂吸収材１０を被覆するチューブ１１の外周面にヒーター２０を密着して巻回する。
ヒーター２０は、図３に示したように、一辺がＹで他の一辺がＹ’の矩形あるいは正方形状の絶縁性の布（仮想線で図示）２０ａの内部にニクロム線などの電熱線２０ｂを等ピッチｐ（例えば、７．５ｍｍ）で周期的に蛇行させて配置したヒーターである。Ｙ’はチューブ１１の外周にほぼ等しく、あるいは若干長く、ヒーター２０をチューブ１１に密着して巻回したとき、その両端部が一部重なり合う長さとなっている（図２（ａ））。
電熱線２０ｂは、図３に示したように、Ｙ’方向に所定距離だけ延びると折り返されて再び同距離延びて折り返され、この折り返しを繰り返してピッチｐで周期的に管ライニング材の長さ方向に蛇行して延びている。電熱線２０ｂは一端でプラグ２０ｃに接続され、プラグ２０ｃを幹線２１の電源コンセント２０ｄに差し込むことにより電熱線２０ｂに通電して電熱線２０ｂを発熱させることができる。電熱線２０ｂは、ほぼヒーター全体にわたって均一に分布するので、その発熱量はヒーター２０全体で均一になっている。
管ライニング材１の長さが長いときには、図２（ｂ）に示したように、複数のヒーター２０を互いに隣接して密着させてチューブ１１の外周面に巻き付ける。このとき、管ライニング材の軸方向の長さ（チューブ１１の長さ）をＸ、ヒーター２０の管ライニング材の長さ方向に延びる一辺の長さをＹとして、ＸがＹより大きい場合には、Ｙ＊Ｚ＞Ｘ（＊は掛け算の符号）を満たす最小の整数Ｚを求め、求めたＺ個のヒーター２０を互いに隣接して密着させチューブ１１の外周面に巻回する。各ヒーター２０のプラグ２０ｃを電源コンセント２０ｄに差し込むことによりＺ個のヒーター２０は並列接続される。
なお、図２（ａ）、（ｂ）では、最初のヒーター２０（図で左端）は、チューブ１１の先端より少し右寄りのところで巻回されているが、これは、理解を容易にするためで、実際には、ヒーター２０の左端とチューブ１１の先端は、ほぼ一致するような位置にする。
図２に示した管ライニング材１の場合、その管長方向の長さＸはヒーター２０の一辺Ｙより長いので、上述した式でＺ個のヒーター２０を用意し、各プラグ２０ｃをコンセント２０ｄに差し込み、Ｚ個のヒーター２０を並列接続する。図２（ｂ）の例では、３個目のヒーター２０がチューブ１１に巻回され、並列に接続されている。ただし、同図では、ヒーターのプラグやコンセントは煩雑さを避けるために、図示が省略されている。
所定個数Ｚのヒーター２０をチューブ１１に巻回し、各プラグ２０ｃを電源コンセント２０ｄに差し込んで、各ヒーター２０に通電を行うと、各ヒーター２０の電熱線２０ｂは発熱する。これによりチューブ１１と管状樹脂吸収材１０は均一に加熱され、チューブ１１は管状樹脂吸収材１０に熱溶着され、管状樹脂吸収材１０にはチューブ１１からなるコーティング層が形成される。
このように、管ライニング材の管状樹脂吸収材が長い場合でも、所定の個数のヒーターを連結して用いて、管状樹脂吸収材並びにそれを被覆するチューブ全体を加熱することができるので、効率的でしかも均一な加熱ができ、チューブを高品質に管状樹脂吸収材に熱溶着することができる。
なお、各ヒーター２０が隣接する部分は、発熱が均一になりにくいので、図２（ｂ）で仮想線で示したように、熱伝導性のよい金属製の薄いシート３０（例えばアルミ箔）をチューブ１１に巻回してその上にヒーター２０、２０を隣接して巻回し、加熱量を均一化させるようにする。図２（ｂ）では、シート３０は一箇所しか図示されていないが、他の隣接するヒーターのところも巻回されるものである。
このように、管状樹脂吸収材１０の外周面にチューブ１１が熱溶着されたら、真空ホース１３を介した真空引きを中止すると共に、インライナー１２への圧縮空気供給を中止し、チューブ１１、管状樹脂吸収材１０、インライナー１２を収縮させ、インライナー１２をチューブ１１と管状樹脂吸収材１０から引き抜く。
そして、公知の方法（例えば、特開２００１−１０８５５５号公報）を用いて管状樹脂吸収材１０に加熱により又は光照射により硬化する樹脂あるいは常温で硬化する硬化性樹脂を含浸させる。すなわち、管状樹脂吸収材１０の内部に硬化性樹脂を注入し、管状樹脂吸収材１０を真空引きして管状樹脂吸収材１０に発生する負圧により管状樹脂吸収材１０に硬化性樹脂を含浸させる。このようにして、管状樹脂吸収材の外周面に気密性のプラスチックフィルムからなるチューブを熱溶着し、該管状樹脂吸収材に硬化性樹脂を含浸してなる管ライニング材を製造することができる。
このように製造された管ライニング材は、チューブが内周面となるように、既設管に反転或いは引き込みにより挿入され、空気圧などで膨張されて既設管の内周面に圧接された状態に保持される。この状態で管ライニング材が加熱されあるいは光照射されて管状樹脂吸収材に含浸されていた硬化性樹脂が硬化され既設管がライニングされる。
１ 管ライニング材
１０ 管状樹脂吸収材
１１ チューブ
１２ インライナー
１３ 真空ホース
２０ ヒーター

Claims (4)

  1. 管状樹脂吸収材の外周面に気密性のプラスチックフィルムからなるチューブを熱溶着し、該管状樹脂吸収材に硬化性樹脂を含浸して管ライニング材を製造する管ライニング材の製造方法であって、
    管状樹脂吸収材をチューブ内に挿入して円柱状に膨張させてチューブ内周面に密着させ、
    円柱状に膨張した管状樹脂吸収材を被覆するチューブの外周面にヒーターを密着して巻回し、
    ヒーターに通電することによりチューブと管状樹脂吸収材を加熱し、チューブを管状樹脂吸収材に熱溶着することを特徴とする。
  2. 前記ヒーターは、チューブの外周にほぼ等しい一辺を有する矩形状あるいは正方形状の絶縁性の布内部に電熱線を等ピッチで周期的に蛇行させて配置したヒーターであることを特徴とする請求項１に記載の管ライニング材の製造方法。
  3. 管ライニング材の長さをＸ、ヒーターの管ライニング材の長さ方向に延びる一辺の長さをＹとして、ＸがＹより大きい場合には、Ｙ＊Ｚ＞Ｘを満たす最小の整数Ｚを求め、求めたＺ個のヒーターを互いに隣接してチューブの外周面に巻回し、Ｚ個のヒーターを並列接続して通電することを特徴とする請求項２に記載の管ライニング材の製造方法。
  4. 熱伝導性のシートをチューブに巻回したあと、該熱伝導性のシートを介してヒーターを巻回することを特徴とする請求項３に記載の管ライニング材の製造方法。
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TW099100382A TW201036802A (en) 2009-01-15 2010-01-08 Method of manufacturing tube lining bag
US12/657,145 US20100175818A1 (en) 2009-01-15 2010-01-14 Method for manufacturing pipe-lining material
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US9429265B2 (en) 2012-04-12 2016-08-30 Ashimori Industry Co., Ltd. Lining method for conduit and lining material composite for conduit
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WO2016201484A1 (en) * 2015-06-19 2016-12-22 Christopher Meredith Improvements in apparatus for repairing pipe joints
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