CN105650363A - 一种竹制复合管及其制造方法 - Google Patents
一种竹制复合管及其制造方法 Download PDFInfo
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- CN105650363A CN105650363A CN201610000269.9A CN201610000269A CN105650363A CN 105650363 A CN105650363 A CN 105650363A CN 201610000269 A CN201610000269 A CN 201610000269A CN 105650363 A CN105650363 A CN 105650363A
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- bamboo
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Classifications
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Landscapes
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- General Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Fluid Mechanics (AREA)
- Manufacturing & Machinery (AREA)
- Wood Science & Technology (AREA)
- Forests & Forestry (AREA)
- Textile Engineering (AREA)
- Laminated Bodies (AREA)
Abstract
一种竹制复合管及其制作方法，包括由内向外依次制造的内层、增强层以及外包层。采用该方法制造的竹制复合管，使用了低等级的竹材及其加工剩余物，如小口径竹材、小径级丛生竹、竹材加工剩余物，复合回收的废旧塑料，将贴覆无纺布后的薄竹或纵横向复合后制成的竹单板复合材料逐层覆盖到增强层外壁，因而能够生产满足其强度需求并且节能环保的复合管材。该竹制复合管应用于农业灌溉、给排水、建筑以及石油化工防腐等领域。
Description
技术领域
本发明属于管道领域，具体涉及一种竹制复合管及其制造方法。该管道可应用于农业灌溉、给排水、建筑以及石油化工防腐等领域。
背景技术
目前农业灌溉、给排水及石油化工防腐场合中，常用的管道一般为水泥管、聚氯乙烯管、聚乙烯管、玻璃钢管等。经长期使用证实，上述常用管道因材料的不同而存在着不同的问题，比如传统水泥管成本低，但强度低，质量重，由于材质问题容易出现泄漏；合成树脂材料的管道，质量轻，耐腐蚀，但是强度和刚度水平较差，且均采用石油化工产品制造，污染环境；玻璃钢管的材料能耗过高。出于环保和节能的考虑，越来越需要一种节能环保、强度有保证的新型管道。
发明内容
本发明旨在提供一种能够生产满足强度需求并且节能环保的竹制复合管的方法，即该竹制复合管。
本发明所采用的技术方案是：一种竹制复合管的制造方法，所述竹制复合管包含内层、增强层和外包层，包括以下步骤：（一）内层制造、（二）增强层制造、（三）外包层制造和（四）管道复合：
（一）内层制造：所述内层包括作为本体的塑料管道和含竹炭的纤维复合层，所述含竹炭的纤维复合层贴覆在所述塑料管道的内壁，所述塑料管道采用喷熔成形，之后将所述含竹炭的纤维复合层贴覆到所述塑料管道内壁，形成所述内层；
（二）增强层制造：所述增强层为竹质复合材料，选用粉碎的废旧塑料、无机填料、工业级硬脂酸、助剂和竹纤维材料经搅拌机充分搅拌形成混合物料，然后送入双螺旋杆挤出机对所述混合物料在220℃下挤出造粒，对造粒后的物料进行烘干，再投入管材挤出机，挤出所述增强层；所述竹纤维材料为短纤维丝和/或竹粉，所述短纤维丝为利用小口径竹材、小径级丛生竹、竹材加工剩余物，碾压成纤维丝状后切割形成，所述短纤维丝的直径≤1mm，长度≤2cm；所述竹粉为将小口径竹材、小径级丛生竹、竹材加工剩余物经机械粉碎、研磨，分级制成50-500目形成；
（三）外包层制造：所述外层为竹单板复合材料，使用4-7年生毛竹，截断为900-3200mm的竹段，去黄去青之后，将竹段加工成宽度为15-25mm，厚度≤8mm的竹条，竹条干燥后涂胶组坯，形成竹方，竹方加压浸注之后，干燥至表面无明显水迹，再次浸入50-70℃温水中浸泡至少24小时，得到软化竹方，再根据加工需求对软化后竹方进行刨切，刨切所得薄竹厚度≤0.5mm，再将薄竹放入单板干燥机中干燥至含水率小于10%；涂脲醛胶后，贴上含竹纤维的无纺布，再将贴覆无纺布后的薄竹卷制成外包层材料，或者将刨切薄竹进行纵横向复合后直接制成竹单板复合材料卷制成外包层材料；
（四）管道复合：在所述内层内壁涂覆防水剂及防腐剂，外壁喷涂防水型胶粘剂后***所述增强层内壁形成的管状空间之中，利用异型热压机，施加压力使得所述内层与所述增强层粘合，粘合之后在所述增强层外壁涂覆树脂胶粘剂，将浸胶后的贴覆有无纺布的薄竹逐层贴在所述增强层外壁，相邻两层之间的接口错开，直至厚度满足需要；将初步成型的复合管送入干燥设备中，加温到60-140℃，进行固化处理；最后在所述外包层的最外层上喷涂防水剂和防腐剂。
所述塑料管道的材料选自聚乙烯、聚丙烯、聚氯乙烯、聚苯乙烯。
所述废旧塑料包括回收的废旧聚氯乙烯、聚乙烯、聚丙烯；所述无机填料选自碳酸钙、硅灰石、高岭土、滑石粉中的一种或多种；所述助剂为防霉剂和/或阻燃剂。
所述竹方加压浸渍中所使用的液体为水、或含有渗透剂或软化剂的水溶液。
所述增强层外涂覆的胶粘剂以及所述薄竹所浸胶为脲醛树脂、不饱和聚酯树脂、环氧树脂、酚醛树脂或聚氨酯树脂中的一种。
本发明还提供了一种竹制复合管，包含内层、增强层和外包层，所述内层包括作为本体的塑料管道和含竹炭的纤维复合层，所述含竹炭的纤维复合层贴覆在所述塑料管道的内壁，所述增强层为竹质复合材料，所述内层内壁涂覆防水剂及防腐剂，所述外包层的最外层上喷涂防水剂和防腐剂。
所述塑料管道的材料选自聚乙烯、聚丙烯、聚氯乙烯、聚苯乙烯。
所述废旧塑料包括回收的废旧聚氯乙烯、聚乙烯、聚丙烯；所述无机填料选自碳酸钙、硅灰石、高岭土、滑石粉中的一种或多种；所述助剂为防霉剂和/或阻燃剂。
所述增强层外涂覆的胶粘剂以及所述薄竹所浸胶为脲醛树脂、不饱和聚酯树脂、环氧树脂、酚醛树脂或聚氨酯树脂中的一种。
所述竹单板复合材料为厚度≤0.5mm竹纤维刨切所得薄竹，涂脲醛胶后，贴上含竹纤维的无纺布，再将贴覆无纺布后的薄竹卷制成外包层材料，或者将刨切薄竹进行纵横向复合后直接制成竹单板复合材料卷制成外包层材料。
本发明包括了通过上述方法制造的竹制复合管，依次由内向外包括内层、增强层、外包层。
本发明的优点在于：充分利用竹材的各种优势，结合废旧塑料，形成符合强度要求的管道。一方面能够充分利用竹材加工的剩余物、竹枝丫等材料，另一方面，将废旧塑料变废为宝，充分利用各种材料的优势。
附图说明
图1本发明的工艺流程图。
图2为根据本发明竹制复合管的剖面图。
具体实施方式
如图1所示流程图，本发明的竹制复合管的制造方法，依次制备由内向外的内层、增强层、外包层，具体步骤如下：
内层制造：内层为内壁贴覆含竹炭的纤维复合层的塑料管道，该塑料管道采用喷熔成形，之后将含竹炭的纤维复合层贴覆到塑料管道内壁，形成内层；
增强层制造：为竹塑复合层，利用小口径竹材、小径级丛生竹、竹材加工剩余物，碾压成纤维丝状后切割形成短纤维丝，所述短纤维丝的直径≤1mm，长度≤2cm；或者将小口径竹材、小径级丛生竹、竹材加工剩余物经机械粉碎、研磨、分级制成50-500目的竹粉，备用；选用废旧塑料、改性剂、工业级硬脂酸、助剂，与短纤维丝或者竹粉经搅拌机充分搅拌混合之后，送入双螺旋杆挤出机对初混合的物料在220℃下挤出造粒，对造粒后的物料进行烘干，再投入管材挤出机，挤出增强层；
外包层制造：使用4-7年生毛竹，截断为900-3200mm的竹段，去黄去青之后，将竹段剖成宽度为：15-25mm，厚度≤8mm的竹条，竹条干燥后涂胶组坯，形成竹方，竹方加压浸注之后，干燥至表面无明显水迹，再次浸入50-70℃温水中浸泡至少24小时，得到软化竹方，再根据加工需求对软化后竹方进行刨切，刨切所得薄竹厚度≤0.5mm，再将薄竹放入单板干燥机中干燥至含水率小于10%，涂胶后贴上含竹纤维的无纺布，再根据需要将贴覆无纺布后的薄竹或纵横向复合后制成的竹单板复合材料逐层覆盖到增强层外壁，或者使得贴覆无纺布后的薄竹形成薄竹条，通过缠绕的方式覆贴在增强层外，形成外包层材料；
三层各自制造完成之后，组合成复合管道，组合步骤如下：
在内层内壁涂覆防水剂及防腐剂，外壁喷涂防水型胶粘剂后***增强层内壁形成的管状空间之中，利用异型热压机，施加压力使得内层与增强层粘合，粘合之后在增强层外壁涂覆树脂胶粘剂，将浸胶后的贴覆有无纺布的薄竹层逐层贴在增强层外壁，相邻两层之间的接口错开，直至厚度满足需要；或者利用旋转设备，转动粘合后的内层和增强层，同时将浸胶后、并贴有无纺布的薄竹条逐层缠绕到增强层外壁，直至厚度满足需要；将初步成型的管道送入干燥设备中，加温到60-140℃，进行固化处理；
最后在外层上喷涂防水剂和防腐剂。
其中内层制造中所采用的塑料管道的材料选自聚乙烯、聚丙烯、聚氯乙烯、聚苯乙烯。
增强层制造中所使用的废旧塑料包括回收的废旧聚氯乙烯、聚乙烯、聚丙烯；所选用的无机填料选自：碳酸钙、硅灰石、高岭土、滑石粉中的一种或多种；所选用的助剂为防霉剂或阻燃剂。
竹方加压浸渍的液体为水、含有渗透剂或软化剂的水溶液。
增强层外涂覆的胶粘剂以及薄竹层所浸胶为脲醛树脂、不饱和聚酯树脂、环氧树脂、酚醛树脂或聚氨酯树脂中的一种。
内层制造中所使用的含竹炭的纤维复合层按照如下方式制备：选择4-7年生毛竹，炭化成竹炭之后，初步粉碎成块径为4-6cm的小块，再将小块竹炭进行三次粉碎，得到800目左右的竹炭粉，按照质量比例取30-35%的竹炭粉与65-70%的涤纶切片经混合和常规方法进行混炼、拉丝进而制得竹炭纤维，再将竹炭纤维通过编织方式形成含竹炭的纤维复合层。含竹炭的纤维复合层可根据使用需要设置一层或多层，单层厚度≤1mm。
增强层各主要成分的质量比为，短纤维丝或竹粉：废旧塑料：改性剂：工业级硬脂酸：助剂＝60～90：30～60：12-20：5～10：5～10。挤出加工之时，管材挤出机各段温度不同，第一段温度为90℃，二段温度为160℃，三段温度为200℃，主机转速为60r/min。
在外层制造中，竹青竹黄可以使用传统的切削或者磨砂方式去除，传统的切削方式，较为浪费材料，但是去青去黄速度快；磨砂方式较为节省材料，且磨削下来的竹粉可以收集起来重复利用。加压浸注所需压力为0.4-1.0MPa，时间为24-72h。刨切出来的薄竹可使用三聚氰胺树脂胶粘剂、改性脲醛树脂胶来贴覆无纺布。将薄竹层叠至增强层外壁之前，或者缠绕到增强层外壁上之前，要使得薄竹层的竹面侧涂覆树脂，以便于层与层之间的贴合。
在内层内壁涂覆防水剂及防腐剂，外壁喷涂防水型胶粘剂后***增强层内壁形成的管状空间之中，利用异型热压机，施加压力使得内层与增强层粘合，粘合之后在增强层外壁涂覆树脂胶粘剂，将浸胶后的贴覆有无纺布的薄竹层逐层贴在增强层外壁，相邻两层之间的接口错开，直至厚度满足需要；或者利用旋转设备，转动粘合后的内层和增强层，同时将将浸胶后、并贴有无纺布的薄竹条逐层缠绕到增强层外壁，直至厚度满足需要；将初步成型的管道送入干燥设备中，加温到60-140℃，进行固化处理；
最后在外层上喷涂防水剂和防腐剂。
组合过程中所采用的防水剂为有机硅防水剂，防腐剂为改性壳聚糖金属复合物防腐剂，防水型胶粘剂为改性酚醛树脂或氯丁橡胶树脂。为了使得薄竹层能够与增强层紧密贴合成型，可在内层形成的空腔中套入钢制内模以及在外包层外侧套上钢制外模，并同时在内模和外模上加压，帮助定型。
本申请中还包括了由上述方法制得的竹制复合管，如图2，依次包括由内向外包括内层1、增强层2和外包层3。所述内层1包括作为本体的塑料管道和含竹炭的纤维复合层，所述含竹炭的纤维复合层贴覆在所述塑料管道的内壁，所述增强层2为竹质复合材料，外包层3为竹单板复合材料，所述内层内壁涂覆防水剂及防腐剂，所述外包层的最外层上喷涂防水剂和防腐剂。
所述塑料管道的材料选自聚乙烯、聚丙烯、聚氯乙烯、聚苯乙烯。
所述废旧塑料包括回收的废旧聚氯乙烯、聚乙烯、聚丙烯；所述无机填料选自碳酸钙、硅灰石、高岭土、滑石粉中的一种或多种；所述助剂为防霉剂和/或阻燃剂。
所述增强层外涂覆的胶粘剂以及所述薄竹所浸胶为脲醛树脂、不饱和聚酯树脂、环氧树脂、酚醛树脂或聚氨酯树脂中的一种。
所述竹单板复合材料为厚度≤0.5mm竹纤维刨切所得薄竹，涂脲醛胶后，贴上含竹纤维的无纺布，再将贴覆无纺布后的薄竹卷制成外包层材料，或者将刨切薄竹进行纵横向复合后直接制成竹单板复合材料卷制成外包层材料。
尽管本发明已经在前文详细说明，可以清楚理解的是，于本发明相关的领域中的技术人员可以在不偏离本发明精神的情况下进行改进。
Claims (10)
1.一种竹制复合管的制造方法，所述竹制复合管包含内层、增强层和外包层，包括以下步骤：（一）内层制造、（二）增强层制造、（三）外包层制造和（四）管道复合，其特征在于：
（一）内层制造：所述内层包括作为本体的塑料管道和含竹炭的纤维复合层，所述含竹炭的纤维复合层贴覆在所述塑料管道的内壁，所述塑料管道采用喷熔成形，之后将所述含竹炭的纤维复合层贴覆到所述塑料管道内壁，形成所述内层；
（二）增强层制造：所述增强层为竹质复合材料，选用粉碎的废旧塑料、无机填料、工业级硬脂酸、助剂和竹纤维材料经搅拌机充分搅拌形成混合物料，然后送入双螺旋杆挤出机对所述混合物料在220℃下挤出造粒，对造粒后的物料进行烘干，再投入管材挤出机，挤出所述增强层；所述竹纤维材料为短纤维丝和/或竹粉，所述短纤维丝为利用小口径竹材、小径级丛生竹、竹材加工剩余物，碾压成纤维丝状后切割形成，所述短纤维丝的直径≤1mm，长度≤2cm；所述竹粉为将小口径竹材、小径级丛生竹、竹材加工剩余物经机械粉碎、研磨，分级制成50-500目形成；
（三）外包层制造：所述外层为竹单板复合材料，使用4-7年生毛竹，截断为900-3200mm的竹段，去黄去青之后，将竹段加工成宽度为15-25mm，厚度≤8mm的竹条，竹条干燥后涂胶组坯，形成竹方，竹方加压浸注之后，干燥至表面无明显水迹，再次浸入50-70℃温水中浸泡至少24小时，得到软化竹方，再根据加工需求对软化后竹方进行刨切，刨切所得薄竹厚度≤0.5mm，再将薄竹放入单板干燥机中干燥至含水率小于10%；涂脲醛胶后，贴上含竹纤维的无纺布，再将贴覆无纺布后的薄竹卷制成外包层材料，或者将刨切薄竹进行纵横向复合后直接制成竹单板复合材料卷制成外包层材料；
（四）管道复合：在所述内层内壁涂覆防水剂及防腐剂，外壁喷涂防水型胶粘剂后***所述增强层内壁形成的管状空间之中，利用异型热压机，施加压力使得所述内层与所述增强层粘合，粘合之后在所述增强层外壁涂覆树脂胶粘剂，将浸胶后的贴覆有无纺布的薄竹逐层贴在所述增强层外壁，相邻两层之间的接口错开，直至厚度满足需要；将初步成型的复合管送入干燥设备中，加温到60-140℃，进行固化处理；最后在所述外包层的最外层上喷涂防水剂和防腐剂。
2.根据权利要求1所述竹制复合管的制造方法，其特征在于：所述塑料管道的材料选自聚乙烯、聚丙烯、聚氯乙烯、聚苯乙烯。
3.根据权利要求2所述竹制复合管的制造方法，其特征在于：所述废旧塑料包括回收的废旧聚氯乙烯、聚乙烯、聚丙烯；所述无机填料选自碳酸钙、硅灰石、高岭土、滑石粉中的一种或多种；所述助剂为防霉剂和/或阻燃剂。
4.根据权利要求3所述竹制复合管的制造方法，其特征在于：所述竹方加压浸渍中所使用的液体为水、或含有渗透剂或软化剂的水溶液。
5.根据权利要求4所述竹制复合管的制造方法，其特征在于：所述增强层外涂覆的胶粘剂以及所述薄竹所浸胶为脲醛树脂、不饱和聚酯树脂、环氧树脂、酚醛树脂或聚氨酯树脂中的一种。
6.一种竹制复合管，包含内层、增强层和外包层，其特征在于：所述内层包括作为本体的塑料管道和含竹炭的纤维复合层，所述含竹炭的纤维复合层贴覆在所述塑料管道的内壁，所述增强层为竹质复合材料，所述外层为竹单板复合材料，所述内层内壁涂覆防水剂及防腐剂，所述外包层的最外层上喷涂防水剂和防腐剂。
7.根据权利要求6所述竹制复合管，其特征在于：所述塑料管道的材料选自聚乙烯、聚丙烯、聚氯乙烯、聚苯乙烯。
8.根据权利要求6所述竹制复合管，其特征在于：所述废旧塑料包括回收的废旧聚氯乙烯、聚乙烯、聚丙烯；所述无机填料选自碳酸钙、硅灰石、高岭土、滑石粉中的一种或多种；所述助剂为防霉剂和/或阻燃剂。
9.根据权利要求6所述竹制复合管，其特征在于：所述增强层外涂覆的胶粘剂以及所述薄竹所浸胶为脲醛树脂、不饱和聚酯树脂、环氧树脂、酚醛树脂或聚氨酯树脂中的一种。
10.根据权利要求6所述竹制复合管，其特征在于：所述竹单板复合材料为厚度≤0.5mm竹纤维刨切所得薄竹，涂脲醛胶后，贴上含竹纤维的无纺布，再将贴覆无纺布后的薄竹卷制成外包层材料，或者将刨切薄竹进行纵横向复合后直接制成竹单板复合材料卷制成外包层材料。
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