CN103370465B - 聚合物元件的制造方法 - Google Patents
聚合物元件的制造方法 Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered 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
- B32B5/02—Layered 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/12—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/2481—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including layer of mechanically interengaged strands, strand-portions or strand-like strips
Abstract
一种制造聚合物元件的方法包括:挤出一个或更多个聚合物丝状体;停止固化所述的一个或更多个丝状体;利用被挤出的一个或更多个丝状体形成垫;使所述的一个或更多个丝状体在它们接触的位置上相互连接;以及,固化所述的一个或更多个丝状体。
Description
相关申请的交叉参考
本申请请求享有美国专利申请No.13/029743的权益,该美国专利申请No.13/029743于2011年2月17日申请,该美国申请的全部内容组合在文中作为参考。
背景技术
注射成型法是制造聚合物元件的常用方法。尽管注射成型法对于制造具有特定性能的元件效果十分好,但是这种方法不能让元件的某些参数满足特定应用场合的需要。这类参数例如可包括过滤属性、密度、渗透性和形状记忆性能。一些制造聚合物元件的替换方法可以控制这类参数,这些方法总是引起本领域的技术人员的关注。
发明内容
文中公开了一种制造聚合物元件的方法。该方法包括:挤出一个或更多个聚合物丝状体;停止固化所述的一个或更多个丝状体;利用被挤出的一个或更多个丝状体来形成垫;使所述的一个或更多个丝状体在它们接触的位置处相互连接;以及,固化所述的一个或更多个丝状体。
文中还公开了一种聚合物元件,其包括被压紧的垫结构,该垫结构具有多个被挤出的聚合物材料丝状体,它们在相互之间的接触点处连接,在完全固化所述丝状体之前停止固化,然后完全固化所述丝状体。
附图说明
下面的描述绝不应该认为是限制性的。请参照下面的附图,附图 中的类似元件用类似标记表示,附图如下:
图1示出了聚合物元件的四分之一截面图,该聚合物元件用作文中公开的可膨胀筛;
图2示出了喷丝头的局部透视图,所示的喷丝头挤出多个聚合物材料丝状体;
图3示出了文中公开的聚合物元件的局部截面图;以及
图4示出了图3中的聚合物元件的一部分的放大视图。
具体实施方式
在此,下面将参照附图以示例方式而非限制方式详细描述一个或更多个公开的装置和方法。
参照图1,示出了文中公开的聚合物元件的一实施例,该聚合物元件整体用标记10表示。聚合物元件10具有压紧的垫结构14,该垫结构中具有由聚合材料22制成的多个丝状体18。所述聚合物元件在附图中为可膨胀筛,尽管也可考虑为其他元件。所述聚合材料22可包括形状记忆聚合物(例如为热塑性塑料)。
参照图2至4,该实施例中示出的多个丝状体18通过喷丝头30的孔26被同时挤出而进入结构34中。在丝状体18被形成为垫结构14的过程中,对丝状体18进行骤冷处理,以有效地停止固化丝状体18。例如,可通过冷却丝状体或将其置于特定环境(如,化学环境)下来进行骤冷或停止固化。不管使用何种停止方法,除了要停止固化和交联材料以外,还需要至少局部硬化丝状体18,从而可让丝状体18在放样(lofted)状态下保持垫结构14。丝状体18之间的结合点42或丝状体的一部分46形成在丝状体之间的接触位置上,可有效地将丝状体18连接在一起。在骤冷完成之前使接触的丝状体18之间的聚合物链并合,或进行类似操作,由于被骤冷处理的聚合物的粘着性以及被骤冷处理聚合物的接触表面之间的阻挡,可形成这种结合点42。正因如此,垫结构14具有结构稳定性,但是仍未被完全固化。请注意:通过调节与挤出操作和停止固化操作相关的参数,如被挤出的丝状体 18的温度、孔26的尺寸以及喷丝头30与结构34之间的距离,操作者例如能有效地选择垫结构14的合适放样程度。
在停止固化和硬化操作之后,可执行垫结构14的另外固化和交联操作,包括完全固化和完全交联材料。在硬化时或在已经另外改变垫结构14之后,在放样情况下执行这种另外固化操作。压紧操作是执行的另外过程的例子之一。在压紧过程之前或期间,升高丝状体18的温度会引起形成另外的结合点42。这个过程可让操作者另外控制垫结构14及其相关参数。例如可改变过滤特性、密度、渗透性和形状记忆性能等参数,以适合使用聚合物元件10的应用场合。例如,如果聚合物元件10用作筛来从可在其中流动的流体中滤除颗粒,那么,可根据需要选择过滤效率以及压降特性。垫结构14的其他应用例如包括,改变流动方向、平衡、缓冲以及隔离。
所述垫结构14一旦处于上述被固化的状态下,则可在应用场合中直接使用该垫结构,或首先执行另外的处理过程。在垫结构14是可膨胀筛的应用场合下,另外的处理过程可将垫结构14重新配置为处于稳定容积状态下,此时容积比上述被固化状态下的容积更小,直到垫结构暴露在某环境下使其返回到上述被固化的状态和容积下。这种过程可以包括加热、压紧,然后冷却垫结构14,从而使垫结构在这种更小的容积结构下凝固。这样可保持这种更小的容积结构,直到这种结构暴露在可让其膨胀回到上述被固化的容积状态下的激励温度为止。
图1中所示的垫结构14可用作可膨胀筛,用于井下井眼50的应用场合,例如用于二氧化碳封存和烃类开采领域。所述可膨胀筛被形成为圆筒形形状并被装配到穿孔管54上。如图所示的可膨胀筛处于更小容积的结构,这样可膨胀筛就能下入到井眼50中,而不会与井眼50的壁58进行不利的接触。一旦可膨胀筛被布署在井眼50中的合适位置上,地层井眼中通常会遇到的高温或操作者提供的高温会加热可膨胀筛。在该实施例中,升高的温度会引起可膨胀筛朝上述被固化的结构的容积状态膨胀,然后接触井眼50的壁58。这种接触是有利的,可对地层62提供结构支撑,并将对地层62的侵蚀减小到最小;如果 可膨胀筛和井眼50的壁58之间允许存在环形间隙,那么就会引起对地层62的侵蚀。
根据情况,在垫结构14中可形成空隙66,以形成流动通道、结合承力点或其他有利特征。为了形成空隙66,在丝状体被挤出而进入所述结构34之前,具有空隙66的形状的可消除件70位于结构34内。在垫结构14已经被固化之后,从垫结构14上去除掉可消除件70。一个实施例采用熔芯技术来去除可消除件70。在这种技术中,可消除件70采用可熔化材料(如蜡),需要时,可消除件70熔化并从空隙66中排出。这种情况下,可消除件70的熔化温度高于聚合材料22的固化温度和压紧过程中的后续固化加热温度,但小于聚合材料22的熔化温度。
尽管已经参照典型实施例描述了本发明,但是,本领域的普通技术人员应该能理解,在不超出本发明的范围的情况下,可进行各种改进,本发明的各种元件可由等同元件替换。另外,在不超出本发明的实质范围的情况下,根据本发明提供的相关技术知识,可进行许多改进以适于特定场合或材料。因而,本发明并不局限于作为实施本发明的最佳方式公开的特定实施例,本发明包括落入权利要求书范围内的所有实施例。另外,在附图和说明书中,已经公开了本发明的典型实施例,尽管使用了特定术语,但是,它们仅具有一般的描述性意义,并没有限制性目的,除非另有声明,因而,本发明的范围不受限制。并且,使用的术语“第一”、“第二”等并没有表示任何次序或重要性,使用这些术语仅用于将一个元件与另一个元件区分开。另外,使用的不定冠词并没有限制数量,而是表示具有至少一个其所修饰的元素。
Claims (15)
1.一种制造聚合物元件的方法,包括:
在至少一个可熔化构件周围挤出一个或更多个聚合物丝状体;
停止固化所述一个或更多个丝状体;
由在至少一个可熔化构件周围被挤出的一个或更多个丝状体形成垫;
使所述的一个或更多个丝状体在它们接触的位置上相互结合;以及
固化所述的一个或更多个丝状体;
熔化所述的至少一个可熔化构件;以及
将熔化的至少一个可熔化构件排出以在垫上形成至少一个空隙。
2.根据权利要求1的制造聚合物元件的方法,其中,固化步骤包括加热所述的一个或更多个丝状体。
3.根据权利要求1的制造聚合物元件的方法,其中,通过喷丝头进行所述挤出。
4.根据权利要求1的制造聚合物元件的方法,其中,通过冷却所述的一个或更多个丝状体来停止固化。
5.根据权利要求1的制造聚合物元件的方法,其中,挤出的聚合物丝状体被送入一结构中。
6.根据权利要求1的制造聚合物元件的方法,其中,固化步骤包括交联。
7.根据权利要求1的制造聚合物元件的方法,其中,所述的至少一个可熔化构件由蜡制成。
8.根据权利要求1的制造聚合物元件的方法,其中,所述空隙形成流动通道。
9.根据权利要求1的制造聚合物元件的方法,其中,所述空隙为结合承力点。
10.根据权利要求1的制造聚合物元件的方法,还包括:使已被连接的丝状体相交联。
11.根据权利要求1的制造聚合物元件的方法,其中,被压紧和冷却的垫是可膨胀筛。
12.根据权利要求1的制造聚合物元件的方法,还包括:控制聚合物元件的参数。
13.根据权利要求12的制造聚合物元件的方法,其中,该参数选自于过滤属性、密度、渗透性和形状记忆特性。
14.根据权利要求1的制造聚合物元件的方法,还包括:
加热所述垫;
进一步压紧所述垫至减小的容积;
冷却所述垫;以及
硬化所述垫。
15.根据权利要求14的制造聚合物元件的方法,其中,被压紧和冷却的垫是可膨胀筛。
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US13/029,743 US9017501B2 (en) | 2011-02-17 | 2011-02-17 | Polymeric component and method of making |
US13/029,743 | 2011-02-17 | ||
PCT/US2012/021273 WO2012112246A2 (en) | 2011-02-17 | 2012-01-13 | Polymeric component and method of making |
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CN103370465B true CN103370465B (zh) | 2016-08-31 |
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Also Published As
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WO2012112246A3 (en) | 2012-11-22 |
US9017501B2 (en) | 2015-04-28 |
CN103370465A (zh) | 2013-10-23 |
MY165685A (en) | 2018-04-18 |
WO2012112246A2 (en) | 2012-08-23 |
US20120213979A1 (en) | 2012-08-23 |
SG192827A1 (en) | 2013-09-30 |
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