CN106863975A - 一种防腐带及其制备方法 - Google Patents

一种防腐带及其制备方法 Download PDF

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CN106863975A
CN106863975A CN201510922464.2A CN201510922464A CN106863975A CN 106863975 A CN106863975 A CN 106863975A CN 201510922464 A CN201510922464 A CN 201510922464A CN 106863975 A CN106863975 A CN 106863975A
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anticorrosion
layer
continuous
articulamentum
anticorrosion belt
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杨桂生
李丹
李兰杰
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Shanghai Genius Advanced Materials Group Co Ltd
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Shanghai Genius Advanced Materials Group Co Ltd
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Abstract

本发明公开了一种防腐带，从上至下依次为薄膜层(1)、防腐耐磨层(2)、连接层(3)、粘结剂层(4)。本发明还公开了一种上述防腐带的制备方法，包括以下步骤：防腐耐磨层(2)和连接层(3)经过加热，与薄膜层(1)和粘结剂层(4)共同经过辊压形成防腐带；或者是防腐耐磨层(2)和连接层(3)经过加热，与薄膜层(1)经过辊压形成外表层防腐带，再与粘结剂层(4)复合形成防腐带。本发明公开的管道用防腐带具有绿色环保、高强度、韧性好、耐摩擦、防水、防潮、耐高低温、耐腐蚀和使用寿命长等优点。

Description

一种防腐带及其制备方法
技术领域
本发明属于管道防腐材料技术领域，尤其涉及一种防腐带及其制备方法。
背景技术
目前，管道防腐领域尤其是油田地面油气集输管道领域中，采用的防腐管线仍然是传统的石油沥青管、玻璃钢管、聚乙烯胶带防腐管等等，这些产品在实际应用中都暴露出一些问题，能耗大、污染环境，热收缩性差、层间的粘结性较差等诸多问题，降低了使用寿命。
申请号为201220444716.7公开了一种耐腐蚀防腐带，此专利中的基材PVC与玻璃纤维布是通过氟硅橡胶硫化连接，表层的强度在高强及耐磨等条件下使用时有一定的限制，影响了此防腐带的应用范围。
发明内容
为了克服上述现有技术存在的缺陷，本发明的目的是提供一种防腐带及其制备方法，具有绿色环保、高强度、耐摩擦、防水、防潮、耐高低温、耐腐蚀、使用寿命长和使用方便等优点。
为实现上述目的，本发明采用以下技术方案：
一种防腐带，从上至下依次为薄膜层、防腐耐磨层、连接层、粘结剂层。
所述薄膜层为聚对苯二甲酸乙二醇酯(PET)或聚对苯二甲酸乙二醇酯-铝箔复合膜。
所述防腐耐磨层为连续纤维增强热塑性塑料复合材料。
所述热塑性塑料选自聚乙烯、聚丙烯、聚对苯二甲酸乙二醇酯、聚酰胺6、聚酰胺66、聚对苯二甲酸丁二醇酯或聚氯乙烯中的至少一种。
所述连续纤维为连续玻璃纤维、连续芳纶纤维、超高分子量聚乙烯纤维或连续玄武岩纤维中的至少一种。
所述连接层为涤纶纤维布、锦纶(PA)纤维布或腈纶纤维布中的至少一种。
所述粘结剂层为乙烯-醋酸乙烯酯热熔胶、聚酰胺热熔胶、环氧树脂煤沥青混合胶或丁基橡胶基胶粘剂中的至少一种。
所述薄膜层的厚度为0.1～0.5mm。
所述防腐耐磨层的厚度为0.15～1mm。
所述连接层的厚度为0.2～0.4mm。
所述粘结剂层的厚度为0.5～1.5mm。
一种上述防腐带的制备方法，包括以下步骤：
防腐耐磨层和连接层经过加热，与薄膜层和粘结剂层共同经过辊压形成防腐带；
或者是防腐耐磨层和连接层经过加热，与薄膜层经过辊压形成外表层防腐带，再与粘结剂层复合形成防腐带。
所述防腐耐磨层的制备方法包括以下步骤：将20～50重量份的热塑性塑料加入到挤出机中，通过交错的双挤出模头挤出淋膜，通过张力调节装置将50～80重量份的连续纤维平行排列成带状，导到双挤出模头处，带状连续纤维的两侧分别与双挤出模头接触，在模头处与挤出的熔融树脂进行浸渍，将浸渍后的连续纤维，导入辊压装置，辊压、冷却制得连续纤维增强热塑性塑料复合材料；将连续纤维增强热塑性塑料复合材料堆叠制成防腐耐磨层，连续纤维增强热塑性塑料复合材料的方向是0°/90°或0°/0°。
所述加热的温度为160～280℃。
所述辊压是指依次经过四对冷却辊压装置，冷却温度为20～80℃，压力为5～10MPa，每对辊压的时间为2秒。
由于采用上述技术方案，本发明具有以下优点和有益效果：
1、本发明公开的管道用防腐带具有绿色环保、高强度、韧性好、耐摩擦、防水、防潮、耐高低温、耐腐蚀和使用寿命长等优点。
2、本发明公开的管道用防腐带耐磨防腐层采用可回收再利用的热塑性复合材料，绿色环保，在节能减排及环境保护方面具有突出优点。
3、本发明公开的管道用防腐带制造工艺简单，防腐耐磨效果好，价格低廉，施工简便。
附图说明
图1为实施例1所示的防腐带的结构示意图。
图2为实施例1所示的防腐带的成型工艺流程示意图。
图3为实施例3所示的防腐带的成型工艺流程示意图。
其中，1为薄膜层、2为防腐耐磨层、3为连接层、4为粘结剂层、5为加热装置、61为第一辊压装置、62为第二辊压装置、63为第三辊压装置、64为第四辊压装置、7为收卷装置。
具体实施方式
下面结合附图所示实施例对本发明作进一步详细的说明。
实施例1
如图1所示，图1为实施例1所示的防腐带的结构示意图。图2为实施例1所示的防腐带的成型工艺流程示意图。
一种防腐带，从上至下依次包括薄膜层1、防腐耐磨层2、连接层3、粘结剂层4。
薄膜层的厚度为0.1mm；防腐耐磨层的厚度为0.5mm；连接层的厚度为0.2mm；粘结剂层的厚度为0.5mm。
薄膜层为聚对苯二甲酸乙二醇酯(PET)。
防腐耐磨层为连续纤维增强热塑性塑料复合材料，热塑性塑料基材为聚对苯二甲酸乙二醇酯，连续纤维为连续玻璃纤维。
连接层为涤纶纤维布。
粘结剂层为乙烯-醋酸乙烯酯热熔胶。
一种上述防腐带的制备方法，包括以下步骤：
(1)先制备连续纤维增强热塑性塑料复合材料；将50重量份的聚对苯二甲酸乙二醇酯加入到挤出机中，通过交错的双挤出模头挤出淋膜，通过张力调节装置将50重量份的连续玻璃纤维平行排列成带状，导到双挤出模头处，带状连续纤维的两侧分别与双挤出模头接触，在模头处与挤出的熔融树脂进行浸渍，将浸渍后的连续玻璃纤维，导入辊压装置，辊压、冷却制得连续纤维增强热塑性塑料复合材料；
(2)铺层过程，将2层连续玻璃纤维增强热塑性塑料复合材料，按照需求的厚度堆叠制成防腐耐磨层2，连续纤维增强热塑性塑料复合材料的方向是0°/90°，其中，在0°的连续玻璃纤维增强热塑性塑料复合材料表面人工铺放90°第二层连续玻璃纤维增强热塑性塑料复合材料；
(3)堆叠的2层连续玻璃纤维增强热塑性塑料复合材料与连接层涤纶纤维布，在一定的温度下通过加热装置5后，与粘结剂层4和薄膜层1共同经过冷却辊压装置，冷却辊压装置依次包括第一辊压装置61、第二辊压装置62、第三辊压装置63、第四辊压装置64，在一定的温度和压力下，辊压成防腐带；其中，冷却辊压装置为四对钢辊组成，每对钢辊通过压力控制***来控制辊间隙和辊间压力，确保产品达到要求厚度和质量；最后经过收卷装置7收卷。
所述步骤(3)中加热温度为280℃；
所述步骤(3)中的四对冷却辊压装置的温度和压力分别为：第一对为80℃、10MPa，第二对为60℃、8MPa，第三对为40℃、6MPa，第四对为20℃、5MPa；所述每对冷却辊压装置的冷却辊压时间为2秒。
实施例2
一种防腐带，从上至下依次包括薄膜层1、防腐耐磨层2、连接层3、粘结剂层4。
薄膜层的厚度为0.5mm；防腐耐磨层的厚度为1mm；连接层的厚度为0.4mm；粘结剂层的厚度为1.5mm。
薄膜层为PET-铝箔复合膜。
防腐耐磨层为连续纤维增强热塑性塑料复合材料，热塑性塑料基材选自聚丙烯，连续纤维为连续芳纶纤维。
连接层为为涤纶纤维布。
粘结剂层为聚酰胺热熔胶。
一种上述防腐带的制备方法，包括以下步骤：
(1)先制备连续纤维增强热塑性塑料复合材料；将40重量份的聚丙烯加入到挤出机中，通过交错的双挤出模头挤出淋膜，通过张力调节装置将60重量份的连续芳纶纤维平行排列成带状，导到双挤出模头处，带状连续纤维的两侧分别与双挤出模头接触，在模头处与挤出的熔融树脂进行浸渍，将浸渍后的连续芳纶纤维，导入辊压装置，辊压、冷却制得连续纤维增强热塑性塑料复合材料；
(2)铺层过程，将4层连续芳纶纤维增强热塑性塑料复合材料，按照需求的厚度堆叠制成防腐耐磨层2，连续纤维增强热塑性塑料复合材料的方向是0°/0°，其中，在0°的连续芳纶纤维增强热塑性塑料复合材料表面人工铺放0°第二层连续芳纶纤维增强热塑性塑料复合材料；
(3)堆叠的4层连续芳纶纤维增强热塑性塑料复合材料与连接层涤纶纤维布，在一定的温度下通过加热装置5后，与粘结剂层4和薄膜层1共同经过冷却辊压装置，冷却辊压装置依次包括第一辊压装置61、第二辊压装置62、第三辊压装置63、第四辊压装置64，在一定的温度和压力下，辊压成防腐带；其中，冷却辊压装置为四对钢辊组成，每对钢辊通过压力控制***来控制辊间隙和辊间压力，确保产品达到要求厚度和质量；最后经过收卷装置7收卷。
所述步骤(3)中加热温度为230℃；
所述步骤(3)中的四对冷却辊压装置的温度和压力分别为：第一对为80℃、10MPa，第二对为60℃、8MPa，第三对为40℃、6MPa，第四对为20℃、5MPa；所述每对冷却辊压装置的冷却辊压时间为2秒。
实施例3
如图3所示，图3为实施例3所示的防腐带的成型工艺流程示意图。意图。
一种防腐带，从上至下依次包括薄膜层1、防腐耐磨层2、连接层3、粘结剂层4。
薄膜层的厚度为0.2mm；防腐耐磨层的厚度为0.15mm；连接层的厚度为0.25mm；粘结剂层的厚度为1mm。
薄膜层为PET-铝箔复合膜。
防腐耐磨层为连续纤维增强热塑性塑料复合材料，热塑性塑料基材选自聚乙烯，连续纤维为连续玻璃纤维。
连接层为锦纶纤维布。
粘结剂层为环氧树脂煤沥青混合胶。
一种上述防腐带的制备方法，包括以下步骤：
(1)先制备连续纤维增强热塑性塑料复合材料；将30重量份的聚乙烯加入到挤出机中，通过交错的双挤出模头挤出淋膜，通过张力调节装置将70重量份的连续玻纤纤维平行排列成带状，导到双挤出模头处，带状连续纤维的两侧分别与双挤出模头接触，在模头处与挤出的熔融树脂进行浸渍，将浸渍后的连续玻纤纤维，导入辊压装置，辊压、冷却制得连续纤维增强热塑性塑料复合材料；
(2)1层连续玻璃纤维增强热塑性塑料复合材料与连接层锦纶纤维布，在一定的温度下通过加热装置5后，与薄膜层1共同经过冷却辊压装置，冷却辊压装置依次包括第一辊压装置61、第二辊压装置62、第三辊压装置63、第四辊压装置64，在一定的温度和压力下，辊压成外表层防腐带；其中，冷却辊压装置为四对钢辊组成，每对钢辊通过压力控制***来控制辊间隙和辊间压力，确保产品达到要求厚度和质量；最后经过收卷装置7收卷。
所述步骤(2)中加热温度为160℃；
所述步骤(2)中的四对冷却辊压装置的温度和压力分别为：第一对为80℃、10MPa，第二对为60℃、8MPa，第三对为40℃、6MPa，第四对为20℃、5MPa；所述每对冷却辊压装置的冷却辊压时间为2秒。
(3)外表层防腐带与粘结剂层4的复合过程，在被防腐管道表面喷涂粘结剂层4后，直接将步骤(2)辊压成的外表层防腐带顺序搭接在喷涂胶粘剂的管道上，形成防腐带。
实施例4
一种防腐带，从上至下依次包括薄膜层1、防腐耐磨层2、连接层3、粘结剂层4。
薄膜层的厚度为0.35mm；防腐耐磨层的厚度为0.35mm；连接层的厚度为0.3mm；粘结剂层的厚度为0.75mm。
薄膜层为PET。
防腐耐磨层为连续纤维增强热塑性塑料复合材料，热塑性塑料基材选自聚酰胺6，连续纤维为连续玄武岩纤维。
连接层为涤纶纤维布。
粘结剂层为丁基橡胶基胶粘剂。
一种上述防腐带的制备方法，包括以下步骤：
(1)先制备连续纤维增强热塑性塑料复合材料；将20重量份的聚酰胺6加入到挤出机中，通过交错的双挤出模头挤出淋膜，通过张力调节装置将80重量份的连续玄武岩纤维平行排列成带状，导到双挤出模头处，带状连续纤维的两侧分别与双挤出模头接触，在模头处与挤出的熔融树脂进行浸渍，将浸渍后的连续玄武岩纤维，导入辊压装置，辊压、冷却制得连续纤维增强热塑性塑料复合材料；
(2)1层连续玄武岩纤维增强热塑性塑料复合材料与连接层涤纶纤维布，在一定的温度下通过加热装置5后，与薄膜层1共同经过冷却辊压装置，冷却辊压装置依次包括第一辊压装置61、第二辊压装置62、第三辊压装置63、第四辊压装置64，在一定的温度和压力下，辊压成外表层防腐带；其中，冷却辊压装置为四对钢辊组成，每对钢辊通过压力控制***来控制辊间隙和辊间压力，确保产品达到要求厚度和质量；最后经过收卷装置7收卷。
所述步骤(2)中加热温度为240℃；
所述步骤(2)中的四对冷却辊压装置的温度和压力分别为：第一对为80℃、10MPa，第二对为60℃、8MPa，第三对为40℃、6MPa，第四对为20℃、5MPa；所述每对冷却辊压装置的冷却辊压时间为2秒。
(3)外表层防腐带与粘结剂层4的复合过程，在被防腐管道表面喷涂粘结剂层后，直接将步骤(2)辊压成的外表层防腐带顺序搭接在喷涂胶粘剂的管道上，形成防腐带。
对实施例1～4中制得的防腐带进行性能测试，测试结果见表1：
表1
测试项目 拉伸强度/MPa 弯曲模量/GPa 冲击强度/KJ/㎡ 耐温性/℃
实施例1 ≥850 15 ≥140 -70～120
实施例2 ≥1000 16 ≥180 -40～120
实施例3 ≥800 14 ≥160 -30～80
实施例4 ≥900 16 ≥150 -40～120
实施例5
一种防腐带，从上至下依次包括薄膜层1、防腐耐磨层2、连接层3、粘结剂层4。
薄膜层的厚度为0.4mm；防腐耐磨层的厚度为0.6mm；连接层的厚度为0.3mm；粘结剂层的厚度为1.2mm。
薄膜层为聚对苯二甲酸乙二醇酯(PET)。
防腐耐磨层为连续纤维增强热塑性塑料复合材料，热塑性塑料基材为聚对苯二甲酸丁二醇酯，连续纤维为超高分子量聚乙烯纤维。
连接层为腈纶纤维布。
粘结剂层为乙烯-醋酸乙烯酯热熔胶。
一种上述防腐带的制备方法，包括以下步骤：
(1)先制备连续纤维增强热塑性塑料复合材料；将50重量份的聚对苯二甲酸丁二醇酯加入到挤出机中，通过交错的双挤出模头挤出淋膜，通过张力调节装置将50重量份的超高分子量聚乙烯纤维平行排列成带状，导到双挤出模头处，带状连续纤维的两侧分别与双挤出模头接触，在模头处与挤出的熔融树脂进行浸渍，将浸渍后的连续玻璃纤维，导入辊压装置，辊压、冷却制得连续纤维增强热塑性塑料复合材料；
(2)铺层过程，将超高分子量聚乙烯纤维增强热塑性塑料复合材料按照需求的厚度堆叠制成防腐耐磨层2，连续纤维增强热塑性塑料复合材料的方向是0°/90°，其中，在0°的超高分子量聚乙烯纤维增强热塑性塑料复合材料表面人工铺放90°第二层超高分子量聚乙烯纤维增强热塑性塑料复合材料；
(3)堆叠的超高分子量聚乙烯纤维增强热塑性塑料复合材料与连接层腈纶纤维布，在一定的温度下通过加热装置5后，与粘结剂层4和薄膜层1共同经过冷却辊压装置，冷却辊压装置依次包括第一辊压装置61、第二辊压装置62、第三辊压装置63、第四辊压装置64，在一定的温度和压力下，辊压成防腐带；其中，冷却辊压装置为四对钢辊组成，每对钢辊通过压力控制***来控制辊间隙和辊间压力，确保产品达到要求厚度和质量；最后经过收卷装置7收卷。
所述步骤(3)中加热温度为280℃；
所述步骤(3)中的四对冷却辊压装置的温度和压力分别为：第一对为80℃、10MPa，第二对为60℃、8MPa，第三对为40℃、6MPa，第四对为20℃、5MPa；所述每对冷却辊压装置的冷却辊压时间为2秒。
实施例6
一种防腐带，从上至下依次包括薄膜层1、防腐耐磨层2、连接层3、粘结剂层4。
薄膜层的厚度为0.3mm；防腐耐磨层的厚度为0.8mm；连接层的厚度为0.35mm；粘结剂层的厚度为0.8mm。
薄膜层为聚对苯二甲酸乙二醇酯(PET)。
防腐耐磨层为连续纤维增强热塑性塑料复合材料，热塑性塑料基材为聚氯乙烯，连续纤维为超高分子量聚乙烯纤维。
连接层为腈纶纤维布。
粘结剂层为乙烯-醋酸乙烯酯热熔胶。
一种上述防腐带的制备方法，包括以下步骤：
(1)先制备连续纤维增强热塑性塑料复合材料；将50重量份的聚氯乙烯加入到挤出机中，通过交错的双挤出模头挤出淋膜，通过张力调节装置将50重量份的超高分子量聚乙烯纤维平行排列成带状，导到双挤出模头处，带状连续纤维的两侧分别与双挤出模头接触，在模头处与挤出的熔融树脂进行浸渍，将浸渍后的连续玻璃纤维，导入辊压装置，辊压、冷却制得连续纤维增强热塑性塑料复合材料；
(2)铺层过程，将超高分子量聚乙烯纤维增强热塑性塑料复合材料按照需求的厚度堆叠制成防腐耐磨层2，连续纤维增强热塑性塑料复合材料的方向是0°/90°，其中，在0°的超高分子量聚乙烯纤维增强热塑性塑料复合材料表面人工铺放90°第二层超高分子量聚乙烯纤维增强热塑性塑料复合材料；
(3)堆叠的超高分子量聚乙烯纤维增强热塑性塑料复合材料与连接层腈纶纤维布，在一定的温度下通过加热装置5后，与粘结剂层4和薄膜层1共同经过冷却辊压装置，冷却辊压装置依次包括第一辊压装置61、第二辊压装置62、第三辊压装置63、第四辊压装置64，在一定的温度和压力下，辊压成防腐带；其中，冷却辊压装置为四对钢辊组成，每对钢辊通过压力控制***来控制辊间隙和辊间压力，确保产品达到要求厚度和质量；最后经过收卷装置7收卷。
所述步骤(3)中加热温度为280℃；
所述步骤(3)中的四对冷却辊压装置的温度和压力分别为：第一对为80℃、10MPa，第二对为60℃、8MPa，第三对为40℃、6MPa，第四对为20℃、5MPa；所述每对冷却辊压装置的冷却辊压时间为2秒。
上述的对实施例的描述是为便于该技术领域的普通技术人员能理解和应用本发明。熟悉本领域技术的人员显然可以容易地对这些实施例做出各种修改，并把在此说明的一般原理应用到其他实施例中而不必经过创造性的劳动。因此，本发明不限于这里的实施例，本领域技术人员根据本发明的揭示，不脱离本发明范畴所做出的改进和修改都应该在本发明的保护范围之内。

Claims (10)

1.一种防腐带，其特征在于：从上至下依次为薄膜层(1)、防腐耐磨层(2)、连接层(3)、粘结剂层(4)。
2.根据权利要求1所述的防腐带，其特征在于：所述薄膜层(1)为聚对苯二甲酸乙二醇酯或聚对苯二甲酸乙二醇酯-铝箔复合膜。
3.根据权利要求1所述的防腐带，其特征在于：所述防腐耐磨层(2)为连续纤维增强热塑性塑料复合材料。
4.根据权利要求3所述的防腐带，其特征在于：所述热塑性塑料选自聚乙烯、聚丙烯、聚对苯二甲酸乙二醇酯、聚酰胺6、聚酰胺66、聚对苯二甲酸丁二醇酯或聚氯乙烯中的至少一种。
5.根据权利要求3所述的防腐带，其特征在于：所述连续纤维为连续玻璃纤维、连续芳纶纤维、超高分子量聚乙烯纤维或连续玄武岩纤维中的至少一种。
6.根据权利要求1所述的防腐带，其特征在于：所述连接层(3)为涤纶纤维布、锦纶纤维布或腈纶纤维布中的至少一种；
优选的，所述粘结剂层(4)为乙烯-醋酸乙烯酯热熔胶、聚酰胺热熔胶、环氧树脂煤沥青混合胶或丁基橡胶基胶粘剂中的至少一种。
7.根据权利要求1所述的防腐带，其特征在于：所述薄膜层(1)的厚度为0.1～0.5mm；
优选的，所述防腐耐磨层(2)的厚度为0.15～1mm；
优选的，所述连接层(3)的厚度为0.2～0.4mm；
优选的，所述粘结剂层(4)的厚度为0.5～1.5mm。
8.一种权利要求1至7任一所述的防腐带的制备方法，其特征在于：包括以下步骤：
防腐耐磨层(2)和连接层(3)经过加热，与薄膜层(1)和粘结剂层(4)共同经过辊压形成防腐带；
或者是防腐耐磨层(2)和连接层(3)经过加热，与薄膜层(1)经过辊压形成外表层防腐带，再与粘结剂层(4)复合形成防腐带。
9.根据权利要求8所述的防腐带的制备方法，其特征在于：所述防腐耐磨层(2)的制备方法包括以下步骤：将20～50重量份的热塑性塑料加入到挤出机中，通过交错的双挤出模头挤出淋膜，通过张力调节装置将50～80重量份的连续纤维平行排列成带状，导到双挤出模头处，带状连续纤维的两侧分别与双挤出模头接触，在模头处与挤出的熔融树脂进行浸渍，将浸渍后的连续纤维，导入辊压装置，辊压、冷却制得连续纤维增强热塑性塑料复合材料；将连续纤维增强热塑性塑料复合材料堆叠制成防腐耐磨层(2)，连续纤维增强热塑性塑料复合材料的方向是0°/90°或0°/0°。
10.根据权利要求8所述的防腐带的制备方法，其特征在于：所述加热的温度为160～280℃；
优选的，所述辊压是指依次经过四对冷却辊压装置，冷却温度为20～80℃，压力为5～10MPa，每对辊压的时间为2秒。
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