Method for Production of a Tubular Body

Abstract

A method for production of a tubular body applying the following steps: Pressureless application of at least one first curable plastic layer made of reactive polyurethane materials with a core via a rotational molding process, Curing the at least one plastic layer, Winding at least one reinforcement layer onto the at least one first plastic layer, Pressureless application of at least one second curable plastic layer, wherein the reinforcement layer is embedded without holes between the two plastic layers, and Removal of the core after completion of the body.

Because of this, the position of the reinforcement layer 7 can be individually established and it can be ensured that the reinforcement layer will not penetrate into the first plastic layer during winding after the curing of the first plastic layer.

Claims

1. Method for production of a tubular body (4), in particular a tube for transporting abrasive materials, made up of least one body wall, comprising the following process steps: pressureless application of at least one first curable plastic layer (5, 26, 42) made of reactive polyurethane materials with a core via a rotational molding process, curing the at least one plastic layer (5, 26, 42), winding at least one reinforcement layer (7, 28, 44) onto the at least one first plastic layer (5, 26, 42), pressureless application of at least one second curable plastic layer (6, 27, 43), wherein the reinforcement layer is embedded without holes between the two plastic layers (6, 27, 43), and removal of the core after completion of the body (4, 40).

2. Method according to claim 1, characterized in that at least 90% of the at least one first plastic layer (5, 26, 42) is cured before the reinforcement layer (7, 28, 44) is wound on, or that at least 95% of the first plastic layer (5, 26, 42) is cured before the reinforcement layer (7, 25, 44) is wound on, or that at least 98% of the first plastic layer (5, 26, 42) is cured before the reinforcement layer (7, 25, 44) is wound on.

3. Method according to claim 1, characterized in that at least one further plastic layer is applied to the first plastic layer (5, 26, 42) and/or the second plastic layer (6, 27, 43).

4. Method according to claim 1, characterized in that the reinforcement layer (7, 28, 44) is embedded between the first plastic layer (5, 26, 42) and the second plastic layer (6, 27, 43) or that the reinforcement layer (7, 28, 44) is embedded between the second plastic layer (6, 27, 43) and a third plastic layer.

5. Method according to claim 1, characterized in that at least one further reinforcement layer (7, 28, 44) is wound onto the reinforcement layer (7, 28, 44) or that a further plastic layer (7, 28, 44) is first wound onto the reinforcement layer (7, 28, 44) and then at least one further reinforcement layer (7, 28, 44).

6. Method according to claim 1, characterized in that the at least one second plastic layer (6, 27, 43) is additionally coated with a protective layer as a wearing layer.

7. Method according to claim 1, characterized in that a ring-shaped stiffening element (61) or a spiral-shaped stiffening element (71) with spaced-apart sections is applied in a rotational molding process to the last plastic layer (6, 27, 43), especially the wearing layer, or that a ring-shaped stiffening element (61) or a spiral-shaped stiffening element (71) with spaced-apart sections is wound onto the last plastic layer (6, 27, 43), especially the wearing layer.

8. Method according to claim 1, characterized in that the stiffening elements (61, 71) made of hard polyurethane are poured on, or that the stiffening elements (61, 72) made of fiber composite materials, glass fibers or metal wire are wound on.

9. Method according to claim 1, characterized in that the fiber composite materials are comprised of fiber bundles, of continuous fibers or of bands in the form of a fabric, wherein the matrix for the fiber composite materials are made of impact-resistant, curable plastic mixtures such as polyurethane or epoxy resins.

10. Method according to claim 1, characterized in that the fiber composite materials with the matrix that is used are wet down before winding and hardened on the last plastic layer (6, 27, 43).

11. Method according to claim 1, characterized in that the first plastic layer (5, 26, 42) and/or the second plastic layer (6, 26, 43) is comprised of a 2 k or multi-component polyurethane system.

12. Method according to claim 1, characterized in that the reinforcement layer (7, 28, 44) is comprised of individual fibers, corduroy or a fiber fabric that is wound on at an angle of 50° to 60°, preferably 55°, and/or that the individual fibers, the corduroy or the fiber fabric is wound on crosswise at least once.

13. Method according to claim 1, characterized in that the pot life of the plastic layers (5, 6, 26, 27, 42, 43) is approximately 45 seconds or 5 to 15 seconds or 7 to 8 seconds.

14. Method according to claim 1, characterized in that the tubular body (4) is provided with a fitting (2, 3, 11, 12, 20, 41) on at least one end, wherein the fittings (2, 3, 11, 12, 20, 41) are comprised of a flange disk (21, 46) with fastening holes (8, 51) and a flange neck (22, 47) or are comprised of a flange disk (21, 46) with fastening holes (8, 51) and a clamping ring made of steel or a plastic, preferably polyurethane material.

15. Method according to claim 1, characterized in that a flange neck (22, 47) is provided with at least one rib or a round ring (23, 48) that is firmly connected, for instance welded, to the flange neck (22, 47), and at least one axially movable round ring (24, 49, 50) is mounted on the flange neck (22, 47).

16. Method according to claim 1, characterized in that the reinforcement layer (7, 28, 44) is passed over the ribs or a first fixed round ring (23, 48) and put around a second, movably mounted round ring (24, 49) on the flange neck (22, 47), wherein the two round rings (23, 24, 48, 49) come to lie next to one another, or that the reinforcement layer (7, 28, 44) is passed over the ribs or a first fixed round ring (23, 48) and subsequently put around a profiled ring (29), and the reinforcement layer (7, 28, 44) and the profiled ring (29) are pressed via a steel band (31) onto the flange neck (22, 47), wherein the profiled ring (29) comes to lie next to the round ring (23, 48), and/or that the reinforcement layer (7, 28, 44) is passed over the ribs or a first fixed round ring (48) and comes to lie beneath a second, movably mounted round ring (49), is passed around a third round ring (50) and is brought back under the second round ring (49) and over the first round ring (48) into the plane of the reinforcement layers (44).

17. Method according to claim 1, characterized in that when there are several reinforcement layers (7, 28, 44), each individual reinforcement layer (7, 28, 44) is passed over a rib or a round ring (23, 48) and fastened in each case, or that the first plastic layer (5, 26, 42) and second plastic layer (6, 27, 43) and the reinforcement layer (7, 28, 44) are clamped between the flange disk (21) and a clamping ring, or that fittings (2, 3, 11, 12, 20, 41) with their flange neck (22, 47) are pushed onto the first plastic layer (5, 26, 42) and connected via cold bonding.

18. Tubular body (4), in particular a tube for transporting abrasive materials, comprised of at least one body wall according claim 1, characterized in that a reinforcement layer (7, 28, 44) is embedded between a first curable plastic layer (5, 26, 42) and a second curable plastic layer (6, 27, 43) made of polyurethane materials that were produced via a pressureless rotational molding process with the aid of a feeder head, wherein the reinforcement layer (7, 28, 44) is made of individual fibers, corduroy or a fiber fabric and is wound on at an angle of 50° to 60°, preferably 55°.

19. Tubular body (4) according to claim 18, characterized in that the individual fibers or the fiber fabric is wound on crosswise at least once.

20. Tubular body (4) according to claim 18, characterized in that at least one further plastic layer is applied to the first plastic layer (5, 26, 42) and/or the second plastic layer (6, 27, 43).

21. Tubular body (4) according to claim 18, characterized in that the plastic layers (5, 6, 26, 27, 42, 43) are comprised of a reactive polyurethane material that is applied as a first layer for stabilization on a removable core or on underlying layers made up of reinforcement layers (7, 28, 44) or plastic layers for hardening.

22. Tubular body (4) according to claim 18, characterized in that a fitting (2, 3, 11, 12, 20, 41) is connected on at least one end to the body (4), wherein the fittings (2, 3, 11, 12, 20, 41) are comprised of a flange disk (21, 46) with fastening holes (8, 51) and a flange neck (22, 47) or are comprised of a flange disk (21, 46) with fastening holes (8, 51) and a clamping ring made of steel or a plastic, preferably polyurethane material.

23. Tubular body (4) according to claim 18, characterized in that the fittings (2, 3, 11, 12, 20, 41) with their flange neck (22, 47) are pushed onto the first inner plastic layer (5, 26, 42) and cold bonded, or that the first plastic layer (5, 26, 42) and second plastic layer (6, 27, 43) and the reinforcement layer (7, 28, 44) are clamped between a flange disk (21) and a clamping ring.

24. Tubular body (4, 40) according to claim 18, characterized in that the fittings (2, 3, 11, 12, 20, 41) are provided with at least one rib or a round ring (23, 48), and the at least one reinforcement layer (7, 28, 44) is passed over the ribs or a first fixed round ring (23, 48) and put around a second, movably mounted round ring (24, 49) on the flange neck (22, 47), wherein the two round rings (23, 24, 48, 49) come to lie next to one another, or that the reinforcement layer (7, 28, 44) is passed over the ribs or a first fixed round ring (23, 48) and subsequently put around a profiled ring (29), and the reinforcement layer (7, 28, 44) and the profiled ring (29) are pressed via a steel band (31) onto the flange neck (22), wherein the profiled ring (29) lies next to the round ring (23), or that the reinforcement layer (7, 28, 44) is passed over the rib or a first fixed round ring (23, 48) and lies beneath a second round ring (49), is passed around a third round ring (50) and is brought back under the second round ring (49) and over the first round ring (48) into the plane of the reinforcement layer.

25. Tubular body (4, 40) according to claim 18, characterized in that the loose round rings (24, 49, 50) are comprised of two half-rings or an open round ring that is clamped via clamping sleeves (52) with a right-hand/left-hand thread (53, 54) on the end.

26. Tubular body (4.40) according to claim 18, characterized in that a ring-shaped stiffening element (61) or a spiral-shaped stiffening element (71) with spaced-apart sections is applied in a rotational molding process to the last plastic layer (6, 27, 43), especially a wearing layer, or that a ring-shaped stiffening element (61) or a spiral-shaped stiffening element (71) is wound onto the last plastic layer (6, 27, 43).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0056] The drawings show the following:

[0057] FIG. 1 shows a pressure tube manufactured according to the method as per the invention in a partially sectioned side view,

[0058] FIG. 2 shows a suction tube manufactured according to the method as per the invention in a partially sectioned side view,

[0059] FIG. 3 shows the pressure tube in accordance with FIG. 1 in a top view,

[0060] FIG. 4 shows the pressure tube in accordance with FIG. 1 in a sectional drawing,

[0061] FIG. 5A shows a connection of the tubular body to a flange in a schematic view,

[0062] FIG. 5B shows a connection of the tubular body to a flange in a top view,

[0063] FIG. 6 shows a further possibility for connecting the tube as per the invention to a flange in a schematic view,

[0064] FIG. 7A shows a further design variant for attachment with a flange in a sectional side view,

[0065] FIG. 7B shows a further design variant for attachment with a flange in a top view,

[0066] FIG. 7C shows a further design variant for attachment with a flange in a sectional top view,

[0067] FIG. 8 shows a further design variant in accordance with FIG. 7 in a top view,

[0068] FIG. 9 shows a pressure tube with ring-shaped stiffening elements in a partially sectioned partial view and

[0069] FIG. 10 shows a pressure tube with spiral-shaped stiffening elements in a partially sectioned partial view.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0070] FIG. 1 shows, in a partially sectioned partial view, a tube section 1 comprised of a body 4 and fittings on the ends 2, 3. This type of tubular bodies 1 with an external surface is preferably used as a pressure tube and can have nominal diameters of 50 mm to >1200 mm; a fixed connection is made with the fittings 2, 3 so that several of these tubular bodies 4 can be connected with one another to form a longer tube. Even individual pieces of the tubular body 4 can have a length of several meters here.

[0071] FIG. 2 shows, in a partially sectioned view, a tube section 9 comprised of a body 10 that is used as a suction tube. The upper half of the body 10 is shown in a sectional view; the tubular body 10 is also equipped in this case with end fittings 11, 12 that are firmly connected to the body 10. This embodiment is jacketed by steel rings or external, rotationally molded polyurethane spirals with a high level of hardness to obtain greater strength and wall stability.

[0072] Both of the examples show possible tubular bodies 1, 10 that can be manufactured according to the method as per the invention.

[0073] FIG. 3 shows, in a top view, the tubular body 4 known from FIG. 1 with a fitting 2. The layered structure of the tubular body 4, which is comprised of an inner plastic layer 5 and an outer plastic layer 6, as well as a central layer in the form of a reinforcement layer 7, can be seen in this view. Several fastening holes 8 are provided for screw connections.

[0074] FIG. 4 shows, in a sectional view, the tubular body 4 with the inner plastic layer 5, the outer plastic layer 6 and the reinforcement layer 7. An embodiment is involved in the example that is shown that can be modified in accordance with the requirements that are placed on it; for instance, the inner plastic layer 5 can be comprised of several individual layers and the outer plastic layer 6 can likewise be comprised of several individual layers. Furthermore, the reinforcement layer 7 can be arranged in a multi-part structure with radial spacings, preferably between the individual or multiple plastic layers 5, 6.

[0075] FIG. 5A shows, in a sectional view, the attachment of a suction or pressure hose to a fitting 20. The fitting 20 is comprised of a flange disk 21 and a flange neck 22, which are either manufactured in one piece or firmly connected to each other. A round ring 23 is fastened to, preferably welded onto, the flange neck; a second round ring 24 is, on the other hand, loosely arranged in a movable fashion on the flange neck 22 between the flange disk 21 and the round ring 23. A tube section 25 comprised of an inner plastic layer 26, an outer plastic layer 27 and a reinforcement layer 28 is connected via the reinforcement layer 28 to the fitting 20. The connection is effected in such a way that the reinforcement layer 28 is passed over the fixed round ring 23 and wrapped around the loose round ring 24. The round ring 24 comes to lie next to the round ring 23 here because of the winding process and is subsequently completely embedded via the application of the outer plastic layer 27. The embedding with the outer plastic layer can, if necessary, be carried on to the flange disk in connection with this. The inner plastic layer 26 extends, on the other hand, to the flange disk 21; it is preferably pushed onto the completed first plastic layer 26 and connected via cold bonding. After that, the reinforcement layer 28 is put in place and the second plastic layer 27 is subsequently applied.

[0076] As is especially evident from FIG. 5B, the round ring 24 involves an open ring that is connected and that can be clamped with the aid of a clamping sleeve 32. To this end, the clamping sleeve 32 has a threaded hole 33, 34, designed as a left-hand/right-hand thread, in each of its faces. The retaining ring 24 with its threaded ends 35, 36 can consequently be screwed into the sleeve and clamped via a rotary movement. The reinforcement layer 28 can therefore be fastened as follows. The reinforcement layer 28 is first passed over the first fixed round ring 23 in the direction of the flange disk 21; after that, the retaining ring 24 is put on and the clamping process takes place so that the reinforcement layer 28 can be subsequently folded back over the loose round ring 24, and it can come to rest on the reinforcement layer 28 that has already been wound. Moreover, the possibility exists after that to pour a further plastic layer 27 over both the first plastic layer 26 and the reinforcement layer 28.

[0077] FIG. 6 shows, in a sectional view, another connection between a fitting 20, with a flange disk 21 and a flange neck 22, and a tube section 25. As in the previous example, the fitting 20 is pushed onto the partially prepared tube and, in fact, onto the first plastic layer 26, and the reinforcement layer 28 is passed once again over the round ring 23 and, after that, wound over a profiled ring 29 placed around the flange neck 22 and led back to the tube section 25. The profiled ring 29 has a slight recess that can have a trapezoidal design or, if appropriate, a U-shaped design. The wound reinforcement layer 28 comes to rest at first in the recess 30 and is additionally held in place by a steel band 31. The steel band 31 is passed around the wound reinforcement layer 28 and clamped in connection with this, so the reinforcement layer 28 and the profiled ring 29 are clamped onto the flange neck 22. The profiled ring 29 is brought up to the round ring 23 here, so the reinforcement layer 28 is likewise located between the round ring 23 and the profiled ring 29. A secure attachment of the reinforcement layer 28 on the fitting 20 is made possible here with the aid of the profiled ring 29 and the steel band 31, so a reliable hold is ensured even in the case of axially acting forces on the tube section 25. The second, outer plastic layer 27 is applied over the reinforcement layer 28, the steel band 31 and the profiled ring 29. The steel band 31 can likewise be comprised of two halves so that clamping can take place with the aid of at least one or, as the case may be, two clamping sleeves or a turnbuckle.

[0078] FIGS. 7A, 7B and 7C show a further example of the connection of a fitting 41 to a tube section 40 in three views and, in fact, in a sectional side view, a top view and a sectional top view. The upper longitudinal section shows the tube section 40 with the fitting 41. The tube section 40 is comprised of a first plastic layer 42, a second outer plastic layer 43 and a reinforcement layer 44. The fitting 41 is comprised of a flange disk 46 and a flange neck 47; the flange neck 47 is pushed onto the first plastic layer, which has already been completed, and is cold bonded if appropriate. A round ring 48 is fastened, for instance welded, at the end to the flange neck 47. A second round ring 49 and a third round ring 50 are located between the flange disk 46 and the round ring 48. The round rings 49, 50 are arranged so as to be axially movable. The reinforcement layer 44 wound onto the first plastic layer 42 is passed over the first round ring, passed through under the second round ring 49, wound around the third round ring 50 and passed once again under the second round ring 49 and over the fixed round ring 48, and led back into the plane of the reinforcement layer 44. Because of this structure, the forces that arise when there are tensile stresses on the tube section 40 are directly introduced into the fitting 41 via the reinforcement layer 44.

[0079] The two loose round rings 49, 50 can be comprised of one open or two divided round rings. They are fixed in place and clamped on the flange neck 47 with a clamping sleeve, as can be seen in FIG. 8. A top view onto the fitting 41 is shown in the center view and, in fact, with the flange disk 46 and the flange neck 47. The flange disk 46 is equipped with several holes 51 distributed over the circumference, so a screw connection with further fittings is enabled. The structure of the tube section 40 is only suggested by the dashed circular rings in this case.

[0080] The tube section 40, which is comprised of an inner plastic layer 42, a reinforcement layer 44 and an outer plastic layer 43, can be seen in the lower partial figure.

[0081] FIG. 8 shows, in a top view, the tube section 40 known from FIG. 7 with the fitting 41; the fixed round ring 48 and the two loose round rings 49, 50 can be seen in this view. The loose round rings 49, 50 are closed up and clamped via a clamping sleeve 52 in each case. Depending on whether a round ring 49, 50 is used or, as the case may be, two half round rings 49, 50, either one clamping sleeve 52 per round ring or, if applicable, two clamping sleeves 52 are to be used. The clamping sleeves 52 have a right-hand/left-hand thread 53, 54 so that the round rings 49, 50 can be loosened or clamping can take place by rotating the clamping sleeve.

[0082] The possibility exists here because of the use of divided round rings 49, 50 to subsequently place them around the flange neck 47.

[0083] To fasten the fitting 41 to the tube section 40, the fitting 41 with its flange neck 47 is first pushed onto the first plastic layer here, or cold bonded if appropriate, and the reinforcement layer 44 is subsequently wound on; the reinforcement layer is passed over the first fixed round ring 48 in the direction of the flange disk 46. After that, the third round ring 50 can be placed on this and, after the reinforcement layer 44 has been brought back, the round ring 49 so that the reinforcement layer 43 is finally brought back over the fixed round ring 48 into the plane of the tube section 40. The round rings 50 are clamped in connection with this before the reinforcement layer 44 is brought back, whereas the second round ring 49 is clamped after the pullback; subsequent assembly does not pose any problems due to the open round rings or half-rings.

[0084] FIG. 9 shows, in a partially sectioned partial view, a pressure tube 60. The pressure tube 60 corresponds in terms of its structure to the tube sections previously described; it is additionally jacketed by ring-shaped stiffening elements 61 on the outer circumferences. The stiffening elements 61 are comprised, for example, of hard PU or a composite material and are either sheathed with a wearing layer or a cover layer 62. The possibility exists here for the stiffening elements 61 to be applied in a rotational molding process to the cover layer 62 or, if the stiffening elements 61 are comprised of a fiber composite or a wire layer as examples, wound onto the cover layer 62. A strengthening layer or cover layer 63 is applied over the stiffening elements 61, so the pressure tube 60 is completely covered by the cover layer 63. The spacing of the individual stiffening elements 61, which are preferably arranged at equidistant intervals, can be determined in accordance with the requirements for the pressure tube 60 here. The thickness of the stiffening elements 61 can likewise be determined.

[0085] FIG. 10 shows, in a partially sectioned partial view, a pressure tube 70 that is jacketed with spiral-shaped stiffening elements 71. The stiffening elements 71 can likewise be comprised of a hard PU or composite material and are applied in a rotational molding process or wound on. A protective layer 72 that covers the entire pressure tube 70 is in turn applied to the stiffening elements 71. The spacing of the spiral-shaped stiffening elements 71 and their thickness can be adapted to the requirements for compression strength.

LIST OF REFERENCE NUMERALS

[0086] 1 Tube section [0087] 2 Fitting [0088] 3 Fitting [0089] 4 Body [0090] 5 Plastic layer [0091] 6 Plastic layer [0092] 7 Reinforcement layer [0093] 8 Fastening holes [0094] 9 Tube section [0095] 10 Body [0096] 11 Fitting [0097] 12 Fitting [0098] 13 Steel ring [0099] 20 Fitting [0100] 21 Flange disk [0101] 22 Flange neck [0102] 23 Round ring [0103] 24 Round ring [0104] 25 Tube section [0105] 26 Plastic layer [0106] 27 Plastic layer [0107] 28 Reinforcement layer [0108] 29 Profiled ring [0109] 30 Recess [0110] 31 Steel band [0111] 40 Tube section [0112] 41 Fitting [0113] 42 Plastic layer [0114] 43 Plastic layer [0115] 44 Reinforcement layer [0116] 46 Flange disk [0117] 47 Flange neck [0118] 48 Round ring [0119] 49 Round ring [0120] 50 Round ring [0121] 51 Holes [0122] 52 Clamping sleeve [0123] 53 Right-hand thread [0124] 54 Left-hand thread [0125] 60 Pressure tube [0126] 61 Ring-shaped stiffening element [0127] 62 Cover layer [0128] 63 Cover layer [0129] 63 Strengthening layer [0130] 70 Pressure tube [0131] 71 Spiral-shaped stiffening element [0132] 72 Protective layer