CN114889279A - 一种增强改性hdpe-iw多边形管材及其制备方法 - Google Patents
一种增强改性hdpe-iw多边形管材及其制备方法 Download PDFInfo
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Abstract
本发明涉及管材制备领域,具体为一种增强改性HDPE‑IW多边形管材及其制备方法。其由内层和外层经热熔复合构成,外层形状呈多边六棱形结构且沿长度方向具有间隔分布的波峰和波谷;外层和内层均采用超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯复合材料制成,超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯复合材料包括如下原料:PE大桶再生颗粒料,超高分子量聚乙烯,茂金属MPE,油膜颗粒,相容增韧剂,硫酸钡,熔脂调节剂,纳米级活性碳酸钙,碳黑,硅扩散油,光稳定剂,抗氧剂1010,抗氧剂168,硬脂酸钙,硬脂酸锌。本发明能提高管材环刚度、环柔度、抗冲击性能和高低温性能。
Description
技术领域
本发明涉及管材制备领域,特别是涉及一种增强改性HDPE-IW多边形管材及其制备方法。
背景技术
目前,排水管网***鱼龙混杂,大部分塑料排污管道产品表现环刚度不高,管材脆性大,抗冲击强力差,管材内外壁粗糙,低温脆性明显,埋地排水管材采用再生塑料,材料结合力差造成管材在运输、使用过程中容易断裂;尤其是在长期的使用中,常常由于破损、渗漏,特别是大面积的污水渗漏,已严重污染了越来越少的地下水资源。在众多的塑料埋地排水管道中,由于双壁波纹结构管以其独特的结构设计,比其它的塑料管道更节省原料,成为排水管道的首选。
双壁波纹结构排污管目前主要用于市政排水、排污***。当前,我国用于双壁波纹结构管生产的原料主要有聚氯乙烯(PVC)、聚乙烯(PE)和聚丙烯(PP),其中PVC主要用于500mm以下的波纹管生产。聚氯乙烯双壁波纹管的优点在于聚氯乙烯材料的刚性高,其材料的弹性模量大于聚乙烯材料。因此达到同等的环刚度可以用较小的惯性矩,如果采用同样的波形设计可以用较小的壁厚。所以在一定范围内聚氯乙烯双壁波纹管在经济性上占优势,但由于聚氯乙烯材料的流动性和热稳定性比较差,生产大口径双壁波纹管有困难,以及聚乙烯材料的良好柔韧性,可以在低温环境下施工,聚乙烯管材可以熔接,比重轻等优点,聚乙烯双壁波纹结构管近年来得到了较快的发展。
国内的一些普通管材料在生产大口径双壁波纹管时会出现熔体强度不够、产品环刚度达不到要求等问题。
环刚度和环柔度是管材最重要的性能指标,因为在埋地排水管的应用中,管材不承受内压或压力很低,而只承受外压负载(包括动负载和静负载)。如果管材的环刚度太小,管材将发生大的变形破坏,这样就不能保证管材的安全使用;若环柔度过低,管材在使用过程中易破坏漏水等。添加无机填料如:短切玻璃纤维、碳酸钙、滑石粉、高岭土、硅灰石等可以降低材料成本、提高材料性能的刚性,然而,在塑料材料中加入无机填充材料后一般都会使材料性能变脆,缺口冲击韧性下降,材料的使用性能因此受到明显影响。早期通常采用橡胶类弹性体增加塑料的韧性,例如:ABS(聚丙烯腈_丁二烯_苯乙烯),HIPS(耐冲击性聚苯乙烯)和EPDM[聚苯乙烯/三元乙丙橡胶(含双环戊二烯)]等增韧体系,橡胶增韧聚合物可使冲击韧性成倍增长,但由于其模量和玻璃化温度低,给增韧塑料带来固有的缺陷,如材料的刚度、强度、热变形温度大幅度降低,成本提高等。综上,聚乙烯复合材料所表现的强度增加或韧性提高总是以牺牲其它性能为代价的,无法保持材料的强度和韧性的平衡。
发明内容
本发明目的是针对背景技术中存在的问题,提出一种能提高管材环刚度、环柔度、抗冲击性能和高低温性能的增强改性HDPE-IW多边形管材及其制备方法。
一方面,本发明提出一种增强改性HDPE-IW多边形管材,由内层和外层经热熔复合构成,内层形状呈多边六棱形结构,外层形状呈多边六棱形结构且沿长度方向具有间隔分布的波峰和波谷;
外层和内层均采用超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯复合材料制成,超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯复合材料包括如下按重量份计的原料:25-45份PE大桶再生颗粒料,5-10份超高分子量聚乙烯,10-20份茂金属MPE,2-5份油膜颗粒,3-5 份相容增韧剂,1-2份硫酸钡,0.2-0.4份熔脂调节剂,30-38份纳米级活性碳酸钙,1-2份碳黑,1-2份硅扩散油,0.3-0.6份光稳定剂,0.3-0.6份抗氧剂 1010,0.3-0.6份抗氧剂168,0.5-1份硬脂酸钙,0.5-1份硬脂酸锌。
优选的,超高分子量聚乙烯为粉末料;茂金属MPE采用三井化学SP1520;相容增韧剂采用PE-G-MAH;纳米活性碳酸钙采用3000目以上的高活化率的重质碳酸钙。
另一方面,本发明提出一种上述增强改性HDPE-IW多边形管材的制备方法,将内层材料和外层材料分别加入两台挤出机中挤出,物料通过挤出机单螺杆加热熔融塑化输送至机头口模,管材内层通过内定径套抽真空再冷却定型,管材外层在内部空气压力和外部真空吸力的共同作用下和模块紧密接触成型,管材内、外层均匀地熔合在一起,内层挤出各段温度:160℃,180℃,190℃,190℃, 190℃,外层挤出各段温度:165℃,185℃,195℃,195℃,195℃。
优选的,超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯复合材料的制备方法包括如下步骤:
S1、按重量份配置如下原料:25-45份PE大桶再生颗粒料,5-10份超高分子量聚乙烯,10-20份茂金属MPE,2-5份油膜颗粒,3-5份相容增韧剂,1-2 份硫酸钡,0.2-0.4份熔脂调节剂,30-38份纳米级活性碳酸钙,1-2份碳黑, 1-2份硅扩散油,0.3-0.6份光稳定剂,0.3-0.6份抗氧剂1010,0.3-0.6份抗氧剂168,0.5-1份硬脂酸钙,0.5-1份硬脂酸锌;
S2、制备方式包括如下两种:
第一种制备方式:将配置好的原料加入高速混合机中混合10-15分钟,再加入到双阶挤出机组中进行熔融、塑化、混炼、挤出、造粒,最后冷却切粒,得到超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯复合材料;
第二种制备方式:利用密炼机进行混合、改性、熔融、塑化、混炼,再通过挤出机组进行挤出、造粒,最后冷却切粒,得到超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯复合材料。
与现有技术相比,本发明具有如下有益的技术效果:
本发明采用超高分子量聚乙烯材和纳料粒子的增强增韧形成多元与复合材料,采用该复合材料制备增强改性(HDPE-IW)多边形管材所制备的增强改性 (HDPE-IW)多边形管材的环刚度、环柔度、抗冲击性能、高低温性能等都明显提高,能满足埋地排污管特殊环境性能要求。
附图说明
图1为本发明实施例中多边形管材的结构示意图;
图2为第一种套筒连接结构的结构示意图;
图3为第二种套筒连接结构的结构示意图;
图4为第三种套筒连接结构的结构示意图。
附图标记:1、套筒;101、开口;11、限位扣a;111、卡台部;12、限位扣b;2、定位块;3、胶圈;4、波纹管;41、波峰;42、波谷。
具体实施方式
实施例一
如图1-4所示,本发明提出的一种增强改性HDPE-IW多边形管材,即波纹管4,由内层和外层经热熔复合构成,内层形状呈多边六棱形结构,外层形状呈多边六棱形结构且沿长度方向具有间隔分布的波峰41和波谷42。外层和内层均采用超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯复合材料制成,超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯复合材料包括如下按重量份计的原料:25份PE大桶再生颗粒料,10份超高分子量聚乙烯,20份茂金属MPE,2份油膜颗粒,3份相容增韧剂,2份硫酸钡,0.4 份熔脂调节剂,38份纳米级活性碳酸钙,2份碳黑,2份硅扩散油,0.6份光稳定剂,0.6份抗氧剂1010,0.6份抗氧剂168,1份硬脂酸钙,1份硬脂酸锌。
超高分子量聚乙烯为粉末料;茂金属MPE采用三井化学SP1520;相容增韧剂采用PE-G-MAH;纳米活性碳酸钙采用3000目以上的高活化率的重质碳酸钙。
在制备超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯复合材料时,将配置好的原料加入高速混合机中混合10-15分钟;再加入到双阶挤出机组中进行熔融、塑化、混炼、挤出、造粒,最后冷却切粒,得到增强改性(HDPE-IW)多边形管材专用料,料筒温度分别为:160℃,180℃,190℃, 190℃,190℃,口模温度为:190℃;或者是,利用密炼机进行混合、改性、熔融、塑化、混炼,再通过挤出机组进行挤出、造粒,最后冷却切粒,得到增强改性(HDPE-IW)多边形管材专用料。
在增强改性(HDPE-IW)多边形管材专用料体系中,用超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯,在熔体共混过程中,因二者分子结构及性能上的特点,由于超高分子量聚乙烯在聚乙烯熔点以上仍保持高粘度,而基体聚乙烯材料的粘度相对较低,超高分子量聚乙烯以沾弹粒子形态悬浮于聚乙烯连续相中,并在双螺杆挤出机中强剪切拉位伸流场作用下分散形变为纤维状态而获得改性效果。用弹性体相容增韧剂PE-G-MAH和茂金属聚乙烯 SP1520改性再生聚乙烯,提高了体系的相容性,并保持了体系材料的刚性和韧性平衡。
制备增强改性(HDPE-IW)多边形管材复合材料:
将内层材料和外层材料分别加入两台挤出机中挤出,物料通过挤出机单螺杆加热熔融塑化输送至机头口模,管材内层通过内定径套抽真空再冷却定型,管材外层在内部空气压力和外部真空吸力的共同作用下和模块紧密接触成型,管材内、外层均匀地熔合在一起,内层挤出各段温度:160℃,180℃,190℃, 190℃,190℃,外层挤出各段温度:165℃,185℃,195℃,195℃,195℃。
表1、实施例一制备的增强改性(HDPE-IW)多边形管材的物理力学性能
波纹管4通过套筒连接结构进行连接,套筒连接结构包括套筒1、定位块2 和胶圈3,套筒1为多边六棱形筒状结构,套筒1穿套在波纹管4外周侧,套筒 1外周具有对称设置的两组开口组件,开口组件包括呈正多边形分布的多个开口 101,并在开口101处形成逐渐向内靠拢并卡紧在一个波谷42处的限位扣。定位块2设置在套筒1内壁,以供波纹管4端部抵接。胶圈3为多边六棱形环状结构,胶圈3在套筒1内壁对称设置两个,胶圈3位于定位块2和限位扣之间,并卡套在另一波谷42处。预先将两个胶圈3设置在套筒1内壁。在使用时,将套筒1穿套到波纹管4外周,穿套过程中,波纹管4的波峰41会挤开限位扣,并将胶圈3挤变形,直至波纹管4端部抵接在定位块2处。此时,限位扣卡紧在波谷42处,起到连接的限位作用,胶圈3卡套在另一个波谷42处,套筒1 能与波纹管4稳固连接,胶圈3位置稳定,能在套筒1和波纹管4之间有效的维持密封效果。管材双头承插后有自动锁扣功能,采用柔性连接方式,此连接方式保证管材永不漏水。
进一步的,开口101呈U形,且U形开口朝向套筒1端部,则能方便限位扣被波纹管4的波峰41挤开,并最终使限位扣卡紧在波谷42处。
如图2所示,限位扣为限位扣a11,限位扣a11为直板扣,限位扣a11一体连接在开口101上靠近套筒1端部的一端,限位扣a11沿该连接端至另一端方向逐渐向套筒1内部倾斜,直板扣能更顺畅的被波纹管4的波峰41挤开,然后储存弹性势能,在波纹管4端部抵接在定位块2处时,直板扣会释放弹性势能并卡紧在波谷42处,实现对套筒1与波纹管4连接的限位,保障胶圈3的密封效果。进一步的,如图3所示,限位扣a11上与开口101连接端相对的另一端处设置有卡台部111,卡台部111为三角形柱状结构,则卡台部111也能卡紧在波谷42处,卡台部111能在限位扣a11基础上进一步提高套筒1与波纹管4连接的牢靠性。限位扣a11与卡台部111连接处设置有圆角,在限位扣a11和卡台部111发生形变时,圆角能减轻应力集中,提高抗疲劳强度,延长使用寿命。
如图4所示,限位扣也为限位扣b12,限位扣b12为弯板扣,限位扣b12一体连接在开口101上靠近套筒1端部的一端,限位扣b12沿该连接端至另一端方向逐渐向套筒1内部弯曲,弯板扣更易发生弹性变形,更易被波纹管4的波峰41挤开,并更容易卡紧在波谷42处,且弯板扣能平滑的连接在开口101处,发生变形时不易断裂。
实施例二
本发明提出的一种增强改性HDPE-IW多边形管材,其与实施例一的区别在于,超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯复合材料包括如下按重量份计的原料:45份PE大桶再生颗粒料,5份超高分子量聚乙烯,10份茂金属MPE,5份油膜颗粒,5份相容增韧剂,1份硫酸钡,0.2份熔脂调节剂,30份纳米级活性碳酸钙,1份碳黑,1份硅扩散油,0.3份光稳定剂, 0.3份抗氧剂1010,0.3份抗氧剂168,0.5份硬脂酸钙,0.5份硬脂酸锌。
表2、实施例二制备的增强改性(HDPE-IW)多边形管材的物理力学性能
本发明采用超高分子量聚乙烯材和纳料粒子的增强增韧形成多元与复合材料,采用该复合材料制备增强改性(HDPE-IW)多边形管材所制备的增强改性 (HDPE-IW)多边形管材的环刚度、环柔度、抗冲击性能、高低温性能等都明显提高,能满足埋地排污管特殊环境性能要求。
上面结合附图对本发明的实施方式作了详细说明,但是本发明并不限于此,在所属技术领域的技术人员所具备的知识范围内,在不脱离本发明宗旨的前提下还可以作出各种变化。
Claims (4)
1.一种增强改性HDPE-IW多边形管材,其特征在于,由内层和外层经热熔复合构成,内层形状呈多边六棱形结构,外层形状呈多边六棱形结构且沿长度方向具有间隔分布的波峰和波谷;
外层和内层均采用超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯复合材料制成,所述超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯复合材料包括如下按重量份计的原料:25-45份PE大桶再生颗粒料,5-10份超高分子量聚乙烯,10-20份茂金属MPE,2-5份油膜颗粒,3-5份相容增韧剂,1-2份硫酸钡,0.2-0.4份熔脂调节剂,30-38份纳米级活性碳酸钙,1-2份碳黑,1-2份硅扩散油,0.3-0.6份光稳定剂,0.3-0.6份抗氧剂1010,0.3-0.6份抗氧剂168,0.5-1份硬脂酸钙,0.5-1份硬脂酸锌。
2.根据权利要求1所述的增强改性HDPE-IW多边形管材,其特征在于,超高分子量聚乙烯为粉末料;茂金属MPE采用三井化学SP1520;相容增韧剂采用PE-G-MAH;纳米活性碳酸钙采用3000目以上的高活化率的重质碳酸钙。
3.一种根据权利要求1所述的增强改性HDPE-IW多边形管材的制备方法,其特征在于,将内层材料和外层材料分别加入两台挤出机中挤出,物料通过挤出机单螺杆加热熔融塑化输送至机头口模,管材内层通过内定径套抽真空再冷却定型,管材外层在内部空气压力和外部真空吸力的共同作用下和模块紧密接触成型,管材内、外层均匀地熔合在一起,内层挤出各段温度:160℃,180℃,190℃,190℃,190℃,外层挤出各段温度:165℃,185℃,195℃,195℃,195℃。
4.根据权利要求3所述的增强改性HDPE-IW多边形管材的制备方法,其特征在于,超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯复合材料的制备方法包括如下步骤:
S1、按重量份配置如下原料:25-45份PE大桶再生颗粒料,5-10份超高分子量聚乙烯,10-20份茂金属MPE,2-5份油膜颗粒,3-5份相容增韧剂,1-2份硫酸钡,0.2-0.4份熔脂调节剂,30-38份纳米级活性碳酸钙,1-2份碳黑,1-2份硅扩散油,0.3-0.6份光稳定剂,0.3-0.6份抗氧剂1010,0.3-0.6份抗氧剂168,0.5-1份硬脂酸钙,0.5-1份硬脂酸锌;
S2、制备方式包括如下两种:
第一种制备方式:将配置好的原料加入高速混合机中混合10-15分钟,再加入到双阶挤出机组中进行熔融、塑化、混炼、挤出、造粒,最后冷却切粒,得到超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯复合材料;
第二种制备方式:利用密炼机进行混合、改性、熔融、塑化、混炼,再通过挤出机组进行挤出、造粒,最后冷却切粒,得到超高分子量聚乙烯、茂金属聚乙烯和纳米粒子增强改性再生聚乙烯复合材料。
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