CN105109055A - 一种聚合物管道喷流堆砌成型方法及装置 - Google Patents

一种聚合物管道喷流堆砌成型方法及装置 Download PDF

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CN105109055A
CN105109055A CN201510494014.8A CN201510494014A CN105109055A CN 105109055 A CN105109055 A CN 105109055A CN 201510494014 A CN201510494014 A CN 201510494014A CN 105109055 A CN105109055 A CN 105109055A
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CN105109055B (zh
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瞿金平
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South China University of Technology SCUT
Guangzhou Huaxinke Industrial Co Ltd
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South China University of Technology SCUT
Guangzhou Huaxinke Industrial Co Ltd
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Priority to CN201510494014.8A priority Critical patent/CN105109055B/zh
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Priority to CA2992957A priority patent/CA2992957C/en
Priority to BR112018002121-0A priority patent/BR112018002121A2/pt
Priority to JP2018506958A priority patent/JP6578054B2/ja
Priority to AU2015405308A priority patent/AU2015405308A1/en
Priority to KR1020187003661A priority patent/KR102050859B1/ko
Priority to PCT/CN2015/100077 priority patent/WO2017024746A1/zh
Priority to MYPI2018700307A priority patent/MY197065A/en
Priority to US15/748,693 priority patent/US20190001535A1/en
Priority to RU2018105908A priority patent/RU2685664C1/ru
Priority to EP15900935.6A priority patent/EP3335864A4/en
Priority to MX2018000843A priority patent/MX2018000843A/es
Priority to SG11201800324RA priority patent/SG11201800324RA/en
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Abstract

本发明公开一种聚合物管道喷流堆砌成型方法及装置，在螺旋缠绕堆砌成型过程中，通过在已形成的管胚中埋入熔体，结合熔体产生的喷流熔接作用和局部压延的定型作用，连续形成管道。其装置包括挤出机、熔体喷射机构、局部压延机构和管径定型调整机构，熔体喷射机构设于挤出机的挤出末端且埋入已形成的管胚中，局部压延机构和管径定型调整机构分布于管胚圆周方向的管壁上，且局部压延机构设于熔体喷射机构对应的位置，熔体喷射机构位于管壁内，局部压延机构位于管壁外，局部压延机构和熔体喷射机构之间形成约束空间。本发明可解决成型聚合物管道中成型尺寸受限、模具成本高、成型工艺复杂、能耗高、力学性能差、成型效率低、成型原料受限等问题。

Description

一种聚合物管道喷流堆砌成型方法及装置
技术领域
本发明涉及高分子材料加工成型技术领域，特别涉及一种聚合物管道喷流堆砌成型方法及装置。
背景技术
与金属管道等传统管道比较，高聚物管具有耐腐蚀，易安装，节能，输送流体阻力小，环保，输送热介质时热量损失小、优异的抗震性，质量轻、运输施工维护综合成本低，连接快捷可靠，使用寿命长且周期费用低，生产效率高、适合工业化大规模生产，原料资源丰富且可回收再利用等优点。因此，高聚物管道在给排水、天然气输送、建筑采暖、电力通信护套管、节水灌溉等领域得到广泛应用。
目前，可用来成型聚合物管道的工艺方法有挤出成型和缠绕熔接成型。
挤出成型存在需要专用模具，在成型大口径管道时，需要用到大型挤出机和挤出模具；挤出成型大口径管道由于取向作用导致管道周向强度小于轴向强度；同时由于大口径管道壁厚大，成型过程中熔体的流动控制比较难，易发生熔垂现象，易出现成型缺陷(如缩孔或气泡)从而导致管道力学性能差，故直接挤出成型很难成型大口径管道；另外，每挤出一种直径的管材需更换模具、挤出设备和相关辅助设备，故挤出成型大口径管道又存在成本高和灵活性较差等缺点。
缠绕熔接成型是指先挤出一定截面形状的塑料条(纯塑料条或复合其他材料)，然后通过缠绕设备把塑料条以互相搭接方式缠绕到芯棒模具上，然后在塑料条之间局部加热喷涂粘结剂(或者直接以熔融态直接缠绕到芯棒模具上或者直接缠绕外表面有塑料熔体小口径塑料管道)并经滚柱压实，使样条之间熔接复合在一起，最后取出芯棒模具最终成型管道。德国克拉公司及公开号为CN101380819A的发明申请公开了一种缠绕熔接大口径管道的方法，但这种方法需要预先成型小口径管道，成型时小口径管道先涂覆塑料熔体再缠绕到芯轴上；缠绕成型时需用到专用芯轴模具，每成型一种口径的管道时需更换芯轴模具，同时在成型时需用到二次加热设备；另外，成型时熔体料条及小口径管道之间存在熔接痕，故该成型方法存在缠绕工艺复杂、灵活性差、能耗高、耗材多、流阻大、易泄漏、承压低等缺点。
为此，针对目前聚合物管道成型中存在的问题，有必要开发一种成型灵活、成型制品力学性能高、成本低、表面质量好、能耗低、工艺简单且生产效率高的新工艺方法和装置。
发明内容
本发明的目的在于克服现有技术的不足，提供一种聚合物管道喷流堆砌成型方法，以解决成型聚合物管道中成型尺寸受限、模具成本高、成型工艺复杂、能耗高、力学性能差、成型效率低、成型原料受限等问题。
本发明的另一目的在于提供一种用于实现上述方法的聚合物管道喷流堆砌成型装置。
本发明的技术方案为：一种聚合物管道喷流堆砌成型方法，在螺旋缠绕堆砌成型(即聚合物熔体在一定压力下绕中心轴螺旋堆积在一定空间内，螺旋层与层之间无间隙缠绕融合在一起)过程中，通过在已形成的管胚中埋入熔体，结合熔体产生的喷流熔接作用和局部压延的定型作用，连续形成管道。
管道成型过程中，聚合物熔体作连续螺旋缠绕运动，且熔体经由预埋式的熔体喷射机构喷流入已成型的管道中与前续聚合物熔合，并通过局部压延机构的压延作用定型，在管径定型调整机构和旋转牵引机构的辅助作用下成型连续的聚合物管道。
本发明用于实现上述方法的聚合物管道喷流堆砌成型装置，包括挤出机、熔体喷射机构、局部压延机构和管径定型调整机构，熔体喷射机构设于挤出机的挤出末端，且熔体喷射机构埋入已形成的管胚中，局部压延机构和管径定型调整机构分布于管胚圆周方向的管壁上，且局部压延机构设于熔体喷射机构对应的位置，熔体喷射机构位于管壁内，局部压延机构位于管壁外，局部压延机构和熔体喷射机构之间形成约束空间。
所述熔体喷射机构为预埋式的供料喷嘴，在管道成型时伸入到约束空间中，并埋入到预成型管道熔体内部产生喷流。
所述挤出机底部设有机架，位于挤出机挤出末端的机架一侧设有安装板，熔体喷射机构、局部压延机构和管径定型调整机构分别安装于安装板上。
所述管胚外周还设有旋转牵引机构，旋转牵引机构包括螺旋牵引件和支撑杆，管胚外周分布有多个螺旋牵引件，各螺旋牵引件分别通过相应的支撑杆与安装板连接。旋转牵引机构对管胚进行牵引，带动已成型的管胚进行螺旋运动，使其成型连续的聚合物管道。
所述局部压延机构包括主动压延辊、从动压延辊和驱动电机，主动压延辊和从动压延辊分别设于管胚的内外两侧，主动压延辊与驱动电机连接，熔体喷射机构设于主动压延辊和从动压延辊之间的空间内。两个压延辊在成型中起到局部压延定型作用；压延辊上外接温度调节***，且压延辊的位置可调，即通过调位零件的作用，在不更换压延辊的前提下，调整压延辊的位置，同时通过管径定型调整机构对定型滚轮在管径方向的自动调整位置，实现不同口径和壁厚管道的成型。
所述局部压延机构上方还设有调节管壁厚度用的调位零件。
所述主动压延辊和从动压延辊还外接温度调节***。
所述管径定型调整机构包括多组定型滚轮组和调整件，各定型滚轮组和调整件一一对应并沿着管胚的圆周方向分布。在管胚内的中心设有阿基米德螺线钩槽凸轮机构，各组定型滚轮组和相应的调整件分别与阿基米德螺线钩槽凸轮机构连接，从而实现对不同直径和壁厚管道的定型。
所述多组定型滚轮组的结构相同，各定型滚轮组包括内定型滚轮和外定型滚轮，内定型滚轮设于管胚内侧，外定型滚轮设于管胚外侧，内定型滚轮和外定型滚轮之间设于约束弹簧。
上述聚合物管道喷流堆砌成型装置使用时，其原理是：成型时，挤出机提供的聚合物熔体经由喷嘴，喷流到约束空间中，在熔体喷流的同时，局部压延机构压延熔体旋转，在管径定型调整机构中定型滚轮的引导下先成型一段管道后，接着管道在旋转牵引机构和管径定型调整机构的共同作用下螺旋向前运动，成型连续的管道。其中，管坯最初是由局部压延机构中的两个压延辊驱动旋转，由螺旋牵引件与管道表面之间的螺纹传动而连续成型管道。
本发明相对于现有技术，具有以下有益效果：
1、利用本聚合物管道喷流堆砌成型方法及装置可成型大口径聚合物管道。
2、相对于传统的聚合物挤出成型，本聚合物管道喷流堆砌成型装置不需要挤出模具，所成型大口径管道的质量可达到甚至优于利用模具成型的管道。
3、利用本聚合物管道喷流堆砌成型方法及装置成型管道时，埋入式喷嘴喷流聚合物熔体产生局部压力，使先成型的管道与后成型的管道之间充分融合到一起，大大减少熔接痕的产生，故成型的聚合物管道力学性能比缠绕熔接成型的得到根本提高。
4、利用本聚合物管道喷流堆砌成型方法能柔性成型管道，即无需改变挤出机，仅局部改变关键零件的相对位置，可生产多种不同口径和壁厚的管道。
5、相对于传统的大口径管道成型，利用本聚合物管道喷流堆砌成型方法及装置成型管道时，由于喷流熔接和压延局部定型作用，沿管道周向成型，管道周向强度大于轴向强度，具有一定的自增强作用。
6、利用本聚合物管道喷流堆砌成型方法及装置，大口径聚合物管道直接由熔体制备，不需经过中间环节，相对于缠绕成型，能降低能耗；同时利用较小塑化能力的挤出机成型大口径管道，减少大型设备的投资；成型过程中无需模具，故降低产品成本。
附图说明
图1为本聚合物管道喷流堆砌成型装置的结构示意图。
图2为图1中预埋式的供料喷嘴的局部放大图。
图3为局部压延机构与供料喷嘴的位置关系示意图。
图4为管径定型调整机构的原理图。
具体实施方式
下面结合实施例，对本发明作进一步的详细说明，但本发明的实施方式不限于此。
实施例
本实施例一种聚合物管道喷流堆砌成型方法及装置，其熔体供给装置是挤出机。
如图1或4所示，本喷流堆砌成型装置包括挤出机1(作为聚合物熔体供给装置)、预埋式的供料喷嘴3(作为熔体喷射机构)、主动压延辊6、从动压延辊7、驱动电机2、旋转牵引机构、机架12和管径定型调整机构。主动压延辊6、从动压延辊7和驱动电机2组成局部压延机构；旋转牵引机构由螺旋牵引件10和支撑杆9组成；预埋式供料喷嘴3与挤出机1相连接；供料喷嘴上还设有挡板15，且预埋式供料喷嘴固定在挡板上；主动压延辊6、从动压延辊7分别固定在安装板4上，主动压延辊6与驱动电机连接，可作主动旋转运动，且主动压延辊6、从动压延辊7可以沿聚合物管道径向移动；管径定型调整机构中，定型滚轮组8在调整件13作用下能沿管径方向调整位置，如图1所示；挤出机1和安装板4固定在机架12上。
挤出机1挤出一定压力和温度的高聚物熔体，熔体经供料喷嘴3喷流到约束空间(由主动压延辊6、从动压延辊7和挡板15构成，如图2或图3所示)内，且供料喷嘴伸入到熔体内部，并借助两个压延辊约束及压延定型作用，同时在管径定型调整机构的作用下，被压延的塑料熔体沿着管径定型调整机构中定型滚轮组8先形成一段聚合物管道，该段管道在螺旋牵引件10及管径定型调整机构的共同作用下向前螺旋运动，后续聚合物熔体继续喷流堆砌在两个压延辊和初始聚合物管道之间；成型时，供料喷嘴固定不动，主动压延辊6和从动压延辊7转动，在压力的作用下，先成型的管道与后续喷流的熔体充分融合在一起，冷却定型后形成连续的聚合物管道11。当成型所要的一段聚合物管道后，切割装置切断管道。如此循环，成型一定长度的聚合物管道。局部压延机构上方还设有调节管壁厚度用的调位零件5，当聚合管道的尺寸如管径、壁厚变化时，可通过分别调整主动压延辊6、从动压延辊7、螺旋牵引件及定型滚轮组8在安装板上的位置，同时调整供料喷嘴3的位置，可实现成型不同规格的管道。
如上所述，便可较好地实现本发明，上述实施例仅为本发明的较佳实施例，并非用来限定本发明的实施范围；即凡依本发明内容所作的均等变化与修饰，都为本发明权利要求所要求保护的范围所涵盖。

Claims (10)

1.一种聚合物管道喷流堆砌成型方法，其特征在于，在螺旋缠绕堆砌成型过程中，通过在已形成的管胚中埋入熔体，结合熔体产生的喷流熔接作用和局部压延的定型作用，连续形成管道。
2.一种实现权利要求1所述方法的聚合物管道喷流堆砌成型装置，其特征在于，包括挤出机、熔体喷射机构、局部压延机构和管径定型调整机构，熔体喷射机构设于挤出机的挤出末端，且熔体喷射机构埋入已形成的管胚中，局部压延机构和管径定型调整机构分布于管胚圆周方向的管壁上，且局部压延机构设于熔体喷射机构对应的位置，熔体喷射机构位于管壁内，局部压延机构位于管壁外，局部压延机构和熔体喷射机构之间形成约束空间。
3.根据权利要求2所述一种聚合物管道喷流堆砌成型装置，其特征在于，所述熔体喷射机构为预埋式的供料喷嘴。
4.根据权利要求2所述一种聚合物管道喷流堆砌成型装置，其特征在于，所述挤出机底部设有机架，位于挤出机挤出末端的机架一侧设有安装板，熔体喷射机构、局部压延机构和管径定型调整机构分别安装于安装板上。
5.根据权利要求4所述一种聚合物管道喷流堆砌成型装置，其特征在于，所述管胚外周还设有旋转牵引机构，旋转牵引机构包括螺旋牵引件和支撑杆，管胚外周分布有多个螺旋牵引件，各螺旋牵引件分别通过相应的支撑杆与安装板连接。
6.根据权利要求2所述一种聚合物管道喷流堆砌成型装置，其特征在于，所述局部压延机构包括主动压延辊、从动压延辊和驱动电机，主动压延辊和从动压延辊分别设于管胚的内外两侧，主动压延辊与驱动电机连接，熔体喷射机构设于主动压延辊和从动压延辊之间的空间内。
7.根据权利要求6所述一种聚合物管道喷流堆砌成型装置，其特征在于，所述局部压延机构上方还设有调节管壁厚度用的调位零件。
8.根据权利要求6所述一种聚合物管道喷流堆砌成型装置，其特征在于，所述主动压延辊和从动压延辊还外接温度调节***。
9.根据权利要求2所述一种聚合物管道喷流堆砌成型装置，其特征在于，所述管径定型调整机构包括多组定型滚轮组和调整件，各定型滚轮组和调整件一一对应并沿着管胚的圆周方向分布。
10.根据权利要求2所述一种聚合物管道喷流堆砌成型装置，其特征在于，所述多组定型滚轮组的结构相同，各定型滚轮组包括内定型滚轮和外定型滚轮，内定型滚轮设于管胚内侧，外定型滚轮设于管胚外侧，内定型滚轮和外定型滚轮之间设于约束弹簧。
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