A kind of fabric reinforced polyurethane fine sieve and forming method thereof
Technical field
The present invention relates to a kind of fine screen mesh and forming method thereof that is applicable to selected powders in field such as pharmacy, mining, metallurgy, petrochemical industry and water treatment or filter liquide.
Background technology
Selected powders in field such as pharmacy, mining, metallurgy, petrochemical industry and water treatment or filter liquide have three important technology indexs with screen cloth: the one, and percent opening, the i.e. ratio of the sieve aperture gross area and the screen cloth gross area; The 2nd, screen size promptly is fit to other sieve aperture of different sieve classifications; Three are to use the life-span.Wherein, percent opening is big more, and screening efficiency is high more; Service life is short more, and it is frequent more to change screen cloth, and influence is produced, and increases cost.
Tradition mine fine screen mesh generally uses metal woven screen or injection nylon screen cloth.Though the metal woven screen percent opening is up to 50-55%, owing to wear no resistance, corrosion-resistant change frequently, so labour intensity is big, the cost height; Secondly, the metallic sieve poor flexibility, slot size is fixed, and causes sieve pore blockade easily when screening, influence screening efficiency, and operating noise is big.
The injection nylon fine screen mesh adopts thermoplastic nylon injection moulding, because the restriction of heated plastic macromolecule injection moulding processing can not make large-sized whole screen cloth, during use, can only take polylith small size screen cloth to be spliced.Because have shortcomings such as piece, sieve aperture divider are big, net hole rate of screen cloth is low, is generally less than 10%, screening efficiency is very low.For example, domestic patent CN2571508Y discloses the meticulous sieve sheet of a kind of nylon, and bar seam width is 0.12~0.5mm, but screen mesh size is 405 * 200mm only, need splice during use, and piece is many.
For overcoming the above-mentioned shortcoming of metallic sieve and injection nylon screen cloth, people succeed in developing polyurethane screen.Polyurethane screen has that dimensions is big, good springiness, wear-resisting, light weight, life-span are long, need not piece together the boundary during use, and labour intensity is low, and operating noise is little.But existing polyurethane screen sieve aperture is big, dimensional accuracy is low, roughly selecting of suitable material only, inapplicable material selected.Domestic patent CN 2663025Y discloses a kind of polyurethane fine screen mesh, sieve aperture minor face 0.1mm~0.3mm, long limit 15mm~18mm, percent opening is more than 25%, though this screen cloth has higher screening efficiency, but sieve aperture length is excessive, causes the particle of greater particle size to sieve thoroughly easily, influences screening quality.
But, screen cloth by simple polyurethane preparation, its hot strength is less, so patent CN2250819Y, CN2149255Y, CN2149981Y and CN2805954Y adopt polyurethane to coat steel bar or steel wire improves intensity, sacrificed the flexibility of polyurethane screen, increased the quality and the sieve aperture divider cross sectional area of screen cloth, percent opening is low.
United States Patent (USP) 4819809 discloses a kind of enhancing molded polyurethane vibration screen, and its sieve aperture is rectangle, and is surrounded by two kinds of gratings in length and breadth, and its sieve aperture width is 0.25mm~3mm, and length is about 25mm, and thickness is 3mm.Screen cloth uses the fiber reinforcement of virtue wheel, and the fortifying fibre diameter is 0.5mm, and the screen cloth overall dimensions is 1200mm * 1600m to the maximum.But this patent is not set forth percent opening.
Sum up above-mentionedly, the characteristics of variety classes screen cloth can reduce table 1.
The characteristics of the existing screen cloth of table 1
Secondly, the forming method of existing polyurethane screen has methods such as injection moulding, normal pressure moulding by casting and sheet material punching.
Patent CN 1923498A discloses a kind of moulding process of polyurethane screen, first centrifugal forming polyurethane sheet, and screen cloth is made in laser boring then.Though the screen mesh size that this method is made is big, without assembly unit, its screen cloth adjacent holes spacing is bigger, is 0.6mm during use, and Kong Kuanwei 0.1mm~2mm, percent opening only are 22%, and the enhancing skeleton is not set.
" polyurethane industrial " (1999,14 (3): reported a kind of employing casting type polyurethane centrifugal forming sheet material 18-20), the method of mechanical punching prepares the forming method of polyurethane flip-flow screening machine plate then, this method can not the one-shot forming screen cloth, production efficiency is lower, percent opening is low, and the sieve aperture wall is rough." specific rubber goods " (2002,23 (6): 32-36), " plastics industry " (2003,31 (5): 48-51) and " scientific and technological information exploitation with economic " (2002,12 (2): all reported 70-72) and adopted the normal pressure casting to prepare the method that firm skeleton strengthens polyurethane sieve plate, but adopted its thickness of polyurethane screen and the quality of this method preparation all bigger.In addition, normal pressure casting pouring pressure is low, and casting system can not be in the fine screen mesh shaping mold cavity of the narrow complexity of runner flows smoothly, thereby is not suitable for that the moulding screen size is little, the closely spaced fine screen mesh of adjacent holes.
Summary of the invention
One of the object of the invention provides a kind of fibre-reinforced polyurethane fine screen mesh.Its fortifying fibre is glass fibre, aramid fiber, nylon fiber or polyester fiber, the about 0.1mm~0.4mm of fibre diameter; Long 1mm~the 5mm in the hole of its rectangle sieve aperture, the wide 0.1mm~0.5mm in hole; Thickness 0.1mm~the 0.5mm of divider, thickness 0.3mm~1.0mm between the hole; Percent opening is equal to or greater than 32%; The divider cross section is between the hole
Font, sieve aperture is difficult for by clogged up with material, and screen-penetrating performance is good, the screening efficiency height.Rectangle sieve aperture both sides are provided with the rough segmentation parting bead, are equipped with fortifying fibre in the bottom of rough segmentation parting bead, have both improved the mechanical strength of screen cloth, have overcome the steel skeleton again and have strengthened the shortcoming that polyurethane screen thickness is big, quality big, flexibility is poor.
Specifically, one of purpose of the present invention provides a kind of polyurethane screen, it is characterized in that: the length of described screen cloth (1) is 770mm~2470mm, width is 50mm~2000mm, and is made up of rectangle sieve aperture (10), rough segmentation parting bead (7), segmentation parting bead (8), reinforcement (4) and frame (2); Reinforcement (4) is separated into 8~20 hurdles to sieve aperture district (3); Adjacent reinforcement spacing is 90mm~120mm; Numerous rectangular mesh that are made of rough segmentation parting bead (7) and segmentation parting bead (8) are distributing in each hurdle; Parallel 15~25 the rectangle sieve apertures (10) that are distributed with in each rectangular mesh; Sieve aperture (10) is surrounded by divider (9) between segmentation parting bead (8) and hole, and sieve aperture is long to be 1mm~5mm, and sieve aperture is wide to be 0.1mm~0.5mm, and thickness is 0.3mm~1mm; Wall thickness 0.1mm~0.5mm between adjacent sieve aperture; Bottom at rough segmentation parting bead (7) is equipped with fortifying fibre, has both improved the mechanical strength of screen cloth, has overcome the steel skeleton again and has strengthened the shortcoming that polyurethane screen thickness is big, quality big, flexibility is poor.
Two of the object of the invention provides a kind of fabric reinforced polyurethane fine sieve disposal integral molding method that is suitable for.Adopt vacuum aided, many cast gates, (Vacuum-Assisted Muti-Pouring Gate ResinTransfer Molding, VA-MPG-RTM) method moulding abbreviates vacuum aided MPG-RTM as to low-viscosity polyurethane system transfer modling.By choosing suitable gate location, the method that adopts many cast gates to pour into a mould in proper order makes the fabric reinforced polyurethane fine sieve of no air pocket under vacuum aided.Make the moulding of the high polyurethane fine screen mesh of Kong Kuanxiao, percent opening that the normal pressure casting can't moulding become possibility.
(1) structure of polyurethane fine screen mesh and characteristics thereof
This
screen cloth 1 is formed (see figure 1) by
screen cloth frame 2,
sieve aperture district 3 and
reinforcement 4, and
screen cloth 1 length and width are 50mm~
2000mm.Frame 2 is made up of
horizontal edge frame 5 and
longitudinal edge frame 6, constitutes the outward flange of whole screen cloth.The thickness of
horizontal edge frame 5 is 3mm~5mm, and width is 20mm~30mm;
Longitudinal edge frame 6 thickness are 4mm~6mm greater than horizontal edge frame thickness, and width is 25mm~35mm.Size according to screen cloth,
reinforcement 4 is separated into 8~20 hurdle (see figure 1)s to
sieve aperture district 3, adjacent reinforcement spacing is 90mm~120mm, numerous rectangular mesh (seeing Fig. 3 and Fig. 4) that are made of rough
segmentation parting bead 7 and
segmentation parting bead 8 that distributing in each hurdle, the length of rectangular mesh is that 5mm~10mm, width are that 1mm~5mm, thickness are 1mm~2mm.Rough
segmentation parting bead 7 with
segmentation parting bead 8 cross sections all is
It is 0.1mm~0.4
mm fortifying fibre 11 that font, the bottom of rough
segmentation parting bead 7 are equipped with the diameter that runs through whole screen cloth.Rough
segmentation parting bead 7 top width are 0.8mm~1.0mm, highly are 1mm~2mm;
Segmentation parting bead 8 top width are 0.4mm~0.6mm, highly are 1mm~2mm.Interior parallel 15~25 rectangle sieve aperture 10 (see figure 7)s that are distributed with of each rectangular mesh, its Kong Changwei 1mm~5mm, Kong Kuanwei 0.1mm~0.5mm, thickness are 0.3mm~1mm.Sieve
aperture 10 constitutes (see figure 6) by the top that divider between the
hole 9 is vertically connected at
segmentation parting bead 8, the top of
divider 9 is concordant with screen cloth
upper surface 12 between the hole, but the bottom is away from screen cloth
lower surface 13, so screen cloth
upper surface 12 has different architectural feature (see figure 5)s with screen cloth lower surface 13.
Divider 9 cross sections are little between the hole
The font (see figure 6) makes the cross section formation of sieve aperture (10) trapezoidal, and promptly sieve aperture is up-narrow and down-wide, thereby can avoid material particles to block sieve aperture, improves
screening efficiency.Divider 9 top width only are 0.1mm~0.5mm between the hole, and promptly
sieve aperture 10 is arranged closely, makes whole screen cloth have very high percent opening, reaches more than 32%.
Divider 9 is 0.3mm~1mm with the identical (see figure 6) of height of
sieve aperture 10 between the hole, and so little compass screen surface thickness makes the very light weight of whole screen cloth.
Reinforcement 4 is triangle at screen cloth upper surface 12 with the top shape of cross section, is called reinforcement top 14; Part shape of cross section between screen cloth upper surface 12 and screen cloth lower surface 13 is rectangle (seeing Fig. 2 and Fig. 5), is called reinforcement bottom 15.The bottom side length of reinforcement top 14 cross-sectional triangles is 8mm~12mm, highly is 6mm~10mm.Reinforcement bottom 15 cross section rectangle length are 5mm~8mm, highly are 3mm~5mm.Reinforcement 4 can also make the material that will sieve be evenly distributed on the whole screen cloth except playing the effect that strengthens screen cloth, avoids material to concentrate on the local influence screening efficiency of screen cloth.In addition, the inclined-plane 16 of the triangular cross section of reinforcement 4 (14) can directing material flows near the sieve aperture district the reinforcement 4, avoids partial material through screening and directly do not flow through screen cloth along the reinforcement upper surface, thereby influences screening quality.
As mentioned above, this kind screen cloth has the following advantages:
The first, little, the sieve aperture of divider thickness is arranged closely between the Kong Kuanxiao of this screen cloth, hole, thereby percent opening height, screening efficiency height; The sieve aperture cross section is trapezoidal, thisly becomes big sieve aperture from top to bottom gradually, is difficult for blocking, screen-penetrating performance is good.
The second, this screen cloth is equipped with pliable and tough fortifying fibre in the bottom of rough segmentation parting bead, not only gives screen cloth very high tensile strength, and has kept polyurethane light weight, flexible good advantage.This is that metal material skeleton enhancing polyurethane screen is not available.
Three, this screen cloth is distributed with and highly only is divider and sieve aperture between the hole of 0.3mm~1mm, and both area sums account for more than 70% of the screen cloth gross area, and therefore, most area thickness of whole screen cloth are very little.By the rectangular mesh that rough segmentation parting bead and segmentation parting bead constitute, its topside area accounts for the ratio of the screen cloth gross area less than 30%, but gives screen cloth bigger tensile strength.
Four, be uniform-distribution with the reinforcement of projection in the screen cloth, its cross section is triangle with top exceeding screening district upper surface, the effect that this triangular cross section reinforcement can play guiding, separate material, make material when screening, not be concentrated in certain regional area of screen cloth, guarantee that each sieve aperture can both play a role, and has made full use of effective sifting area.
Description of drawings:
Fig. 1 is the polyurethane fine screen mesh front view
Fig. 2 is that polyurethane fine screen mesh A-A is to view
Fig. 3 is the local forward schematic diagram (rectangle region part among Fig. 1) that amplifies of fine screen mesh
Fig. 4 is the local reverse schematic diagram a of amplification of fine screen mesh (the interior part of rectangle region among Fig. 1)
Fig. 5 is that the local B-B of fine screen mesh is to schematic diagram
Fig. 6 is that fine screen mesh Local C-C is to schematic diagram
Fig. 7 is among the local enlarged diagram b of fine screen mesh (the interior part of rectangle region among Fig. 3) figure: divider, 10-sieve aperture, 11-fortifying fibre, 12-screen cloth upper surface, 13-screen cloth lower surface, 14-reinforcement top, 15-reinforcement bottom, 16-reinforcement inclined-plane between 1-screen cloth, 2-screen cloth frame, 3-sieve aperture district, 4-reinforcement, 5-horizontal edge frame, 6-longitudinal edge frame, 7-rough segmentation parting bead, 8-segmentation parting bead, 9-hole.
(2) polyurethane fine screen mesh forming method
By the structure of above-mentioned polyurethane fine screen mesh as can be known, this mesh structure is complicated, and sieve aperture is meticulous, and overall dimensions is large. If adopt the injection mo(u)lding of polyurethane melt, then because its melt viscosity is large, can not be full of elongated and complicated runner or die cavity, generation is shorted. As adopt polyurethane liquid normal pressure casting forming method, can not avoid gas stranded and form air pocket in complicated runner.
The VA RTM forming method is a kind of under the condition that die cavity vacuumizes, by the method for the pressure die cavity that resin injection is airtight, curing molding. When adopting VA RTM forming method molded polyurethanes fine screen mesh, the position setting at sprue gate and quantity and feed way have considerable influence to forming process. Gate location is incorrect, causes easily tired gas, causes goods to produce defective; Cast gate quantity is very few, and resin system just reaches viscosity higher in the time of may going back the underfill die cavity, affects further mold filling, causes shorting; Cast gate quantity is too much, and material stream number of share of stock is also many, when several flow fronts are met, is easy to form air pocket. Therefore, selecting suitable gate location, quantity and feed way, is very important for the high-quality screen cloth of moulding.
In the present invention, adopt vacuum-assisted, many cast gates, low-viscosity polyurethane system transfer modling method (VA-MPG-RTM) shaping fiber to strengthen fine screen mesh (as shown in Figure 9). Gate location is arranged on reinforcement position (as shown in Figure 8). According to screen mesh size, cast gate quantity can be different. When adopting many cast gate cast, 0 grade of cast gate in the middle of opening first when flow fronts is crossed the 1 grade of cast gate in both sides, is opened this two 1 grade of cast gates again, when flow fronts is crossed 2 grades of cast gates, opens this two 2 grades of cast gates again, carries out (as shown in figure 10) successively. Although be many cast gate cast, resin flows forward only has one, multiply material stream meets and forms the problem of air pocket when having avoided many cast gates to begin to pour into a mould simultaneously. And, when cast, die cavity is vacuumized, avoid being stranded the generation of gas phenomenon. Before vacuumizing, with the seam crossing good seal of the upper and lower template of mould, establish a bleeding point in edge, bleeding point is linked to each other (as shown in Figure 9) with vacuum equipment.
Description of drawings:
Fig. 8 is the gate location schematic diagram
Fig. 9 is vacuum-assisted, many cast gates, resin transfer moulding (VA-MPG-RTM) device schematic diagram
Figure 10 is the feed way schematic diagram
The specific embodiment
1) fortifying fibre is routed in the treated mould, close die with the joint seal of the upper and lower template of mould, links to each other bleeding point with vacuum equipment, then with mold heated to 70 ℃~90 ℃;
2) (the cast polyurethane system of 0.5Pas~2Pas) the material still of putting into casting machine is heated to 60 ℃~80 ℃, and each pouring head of casting machine is connected with each cast gate on the mould respectively with low viscosity.
3) open vacuum equipment, when vacuum reaches 0.08MPa~0.09MPa, open the cast gate that is positioned in the middle of the reinforcement, under the pressure of 3MPa~10MPa, the low viscosity resin system is injected die cavity; When flow fronts surpasses two cast gates of both sides, open two cast gates more simultaneously, pouring pressure also is 3MPa~10MPa; If both sides also have cast gate, then carry out successively by aforesaid operations.
4) after resin is full of die cavity fully, at first stop to vacuumize, all cast gates still keep linking to each other with cast gate, and dwell pressure is 2MPa~5MPa, reaches gel point until polyurethane system.
5) pouring head is removed from cast gate, to 100 ℃~120 ℃ of resin solidification temperature, be 0.5h~1h hardening time with mold heated.Then, cooling die to 70 ℃~90 ℃, the opening mold demoulding promptly gets goods.
Specific embodiment
Embodiment 1
1) surface treated fortifying fibre is routed in about 85 ℃ die cavity, close die with the joint seal of the upper and lower template of mould, links to each other bleeding point with vacuum equipment.
2) low viscosity (1.5Pas) cast polyurethane system 1 is poured in the casting machine material still, be heated to 80 ℃, each needle-valve pouring head of casting machine is connected with each cast gate on the mould respectively.
3) open vacuum equipment, when vacuum reached 0.09MPa, unlatching was positioned at the cast gate in the middle of the reinforcement, under the pressure of 5MPa, the low viscosity resin system was injected die cavity; After pouring into a mould about 20 seconds, when flow fronts surpasses two cast gates of both sides, open two pouring heads simultaneously, pouring pressure also is 5MPa.
4) behind about 1min, resin is full of die cavity fully, at this moment stops to vacuumize, and all cast gates still keep linking to each other with cast gate, and dwell pressure is 3MPa, and polyurethane system reaches gel point behind the 6min, and pressurize finishes.
5) the needle-valve pouring head is removed from cast gate, mold heated to 120 ℃ of resins, is solidified 0.5h; Then, cooling die to 85 ℃, the opening mold demoulding gets promptly that dimensional accuracy height, mechanical property excellence, apparent mass are good, the fabric reinforced polyurethane fine sieve of no air blister defect.
Embodiment 2
1) surface treated fortifying fibre is routed in about 80 ℃ die cavity, close die with the joint seal of the upper and lower template of mould, links to each other bleeding point with vacuum equipment.
2) low viscosity (0.8Pas) cast polyurethane system 2 is poured in the material still of casting machine, be heated to 75 ℃, each needle-valve pouring head of casting machine is connected with each cast gate on the mould respectively.
3) open vacuum equipment, when vacuum reached 0.08MPa, unlatching was positioned at the cast gate in the middle of the reinforcement, under the pressure of 4MPa, the low viscosity resin system was injected die cavity; After pouring into a mould for 18 seconds, when flow fronts surpasses two cast gates of both sides, open two pouring heads simultaneously, pouring pressure also is 4MPa.
4) resin is full of die cavity fully after 50 seconds, stops then vacuumizing, and all cast gates still keep linking to each other with cast gate, and dwell pressure is 3MPa, and polyurethane system reaches gel point behind the 8min.
5) the needle-valve pouring head is removed from cast gate, to 100 ℃ of resin solidification temperature, be 1h hardening time with mold heated.Then, cooling die to 80 ℃, the opening mold demoulding gets promptly that dimensional accuracy height, mechanical property excellence, apparent mass are good, the fabric reinforced polyurethane fine sieve of no air blister defect.
Vacuum aided MPG-RTM technology is compared with other traditional polyurethane fine screen mesh forming method and to be had following characteristics, lists in the table 2.
Table 2 polyurethane fine screen mesh forming method relatively
Forming method |
Vacuum aided MPG-RTM |
The normal pressure cast |
Centrifugal-punching |
Formed precision |
High |
Low |
Low |
Molding cycle/h |
1~1.5 |
1~2 |
>3 |
Sieve aperture wall thickness/mm |
0.1 |
0.5 |
0.6 |
Product defect |
Do not have |
Many |
Many |
Automaticity |
High |
Low |
Low |
Secondary operations whether |
Not |
Be |
Be |
The goods apparent mass |
Excellent |
Very |
Difference |
Whether can establish the enhancing body |
Be |
Be |
Not |
Therefore, traditional forming method of the vacuum aided MPG-RTM forming method of polyurethane fine screen mesh and normal pressure cast and centrifugal-punch is compared, advantage such as have the formed precision height, the sieve aperture wall thickness is little, product defect is few, automaticity is high, working condition is good, do not need secondary operations, the goods apparent mass is good.
Vacuum aided, many cast gates order casting forming method have been avoided the multiply materials flow to meet in complicated die and have been formed the problem of air pocket; Make the disposal integral molding of large scale polyurethane fine screen mesh become possibility, and goods do not have the air pocket defective, improved yield rate.