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CN104395056A - 形成大直径热塑性密封件的方法 - Google Patents

形成大直径热塑性密封件的方法 Download PDF

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Publication number
CN104395056A
CN104395056A CN201380026405.6A CN201380026405A CN104395056A CN 104395056 A CN104395056 A CN 104395056A CN 201380026405 A CN201380026405 A CN 201380026405A CN 104395056 A CN104395056 A CN 104395056A
Authority
CN
China
Prior art keywords
polymer
layer
rod
elongation
thermoplastic
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201380026405.6A
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English (en)
Inventor
Y·刘
R·辛格
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saint Gobain Performance Plastics Corp
Original Assignee
Saint Gobain Performance Plastics Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Saint Gobain Performance Plastics Corp filed Critical Saint Gobain Performance Plastics Corp
Priority to CN201810615737.2A priority Critical patent/CN108943731A/zh
Publication of CN104395056A publication Critical patent/CN104395056A/zh
Pending legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0053—Producing sealings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/36—Bending and joining, e.g. for making hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
    • B29C66/4322—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms by joining a single sheet to itself
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
    • B29C66/4324—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms for making closed loops, e.g. belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/526—Joining bars
    • B29C66/5261—Joining bars for forming coaxial connections, i.e. the bars to be joined forming a zero angle relative to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/526—Joining bars
    • B29C66/5268—Joining bars characterised by their solid cross sections being non-circular, e.g. being elliptical, square or rectangular
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91441—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time
    • B29C66/91443—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time following a temperature-time profile
    • B29C66/91445—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time following a temperature-time profile by steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91921—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
    • B29C66/91931—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to the fusion temperature or melting point of the material of one of the parts to be joined
    • B29C66/91933—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to the fusion temperature or melting point of the material of one of the parts to be joined higher than said fusion temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91921—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
    • B29C66/91941—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to Tg, i.e. the glass transition temperature, of the material of one of the parts to be joined
    • B29C66/91943—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to Tg, i.e. the glass transition temperature, of the material of one of the parts to be joined higher than said glass transition temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0082—Producing articles in the form of closed loops, e.g. rings
    • B29D99/0085—Producing articles in the form of closed loops, e.g. rings for sealing purposes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16J—PISTONS; CYLINDERS; SEALINGS
    • F16J15/00—Sealings
    • F16J15/02—Sealings between relatively-stationary surfaces
    • F16J15/021—Sealings between relatively-stationary surfaces with elastic packing
    • F16J15/022—Sealings between relatively-stationary surfaces with elastic packing characterised by structure or material
    • F16J15/024—Sealings between relatively-stationary surfaces with elastic packing characterised by structure or material the packing being locally weakened in order to increase elasticity
    • F16J15/027—Sealings between relatively-stationary surfaces with elastic packing characterised by structure or material the packing being locally weakened in order to increase elasticity and with a hollow profile
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/04—Dielectric heating, e.g. high-frequency welding, i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
    • B29C65/1425—Microwave radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/20—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror"
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/40—Applying molten plastics, e.g. hot melt
    • B29C65/42—Applying molten plastics, e.g. hot melt between pre-assembled parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/72—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by combined operations or combined techniques, e.g. welding and stitching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
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  • General Engineering & Computer Science (AREA)
  • High Energy & Nuclear Physics (AREA)
  • Plasma & Fusion (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Sealing Material Composition (AREA)
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Abstract

本发明公开了一种用于制造大直径密封环的结构和方法。本发明的优选实施例利用显示出更好焊接质量和强度的聚合物的共挤出“载体”层。粘结到功能聚合物的共挤出载体聚合物的使用可用来改善整个焊接点、包括功能聚合物层的焊接点的强度。

Description

形成大直径热塑性密封件的方法
技术领域
本发明总的涉及热塑性密封件，特别地，涉及使用填充了PTFE或其它填料的聚合物形成的大直径热塑性密封件。
背景技术
各种工业正越来越多地转向大型设备以满足运行需要。随着工业开发大型设备，其将寻求大型部件如密封件和O-形环。大型设备常常安置在偏远的严苛环境中，从而增大对耐久且结实的密封件的需求。例如，随着石油天然气工业寻求在更深的水域钻井，采用的设备规模不断增大，并因此，对可承受严苛环境的更耐久大型产品的需求增大。
PTFE填充聚合物对于多种应用如大直径密封环、支承环或其它密封装置(本文中统称为密封环)来说是高度期望的。这些大直径密封环常为例如石油天然气工业所使用。如本文所用，表述“大直径”用来描述至少600mm的直径。这样的大直径密封环不能通过用于较小环的常规模制技术轻松地制成。
Vaideeswaran等人的美国专利申请第2010/0116422号“Method ofForming Large Diameter Thermoplastic Seal”中描述了形成这些类型的大直径环的一种方法，所述专利申请被转让给本申请的受让人并以引用方式并入本文。根据Vaideeswaran所描述的方法，使用挤出的热塑性棒来形成大直径密封环，所述热塑性棒被弯曲成圆形形状并然后在端部处焊接于一起以形成密封环。
不幸的是，PTFE填充材料虽然就其磨损特性和低摩擦而言是高度期望的，但它们常常难以与典型的热焊接工艺一起使用。具体而言，与未填充的聚合物相比，PTFE聚合物的焊接部分常将显示出减小的断裂伸长率。这使得此类PTFE填充材料较不适合于如需要至少3％的断裂伸长率的大直径密封环、支承环或其它密封装置的应用。
因此，需要使用填充了PTFE或其它填料的聚合物形成大直径密封件的新方法。
发明内容
本发明的一个优选实施例涉及一种用于制造大直径密封环、支承环或其它密封装置的新型结构和方法。各种类型的密封聚合物，虽然具有有利的物理特性，但难以与采用热焊接的形成大直径密封环的方法一起使用。本发明的优选实施例利用显示出更好焊接质量和强度的聚合物的共挤出“载体”层。申请人已发现，粘结到功能聚合物的共挤出载体聚合物的使用令人惊奇地改善整个焊接点(weld)、包括功能聚合物层的焊接点的强度。
前文已相当宽泛地略述了本发明的特征和技术优点以便随后的本发明具体实施方式可得到更好的理解。本发明的其它特征和优点将在下文描述。本领域技术人员应理解，所公开的概念和具体实施例可容易地用作改变或设计其它结构以实施本发明的相同目的的基础。本领域技术人员还应认识，这样的等价构造不偏离如附随的权利要求中所陈述的本发明的精神和范围。
附图说明
通过结合附图，本发明可得到更好的理解，并且其众多特征和优点对于本领域技术人员来说将显而易见。
图1示出了根据本发明的一个优选实施例的密封环。
图2为示意图，示意了根据本发明的实施例具有两个聚合物层的挤出热塑性棒。
图3为流程图，示出了根据本发明的优选实施例制造密封环的方法中的步骤。
图4A和4B为示意图，示意了根据本发明的实施例焊接弯曲成圆形形状的热塑性棒的端部的方法。
图5为可用来制造根据本发明的优选实施例的密封环的现有技术成型装置的示意图。
图6示出了根据本发明的一个优选实施例的密封环，其中两根热塑性棒被接合以形成具有两个焊接点的密封环。
图7示出了根据本发明的另一个优选实施例的密封环。
附图非意在按比例绘制。在附图中，各个图中所示每个相同或接近相同的部件均由相似的数字表示。为清楚起见，不是每一个部件都在每一个附图中作了标注。
具体实施方式
虽然填充的聚合物如PTFE填充材料常常具有高度期望的特性，但它们可能难以与典型的热焊接工艺一起使用。具体而言，与未填充的聚合物相比，填充的聚合物如PTFE填充聚合物的焊接部分常将显示出减小的断裂伸长率。这使得此类PTFE填充材料较不适合于如需要至少3％的断裂伸长率的大直径密封环、支承环或其它密封装置的应用。
申请人已发现，未填充聚合物的共挤出“载体”层的使用令人惊奇地改善整个焊接点、包括PTFE填充聚合物层的焊接点的强度。功能性PTFE填充层可朝向密封件的内部(在内周长上向着开口)或朝向外部(在外周长上)，具体取决于特定的密封应用需要功能性PTFE填料的地方。在许多典型的应用中，PTFE填充层优选朝向密封件的内部，如下面所述图1中所示。
如图1和2中所示，密封环100可自热塑性棒200形成。优选地，所述热塑性棒为挤出的热塑性棒，例如熔融挤出棒。或者，棒200可为压塑棒。热塑性棒200优选包含至少两种共挤出的热塑性聚合物，所述两种聚合物形成第一纵向层102和第二纵向层104，其由焊接点106接合于一起。在本发明的优选实施例中，至少一个层包含PTFE填充化合物如PTFE填充PEEK。如上面所讨论，PTFE填充化合物如PTFE填充PEEK可能非常难以焊接。此类材料的典型焊接点的断裂伸长率小于许多密封环应用所需的3％值。通过共挤出PTFE填充聚合物层与另一具有优异的焊接拉伸强度或焊接断裂伸长率的未填充聚合物层，申请人已发现，整个焊接点、包括PTFE填充聚合物的焊接点的强度可得到改善。
图3为流程图，示出了根据本发明的优选实施例制造密封环的方法中的步骤。形成密封环的优选方法包括在步骤301中通过功能聚合物如聚四氟乙烯(PTFE)填充聚合物和载体聚合物的共挤出来形成热塑性棒，使得所形成的热塑性棒至少包括功能聚合物的第一层和未填充聚合物的第二层。图2中示意性地示出了这样的两层挤出棒。在挤出棒被切割至所需长度(步骤302)后，然后在步骤303中将棒加热至两个聚合物层的玻璃化转变温度以上的温度。在步骤304中，棒被弯曲成圆形形状。一旦棒已被弯曲形成环，即在步骤305中将棒的第一端部和第二端部加热至两个层的熔化温度以上的温度。然后在步骤306中将熔化的端部压制于一起以形成焊接环。优选地，接合端部使得PTFE填充层的端部接合在一起并且未填充聚合物层的端部接合在一起；换句话说，使得PTFE填充聚合物焊接到PTFE填充聚合物并且未填充聚合物焊接到未填充聚合物。最后，在步骤307中，使焊接环退火以增强共挤出层之间的焊接和粘结。
热塑性棒可具有任何所需的形状。例如，所述棒可形成为具有矩形横截面和两个大约相等尺寸的纵向层的直棒，如图2中所示。或者，所述棒可具有圆形横截面或多边形横截面。在一个例子中，对于多边形横截面，多边形可具有四条或更多条边。作为加热和弯曲的一个替代方案，挤出棒可以圆弧的形式挤出并接合圆弧的端部以形成密封装置。在另一替代方案中，可自材料的片材如挤出片材或压塑片材切割圆弧并接合圆弧的端部。
热塑性棒可由热塑性材料如工程热塑性聚合物或高性能热塑性聚合物的两个或更多个层形成。在优选的实施例中，至少一个层(本文中也称功能层)由具有期望的特性但对于焊接材料来说具有不期望的物理特性的热塑性材料形成。例如，具有期望的特性的热塑性材料可为由热塑性材料基质和填料形成的复合材料。在一个特别的例子中，填料为固体润滑剂。在另一个例子中，填料包括含氟聚合物。在又一个例子中，填料包括固体润滑剂和含氟聚合物的组合。在一个实施例中，复合材料包括聚酮基质如PEEK，以PTFE作为填料。如下所述，也可使用其它固体润滑剂作为填料。
虽然本文中的许多讨论针对的是PTFE填充聚合物，但本发明的实施例也可与显示出减小的焊接拉伸强度或焊接断裂伸长率的各种其它类型填充聚合物一起使用。在优选的实施例中，可根据本发明使用非PTFE的填料。例如，使用的填料可包括不同的固体润滑剂、陶瓷或矿物填料、聚合物填料、纤维填料、金属微粒填料或盐或它们的任何组合。可使用的非PTFE的示例性固体润滑剂包括二硫化钼、二硫化钨、石墨、石墨烯、膨胀石墨、氮化硼、滑石、氟化钙、氟化铈或它们的任何组合。示例性的陶瓷或矿物填料可包括氧化铝、氧化硅、二氧化钛、氟化钙、氮化硼、云母、硅灰石、碳化硅、氮化硅、氧化锆、炭黑、颜料或它们的任何组合。示例性的聚合物填料可包括聚酰亚胺、液晶聚合物如聚酯、聚苯并咪唑、聚四氟乙烯、任何上面列出的热塑性聚合物中任一种或它们的任何组合。示例性的纤维填料可包括尼龙纤维、玻璃纤维、碳纤维、聚丙烯腈纤维、聚芳酰胺纤维、聚四氟乙烯纤维、玄武岩纤维、石墨纤维、陶瓷纤维或它们的任何组合。示例性的金属填料可包括青铜、铜、不锈钢或它们的任何组合。示例性的盐填料可包括硫酸盐、硫化物、磷酸盐或它们的任何组合。
在一些实施例中，其它类型的热塑性材料可充当热塑性材料基质(被填充材料)，包括聚合物如聚酮、聚芳酰胺、热塑性聚酰亚胺、聚醚酰亚胺、聚苯硫醚、聚醚砜、聚砜、聚亚苯基砜、聚酰胺酰亚胺、超高分子量聚乙烯、热塑性含氟聚合物、聚酰胺、聚苯并咪唑、液晶聚合物或它们的任何组合。在一个例子中，热塑性材料包括聚酮、聚芳酰胺、聚酰亚胺、聚醚酰亚胺、聚酰胺酰亚胺、聚苯硫醚、聚亚苯基砜、含氟聚合物、聚苯并咪唑、它们的衍生物或它们的组合。在一个特别的例子中，热塑性材料包括聚合物如聚酮、热塑性聚酰亚胺、聚醚酰亚胺、聚苯硫醚、聚醚砜、聚砜、聚酰胺酰亚胺、它们的衍生物或它们的组合。在又一个例子中，热塑性材料包括聚酮，包括如上所讨论的PEEK、聚醚酮、聚醚酮酮、聚醚酮醚酮酮、它们的衍生物或它们的组合。示例性的热塑性材料也可包括芳族聚酯聚合物，如可以商品名(Amoco)、(HoechstCelanese)、SUMIKOSUPERTM或EKONOLTM(Sumitomo Chemical)、DuPontHXTM或DuPont ZENITETM(E.I.DuPont de Nemours)、RODRUNTM(Unitika)、GRANLARTM(Grandmont)得到的那些或它们的任何组合。在另一个例子中，热塑性聚合物可为超高分子量聚乙烯。本方法中可使用超高分子量聚乙烯，尽管其玻璃化转变温度为大约-160℃。
在其它实施例中，热塑性材料可包括热塑性含氟聚合物如氟化乙烯丙烯(FEP)，聚四氟乙烯(PTFE)，聚偏二氟乙烯(PVDF)，全氟烷氧基(PFA)，四氟乙烯、六氟丙烯和偏二氟乙烯的三元共聚物(THV)，聚三氟氯乙烯(PCTFE)，乙烯-四氟乙烯共聚物(ETFE)，乙烯-三氟氯乙烯共聚物(ECTFE)或它们的任何组合。在一些情况下，根据本发明的实施例，也可使用具有期望的特性的未填充聚合物，如单独使用PTFE。
使用上面的具体例子，由PTFE填充PEEK形成的密封环具有非常期望的特性，包括期望的磨损特性和低摩擦。不幸的是，通过如上所述焊接PTFE填充PEEK棒形成的密封环也具有不期望的物理特性。具体而言，焊接的PTFE填充PEEK具有小于3％的断裂伸长率，这对于大直径密封环来说是不期望的。本发明的实施例提供了其中可保持PTFE填充PEEK的期望性能而可改善不期望的断裂伸长率特性的成品密封环。申请人已发现，PTFE填充PEEK的层与具有更期望的特性如断裂伸长率或拉伸强度的聚合物的共挤出“载体”层的组合令人惊奇地改善整个焊接点、包含PTFE填充聚合物层的焊接点的强度。
根据本发明的“载体”聚合物可为任何具有所需物理特性如断裂伸长率或拉伸强度的热塑性材料，其足以补偿功能聚合物层的缺点(不期望的特性)。上面描述的适合用作热塑性材料基质(被填充材料)的任何热塑性材料也可用作载体聚合物。在一些优选的实施例中，用于载体聚合物的材料为与功能层中用作热塑性材料基质(被填充材料)的相同材料。例如，在一个优选的实施例中，功能层可使用PTFE填充PEEK，而未填充PEEK可作为载体层共挤出。优选地，载体聚合物和热塑性材料基质具有相似的玻璃化转变温度和熔化温度。
优选地，通过共挤出热塑性材料的两个或更多个层来形成热塑性棒。共挤出是一种熟知的现有技术工艺，其中挤出两种或更多种聚合物并一起接合成连续剖面。在一个优选的实施例中，所述两个或更多个层是熔融挤出的。在一些实施例中，作为加热和弯曲的替代方案，可通过控制所挤出材料的相对速度和量将层挤出为圆弧的形状。优选地，两个层在挤出过程中保持均匀的厚度。在图2中示出的实施例中，两个层具有基本相等的厚度，但可使用不同的层厚度，具体取决于层的机械性能和成品密封环的所需功能行为。在一些实施例中，热塑性棒可通过其它合适的已知工艺如压塑来形成，但如果采用其它方法，则可能需要如下所述另外的加热或退火步骤来在棒层之间生成所需程度的粘结强度。
在一个例子中，挤出棒的横截面的厚度(弯曲后其变为径向厚度)可小于由弯曲的挤出棒的圆弧所限定的圆的外径的1/5或20％。例如，包括由弯曲棒所限定的圆弧的圆的外径可为棒的径向厚度的至少5倍，例如径向厚度的至少10倍或甚至径向厚度的至少20倍。在一个特别的实施例中，径向厚度为至少1英寸，例如至少2英寸。
挤出棒的横截面可呈圆的形状或呈多边形的形状。特别地，多边形可具有至少三条边，例如至少四条边。在一个例子中，多边形的横截面是四边的，例如矩形或正方形。在一个特别的例子中，棒的横截面积为至少1平方英寸，例如至少2平方英寸或甚至至少3平方英寸。另外，在一些实施例中，所述横截面积可不大于50平方英寸。
因为挤出工艺产生连续长度的材料，故挤出棒必须被切割至所需的长度。棒的实际长度取决于待在弯曲并焊接棒后形成的密封环的所需直径。在优选的实施例中，如本文所述的密封环具有至少0.62米的周长，例如至少1.0米、至少1.5米、至少2.0米、至少4.1米、至少4.5米或甚至至少4.8米的周长。
一旦形成具有所需组成和长度的热塑性棒，然后必须将棒形成为密封环。这可通过首先加热棒至所有聚合物层的玻璃化转变温度以上的温度使得棒可容易地弯曲成圆形形状来完成。例如，挤出的PEEK具有大约143℃的玻璃化转变温度和大约343℃的熔点。PTFE填料具有大约130℃(Tg)和327℃(MP)的相当的玻璃化转变温度和熔化温度。PEEK和PTFE的复合物可更易于在两种组分的玻璃化转变温度以上而任一材料的实际熔点以下的温度下形成为所需形状。通常，挤出棒的柔性将随温度增加而增大。在一个优选的实施例中，热塑性棒(包括PTFE填充PEEK的层和未填充PEEK的载体层)被加热到大约310℃以获得最大柔性。技术人员应认识，在弯曲步骤过程中加热棒到任何材料的熔化温度以上常常是不可取的。
在优选的实施例中，热塑性载体材料和功能层基质包含玻璃化转变温度高于100℃、例如至少125℃或甚至至少145℃的热塑性材料。一个例外是玻璃化转变温度为160℃并且熔点为135℃的超高分子量聚乙烯。可在0.60至0.999的热指数范围内加热热塑性材料。热指数为材料被加热至的温度除以熔点的比率。在又一个例子中，热指数可在0.70至0.999的范围内，例如0.8至0.999的范围或甚至0.9至0.99的范围。
一旦功能和载体材料的热塑性棒已被加热到其充分柔性的点，即可将其形成为圆形形状，例如通过使用如美国专利申请第2010/0116422号中所述的成型机。图5示出了根据本发明的实施例用于将热塑性棒弯曲成圆形形状的合适成型机500。成型机500包括关于轴503转动的圆形模具502。绕圆形模具502的周缘有用于啮合制品506的凹槽504。特别地，制品506可由夹钳508夹入凹槽中。另外，成型机500可包括一组绕圆形模具502的周缘分布的辊510。辊510的轴可附接到在轨道512上来回移动的卡车或导杆。相应地，辊510可啮合圆形模具502或可从圆形模具502脱离和离开。
在使用中，夹钳508紧固制品506到圆形模具502。圆形模具502转动并且夹钳508与圆形模具502一起转动，从而绕圆形模具502的周缘牵引制品506并进入凹槽504中。随着夹钳508移过辊510，辊510与制品506和圆形模具502啮合，从而在制品506上施加径向力。相应地，制品506形成为圆弧结构，其可用来形成密封环。在又一个例子中，可将圆形模具502加热以以传导方式加热制品506。在另一个例子中，弯曲可在经加热的环境如烘箱中进行。
一旦形成为适当的形状，即可让弯曲的挤出棒冷却。例如，可将弯曲的挤出棒冷却至玻璃化转变温度以下的温度。特别地，可让弯曲的挤出棒冷却至接近室温的温度。在一个例子中，用强制对流冷却弯曲棒。随后可从模具取走弯曲棒。
在为接合棒的端部作准备时，可任选地将棒干燥。例如，可将棒加热到超过100℃的温度。在一个特别的例子中，可将棒加热到至少约110℃、例如至少130℃或甚至至少约145℃的温度达至少一小时、例如至少两小时或甚至三小时或更多的时间段。或者，可在热态但其玻璃化转变温度以下从模具取走棒。当棒呈热态时，可例如通过下面描述的熔体焊接方法接合端部，所述热态用来使棒保持在干燥条件中而无需另外的干燥步骤。
一旦棒已被弯曲成所需的圆形形状，即可通过熔化棒的端部并且将它们压制于一起来将挤出棒的端部焊接在一起以形成环。在一个例子中，使用热源来熔化端部。例如，热源可为接触热源，在其中，两个端部都接触热源并且经由传导熔化。在一个例子中，接触热源为加热平板。在另一个例子中，热源可为非接触热源如辐射热源或对流热源。或者，可使用技术如射频技术接合端部，包括微波技术、感应技术、激光技术或它们的任何组合。在一个特别的例子中，通过热熔焊接接合棒的端部。例如，热熔焊接可包括向棒的端部施加热源以使棒的近端部分熔化并在熔化后将端部压制于一起。在这样的例子中，棒的端部熔化而不熔化整个棒。
热源的温度将取决于构成棒的热塑性材料。在一个例子中，热塑性材料具有至少250℃的熔点。例如，热塑性材料可具有至少300℃、例如至少320℃的熔点。使用上面的例子，挤出的PEEK具有大约343℃的熔化温度，而PTFE填料具有大约327℃的熔化温度。在一个优选的实施例中，可将具有PEEK和PTFE填充PEEK的层的热塑性棒的端部加热到343℃以上但在其下任一材料将降解的温度以下的温度。例如，申请人已通过实验发现，当端部被加热到420℃左右的温度时，焊接的PEEK具有较高的断裂伸长率。较低的温度(385℃左右)看起来太低而不能引起充分的粘结，而较高的温度(445℃左右)可能导致样品降解。
图4A和4B示出了弯曲棒的端部接近彼此并然后被压制于一起。当熔化的端部被压制于一起时，形成接合棒的两个端部的焊接点404。在一些优选的实施例中，根据本发明的密封环可包含不止一个焊接点，例如两个焊接点或甚至三个焊接点或更多。图6示出了根据本发明的一个优选实施例的密封环，其中接合了两根热塑性棒以形成具有两个焊接点的密封环。在多根棒一起形成时，优选如上所述接合棒的末端，其中载体聚合物接合到载体聚合物并且功能聚合物接合到功能聚合物。
另外，圆弧或部分的焊接或接合可用来形成圆形、卵形、多边形或复杂形状的密封件。例如，密封件可具有多边形形状如三角形、正方形、矩形、五边形、六边形、七边形、八边形或它们的任何组合。多边形可具有至少四条边，例如至少6条边、至少8条边或甚至至少10条边。在另一个例子中，复杂形状可为图8、不规则多边形或其它复杂形状。特别地，形状可以是闭合的。或者，形状可以是开放的，沿其广度具有一个或多个中断。
也可采用所述示例性焊接方法来焊接自板切割的挤出或压塑热塑性材料的圆弧以在退火后产生具有期望的性能的焊接环。虽然本文中使用焊接来明确地指示加热棒的端部并且压制端部于一起的方法，但可采用其它接合技术来接合棒的端部。例如，其它接合技术可包括注塑以接合端部、超声处理、感应加热或辐照技术如激光或微波技术。通过任何此类方法形成的相结合的端部之间的连接在本文中都称为“焊接点”。
当包括热塑性材料的两个或更多个层的挤出棒的端部被接合于一起时，所述端部优选接合为使得每一个层的一个端部接合到相同的层的另一个端部，如图4A和4B中所示。换句话说，使用上面的例子，PEEK层102将被焊接到PEEK层102’的另一个端部，而PTFE填充PEEK 104和104’的端部也将被焊接于一起。这通常将允许机械上期望的材料(本例子中为未填充PEEK)具有最强的可能焊接点106。
优选地，将层状棒弯曲成一个层形成环的内周长而另一聚合物层形成环的外周长的圆形形状，如图1中所示。在其它实施例中，可将层状棒弯曲成使得一个层形成所得环的一个面而另一个层形成另一个面，如图6中所示。技术人员将认识，环的所需最终形状将由环、具体而言环的功能层的特定用途决定。在许多情况下，将期望功能层如PTFE填充PEEK层朝向环的内部(向着开口)而载体层朝向环的外周长，如图1中所示。
一旦棒的端部已通过焊接接合，挤出棒即形成焊接环。优选地，然后通过加热环至高于热塑性材料的玻璃化转变温度的温度使焊接环退火。通过以这种方式加热焊接环，聚合物材料将优选在整个焊接点中扩散，从而促进焊接区处的链缠结和产生更高的伸长率值。
特别地，退火温度可为所述层中之一或二者的至少一种聚合物组分的玻璃化转变温度的至少1.2倍，例如所述玻璃化转变温度的至少1.5倍或甚至至少1.7倍，前提条件是不超过熔点。虽然较高的温度将减少获得最佳粘合力所需的在退火温度下的时间的量，但温度应在层的材料的流动温度以下以避免焊接环的变形。
焊接环优选在退火温度下保持足以使至少一种层组分部分地扩散到相邻层中的时间。获得所需结果或最大焊接粘合力所需的在退火步骤中的时间和温度的量可通过直接测试确定并将取决于对本领域技术人员来说显而易见的因素如每个层的厚度和层的特定组成。一般来说，较厚的层和较高分子量的组分将需要较长的时间或较高的温度。
例如，焊接环可在高于挤出的热塑性材料的玻璃化转变温度的温度下退火至少两小时、例如至少四小时或甚至至少六小时的时间段。在一个特别的例子中，焊接环可例如在高于100℃的温度、例如高于120℃的温度下退火至少一小时、例如至少两小时的时间段。温度可在5℃每小时至15℃每小时、例如8℃每小时至12℃每小时范围内的速率下渐变至退火温度。一旦达到退火温度，即可让温度保持至少两小时、例如至少四小时、至少六小时或甚至八小时或更多的时间段。然后可让环在受控的速率下例如在5℃每小时至15℃每小时的范围内、例如8℃每小时至12℃每小时的范围内的速率下冷却至低于玻璃化转变温度的温度。然后可让焊接环冷却至室温。在一个例子中，在关掉烘箱的同时让环留在烘箱中直至达到室温。
使焊接环退火不仅起到增强接合热塑性棒的端部于一起的焊接点的作用，其还增强共挤出的层之间的粘结。申请人已发现，在改善焊接特性如拉伸强度和断裂伸长率时，层之间的粘结也很重要。申请人相信载体层和功能层之间的粘结起到隔离因焊接的功能层的伸长所致的撕裂或缺陷的作用，从而防止焊接点中的薄弱点的撕裂灾难性地传播。这样，较弱的功能层的断裂伸长率可得到改善，优选至3％以上的值。例如，焊接断裂伸长率可为至少5％、至少10％、至少20％或甚至至少30％。优选地，功能材料与粘结的载体材料的焊接点还具有至少3100psi、例如至少10000psi或甚至至少15000psi的拉伸强度。此外，功能材料与粘结的载体材料的焊接点优选具有至少100ksi、例如至少750ksi或甚至至少850ksi的拉伸模量。
此外，申请人已认识到，粘结的载体层的存在允许密封环起作用，即便功能聚合物层受损。这是因为载体层将继续固持功能层于适当的位置。因此，如果功能层中确实发生了撕裂或断裂，则只要载体层保持完好，功能层将保持就位并且密封环将继续起作用。
因此之故，申请人已发现，层之间的粘结是选择载体聚合物的一个重要因素。在优选的实施例中，载体材料和基质材料相同。这允许跨越边界(焊接边界和层边界二者)的最大扩散。在使用不同的材料时，期望聚合物熔体的表面张力充分相似以允许界面处的润湿和相邻层的粘附。此外，具有相似极性和溶解度参数的聚合物通常显示出更高的扩散度和因此更高的粘结强度。一般来说，较高分子量的聚合物将显示出更大的粘结强度，但需要更长的退火时间段。
虽然本文中的许多讨论针对的是挤出棒的使用，但可采用形成合适的热塑性棒的其它方法，包括压塑或从形成的聚合物片材切出一个或多个圆弧。另外，虽然本文的许多讨论针对的是具有两个不同的层的热塑性棒的使用，但在本发明的一些优选实施例中，可采用三个或更多个层。例如，一个优选的实施例可采用三个层：两个功能层夹着一个载体层。
此外，虽然本文中描述的方法通常关于由单根弯曲棒所形成的密封环来描述，但所述方法可延伸到由不止一根热塑性棒例如2、3、4或更多挤出棒所形成的密封环。例如，图7示出了根据本发明的另一个优选实施例的由两根单独的棒808、809形成并包括两个单独的焊接点706、707的密封环。
图8A和8B示出了本发明的另外的实施例，其中载体层为完全被功能层所包围的中心部分。在这些实施例中，棒可通过环形挤出形成，使得棒的外表面由功能层802(例如，PTFE填充PEEK的层)构成而棒的芯由载体材料804(例如，未填充的PEEK)形成。一旦棒如上所述被弯曲成圆形形状并焊接，功能层802将完全包围载体材料804的内芯。如同上述热塑性棒一样，如图8A和8B的实施例中所示的挤出棒可具有任何所需的横截面，包括如图8A中所示的圆形横截面、如图8B中所示的矩形横截面或者具有3条或更多条边的多边形横截面。
本发明具有广泛的适用性并可提供许多有益效果，如上面的例子中所述和所示。取决于特定的应用，实施例会有很大变化，并且不是每个实施例都将提供所有有益效果并满足可通过本发明获得的所有目的。注意不是上面在具体实施方式或例子中描述的所有行为都是需要的，一部分特定行为可能不需要，并且除所描述的那些外可还执行一种或多种其它行为。还此外，列出行为的顺序不一定为执行它们的顺序。
在前面的说明书中，已结合特定实施例描述了概念。然而，本领域普通技术人员应认识，可作各种修改和变化而不偏离如下面的权利要求中所陈述的本发明的范围。相应地，说明书和附图应视为示意性的而非限制性的意义，并且所有此类修改均意在包括在本发明的范围内。在阅读说明书后，熟练技术人员应认识，为清楚起见，在单独的实施例的上下文中本文所述某些特征也可在单个实施例中组合地提供。相反，为简便起见，在单个实施例的上下文中描述的各种特征也可单独地或以任何子组合提供。此外，以范围述及的值的提及包括该范围内的每一个值。
如本文所用，术语“包含”、“包括”、“具有”或它们的任何其它变型意在涵盖非排他性的包括。例如，包含特征的列表的工艺、方法、制品或装置不一定仅限于那些特征而是可包括未明确列出的或此类工艺、方法、制品或装置所固有的其它特征。另外，除非明确指出相反，否则“或”指包括性的或而非排他性的或。例如，条件A或B由以下中的任何一者满足：A为真(或存在)并且B为假(或不存在)，A为假(或不存在)并且B为真(或存在)，和A和B二者均为真(或存在)。另外，采用“一种”的使用来描述本文所述的元素和组分。这样做仅是为了方便和给出本发明的范围的一般意义。此描述应理解为包括一种或至少一种并且单数也包括复数，除非很明显其另有所指。
上面已结合特定实施例描述了有益效果、其它优点和问题的解决方案。然而，所述有益效果、优点、问题的解决方案和可能引起任何有益效果、优点或解决方案的出现或变得更明显的任何特征不应理解为任何或全部权利要求的决定性、必需或基本的特征。
虽然已详细描述了本发明及其优点，但应理解可对本文所述实施例作各种改变、取代和变更而不偏离如附随的权利要求所限定的本发明的精神和范围。此外，本申请的范围非意在限制于说明书中描述的工艺、机器、制造、物质组成、措施、方法和步骤的特定实施例。如本领域普通技术人员将从本发明的公开容易地认识的，可根据本发明采用目前存在的或将在以后开发的实现基本相同的功能或获得基本相同的结果的工艺、机器、制造、物质组成、措施、方法或步骤。因此，附随的权利要求意在在其范围内涵盖此类工艺、机器、制造、物质组成、措施、方法或步骤。

Claims (45)

1.一种形成密封环的方法，所述方法包括：
由至少第一聚合物的纵向层和第二聚合物的纵向层形成热塑性棒，并且挤出棒具有第一端部和第二端部；
加热所述热塑性棒至所述第一聚合物和第二聚合物的玻璃化转变温度以上的第一温度；
在至少保持温度于所述第一温度下的同时将所述热塑性棒弯曲成圆形结构；
加热所述挤出棒的所述第一端部和第二端部至所述第一聚合物和第二聚合物的熔化温度以上的温度；和
将所述挤出棒的所述经加热的第一端部和第二端部聚在一起以形成接合所述端部于一起的焊接点，其中经焊接的第二聚合物至少具有比经焊接的第一聚合物的第一机械性能更期望的第一机械性能，使得接合所述挤出棒的所述端部于一起的所述焊接点的第一机械性能也是比所述经焊接的第一聚合物的第一机械性能更期望的。
2.根据权利要求1所述的方法，其中所述第一机械性能选自断裂伸长率、拉伸强度或拉伸模量。
3.根据前述权利要求中任一项所述的方法，其中将所述挤出棒的所述经加热的第一端部和第二端部聚在一起以形成焊接点包括将所述热塑性棒的所述经加热的第一端部和第二端部聚在一起以形成接合所述端部于一起的焊接点，使得所述第一聚合物的层的所述第一端部和第二端部相接合并且所述第二聚合物的层的所述第一端部和第二端部相接合。
4.根据前述权利要求中任一项所述的方法，其中所述第一聚合物包含由基质聚合物和填料所形成的填充聚合物。
5.根据前述权利要求中任一项所述的方法，其中所述第一聚合物包含由基质聚合物和聚四氟乙烯(PTFE)填料所形成的PTFE填充聚合物。
6.根据前述权利要求中任一项所述的方法，其中所述第二聚合物包含未填充聚合物。
7.根据前述权利要求中任一项所述的方法，其中对所述第二聚合物和所述基质聚合物采用相同的聚合物材料。
8.根据前述权利要求中任一项所述的方法，其中所述热塑性棒通过所述第一聚合物与所述第二聚合物的共挤出形成。
9.根据前述权利要求中任一项所述的方法，其中所述热塑性棒通过压塑形成。
10.一种形成密封环的方法，所述方法包括：
通过聚四氟乙烯(PTFE)填充聚合物与未填充聚合物的共挤出形成热塑性棒，使得所形成的热塑性棒至少包括PTFE填充聚合物的第一层和未填充聚合物的第二层，所述热塑性棒具有第一端部和第二端部；
加热所述热塑性棒至所述PTFE填充聚合物和所述未填充聚合物的玻璃化转变温度以上的温度；
在保持所述温度在所述玻璃化转变温度以上的同时将所述热塑性棒弯曲成圆形结构；
将所述热塑性棒的所述经加热的第一端部和第二端部聚在一起以形成接合所述端部于一起的焊接点，使得所述PTFE填充聚合物的层的所述第一端部和第二端部相接合并且所述未填充聚合物的层的所述第一端部和第二端部相接合。
11.根据前述权利要求中任一项所述的方法，其中接合所述热塑性棒的所述端部于一起的所述焊接点具有至少3％的断裂伸长率。
12.根据前述权利要求中任一项所述的方法，其中接合所述热塑性棒的所述端部于一起的所述焊接点具有至少5％的断裂伸长率。
13.根据前述权利要求中任一项所述的方法，其中接合所述热塑性棒的所述端部于一起的所述焊接点具有至少10％的断裂伸长率。
14.根据前述权利要求中任一项所述的方法，其中当焊接时所述PTFE填充聚合物具有小于10％的断裂伸长率。
15.根据前述权利要求中任一项所述的方法，其中当焊接时所述PTFE填充聚合物具有小于5％的断裂伸长率。
16.根据前述权利要求中任一项所述的方法，其中当焊接时所述PTFE填充聚合物具有小于3％的断裂伸长率。
17.根据前述权利要求中任一项所述的方法，其中当焊接时所述未填充聚合物具有大于3％的断裂伸长率。
18.根据前述权利要求中任一项所述的方法，其中当焊接时所述未填充聚合物具有大于5％的断裂伸长率。
19.根据前述权利要求中任一项所述的方法，其中当焊接时所述未填充聚合物具有大于10％的断裂伸长率。
20.一种通过聚合物焊接形成密封环的方法，所述方法包括：
通过共挤出PTFE填充聚合物的第一层和载体聚合物的第二层形成包括至少两个层的热塑性棒，当焊接时所述PTFE填充聚合物具有小于3％的断裂伸长率，当焊接时所述载体聚合物具有至少3％的断裂伸长率，并且所形成的热塑性棒具有第一端部和第二端部；
加热所述热塑性棒至所述第一层和第二层的玻璃化转变温度以上的温度；
将所述热塑性棒弯曲成圆形形状；
加热所述热塑性棒的所述第一端部和第二端部至所述第一层和第二层的熔化温度以上的温度；和
将所述热塑性棒的所述经加热的第一端部和第二端部聚在一起以形成接合所述端部于一起的焊接点，使得所述第一层的所述第一端部和第二端部相接合并且所述第二层的所述第一端部和第二端部相接合，所述焊接点具有至少3％的断裂伸长率。
21.根据前述权利要求中任一项所述的方法，其中接合所述热塑性棒的所述端部于一起的所述焊接点具有比当焊接时所述PTFE填充聚合物的断裂伸长率大的断裂伸长率。
22.根据前述权利要求中任一项所述的方法，所述方法还包括使所述接合的端部退火。
23.根据前述权利要求中任一项所述的方法，所述方法还包括通过使所述接合的端部的温度渐变至高于所述第一层和第二层的玻璃化转变温度的温度、保持所述接合的端部于所述温度下达至少2小时的时间段并冷却所述密封环来使所述接合的端部退火。
24.根据前述权利要求中任一项所述的方法，其中将所述经加热的第一端部和第二端部聚在一起包括使用至少50psi的压力将所述第一端部和第二端部压制于一起。
25.根据前述权利要求中任一项所述的方法，其中将所述热塑性棒弯曲成圆形形状包括将所述热塑性棒弯曲成圆形形状使得一个聚合物层形成所述圆形形状的内周长并且另一聚合物层形成所述圆形形状的外周长。
26.根据前述权利要求中任一项所述的方法，其中加热所述第一端部和第二端部包括使用非接触热源加热。
27.一种密封环，所述密封环通过根据前述权利要求中任一项所述的方法形成。
28.一种圆形密封环，所述圆形密封环包括：
形成所述圆形密封环的内周长的第一聚合物的内层；
至少一个形成所述圆形环的外周长的第二聚合物的外层；
接合每个所述层的所述端部于一起使得所述第一聚合物焊接到所述第一聚合物并且所述第二聚合物焊接到所述第二聚合物的焊接点。
29.根据前述权利要求中任一项所述的方法，其中将所述热塑性棒弯曲成圆形形状包括将所述热塑性棒弯曲成圆形形状使得一个聚合物层形成所述圆形形状的内周长并且另一聚合物层形成所述圆形形状的外周长。
30.一种圆形密封环，所述圆形密封环包括：
形成所述圆形密封环的内周长的第一聚合物的内层；
至少一个形成所述圆形环的外周长的第二聚合物的外层；
接合每个所述层的所述端部于一起使得所述第一聚合物焊接到所述第一聚合物并且所述第二聚合物焊接到所述第二聚合物的焊接点；
其中一个聚合物层包含PTFE填充PEEK并且一个聚合物层包含未填充PEEK。
31.根据权利要求27至30中任一项所述的密封环，所述密封环具有至少3％的焊接断裂伸长率。
32.根据权利要求27至31中任一项所述的密封环，其中所述密封环具有至少0.62米的圆周。
33.根据权利要求27至32中任一项所述的密封环，其中所述密封环具有至少0.2米的直径。
34.根据权利要求27至33中任一项所述的密封环，其中所述密封环具有至少1.3米的直径。
35.根据前述权利要求中的任一项，其中所述PTFE填充聚合物包含选自以下的聚合物：聚酮、聚芳酰胺、聚酰亚胺、聚醚酰亚胺、聚酰胺酰亚胺、聚苯硫醚、聚亚苯基砜、含氟聚合物、聚苯并咪唑、液晶聚合物、它们的衍生物或它们的组合。
36.根据前述权利要求中的任一项，其中所述PTFE填充聚合物包含选自以下的聚酮材料：聚醚醚酮、聚醚酮、聚醚酮酮、它们的衍生物以及它们的组合。
37.根据前述权利要求中的任一项，其中所述PTFE填充聚合物包含PTFE填充聚醚醚酮(PEEK)。
38.根据前述权利要求中的任一项，其中所述第二或载体聚合物包含选自以下的聚合物：聚酮、聚芳酰胺、聚酰亚胺、聚醚酰亚胺、聚酰胺酰亚胺、聚苯硫醚、聚亚苯基砜、含氟聚合物、聚苯并咪唑、液晶聚合物、它们的衍生物或它们的组合。
39.根据前述权利要求中的任一项，其中所述第二或载体聚合物包含选自以下的聚酮材料：聚醚醚酮、聚醚酮、聚醚酮酮、它们的衍生物以及它们的组合。
40.根据前述权利要求中的任一项所述的方法，其中所述第二或载体聚合物包含PEEK。
41.根据前述权利要求中的任一项，其中所述第二或载体聚合物包含超高分子量聚乙烯。
42.根据前述权利要求中的任一项，其中所述第二或载体聚合物具有至少250℃的熔点。
43.根据前述权利要求中的任一项，其中所述第二或载体聚合物具有至少100℃的玻璃化转变温度。
44.根据前述权利要求中的任一项，其中所述焊接点具有至少3100psi的拉伸强度。
45.根据前述权利要求中的任一项，其中所述焊接点的拉伸模量为至少100ksi。
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US10093069B2 (en) 2018-10-09
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