CN103987515A - 用于制造纤维强化复合管的方法以及纤维强化复合管 - Google Patents

用于制造纤维强化复合管的方法以及纤维强化复合管 Download PDF

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CN103987515A
CN103987515A CN201280061744.3A CN201280061744A CN103987515A CN 103987515 A CN103987515 A CN 103987515A CN 201280061744 A CN201280061744 A CN 201280061744A CN 103987515 A CN103987515 A CN 103987515A
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strengthening layer
plastic tube
tube
plastic
reinforced composite
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CN103987515B (zh
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艾哈迈德·阿尔—舍亚布
亚历山大·厄尔施勒格尔
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Rehau Automotive SE and Co KG
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    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
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    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/446—Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames
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Abstract

本发明涉及一种用于制造纤维强化复合管(1)的方法，其中，制造塑料管，继而将含有强化丝的强化层涂覆在塑料管上。随后根据本发明对这样制成的复合管进行再处理，其中，将强化层中存在于丝之间的间隙密封，从而在强化层中能够至少基本上不再有毛细效应。本发明还涉及一种纤维强化复合管(1)。

Description

用于制造纤维强化复合管的方法以及纤维强化复合管
技术领域
本发明涉及一种用于制造纤维强化复合管的方法，其中，该方法包括以下方法步骤：
-优选通过挤压工艺制造塑料管，并且
-随后将含有强化丝的强化层涂覆在塑料管上。
背景技术
过去，已经建立了多种不同的用于制造纤维复合材料的制造工艺。一方面是高压工艺，尤其是注塑成型工艺、挤压工艺以及冲压工艺，而另一方面是低压工艺，例如RTM(树脂传递成型)和热压工艺。高压工艺的特征具体在于能够实现高生产速率，而利用低压工艺能够制造出具有极高机械强度的构件。这样的构件特性不能单独利用高压工艺或者只能以更高的投入(Aufwand)获得。相反，低压工艺的缺点在于需要对在此所使用的塑料进行较长时间的固化，这降低了产出率并由此提高了构件的制造成本。
当在高压(例如10bar或更高的过压)条件下传输液态介质(例如水)时，一般都使用金属管或厚壁塑料管，这种金属管或厚壁塑料管作为水提升管安装在多层建筑中。由于在过去金属价格的明显上升，因此越来越需要替代方案。此外，金属管还具有较大的重量，并且运送到建筑工地和在建筑工地搬运的费用也是相当高的。此外，金属管易被腐蚀。厚壁塑料管的缺点在于，其在给定的最大外径的情况下仅具有相对较小的自由流动横截面以及同样较高的重量或材料要求。
专利文献DE 10 2009 016 596 A1公开了一种具有上述特征的方法。在此方法中，在挤压而成的塑料管上缠绕混合型粗纱(Roving)，这种粗纱除了强化纤维之外还含有塑料纤维。为了在缠绕过程中提高粗纱的刚性，需要将塑料纤维熔化。但是如果将这样制成的复合管例如为了输送处于高压下的水而使用在建筑物提升管路中，在一定时间之后液体肯定会从复合管的外表面渗出。由于较高的内压，液体会从各个复合管之间的连接件部位通过复合管的端面向强化层扩散。强化层则由于紧密相邻排列的丝而具有大量的、具有极小气孔直径的中间空腔。由此使得强化层在此具有所谓的毛细效应，并且使扩散到复合管中的液体能够非常轻易地通过强化层的毛细管向外渗出。其结果是在较短时间内就形成了潮湿的复合管外表面，这种潮湿的外表面对于使用在建筑物中的复合管是尤其不能容忍的。此外，由于在此的强化并不完全，因此这种复合管随着时间的推移还将出现明显的机械性能下降，因为上述效应也将导致对强化层的损伤。
发明内容
在此背景下，本发明的目的在于，提供一种用于制造具有最初所述特征的纤维强化复合管的方法，这种纤维强化复合管在输送处于高压下的液体时能够确保持久的密封性。
本发明的目的通过一种根据前述特征制造而成并随后经过再处理的复合管来实现，其中，将强化层中的存在于丝之间的间隙密封，从而使得在强化层中至少基本没有，优选根本不会出现毛细效应。密封在此特别是指填充和/或密封间隙。本发明基于这样的认识，即只要去除了包含在强化层中的间隙，从而实质上不再出现、优选完全不再出现毛细效应，则相对合适的、具有较小重量且不会被腐蚀的纤维复合管也可用于输送处于高压下的液体，例如在建筑物的水提升管路中的液体。
毛细效应通常完全是一种流动现象，这种现象使得液体在接触毛细管(例如细管、夹缝或空腔)时被吸入固体材料中。例如，当玻璃管竖立地浸在水中时，水在细小的玻璃管中将克服重力上升。这种毛细效应是通过液体自身的表面张力和液体与固体表面的界面应力造成的。毛细管的直径越小，毛细压力和上升高度越大。通过根据本发明的教导，现在可以去除在强化层中由丝构成的不需要的毛细管，并且复合管能够用于上述应用目标。
根据本发明的一种优选的实施方式，强化层除了强化丝之外还包含塑料丝。在该实施方式中，再处理是指再固结，其中，塑料丝被加热到能导致其至少部分熔化的温度，从而使强化层中的间隙被所产生的熔化物密封。在此，显然再固结是在将强化层涂覆到塑料管上之后进行的，因为一旦完成涂覆，则强化层的毛细管结构就被固定了。优选塑料管在再固结过程中自内部冷却，从而使塑料管至少本质上保持固相状态。由此确保包含在强化层中的塑料丝的熔化工序所需要的导入热量不会对塑料管造成损伤。
优选，塑料丝和塑料管由相同的塑料材料制成。例如，当塑料管由聚丙烯制成时，优选将聚丙烯丝集成在强化层中，这种聚丙烯丝在熔化时能够相应较好地与塑料管的外表面相结合。在本发明的范畴内，塑料管和塑料丝可以使用不同密度的聚丙烯材料。例如在塑料管的聚丙烯材料中还可以含有添加剂。在本发明的范畴内，塑料管和塑料材料应由彼此发生反应的材料制成，例如具有PET的PVC管。
优选，对塑料管的冷却通过流动通过塑料管的流体进行。在此，流体可以是气体，例如空气，也可以是液体，例如水。基于上述流动可以确保将热量连续地从塑料管的内表面带走。优选地，在塑料管中安装被加载流体的软管。由此可以例如在空气冷却时将软管连接在压缩空气泵上，该压缩空气泵能够确保均匀的流动和由此从内管壁连续地排出热量。可选地，也可以将软管连接在水管上并相应地加载冷水。通过这种软管可以更容易地实现塑料管的内部冷却。
优选地，进行再固结，使得塑料管的外表面温度保持在塑料的熔化温度TM的范围内。塑料管的内表面温度则优选保持在塑料的晶体化温度TC以下。在此要注意的是，塑料的晶体化温度TC通常与熔化温度TM明显不同。熔化温度TM是指在加热塑料的过程中塑料由固相状态刚刚出现熔化的温度。而晶体化温度TC是指在冷却塑料的过程中塑料刚刚开始形成固体颗粒的温度。通过调整所述的温度曲线，一方面可以确保强化层中的塑料丝熔化，另一方面也可以确保与此同时不损伤塑料管。
优选地，塑料丝在强化层中的重量比例为40-80％，例如40-60％。根据应用情况的不同，塑料丝在强化层中的重量比例也可以为20-40％或60-80％。
对于上述的再固结，替代地还可以借助粘合剂密封间隙，优选在将强化层涂覆在塑料管上之后将粘合剂施加在强化层上。粘合剂例如可以是环氧树脂粘合剂或所谓的表面密封剂、例如Fa.公司的在此显而易见的是，通过应用粘合剂，可以根据本发明使包含在强化层中的间隙密封。
总的来说，例如通过根据本发明对间隙进行密封可以在向复合管的强化层的端面加载具有10bar过压()，优选15bar过压()，特别为20bar过压()的运行压力的情况下，一直不会发生水对强化层外表面的渗透。在此优选强化层的最大壁厚为50mm，优选10mm，特别为5mm。
优选强化层由带和/或粗纱构成，例如，是带和/或粗纱的强化层。强化层的丝在此可以优选是连续不断的纤维或是分别由多种连续不断的纤维组成的线。粗纱例如可以是连续不断的、不扭结的拉伸丝。相应地，丝在此可以单向取向的。然而粗纱也可以设计使得丝交叉，例如编织而成的粗纱的形式。粗纱的丝可以彼此对齐，从而使丝总体上形成菱形结构。由此，粗纱具有扁平的连接部位，这些连接部位在平面内沿任意方向都具有高负载承受能力，从而能够以非常简单的方式进行加工。粗纱还可以被设计为织物。在带中，丝也是单向取向的，并以合适的方式相互固定(例如通过由例如塑料或与相应的强化丝相同的材料制成的纬线)，从而使丝整体上呈带状结构。带或粗纱自身已经可以具有混合结构，原因在于带或粗纱一方面可以由强化丝制成，另一方面可以由塑料丝制成。然而还可以考虑使由强化丝制成的带/粗纱与由塑料丝制成的带/粗纱相结合。
为了形成强化层，适宜地使丝优选围绕塑料管多层缠绕和/或编织。优选该强化丝由矿物、和/或碳元素、和/或塑料、和/或玄武岩、和/或陶瓷、和/或金属，其中矿物优选为玻璃，塑料优选为芳纶。优选适用于强化丝的材料的熔点高于塑料丝的熔化温度TM。塑料复合管的内径优选为10mm至1000mm，特别为50mm至300mm，而塑料管的壁厚应在2mm至50mm之间，特别为2mm至10mm，而强化层的壁厚应在0.5mm至50mm的区间内，尤其为0.5mm至10mm，例如0.5mm至3mm。在本发明的框架内还涉及到在强化层上涂覆保护层，该保护层可以被挤出并且例如由塑料制成。根据本发明的教导还有利地涉及借助挤压工艺制得的塑料管，该塑料管配备有强化层。在本发明的框架内还涉及以其他方式(例如采用拉挤成型工艺)制成的塑料管。
此外，本发明还涉及一种根据权利要求15的纤维强化复合管。根据本发明的复合管可以特别应用在处于例如10bar过压()或更高的高压下的水或其他液体(例如原油/中间炼油产物或化学制剂)的输送，并且例如还作为供水的提升管路应用在多层式建筑(例如高楼)或石油工业或/和化学工业中。
附图说明
下面结合仅示出一个实施例的附图对本发明进行详细阐述。在附图中：
图1a以横截面图示出了根据本发明的具有塑料管和强化层的复合管的制造；
图1b示出了图1a中X部分的局部放大视图；
图2示出了根据图1a所示视图的本发明的另一实施方式；
图3以纵向视图示出了在根据本发明的再固结过程中图2所示的复合管。
具体实施方式
图1示出了用于制造纤维强化复合管1的方法，该复合管通过未示出的连接件(例如压装配件)与其他复合管连接成较长的管路。在此，首先利用(未示出的)挤压工艺制备塑料管2。塑料管具有圆形横截面，然而也不排除其他的横截面形状。在挤压塑料管2之后，在塑料管上涂覆包含强化丝3的强化层4(参照图1a)。随后对所制备的复合管进行再处理，在此，将强化层4中存在于丝3、5之间的间隙6密封，从而当在强化层4的端面15(参照图3)上加载低于10bar过压下的水时，强化层4中将一直不会出现毛细效应，并相应地不会发生水向强化层外表面的渗透。在此密封中，间隙6将被填充和/或封住。在该实施例中，本发明的密封将按如下方式进行：强化层4除了含有强化丝3之外还含有塑料丝5。再处理是指再固结，在此过程中，塑料丝5处于能够导致其熔化的温度下，从而使强化层4中的间隙6被所产生的熔化物密封。塑料管2在再固结过程中从内部被冷却(参照图3)，从而使塑料管至少实质保持固相状态。由图1a上侧所示的在复合管1中的径向温度曲线可知，在再固结过程中，塑料管2的外表面温度保持在其塑料的熔化温度TM的范围内。相反，塑料管2的内表面温度则优选保持在其塑料的晶体化温度TC以下。强化层4的外表面上的温度高于所谓的熔化温度TM。塑料丝5和塑料管2由相同的塑料材料制成，在该实施例中为聚丙烯。
为了对复合管1进行再固结，将复合管放置在具有两个半部7、7'的强化工具8中，该强化工具被相应地加热并由此将热通量Q(参照图3)传递到复合管1上。强化层4在该实施例中由单向的带9构成(参照图1b中虚线所示)，带9利用编织技术被多层地加装在塑料管2上。带9的强化丝3为碳、玻璃或芳纶。塑料丝5在带9中的重量比例约为50％。
在根据图2的实施例中，在强化层4上附加地挤压形成保护层10。对此选择这样的合成材料：其熔化温度高于塑料管2或塑料丝5的熔化温度TM。由此，即使为了进行热传递而必须将温度提高到塑料管2以及塑料丝5的熔化温度TM以上，也能够确保保护层10在再固结过程中保持在固相状态。
图3示出了沿复合管1的纵向x观察到的再固结过程。如上所述，塑料管2在再固结过程中从内部冷却。在该实施例中，塑料管2的冷却是借助以压力P在管中穿流的空气11进行的。对此，在塑料管2中***软管12，用于加载空气11。由于内压P，该软管12扁平地贴靠在塑料管2的内表面上。借助压缩空气泵13，通过管路14，可以实现穿过软管12以及塑料管2的相应的强制流动，从而持续地带走热量。
在该实施例中没有示出但同样也处于本发明范围中的是：可替代地，间隙6还可以利用粘合剂密封，在完成对强化层4的涂覆之后将粘合剂例如涂覆在强化层4上。

Claims (15)

1.一种用于制造纤维强化复合管(1)的方法，其中，该方法包括以下方法步骤：
-优选借助挤压工艺制造塑料管，以及
-随后将含有强化丝的强化层涂覆在所述塑料管上，
其特征在于，随后对由此制成的复合管进行再处理，其中，所述强化层中存在于丝之间的间隙被密封，使得所述强化层中能够至少基本上不再产生毛细效应。
2.根据权利要求1所述的方法，其特征在于，所述强化层除了含有强化丝之外还含有塑料丝，并且所述再处理是指再固结，其中，使所述塑料丝处于能够导致该塑料丝至少部分熔化的温度下，从而使所述强化层中的间隙被所产生的熔化物密封。
3.根据权利要求2所述的方法，其特征在于，所述塑料管在再固结过程中从内部被冷却，从而使所述塑料管至少实质上保持在固相状态。
4.根据权利要求2或3所述的方法，其特征在于，所述塑料丝和所述塑料管由相同的塑料材料制成。
5.根据权利要求3或4所述的方法，其特征在于，所述塑料管的冷却借助于优选流动通过该管的流体进行。
6.根据权利要求5所述的方法，其特征在于，为了进行再固结，在所述塑料管中***软管，所述软管提供有所述流体。
7.根据权利要求2-6中任一项所述的方法，其特征在于，进行再固结使得所述塑料管的外表面温度保持在其塑料的熔化温度的范围内。
8.根据权利要求2-7中任一项所述的方法，其特征在于，进行再固结使得所述塑料管的内表面温度保持在其塑料的晶体化温度以下。
9.根据权利要求2-8中任一项所述的方法，其特征在于，所述塑料丝在所述强化层中的重量比例为40-80％。
10.根据权利要求1所述的方法，其特征在于，所述间隙被涂覆在所述强化层上的粘合剂密封。
11.根据权利要求1-10中任一项所述的方法，其特征在于，所述强化层由带和/或粗纱制成。
12.根据权利要求1-11中任一项所述的方法，其特征在于，为了形成所述强化层，所述丝围绕所述塑料管缠绕和/或编织。
13.根据权利要求1-12中任一项所述的方法，其特征在于，所述强化丝由矿物、和/或碳元素、和/或塑料、和/或玄武岩、和/或陶瓷、和/或金属制成，其中所述矿物优选为玻璃，所述塑料优选为芳纶。
14.根据权利要求1-13中任一项所述的方法，其特征在于，在所述强化层上涂覆保护层。
15.一种纤维强化复合管(1)，根据权利要求1-14中任一项所述的方法制得。
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