WO2018132029A1

WO2018132029A1 - Flexible reinforced polymeric pipe, hose and production methods

Info

Publication number: WO2018132029A1
Application number: PCT/RU2017/000013
Authority: WO
Inventors: Юрий Максимович ПЕТРОВ
Original assignee: Юрий Максимович ПЕТРОВ
Priority date: 2017-01-13
Filing date: 2017-01-13
Publication date: 2018-07-19

Abstract

The group of inventions relates to the production of spiral-reinforced seamless flexible pipes with a polymer matrix, and solves the problem of creating cost-effective and highly efficient technology for the production thereof. The claimed method includes spiral winding reinforcing elements on a conductor and subsequently applying a polymer matrix to said reinforcing elements to form a pipe. Prior to spiral winding, the reinforcing elements are fed onto an idler roller coaxially mounted upstream of the conductor. The reinforcing elements make at least one turn around the surface of the idler roller, coaxially with the spiral winding turns of a casing on the conductor. After leaving the idler roller, the reinforcing elements are consecutively fed first onto a guide roller and then onto a clamping roller of a laying device which forms a spiral casing on the conductor. The conductor is provided with a means for conveying the spiral casing into the chamber of an extruder, formed by a mandrel and an outer shaping sleeve. A polymer is injected into the chamber of the extruder through an offset head mounted above the mandrel. After leaving the extruder, the pipe is cooled and cut into specified lengths, whereupon the end portions are processed to fix the reinforcing elements in a given position.

Description

A method of manufacturing a flexible polymer reinforced pipe, hose and non-pressure pipe obtained by this method

The invention relates to the manufacture of spirally reinforced seamless flexible pipes with a polymer matrix, in particular to the manufacture of lightweight reinforced hoses and non-pressure (non-pressure) pipes with high corrosion resistance, wear resistance, flexibility and radial strength.

The prior art various methods of reinforcing polymer pipes, for example, weaving reinforcing cages on the surface of the finished polymer mandrel (fixed), followed by coating the frame with a second or several subsequent layers of polymer. In another embodiment, instead of a fixed mandrel to create a reinforcing casing of the pipe using a rotating pipe section with a preliminary or subsequent coating it with a second layer of polymer.

In the description of the international application WO 01 13022, IPC: F16L 1 1/08, published February 22, 2001, a method of manufacturing a reinforced polymer pipe is disclosed, including forming a metal mesh frame by double spiral winding of the wire in opposite directions at a given angle using a shaft, whose rotation coordinated with the rotation of the planetary system of winding rollers. As a means for transporting the spiral frame from the shaft into the extruder cavity, use longitudinal rods mounted on the shaft, made with screw thread. To implement this method requires energy-intensive equipment for winding reinforcing frame, difficult to configure and use, which increases the cost of finished products, and the resulting composite pipe with multi-layer reinforcement has a high rigidity, resulting in not flexible enough.

From the description of the patent RU 2026507, IPC: F16L1 1/08, published 09/01/1995, a method for producing a flexible PTFE tube for the manufacture of flexible pipelines is known. The flexible tubing contains PTFE tubes with metal tips. Mentioned PTFE tubes contain a reinforcing braid in the form of a pre-woven closed shell, molded into the inner surface of the PTFE tube. For in the process of extrusion, the manufacture of the fluoroplastic tube provides axial flow from the longitudinal cavity of the mandrel of a previously woven closed shell together with a guide rod. This allows you to form a polymer fluoroplastic matrix in the forming gap of the extruder, getting a flow section of the tube of a stable form with a reinforcing element embedded in it. The disadvantage of this method is its low performance associated with the complexity and multi-stage process of manufacturing a flexible reinforced fluoroplastic tube.

From the description of the utility model RU 138064, IGL: F16L9 / 12, published on 02/27/2014, is known spiral-polymer polymer pressureless pipe, intended for the construction of pipelines, mainly for drainage systems, as well as for the device tanks and wells for various purposes. Spiral tube contains a wall formed by coils of a closed hollow rectangular profile of thermoplastic. The side surfaces of the profile turns are interconnected by a seam of thermoplastic. In order to increase stability, a non-pressure pipe can be provided with an additional outer layer wound on the outer surface of the pipe, or an additional inner layer mated with the inner surface of the pipe. Method for the production of non-pressure pipe is as follows. An extruded thermoplastic hollow profile with an inner layer applied by coextrusion is fed by a broaching device to the winding unit, where the profile is wound onto the drum due to the tension force generated by the drum. At the same time, the inner layer covers the surface of the profile windings forming the inner wall of the pipe. Adjacent turns of the profile on the drum are interconnected by a seam from a melt of a thermoplastic fed through an extrusion die located between adjacent turns. The location of the profile turns at the required distance from each other is ensured by pressing to a smooth bearing surface. The seam zone is preheated with hot air to improve the quality of the joint and better polymer distribution in the seam. Smoothing the inner surface of the seam is carried out on the surface of the drum. Following the winding of the thermoplastic profile of the spiral-wound pipe, the outer protective layer is produced by winding a melt tape from thermoplastic-based compositions. The tape is wound with an overlap for the formation of a solid surface. To ensure a good connection with the pipe, the tape is wound with a longitudinal tension and during winding it is rolled by a pressure roller. A pipe made according to the proposed utility model may have an internal diameter of 300 to 3000 mm.

The disadvantage of this method of manufacturing a free-flow pipe is its low productivity associated with the complexity and multi-stage manufacturing process. When bending, said pipe has low radial strength and low resistance to cross-sectional shape.

In addition to the methods described above for the manufacture of a reinforced polymer pipe, the technology of preparing a welded metal or glued non-metallic reinforcing frame on the conductor, that is, on a cylindrical support that allows the formed frame to be pushed forward along it, with subsequent coating of the frame with polymer in the extruder cavity is known.

A method of continuous manufacture of metal-polymer reinforced pipes and a device for its implementation are disclosed in the description of the patent RU2492047, IPC: V29S47 / 02, published 10.09.2013. The method of continuous manufacture of a metal-polymer reinforced pipe by the extrusion method provides for preliminary spiral winding of transverse reinforcing elements onto longitudinal reinforcing elements with the formation of a skeleton on a conductor support, subsequent extrusion drawing onto the framework of a polymer matrix to form a pipe, cooling and cutting the pipe into segments of a given length.

Extrusion deposition on the framework of the polymer matrix provides for the supply of polymer melt from the extrusion head into the forming cavity formed by a cooled mandrel and outer forming sleeve, while simultaneously feeding into the specified cavity of the welded reinforcing frame. Means for transporting the welded frame into the extruder cavity are longitudinal reinforcing elements, which at the initial stage of equipment start-up are loaded into a pulling device, coaxially placed behind the extruder with its cooling system. The disadvantages of the method are in the complexity and intensity of the operation of forming the circumferential reinforcement of the metal pipe. So for the manufacture of reinforced polymer pipe with a diameter of 500 mm at a speed of 1 m / min only for one day of continuous work, it is required to turn transverse reinforcement around the process line axis in the amount of 65,000 kg kg. Another disadvantage of this method is the difficulty of using tape materials for circumferential reinforcement of composite pipes, since the kinematics of feeding reinforcing elements for transverse reinforcement involves the use of both transverse bending and longitudinal bending of reinforcement.

The main disadvantage of this method is the high longitudinal rigidity and low flexibility of the polymer reinforced pipe, since the longitudinal reinforcing elements do not allow the pipe to be bent when the pipeline is installed from it.

The claimed invention is directed to eliminating the disadvantages of the above analogues and to simplify the manufacturing technology of reinforced polymer pipes.

The task, which the claimed invention is directed to, is the creation of an economical and high-performance technology for manufacturing a polymer reinforced pipe with ensuring the radial strength and flexibility of a polymer reinforced pipe with its dimensional stability of cross section.

The technical result is to improve the quality of finished products while reducing their cost, reducing energy intensity and material intensity of production.

To solve this problem, a method of obtaining a flexible polymer reinforced pipe is declared, including spiral winding of reinforcing elements on the conductor and subsequent extrusion coating of a polymer matrix on them to form a pipe, cooling and cutting the pipe into segments of a given length. In this case, prior to the spiral winding operation, the reinforcing elements are fed to a bypass roller coaxially mounted in front of the conductor and configured to carry at least one turn on the roller surface coaxially to the helical winding of the frame on the conductor. And after the output from the bypass roller reinforcing elements are successively fed first to the guide roller, then to the pressure roller of the stacker forming the spiral frame on the conductor. The jig is equipped with a means of transporting the spiral frame in the cavity of the extruder formed by the mandrel and the outer forming sleeve. The polymer is injected into the extruder cavity through an offset head mounted above the mandrel. After leaving the extruder, cooling and cutting the pipe into segments of a given length, the end sections are machined to fix the predetermined position of the reinforcing elements.

As the reinforcing elements for spiral winding use metal wire or tape.

As a means for transporting the spiral frame into the forming cavity of the extruder, use the chassis transporting nut, which guides the spiral reinforcing frame after leaving the conductor directly into the forming cavity of the extruder.

In another embodiment of the inventive method, synchronous timing belts are used as a means for transporting the spiral frame into the extruder forming cavity.

Means for transporting the spiral frame to the forming cavity of the extruder, in addition to the above, can be other mechanisms suitable for completing the production line, for example, roller chains with toothed plates.

Another variant of the implementation of the claimed method involves the use of polymer strands installed in the longitudinal grooves of the conductor (like the longitudinal reinforcing elements), which are tucked into the pulling device located after the extruder, as a means for transporting the spiral frame into the forming cavity of the extruder. Under the action of the stacker roller, polymer harnesses can be bonded to the spiral reinforcing frame by heat sealing, ultrasonic welding or gluing, which will allow the frame to be pulled through the extruder cavity. With this use of longitudinal polymer bundles or fibers do not reduce the flexibility of the manufactured pipe, since they are not reinforcing elements. Another distinctive feature of the claimed method is the processing of the end portion of each section of the manufactured pipe.

To fix the specified position of the reinforcing elements, the processing of the end section can be performed as follows. At the end section of the pipe section, on its external or internal surface, remove the polymer matrix layer from several turns of the reinforcing elements and weld the longitudinal metal bar to the bare turns of the reinforcing elements, which allows to fix the spiral reinforcing frame in a predetermined position, preventing the relaxation of elastic stresses . Fixation of a predetermined position of the reinforcing elements is necessary, since the reinforcing frame is a stretched spiral spring, the elastic forces of which can exceed the strength of the adhesive interaction of the reinforcing elements with the polymer matrix. Fixing a predetermined position of the reinforcing elements makes it possible to ensure long-term strength and reliability indicators of the reinforced polymer pipe, preventing the relative displacement of the reinforcing elements relative to the polymer matrix of the pipe walls during compression of the said spring.

In addition, after processing the end section by welding several turns of the helix, the installation is carried out on the end section of the sleeve of a polymeric or metallic material.

When implementing the claimed invention as a flexible polymer reinforced pipe can be made hose.

The method of obtaining a reinforced polymer hose includes spiral winding of reinforcing elements on the conductor with the formation of a reinforcing frame and subsequent extrusion drawing on the reinforcing frame of the polymer matrix to form the hose, cooling and cutting the hose into segments of a given length. At the same time for the reinforcement is preferably used metal reinforcing elements. Before the operation of their spiral winding, the reinforcing elements are fed to a bypass roller installed in front of the conductor coaxially with it, and made with the possibility of at least one turn of the reinforcing elements along the surface of said roller to coaxially winding of spiral winding, and after leaving bypass roller reinforcing elements are sequentially fed first to the guide roller, then to the pressure roller of the stacker forming the spiral frame on the conductor. And after leaving the conductor spiral reinforcing frame is directed into the cavity of the extruder formed by the mandrel and the outer forming sleeve, while the injection of the polymer is carried out through an offset head mounted above the mandrel. After completion of the process of extrusion and cooling of the resulting hose, the hose is cut into segments of a given length. The end sections of the hose are machined for fixing the reinforcing elements by removing the polymer matrix layer from several extreme turns of the reinforcing elements at the end section and welding to the bare turns of the reinforcing elements of the longitudinal metal bar, allowing them to be fixed (fixed). After fixing the reinforcing elements on the machined end section, a polymeric bushing is installed, having a protrusion on the end, located on the inner surface of the bushing cavity, covering the outlets of the reinforcing elements at the pipe end. In another embodiment, after fixing the reinforcing elements, a metal sleeve is installed on the treated end section and compressed.

The product of the inventive method is a reinforced polymer hose manufactured using features of the method described above.

In addition, the claimed method allows to produce high-quality reinforced non-pressure reinforced pipes efficiently and cheaply.

The method of obtaining a free-flow polymer reinforced pipe includes spiral winding of reinforcing elements on the conductor and subsequent extrusion coating of the reinforcing elements of the polymer matrix to form a pipe, cooling and cutting the pipe into segments of a given length.

Before the spiral winding operation, the reinforcing elements are fed to a bypass roller, which is designed to make a coil on the surface of the specified roller with reinforcing elements coaxially to the spiral winding coils, and after leaving the bypass roller, the reinforcing elements are successively first fed to a guide roller, then to a pressure roller that forms a spiral frame on the conductor. After leaving the conductor, the spiral reinforcing cage is guided by a running transporting nut into the cavity. extruder formed by the mandrel and the outer forming sleeve, while the injection of the polymer is carried out through an offset head mounted above the mandrel. And after cutting the pipe into segments of a given length, the ends are processed to fix and seal the reinforcing elements.

If necessary, on the outer surface of a free-flow polymer reinforced pipe, stiffening ribs are formed by spiral winding of a profiled polymer material using a second bypass roller.

Non-pressure polymer reinforced pipe in accordance with the claimed method can be made not only of circular cross section, but also a different section shape, which is determined by the configuration of the forming surface of the conductor. The cross section of the mandrel and extrusion head repeat the configuration of the cross section of the conductor.

The product of the inventive method is a free-flow polymer reinforced pipe, manufactured using the features of the method described above.

The invention is illustrated in figures 1 and 2.

FIG. 1 schematically shows a longitudinal section of the end section of a polymer reinforced pipe.

FIG. Figure 2 shows a longitudinal section of the undercarriage transporting nut, which guides the spiral reinforcing frame when it leaves the conductor directly into the forming cavity of the extruder.

In figures 1-2 positions indicated the following elements.

1 - reinforcing elements

2 - polymer matrix flexible polymer reinforced pipe,

3 - sleeve of polymeric or metallic material (ending),

4 - longitudinal metal plate, welded to the extreme turns of the reinforcing elements of the end section of the reinforced polymer pipe,

5 - finished section of a polymer reinforced pipe,

6 - welded joint of a round of a reinforcing element with a longitudinal metal bar,

7 - running transporting nut, 8 - jig,

9 - extruder head (conditionally).

The implementation of the claimed invention involves the use of the technological line for the continuous production of polymer pipes and hoses, reinforced spiral wound frame, made on the conductor before it enters the extrusion zone to cover the frame with polymer. The process line in the drawings is not shown because it is composed mainly of known equipment. The technological line consists of successively installed devices interconnected in the direction of the longitudinal axis of advancement of the resulting product. The process line contains a jig with a stacker reinforcing elements. Stacker reinforcing elements contains a guide roller and a pressure roller mounted on the faceplate with the possibility of rotation around the longitudinal axis of the conductor. In front of the conductor for feeding reinforcing elements, a bypass roller is installed. After the conductor, an extruder and a cooling system are installed, then a pulling mechanism and a cutting mechanism. Moreover, the coil, which serves reinforcing element located on the side of the longitudinal axis of the technological line at the level of the bypass roller.

Flexible polymer reinforced pipe was obtained as follows. The operation of the spiral winding is carried out on the conductor 8 (figure 2). From the coil placed from the side of the process line, reinforcing elements 1 are fed to a bypass roller (not shown), on the surface of which the reinforcing elements 1 carry at least one turn coaxially with the surface of the conductor 8, which is a support for the spiral winding. After exiting the bypass roller, the reinforcing elements 1 are successively supplied first to the guide roller, then to the stacker pressure roller, rotating around the conductor 8, to form a spiral frame. A means for transporting the spiral frame in the continuous mode in the extruder cavity is the undercarriage transporting nut 7.

Since the turns of the reinforcing element of the created flexible hose are located at a certain angle to the centerline of the conductor, and the reinforcement cage can be considered as a screw or a spring, the optimum a variant of the transport means is to create a knot using the nut guide principle.

The rotation of the transporting travel nut must be synchronized with the frequency of rotation of the reinforcement elements stacker. In this case, it is possible to dispense with a separate drive and remove the torque directly from the stacker drive.

The transporting nut fits snugly to the extruder assembly and eliminates the possibility of skewing or gathering the turns of the reinforcement at the inlet to the extruder head.

The material of the running nut is anti-friction bronze or fluoroplastic.

The polymer is injected through an offset head installed above the extruder mandrel, and after cutting the pipe into segments of a given length, the end sections are processed to fix the reinforcing elements 1. In FIG. 1 shows that metal wires of circular cross section are used as reinforcing elements 1 for spiral winding. Processing the end section involves removing a layer of polymer matrix 2 from several extreme turns of the reinforcing elements 1. A longitudinal metal strip 4 is welded to the bare turns of the reinforcing elements, allowing the turns to be fixed in a predetermined position. After processing the end section, the sleeve 3 is made of a polymeric material, so that the end of the pipe with the outlets of the reinforcing elements and the welded bar 4 are closed.

Reinforced hose and non-pressure polymer reinforced pipe get as described above, and to improve the strength properties of these products, preferably using a reinforcing element in the form of metal tape. The use of metal flax allows you to further reduce polymer consumption for the formation of the matrix of the product.

Claims

Claim

1. A method of obtaining a flexible polymer reinforced pipe, including spiral winding of reinforcing elements on the conductor and the subsequent extrusion deposition of a polymer matrix on them to form a pipe, cooling and cutting the pipe into segments of a given length,

characterized in that prior to the spiral winding operation, the reinforcing elements are fed to the bypass roller, which is adapted to make at least one turn on the surface of the said roller coaxially with the spiral winding, and after leaving the bypass roller, the reinforcing elements are successively first fed to the guide roller , then on the pressure roller, forming a spiral frame on the conductor, equipped with a means of transporting the spiral frame into the cavity extruder Formed by the mandrel and the outer forming sleeve, wherein the polymer is carried out by injecting offset head, mounted on the mandrel, and then cutting the tube into segments of predetermined length end portions treated for fixing reinforcing elements.

2. The method according to p. 1, characterized in that as the reinforcing elements for spiral winding using metal wire or tape.

3. The method according to p. 2, characterized in that, as a means for transporting a spiral frame in the forming cavity of the extruder use chassis transporting nut, which directs the spiral reinforcing frame after leaving the conductor directly into the forming cavity of the extruder.

4. The method according to p. 2, characterized in that, as a means for transporting a spiral frame in the forming cavity of the extruder use synchronous timing belts.

5. The method according to p. 1, characterized in that the processing of the end section includes removing a layer of polymer matrix with several turns of reinforcing elements at the end section and welding to the bare turns of the reinforcing elements of the longitudinal metal strip, allowing them to be fixed in a predetermined position.

6. The method according to any one of p. 1, characterized in that after processing the end section, a sleeve of a polymeric or metallic material is installed on it.

7. A method of obtaining a reinforced polymer hose, comprising spiral winding of reinforcing elements on the conductor and the subsequent extrusion coating of a polymer matrix on them to form the hose, cooling and cutting the hose into segments of a given length,

characterized in that for reinforcement metal reinforcing elements are used, before the operation of their spiral winding, reinforcing elements are fed to a bypass roller, made with the possibility of at least one turn of the reinforcing elements along the surface of the specified roller to coaxially spiraling windings, and after leaving the bypass roller the reinforcing elements are successively served first on the guide roller, then on the pressure roller, forming a spiral frame on the conductor, and after descending from conductor spiral reinforcing frame is directed into the extruder cavity formed by the mandrel and the outer forming sleeve, while the polymer is injected through an offset head mounted above the mandrel, and after cutting the hose into segments of a given length, the end sections of the hose are processed to fix the reinforcing elements by removing the polymer layer dies with several turns of reinforcing elements at the end section and welding to the bare turns of reinforcing elements of a longitudinal metal strip, allowing Fasten them to the desired position.

8. The method according to p. 7, characterized in that after fixing the reinforcing elements on the treated end section install polymer sleeve having an end with a protrusion located on the inner surface of the cavity of the sleeve, closing the outputs of the reinforcing elements at the end of the pipe.

9. The method according to p. 7, characterized in that after fixing the reinforcing elements on the treated end section install metal sleeve and compresses it.

10. Reinforced polymer hose, characterized in that it is made by the method according to claim 7.

1 1. A method of obtaining a free-flow polymer reinforced pipe, including spiral winding of reinforcing elements on a conductor and subsequent extrusion coating of a polymer matrix on them to form a pipe, cooling and cutting the pipe into segments of a given length,

characterized in that prior to the spiral winding operation, the reinforcing elements are fed to the bypass roller, which is adapted to make at least one turn on the surface of the said roller coaxially with the spiral winding, and after leaving the bypass roller, the reinforcing elements are successively first fed to the guide roller then on the pressure roller forming the spiral frame on the conductor, and after leaving the conductor the spiral reinforcing frame directs the running trans porting nut into the extruder cavity formed by the mandrel and the outer forming sleeve, while polymer is injected through an offset head mounted above the mandrel, and after cutting the pipe into segments of a given length, the end sections are processed to fix and seal the reinforcing elements.

12. Non-pressure polymer reinforced pipe, characterized in that it is made by the method according to claim 1.