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CN106170386A - 用于开采页岩油气的压裂液体输送软管及其制造方法 - Google Patents

用于开采页岩油气的压裂液体输送软管及其制造方法 Download PDF

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CN106170386A
CN106170386A CN201480001428.6A CN201480001428A CN106170386A CN 106170386 A CN106170386 A CN 106170386A CN 201480001428 A CN201480001428 A CN 201480001428A CN 106170386 A CN106170386 A CN 106170386A
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polymer
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flexible pipe
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CN106170386B (zh
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沙月华
王金马
王东辉
周杉鸿
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5Elem Hi Tech Corp Technology Co Ltd
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16LPIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L11/00Hoses, i.e. flexible pipes
    • F16L11/04Hoses, i.e. flexible pipes made of rubber or flexible plastics
    • F16L11/08Hoses, i.e. flexible pipes made of rubber or flexible plastics with reinforcements embedded in the wall
    • F16L11/085Hoses, i.e. flexible pipes made of rubber or flexible plastics with reinforcements embedded in the wall comprising one or more braided layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B29C48/10Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels flexible, e.g. blown foils
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/15Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
    • B29C48/151Coating hollow articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/21Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/10Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481Non-reactive adhesives, e.g. physically hardening adhesives
    • B29C65/4815Hot melt adhesives, e.g. thermoplastic adhesives
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/52Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
    • B29C65/524Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive by applying the adhesive from an outlet device in contact with, or almost in contact with, the surface of the part to be joined
    • B29C65/525Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive by applying the adhesive from an outlet device in contact with, or almost in contact with, the surface of the part to be joined by extrusion coating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General 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
    • B29C66/51Joining 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
    • B29C66/52Joining tubular articles, bars or profiled elements
    • B29C66/522Joining tubular articles
    • B29C66/5221Joining tubular articles for forming coaxial connections, i.e. the tubular articles to be joined forming a zero angle relative to each other
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General 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
    • B29C66/71General 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 composition of the plastics material of the parts to be joined
    • B29C66/712General 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 composition of the plastics material of the parts to be joined the composition of one of the parts to be joined being different from the composition of the other part
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00Layered products comprising a layer of natural or synthetic rubber
    • B32B25/10Layered products comprising a layer of natural or synthetic rubber next to a fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024Woven fabric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21BEARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B17/00Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
    • E21B17/20Flexible or articulated drilling pipes, e.g. flexible or articulated rods, pipes or cables
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16LPIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L11/00Hoses, i.e. flexible pipes
    • F16L11/04Hoses, i.e. flexible pipes made of rubber or flexible plastics
    • F16L11/12Hoses, i.e. flexible pipes made of rubber or flexible plastics with arrangements for particular purposes, e.g. specially profiled, with protecting layer, heated, electrically conducting
    • F16L11/127Hoses, i.e. flexible pipes made of rubber or flexible plastics with arrangements for particular purposes, e.g. specially profiled, with protecting layer, heated, electrically conducting electrically conducting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001Combinations of extrusion moulding with other shaping operations
    • B29C48/0021Combinations of extrusion moulding with other shaping operations combined with joining, lining or laminating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/16EPM, i.e. ethylene-propylene copolymers; EPDM, i.e. ethylene-propylene-diene copolymers; EPT, i.e. ethylene-propylene terpolymers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2077/00Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02Synthetic macromolecular fibres
    • B32B2262/0261Polyamide fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2597/00Tubular articles, e.g. hoses, pipes

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Abstract

本发明提供一种多层软管,所述多层软管包括:覆盖层,其包括第一聚合物;增强层,其包括织造长丝;以及内部衬里,其包括第二聚合物,其中所述第一聚合物和所述第二聚合物是不相似的。所述第一聚合物优选地是具有良好耐磨性特性的聚合物,例如,热塑性聚氨酯(TPU)、TPU/PVC,或PVC,或PVC/NBR。所述第二聚合物优选地是具有良好耐化学性特性的聚合物,例如,乙烯‑丙烯‑二烯单体(EPDM)橡胶。本发明还提供了制造所述多层软管的方法。

Description

用于开采页岩油气的压裂液体输送软管及其制造方法
技术领域
本发明涉及用于输送流体的多层软管及制造方法并且属于流体输送设备的领域内,所述流体确切地说是用于开采页岩油气的水力压裂液体。
背景技术
水力压裂或液压压裂技术是通过加压液体来压裂岩石。它已经成为用于提取和开采页岩油气、致密气、致密油和煤层气的优选方法。高压液体填充在井眼中并且使岩层发生断裂。高压液体中的支撑剂允许裂缝保持打开,并且还充当用于油气导向钻探的快速渗透通道。
在用于开采页岩气的水力压裂方法中使用的压裂液体通常包含水、沙和化学添加剂(例如,盐和乳化剂)。所述压裂液体通常由99%或更多的水和沙所组成。通常需要非常大量的压裂液体用于页岩气的开采。一口典型的页岩气井眼可能需要大约4到5百万加仑(1加仑对应于大约3.78 L)的压裂液体。
在页岩油气开采中,金属管道通常用于长距离输送(在大约10英里的数量级)。铺设长距离的金属管道是劳动力密集的并且在复杂的地形中是非常困难的,例如,在斜坡、沟壑和池塘中。更重要的是,金属管道的接合部易受破裂和渗漏的影响,这引起由泄漏的压裂液体造成的土壤污染的极大风险。
非常需要可以承受商业水力压裂操作的严苛度的柔性软管。
发明内容
本发明提供柔性软管,所述柔性软管具有高结构完整性、长使用寿命和耐候性以及耐化学性,所述柔性软管是抗弯曲破裂和高压的,可以承受压裂流体的高输送速率,并且适合于各种地形表面形态。当不使用时,它平坦铺设并且可以容易地缠绕,储存和运输时占据较少空间。
附图说明
在以下描述中,相同的数字编号指代相似元件。所提到实施例、几何配置、材料和/或在附图中示出或在本发明实施方式中描述的尺寸仅仅是仅出于范例目的给出的优选实施例。
图1是本发明的多层软管的一个实施例的图示;
图2是图示本发明的多层软管的制造方法的实施例的流程图;以及
图3是本发明的共挤压模的结构的示意性图示,其中,1:外壳,2:轴杆,3:夹持环,4:分配器,5:模具壳体,6:第一供给入口,7:第二供给入口。
具体实施方式
在以下描述中,相同的数字编号指代相似元件。所提到实施例、几何配置、材料和/或在附图中示出或在本发明实施方式中描述的尺寸仅仅是仅出于范例目的给出的优选实施例。
参考图1,示出了根据本发明的一个实施例的包含在多层软管中的不同层的图示。如图1所示,根据本发明的实施例的多层软管100包括覆盖层110、织造增强层120和内部衬里130。覆盖层110、增强层120和内部衬里粘合在一起形成本发明的多层软管。在替代实施例中,可以提供额外的层而不脱离本发明的范围。
在上述优选实施例中,覆盖层110由第一聚合物制成,优选地是具有良好的耐磨性、耐蚀性和耐候性特征的聚合物。适于用作覆盖层的聚合物的实例是热塑性聚氨酯材料(TPU)、聚氯乙烯(PVC)、TPU/PVC混合物,或PVC/丁腈橡胶(NBR)混合物。TPU/PVC混合物的质量比是TPU:PVC=100:0-70。PVC与粉末状NBR的质量比是PVC:NBR=100:0-70,优选地是100:0-50。TPU是轻质材料,其在低温下提供极大的柔性同时提供优良的耐磨性、耐蚀性和耐候性。然而,如同所属领域的技术人员将容易地理解的,其它橡胶或热塑性材料等等也可以用于覆盖层的制造,而不会脱离本发明的范围。
覆盖层110形成到管中,优选地通过挤压过程。优选地,外部覆盖层110的厚度将在0.5到4.0 mm之间改变,但是也可能更厚或更薄。并且,外部覆盖层110具有能够通过适度热的使用粘合到织造增强层120的表面。在某些实施例中,第一粘合剂层(未图示)施加于管状覆盖层110的一个表面,其粘合到增强层120。第一粘合剂层通常具有0.10到0.35 mm的厚度,但是还可能更厚或更薄。
增强层120是在织机上,使用相对于增强层120纵向延伸的经线和沿增强层120成螺旋形延伸的纬线织造的。增强层120可以由涤纶长丝或尼龙或芳纶纤维或所属领域的技术人员已知的任何其它合适的纤维织造,包含但不局限于维尼昂纤维、聚乙烯或聚丙烯纤维、木纤维、棉纤维、麻纤维等。增强层可以由管状的经线和纬线纤维织造。增强层也可以包括至少一条导电金属线,优选地是细铜线。铜线是出于抗静电效果在增强层上在轴向方向上织造的。
内部衬里130由第二聚合物制成,所述第二聚合物可以与覆盖层110的第一聚合物不相似。第二聚合物优选地是具有良好耐化学性特征的聚合物,确切地说是耐压裂液体的成分。用于内部衬里层的合适的聚合物的实例是乙烯-丙烯-二烯单体(EPDM)橡胶。与TPU相比EPDM具有优良的化学稳定性,并且还具有较大的温度范围,其可以在40℃以下的温度下使用。所属领域的技术人员容易理解,其它橡胶或热塑性材料等等也可以在内部衬里的制造中使用,而不会脱离本发明的范围。替代的聚合物可以是热塑性弹性体(TPE),包含但不限于硅酮修饰的EPDM橡胶、氟橡胶、热塑性聚酰胺、高密度聚乙烯、热塑性聚酯。
内部衬里130还形成到管中,优选地通过挤压过程。优选地,内部衬里130的厚度将在0.5到4.0 mm之间改变,但是也可能更厚或更薄。并且,内部衬里130具有能够通过使用适度热粘合到织造增强层120的表面。在某些实施例中,第二粘合剂层(未图示)施加于管状内部衬里130的一个表面,其粘合到增强层120。第二粘合剂层通常具有0.10到0.35 mm的厚度,但是还可能更厚或更薄。
为使软管适当地表现,每一层的直径使得不同层紧紧地配合在彼此内,并且随后通过施加适度热和压力粘合。
用于第一粘合剂层的应用的优选方法是通过覆盖层110和第一粘合剂层的共挤压。用于第二粘合剂层的应用的优选方法也是通过内部衬里130和第二粘合剂层的共挤压。
在图2中示出了图示本发明的多层软管的制造方法的一项实施例的示例性流程图。所述制造方法通常包括以下步骤:
(1)带有第一粘合剂层210的覆盖层的共挤,优选地通过两个挤压机将覆盖层颗粒和粘合剂颗粒挤压到共挤压模中,并且使共挤过的叠层经受冷却、拉伸和压挤从而得到平坦的管,即,带有粘合剂层的覆盖层,其中粘合剂层具有典型的0.10到0.35 mm的厚度并且覆盖层具有典型的0.5到4.0 mm的厚度;
(2)带有粘合剂层的内部衬里的共挤,优选地通过两个挤压机将内部衬里颗粒和粘合剂颗粒挤压到共挤压模中,并且使共挤过的叠层经受冷却、拉伸和压挤从而得到平坦的管,即,带有粘合剂层的内部衬里,其中粘合剂层具有典型的0.10到0.35 mm的厚度并且内部衬里具有典型的0.5到4.0 mm的厚度;
(3)在步骤(1)和步骤(2)220、270施加固化剂到第一和第二粘合剂层,优选地通过在使用之前将其浸没到用于物理渗透的溶液中,其中溶液是通过10-30:70-90的比例的固化剂和溶剂配制的;
(4)形成增强层230。通常根据产品设计规格织造管状增强层;
(5)粘合覆盖层和增强层,优选地通过将来自步骤(3)的表面处理过的覆盖层与粘合剂层拉伸到管状增强层中,在两端处固定,通过0.10到0.35 MPa的蒸汽4到10分钟,随后用空气替代蒸汽冷却同时保持压力到希望的温度;
(6)翻转步骤(5)的粘合覆盖层和增强层,由此翻转之后覆盖层在增强层的外部上;
(7)粘合内部衬里和增强层,优选地通过将来自步骤(3)的表面处理过的内部衬里与粘合剂层拉伸到来自步骤(6)的产品中,在两端处固定,通过0.10到0.35 MPa的蒸汽4到10分钟,随后用空气替代蒸汽冷却同时保持压力到希望的温度。
在制造多层软管的方法中,TPU颗粒或TPU/PVC混合物用于在步骤(1)中描述的覆盖层,并且TPU颗粒或TPU/PVC混合物或PVC或PVC/NBR混合物用于在步骤(2)中描述的内部衬里,其中在TPU/PVC混合物中,TPU:PVC=100:0-70;在PVC/NBR中,PVC:NBR=100:0-70;并且在步骤(1)和步骤(2)中,覆盖层和内部衬里颗粒优选地在150到210℃的温度下挤压,并且粘合剂颗粒优选地在140到175℃的温度下挤压。
在此实施例中,使用的粘合剂颗粒可以是TPU热熔粘合剂,例如,购自LubrizolCorp的UB410B。同样在此实施例中,固化剂可以是称为二苯甲烷二异氰酸酯(MDI)的材料,例如,巴斯夫M20S。固化剂(包含活性NCO基团)可以牢固地粘合到含有羟基的涤纶长丝、尼龙纤维或处理过的芳纶纤维,其含有氨基作为活性位点,从而通过一定温度和压力下的物理渗透和化学反应分别形成氨基甲酸酯和脲结构。
来自步骤(5)的中间产物的翻转可以通过由所属领域的技术人员熟知的多个设备进行。经由设备通过空气压力或液体压力的层的翻转在颁予Driver等人的第8,066,499号美国专利中描述。
在制造多层软管的方法中,还优选地将色母粒添加到在步骤(1)和/或步骤(2)中描述的覆盖层颗粒和内部衬里颗粒,覆盖层颗粒或内部衬里颗粒与色母粒的质量比是100:(0.5-1.5),并且随后均匀地搅拌且干燥。
在制造多层软管的方法中,在步骤(4)中描述的增强层是通过涤纶长丝,或尼龙长丝,或芳纶纤维,或涤纶或尼龙长丝或芳纶纤维的混合物织造的。
制造多层软管的方法可以进一步包括在翻转之后在表面上辊压的步骤。辊压的步骤可以通过特定的机器来执行,例如,辊压机。在典型的实例中,辊压机配备有两个按压辊,所述辊一起形成按压间隙并且其轴线位于按压平面中。按压辊可以进一步包括多个短针。当软管穿过按压间隙进入时,按压辊旋转并且按压软管以改进表面特性,例如,光滑度和光泽度,并且排出软管的邻近层之间的空腔中的气体。
在图3中示出了一个示例性共挤压模。共挤压模,包含:外壳,其中配备有轴杆;分配器,其提供在轴杆下方、呈用于其下部部分的平截头体形式,其中在轴杆与分配器之间存在间隙,分配器固定地连接到外壳,所述外壳具有连接到覆盖层或内部衬里颗粒挤压机的第一供给入口,第一供给入口穿过外壳并且与轴杆与分配器之间的间隙流体连接;模具壳体,其提供在分配器外部,其中在模具壳体与分配器之间存在间隙,模具壳体固定地连接到外壳,模具壳体具有连接到粘合剂挤压机的第二供给入口,第二供给入口穿过模具壳体并且与模具壳体与分配器之间的间隙流体连接;以及夹持环,其提供在分配器与外壳之间。
由本发明提供的软管提供了至少以下有益效应。本发明的软管可以具有耐磨蚀的高度结构完整性、耐高压的长耐久性以及令人满意的耐候性和耐化学性,并且适合于各种地形表面形态。本文中提供的软管当未使用时平坦铺设,适宜于储存和运输。它可以任何长度制造同时保持尺寸均一性,此外,所述软管具有极小的伸长率,因此运输介质时具有良好的稳定性。
示例性实施例
本发明的一个示例性实施例是一种多层软管,所述多层软管具有厚度为1.5±0.2mm的TPU覆盖层、由尼龙66纤维制成的厚度为2.6±0.2 mm的增强层,以及厚度为1.4±0.2mm的EPDM内部衬里。
多层软管呈现优良的结构完整性。TPU层与增强层之间的粘附强度大于80 N/25mm。EPDM层与增强层之间的黏合强度也大于80 N/25 mm。示例性软管的直径是255-258 mm,具有在操作压力下4-5%的纵向延伸、低于1%的反弹、爆裂压力大于3.8 MPa、剥离强度大于80 N/25 mm。
本发明的另一示例性实施例是一种多层软管,所述多层软管具有厚度为1.0±0.2mm的TPU/PVC混合物(质量比TPU/PVC=100:50)的覆盖层、由涤纶纤维制成的厚度为2.5±0.2 mm的增强层,以及厚度为1.4±0.2 mm的EPDM内部衬里。
多层软管还呈现优良的结构完整性。TPU层与增强层之间的粘附强度大于60 N/25mm。EPDM层与增强层之间的黏合强度也大于75 N/25 mm。示例性软管的直径是255-257 mm,具有在操作压力下4%的纵向延伸、低于1%的反弹、爆裂压力大于3.8 MPa、剥离强度大于70N/25 mm。

Claims (24)

1.一种多层软管,其包括:
覆盖层,其包括第一聚合物;
增强层,其包括织造长丝;以及
内部衬里,其包括第二聚合物,其中所述第一聚合物和所述第二聚合物是不相似的。
2.根据权利要求1所述的多层软管,其中所述第一聚合物是具有良好耐磨性特性的聚合物。
3.根据权利要求2所述的多层软管,其中所述第一聚合物选自由以下项组成的群组:热塑性聚氨酯(TPU),或聚氯乙烯(PVC)、TPU/PVC混合物,或PVC/丁腈橡胶(NBR)混合物、丙烯腈-丁二烯-苯乙烯共聚物、乙烯/乙酸乙烯酯共聚物、聚酰胺、聚酰亚胺、天然橡胶、修饰过的天然橡胶、合成橡胶。
4.根据权利要求2所述的多层软管,其中所述第一聚合物是TPU。
5.根据权利要求1所述的多层软管,其中所述覆盖层具有0.1-5.0 mm的厚度。
6.根据权利要求1所述的多层软管,其中所述第二聚合物是具有良好耐化学性特性的聚合物。
7.根据权利要求6所述的多层软管,其中所述第二聚合物是选自由以下项组成的群组:乙烯-丙烯-二烯单体(EPDM)橡胶、硅酮修饰的EPDM橡胶、氟橡胶、高密度聚乙烯。
8.根据权利要求7所述的多层软管,其中所述第二聚合物是EPDM橡胶。
9.根据权利要求1所述的多层软管,其中所述内部衬里具有0.1-5.0 mm的厚度。
10.根据权利要求1所述的多层软管,其进一步包括所述覆盖层与所述增强层之间的第一粘合剂层。
11. 根据权利要求10所述的多层软管,其中所述第一粘合剂层具有0.10-0.50 mm的厚度。
12.根据权利要求1所述的多层软管,其进一步包括所述内部衬里与所述增强层之间的第二粘合剂层。
13.根据权利要求12所述的多层软管,其中所述第二粘合剂层具有0.10-0.50 mm的厚度。
14.根据权利要求1所述的多层软管,其中所述增强层是由涤纶长丝,或尼龙长丝,或芳纶纤维,或涤纶、尼龙长丝、或芳纶纤维的混合物织造的。
15.根据权利要求1所述的多层软管,其中所述增强层具有0.5-7.5mm的厚度。
16.根据权利要求1所述的多层软管,其中所述增强层进一步包括至少一条导电线,所述导电线沿所述软管纵向布置。
17.一种制造多层软管的方法,其包括以下步骤:
(1)通过共挤压第一聚合物和热熔粘合剂形成管状覆盖层和第一粘合剂层,其中所述第一粘合剂层在所述管状覆盖层外部;
(2)通过共挤压第二聚合物和热熔粘合剂形成管状内部衬里和第二粘合剂层,其中所述第一聚合物与所述第二聚合物不相似,并且所述第二粘合剂层在所述管状覆盖层外部;
(3)织造管状增强层;
(4)将所述管状覆盖层和第一粘合剂层放置在所述管状增强层内部,其中所述第一粘合剂层面向所述增强层;
(5)将所述管状覆盖层和第一粘合剂层粘合到所述增强层;
(6)翻转所述粘合管状覆盖层和所述增强层,其中在翻转之后所述覆盖层在所述增强层的外部上;
(7)将所述管状内部衬里和第二粘合剂层放置在所述粘合管状覆盖层和所述增强层内部,其中所述第二粘合剂层面向所述增强层;以及
(8)将所述管状内部衬里和第二粘合剂层粘合到所述增强层。
18.根据权利要求17所述的制造多层软管的方法,其进一步包括以下步骤:用固化剂处理所述管状覆盖层和第一粘合剂层和所述管状内部衬里和第二粘合剂层。
19.根据权利要求17所述的制造多层软管的方法,其中所述第一聚合物选自由以下项组成的群组:热塑性聚氨酯(TPU),TPU/PVC,或PVC,或PVC/NBR、丙烯腈丁二烯苯乙烯、乙烯乙酸乙烯酯、聚酰胺、聚酰亚胺、天然橡胶、修饰过的天然橡胶、合成橡胶。
20.根据权利要求17所述的制造多层软管的方法,其中所述第二聚合物是选自由以下项组成的群组:乙烯-丙烯-二烯单体(EPDM)橡胶、硅酮修饰的EPDM橡胶、氟橡胶、高密度聚乙烯。
21.根据权利要求17所述的制造多层软管的方法,其中所述覆盖层和内部衬里在150到210℃的温度下挤压。
22.根据权利要求17所述的制造多层软管的方法,其中所述第一和第二粘合剂层在140到175℃的温度下挤压。
23.根据权利要求17所述的制造多层软管的方法,其中将所述覆盖层粘合到所述增强层是通过0.10-0.35 MPa的蒸汽4到10分钟。
24.根据权利要求17所述的制造多层软管的方法,其中将所述内部衬里粘合到所述增强层是通过0.10-0.35 MPa的蒸汽4到10分钟。
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