Mounting method rubber plates elastic coating on a curved metal surface

 

(57) Abstract:

The invention relates to a method of mounting an elastic coatings on metal products and can be used in shipbuilding, construction and other industries. The method is designed for mounting rubber plates with a thickness of 40 to 80 mm to curved metal surfaces. The objective of the present invention to provide a resilient coating with uniform characteristics over the entire area of coverage, as well as reducing the complexity of installation and reducing the consumption of expensive materials. The problem is solved due to the fact that when mounting the elastic coating on a curved metal surface to produce cutting plates on the metal surface, apply glue, stack extruded rubber plate thickness of 40 to 80 mm, and press them until curing of the adhesive. Mounted plates stacked alternately butt to another and, Tanavoli them to the metal surface, the ends of the second and all subsequent plates make every effort supporting the docking plates with a clearance of not more than 0.5 mm, the Ends of adjacent plates after cutting pairs mechanically treated to their tight coupling. In private clusname filled with urethane. The ends of the mounted plates as efforts make reusable shock. The clamp plates are carried out with devices for which the metal surface pre-set technological mounts for cables are, and the plates do cut-outs for them, which is sealed after removal of fixtures composition on the basis of filled urethane. 3 C. p. F.-ly, 6 ill.

The invention relates to a method of mounting an elastic coatings on metal products and can be used in shipbuilding, engineering, construction and other industries. The method is designed for mounting rubber plates with a thickness of 40 to 80 mm to curved metal surfaces.

The problem of attaching a rubber plates is that they are fully formed products with characteristics that should be preserved during subsequent processing, the process of installation and operation. In case of considerable thickness and complexity of the internal structure of the plates occurs the problem of obtaining uniform characteristics over the entire area of coverage.

The known method of fastening the elastic coating on which the elastic covering is fixed to the ATEM product impose elastic coating, carry out its deformation from the center to the edges and are joining the opposing edges by welding, after that using fixed clamps provisions provide additional fixation of the coating at the edges of the product (patent of the USSR 1807942, 1993 ). However, the method used to secure continuous coverage and does not apply to the installation of the coating, consisting of plates, as it requires a large amount of welding joints. High temperature during welding affect the physico-mechanical and structural characteristics of the coating, which leads to their deterioration.

Closest to the claimed method is the patent of the Russian Federation 2144553, 2000 , allowing the fastening elastic coating mainly consists of rubber plates with a thickness of 40 to 80 mm to the metal surface. How is that connected to the surface of the applied adhesive material on the metal surface impose plate elastic coating application efforts clamp, after curing of the adhesive smooth out the ends of the plates and fill the gaps between the plates sealing composition based urethane. However, the mechanical Stripping of the ends of the glued plates (removal isback the ditch, and this affects the quality of the pavement and leads to heterogeneity of its characteristics due to the large number of inclusions of foreign material.

The objective of the present invention to provide a resilient coating with more uniform characteristics over the entire area of coverage, as well as reducing the complexity of installation and reducing the consumption of expensive sealing materials.

The problem is solved due to the fact that when mounting the elastic coating on a curved metal surface to produce cutting plates on the metal surface, apply glue, stack extruded rubber plate thickness of 40 to 80 mm, and press them until curing of the adhesive. Mounted plates stacked alternately butt to another and, Tanavoli them to the metal surface, the ends of the second and all subsequent plates make every effort supporting the docking plates with a clearance of not more than 0.5 mm, the Ends of adjacent plates after cutting pairs mechanically treated for their dense dock.

The technical result in the implementation of the proposed method is expressed in the homogeneous characteristics of the coating due to the dense set plastikote and reducing the consumption of expensive materials is achieved by eliminating operations in sealing gaps.

The proposed process sequence allows to solve the problem. Preliminary mechanical treatment allows to compensate the deviation of the ends of the plates normal to the metal surface when mounting the cover on its curved section. The combination of samevolume (clamp) mounted plates and attachment to their backs efforts can reduce the gap between the plates to a minimum. The execution of these operations provides a tight coupling plates with a clearance of not more than 0.5 mm, which allows you to refuse sealing joints, thus precluding the use of materials having characteristics different from the characteristics of the coating.

In special cases the use of the proposed method the cutting position of the plates after cutting seal composition on the basis of filled urethane. The ends of the mounted plates as efforts make reusable shock. The clamp plates are carried out with devices for which the metal surface pre-set technological mounts for cables are, and the plates do cut-outs for them. which seal after removal devices composers Fig. 1 - General view of the cover;

Fig. 2 - cut the covering along a-a;

Fig. 3 - determination of the angle processing of the ends of the plates;

Fig. 4 - installation of the first row cover;

Fig. 5 - section a-a at the interface wafer;

Fig. 6 - installation of the second and subsequent rows of the coating.

The proposed method can be implemented as follows.

In Fig. 1 shows a floor, and in Fig. 2 is a cross - section of the cover along a-a, where 1 - rubber plate; 2 - metal surface; 3 - technological mounts for cables are; 4 - adhesive layer; 5 - technological cutouts mounts for cables are; 6 - the joint of adjacent plates. The plate 1 cover assigned designations 1-1 . . . 1-16 in the order of their installation.

To obtain an elastic cover size 4000325040 mm used a ready rubber plate 1-1 . . . 1-3, 1-5 . . . 1-7, 1-9 . . . 1-11, 1-13 . . . 1-15 size 1000100040 mm and cut plates 1-4, 1-8, 1-12, 1-16 size 100025040 mm (Fig. 1, 2), which was mounted on a cylindrical metal surface 2 with a radius of 3000 mm

Metal surface 2 is pre-prepared in a known manner with the aim of obtaining her relief necessary depth to hold the required quantity of glue. The preparation was carried out by shot blasting method using as the m and welded technological mounts for cables are 3-20 mm diameter for mounting of the retainer snap.

The preparation of the rubber plates 1 was carried out as follows.

To obtain, for example, plates 1 size 100025040 mm was produced by cutting the finished plates size 1000100040 mm on the machine using a band saw. After that, the wafer 1 is performed technological notch 5 under mounts for cables are 3 template with drill pipe with a diameter of 30 mm at the corners of the plates under the corner and mounts for cables are in the middle of the two opposite sides under medium mounts for cables are.

Then have sealed the internal structure of the seat section of the plates, which were used filled with urethane sealant of the following composition containing, by weight. including :

Urethane prepolymer based on polybutadiene and diisocyanate - 100

Amine hardener - 30

Crumb rubber with a particle size of from 0.1 to 0.5 mm - 35

The composition was applied with a spatula, and it is not leaking from the sealing structure of the plate in the horizontal position of the plates. Curing was carried out at a temperature of from 15 to 30oC and relative humidity not more than 70% within the Next 48 hours spent processing of the ends of the plate 1 at an angle, ensuring Squareness of the ends to the metal surface 2. This is because when applying coatings on crooked is in this case the treatment was subjected to only the ends, located along a rectilinear generatrix of the cylindrical surface.

Determination of the angle processing of the ends was carried out, pre-pairwise positioning plate on a metal surface 2, as shown in Fig. 3, where 1 is the rubber plate; 2 - metal surface; 7 - area of the ends of the plate to be processed; 8 - connecting plate after treatment ends.

Processing of the ends produced angle grinders with circles, "Durick", the accuracy of fitting of the ends from 0 to 0.5 mm Dimension "b" for insert size 1000100040 mm and the radius of curvature of the surface to 3000 mm 1.5 mm

Then the mounting surface of the wafer 1 was subjected to Cherkovna on Serkalem machine, was degreased with gasoline, kept for 15 minutes and after that, the surface was subjected to chemical modification. Chemical modification of the mounting surface of the plates was carried out at an ambient temperature of 15 to 25oC and relative humidity not more than 65%.

When chemical modification used the following modifier composition, wt. including :

Dichloramine - 15

Acetone - 75

Distilled water - 10

The flow modifier composition sostavlyaiete 2 was applied adhesive layer 4 with a thickness of 2.0 mm alternately for each plate 1.

As the adhesive composition used composition comprising, by weight. including :

Epoxygenase resin - 20

The ethyl cellosolve - 50

Talc - 38

Hexamethylenediamine were - 4

Ethyl alcohol - 8

Functional additives - 13

When mounting the cover plates were used clamping devices made according to the patent of the Russian Federation 2107000. The design of the devices consists of a rod attached to the ends of the bearing member. Himself bearing element made in the form of straight beams, having at least two symmetrical cantilever beams. The load screw clamps - boots installed on cantilever beams with the possibility of changing the angle of inclination in the direction of the axes of the beams, while supporting Shoe surface symmetrical about the longitudinal axis of the cantilever beams, and on the facing surface of the bearing beams and the supporting surface of each Shoe perpendicularly secured by two rows of bosses of the same height. Clamping devices are mounted on a metal surface 2 by screwing rods in the established technological mounts for cables are 3. Each fixture is provided with a clamp on the square, equal 1000500 mm

For clamping the plate size is th surface on the medium bekah, blocking the middle part of the plate with an area equal to 1000500 mm, and two devices were fixed to the corner bekah and was shared with the other plates, as each side of the plate overlaps an area equal to 1000250 mm

The mounting arrangement illustrated in Fig. 4-6. In Fig. 4 shows the installation of the first row of cover plates in the manner shown in Fig. 1, in Fig. 5 shows the section a-a at the interface of the plates, and Fig. 6 shows the Assembly of the plates covering the second and subsequent rows, where 1 - rubber plate; 2 - metal surface; 3 - technological mounts for cables are; 4 - adhesive layer; 5 - technological cutouts mounts for cables are; 6 - the joint of adjacent plates; 9 - clamping device; 10 - technological lining; 11 - straight beam clamping fixtures; 12 - boss.

The installation of the first row of plates is as follows.

On the adhesive layer 4 deposited on a metal surface 2, stack plate 1-1 so that the mounts for cables are 3 were cut 5 plates. On average 3 mounts for cables are fixed clamping device 9, an alternative device 9 is fixed to the corner mounts for cables are 3 using technological lining 10. Load fixtures to ensure contact of the adhesive is eat, providing a fixation plate in place (in practice, for a given surface to 1000 kg/m2). In this first load clamping device 9 mounted on medium bankah 3. Then stack a plate 1-2 butt plate 1-1 and fix the following clamping device 9, which belongs to both plates 1-1 and 1-2, and the rectilinear beam device is located, as shown in Fig. 5, and load with common effort from 15 to 20 kg for the surface. Then on medium bankah plate 1-2 fix the following clamping device 9 and also load with a total effort from 15 to 20 kg of This load on the plate samevalue it to the metal surface upon further application of force to the end, providing a preview clip from the shift plate and excluding its swelling and distortion. Depending on the form of curved surfaces each device for this operation can be loaded with a force of from 15 to 50 kg While the total load on the plate can be from 30 to 100 kg/m2.

Multiple blows to the face plate 1-2 (the direction of the punches shown in Fig. 4 as arrows) dock plates 1-1 and 1-2, providing the junction 6 is ntact plates with glue (controlled for uniform extrusion of glue around the perimeter). First of all increase the effort fixtures located at the junction of the plates.

These plates in the first row were set the same as setting the plates 1-2.

Installing the second and subsequent rows of plates of the cover shown in Fig. 6, where the previously installed plate of the first row (Fig. 1) shows the relative, without fixed clamping devices.

Plate 1-5 is set similarly to the installation plate 1-1 of the first row of cover plates (Fig. 4) with the difference that the clamping device 9 installed on medium and extreme bekah, are impacted only by the exercise of 15 to 20 kg on each device for samevolume plate. After multiple impact loads (direction arrows), providing joint 6 with a gap from 0 to 0.5 mm, mounted clamping fixture load to ensure complete contact mounting surface with an adhesive for fixing the position of the plate.

The mounting plate 1-6 and subsequent plates similar to the mounting plate 1-2 of the first row of cover plates (Fig. 4) and is characterized by the fact that after pre-loading (samevolume) each plate ends are joined by application of force to the trees shows the application of reusable shock loads.

After curing of the adhesive clamping devices are removed, the holes in the plates under the technology have sealed mounts for cables are filled with urethane sealant.

Using the proposed method allows to obtain reliable fastening plates covering virtually no gaps between the plates, which allows to preserve the homogeneous characteristics of the coating. At the same time reduces complexity, increases productivity and reduces the consumption of polyurethane sealant.

1. Mounting method rubber plates elastic coating on a curved metal surface where the metal surface is applied epoxy adhesive, then stack extruded rubber plate thickness of 40 to 80 mm and pressed to cure the adhesive, characterized in that the plates are stacked alternately butt one another, mechanically treating the ends of adjacent plates to their tight coupling, and, in the process mentioned clamping plates to the metal surface, the ends of the second and all subsequent plates make every effort supporting the docking plates with a clearance of not more than 0.5 mm

2. The method according to p. 1, characterized in that the ends of the fast path is the Method according to p. 1, wherein the pressing is performed using fixtures and to install them on a metal surface attached technological mounts for cables are, as in plates perform technological cut-outs for them.

4. The method according to p. 3, characterized in that the process cuts after removal of the retainer snap-in seal arrangement on the basis of filled urethane.

 

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