CN107099175A - 一种耐高温防腐型电热带涂料及其涂覆方法 - Google Patents
一种耐高温防腐型电热带涂料及其涂覆方法 Download PDFInfo
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Abstract
一种耐高温防腐型电热带涂料及其涂覆方法，涂料由以下重量份数的原料组成：胶水100~135份、改性酚醛树脂25~27份、硅酸钠35~38份、改性无机填料20~35份、纳米碳化硅5~10份、纳米氮化硼5~10份和二氧化硅10~15份；其涂覆方法为：将该涂料盛装在喷枪壶中对电热带进行重复喷涂若干层，然后在200℃下固化24~48h。本发明制得的涂料可以采用喷枪喷涂，与现有人工刷涂相比，提高了涂层的均匀性；涂覆的涂层在高温下结合力好，不脱落；高温下电气绝缘性好，1000V一小时不击穿；导热性好，热导率可达20w/m·k；成本低。
Description
技术领域
本发明涉及电热带技术领域，具体涉及一种耐高温防腐型电热带涂料及其涂覆方法。
背景技术
电热带是一种自限温加热带的电热元件，是在两根平行金属母线之间均匀地挤包一层具有正温系数半导体PTC材料制成的芯带，可广泛应用于存储输送油、水、气等介质的管罐、泵阀、仪表、槽池、房屋地热等处的保温、伴热、加热等。
电热带按结构一般分为并连式和串联式两种，按发热量分自限式和恒功率两种。自限式电加热带的线芯是一种很复杂的高分子聚合物，经特定的化学变化和物理处理后制成的半导体线芯，有两条导线组成一条保持连续平行的加热电路，可随环境温度变化而变化。恒功率电热带是由两根或两根平行绝缘铜导线为电源母线，在其表面上绕缠电热丝，其单位长度发热量是恒定的。自限式和恒功率式电加热带均有多层绝缘。
电热带在使用过程中，因高温着火引发的事故是最大的安全隐患，其原因包括以下几个方面：由于使用时间过长，环境杂物污染，高温长时间封烤，或受潮湿、腐蚀作用，绝缘老化变质而失去绝缘能力，引起短路着火；或者电热带暴露在室外，由于雷击等过电压作用，电热带绝缘可能被击穿形成瞬间短路；也可能因雷电放电电流极大，有类似短路电流但比短路电流更强的热效应，引发火灾甚至爆炸等。为防止电热带在高温状态氧化烧断的问题，一般在现有的电热带完刷涂一层胶，但存在以下缺点：不能喷涂，只能刷涂；高温下结合力不好；高温下导热性不好；电气绝缘性不好；成本高。
发明内容
本发明为了克服现有技术中存在的不足，提供一种耐高温防腐型电热带涂料及其涂覆方法。
本发明为解决上述问题所采用的技术方案为：一种耐高温防腐型电热带涂料，由以下重量份数的原料组成：胶水100~135份、改性酚醛树脂25~27份、硅酸钠35~38份、改性无机填料20~35份、纳米碳化硅5~10份、纳米氮化硼5~10份和二氧化硅10~15份。
一种耐高温防腐型电热带涂料的涂覆方法，包括以下步骤：
步骤一、称取有机硅树脂，并在有机硅树脂中加入其重量1.5~2.0倍的无机填料，搅拌得混合物，然后加入重量为混合物总重1~3%的纳米改性剂，并加入相当于混合物1.5~3倍重量的去离子水，搅拌均匀后，球磨、过滤、干燥得粉末，将粉末置于反应釜中，并加入乙醇、丙三醇和表面活性剂，在1.2~1.5个大气压下，将反应釜加热至70~85℃，反应4~5h后，停止加热，静置2~3h后取出物料，利用去离子水洗涤后，干燥，制得改性无机填料，备用；
步骤二、按照1：4：3的重量比，称取纳米微胶囊粉、酚醛树脂和无水乙醇，混合后超声分散30~35min，然后进行抽滤，当不再有乙醇液滴滴落时停止抽滤，取出滤出物，置于烘箱中烘干后，自然冷却至室温，制得改性酚醛树脂，备用；
步骤三、按照上述重量份数称取各原料，将胶水和硅酸钠混合均匀，然后依次加入步骤二制备的改性酚醛树脂、纳米碳化硅和纳米氮化硼，混合均匀后再加入步骤一制得的改性无机填料和二氧化硅，混合搅拌30~50min，制得涂料，将该涂料盛装在喷枪壶中对电热带进行重复喷涂若干层，然后在200℃下固化24~48h。
其中，步骤一中的无机填料由氧化镁、氧化锌和氧化铝组成，氧化镁、氧化锌和氧化铝三者的重量比为10~20：5~7：5~8。
本发明制得的改性酚醛树脂，若电热带发生拉伸等破坏，胶囊粉破裂，作为其芯材的酚醛树脂与胶水耦合，增强涂层与电热带之间的结合力，避免涂层剥落，进而能够最大限度的防止因电热带绝缘层破坏导致的短路现象。
本发明加入氧化镁，能够增加胶水的定伸应力，提高耐热耐老化性能，还能使胶水具有较高的塑性和比较好的储存稳定性；氧化锌可以提高耐热、耐老化性能，氧化镁和氧化锌同时使用，提高涂料的交联强度。本发明的原料中通过氧化铝、氧化镁、氧化锌为助剂，在受高温作用后，自身能分解出无毒惰性气体和受热分解、相变吸收消耗热量，表层能逐渐形成碳化层进而形成膨胀的发泡层，阻燃主体和热源隔开，从而延缓或终止聚合物分解，有效地减少热量的传导，降低阻燃主体温度升高的速率。
本发明的纳米氮化硼、改性无机填料和纳米碳化硅能够均匀地分散在树脂基体和胶水中，使涂覆后的涂料表面呈现出较低的表面能，可以使水汽等与涂覆后的涂料表面处于不润湿状态，避免电热带受潮湿等腐蚀作用造成绝缘老化变质的现象。同时，氮化硼的高温绝缘性好，25℃为1014Ω·cm，2000℃还可以达到103Ω·cm。
本发明制得的涂料中含有Si-O键，其极性大、键能高，在高温下不易断裂，提高了涂层的热稳定性。同时，添加的硅酸钠能够增强硅氧键，硅酸钠在没到其熔点之前呈分散的片状结构，在其熔点附近的高温条件下，硅酸钠熔融成膜，起着高温防护的作用，具有一定的防腐性。
本发明利用硅酸钠和金属氧化物作为成膜物质，通过水分蒸发和分子间硅氧键的结合所形成的无机高分子聚合物来实现成膜，对光、热具有良好的稳定性，具有良好的耐热、耐老化性能和附着力。
本发明制得的涂料可以采用喷枪喷涂，与现有人工刷涂相比，提高了涂层的均匀性；涂覆的涂层在高温下结合力好，不脱落；高温下电气绝缘性好，1000V一小时不击穿；导热性好，热导率可达20w/m·k；成本低。
具体实施方式
下面结合具体实施例对本发明作进一步说明，以使本领域的技术人员可以更好的理解本发明并能予以实施，但所举实施例不作为对本发明的限定。
一种耐高温防腐型电热带涂料，由以下重量份数的原料组成：胶水100~135份、改性酚醛树脂25~27份、硅酸钠35~38份、改性无机填料20~35份、纳米碳化硅5~10份、纳米氮化硼5~10份和二氧化硅10~15份。
实施例1
一种耐高温防腐型电热带涂料的涂覆方法，包括以下步骤：
步骤一、称取有机硅树脂，并在有机硅树脂中加入其重量2.0倍的无机填料，搅拌得混合物，然后加入重量为混合物总重2.5%的纳米改性剂，并加入相当于混合物3倍重量的去离子水，搅拌均匀后，球磨、过滤、干燥得粉末，将粉末置于反应釜中，并加入乙醇、丙三醇和表面活性剂，在1.3个大气压下，将反应釜加热至85℃，反应4h后，停止加热，静置2.5h后取出物料，利用去离子水洗涤后，干燥，制得改性无机填料，备用；无机填料由氧化镁、氧化锌和氧化铝组成，氧化镁、氧化锌和氧化铝三者的重量比为15：6：7。
步骤二、按照1：4：3的重量比，称取纳米微胶囊粉、酚醛树脂和无水乙醇，混合后超声分散35min，然后进行抽滤，当不再有乙醇液滴滴落时停止抽滤，取出滤出物，置于烘箱中烘干后，自然冷却至室温，制得改性酚醛树脂，备用；
步骤三、按照以下重量份数称取各原料：胶水125份、步骤二制备的改性酚醛树脂26份、硅酸钠37份、步骤一制得的改性无机填料30份、纳米碳化硅8份、纳米氮化硼7份和二氧化硅12份；将称取的胶水和硅酸钠混合均匀，然后依次加入步骤二制备的改性酚醛树脂、纳米碳化硅和纳米氮化硼，混合均匀后再加入步骤一制得的改性无机填料和二氧化硅，混合搅拌30min，制得涂料，将该涂料盛装在喷枪壶中对电热带进行喷涂一层，然后在200℃下固化24h。
实施例2
一种耐高温防腐型电热带涂料的涂覆方法，包括以下步骤：
步骤一、称取有机硅树脂，并在有机硅树脂中加入其重量1.7倍的无机填料，搅拌得混合物，然后加入重量为混合物总重1%的纳米改性剂，并加入相当于混合物2.0倍重量的去离子水，搅拌均匀后，球磨、过滤、干燥得粉末，将粉末置于反应釜中，并加入乙醇、丙三醇和表面活性剂，在1.5个大气压下，将反应釜加热至75℃，反应4.5h后，停止加热，静置2h后取出物料，利用去离子水洗涤后，干燥，制得改性无机填料，备用；无机填料由氧化镁、氧化锌和氧化铝组成，氧化镁、氧化锌和氧化铝三者的重量比为10：5：5。
步骤二、按照1：4：3的重量比，称取纳米微胶囊粉、酚醛树脂和无水乙醇，混合后超声分散30min，然后进行抽滤，当不再有乙醇液滴滴落时停止抽滤，取出滤出物，置于烘箱中烘干后，自然冷却至室温，制得改性酚醛树脂，备用；
步骤三、按照以下重量份数称取各原料：胶水100份、步骤二制备的改性酚醛树脂25份、硅酸钠35份、步骤一制得的改性无机填料20份、纳米碳化硅5份、纳米氮化硼5份和二氧化硅10份；将称取的胶水和硅酸钠混合均匀，然后依次加入步骤二制备的改性酚醛树脂、纳米碳化硅和纳米氮化硼，混合均匀后再加入步骤一制得的改性无机填料和二氧化硅，混合搅拌45min，制得涂料，将该涂料盛装在喷枪壶中对电热带进行重复喷涂两层，然后在200℃下固化24h。
实施例3
一种耐高温防腐型电热带涂料的涂覆方法，包括以下步骤：
步骤一、称取有机硅树脂，并在有机硅树脂中加入其重量1.5倍的无机填料，搅拌得混合物，然后加入重量为混合物总重3%的纳米改性剂，并加入相当于混合物1.5倍重量的去离子水，搅拌均匀后，球磨、过滤、干燥得粉末，将粉末置于反应釜中，并加入乙醇、丙三醇和表面活性剂，在1.2个大气压下，将反应釜加热至70℃，反应5h后，停止加热，静置3h后取出物料，利用去离子水洗涤后，干燥，制得改性无机填料，备用；无机填料由氧化镁、氧化锌和氧化铝组成，氧化镁、氧化锌和氧化铝三者的重量比为20：7：8。
步骤二、按照1：4：3的重量比，称取纳米微胶囊粉、酚醛树脂和无水乙醇，混合后超声分散35min，然后进行抽滤，当不再有乙醇液滴滴落时停止抽滤，取出滤出物，置于烘箱中烘干后，自然冷却至室温，制得改性酚醛树脂，备用；
步骤三、按照以下重量份数称取各原料：胶水135份、步骤二制备的改性酚醛树脂27份、硅酸钠38份、步骤一制得的改性无机填料35份、纳米碳化硅10份、纳米氮化硼10份和二氧化硅15份；将称取的胶水和硅酸钠混合均匀，然后依次加入步骤二制备的改性酚醛树脂、纳米碳化硅和纳米氮化硼，混合均匀后再加入步骤一制得的改性无机填料和二氧化硅，混合搅拌50min，制得涂料，将该涂料盛装在喷枪壶中对电热带进行重复喷涂至少三层，然后在200℃下固化48h。
本发明的涂层既有有机硅树脂的耐热性，还具有酚醛树脂的耐化学品性。本发明加入的氧化铝，能够与二氧化硅熔合生成Si-O-Al合金层，提高涂层与电热带基体的结合力。
将实施例1~3涂覆有涂层的电热带浸于水中的同时，进行120天的紫外老化试验，对试验后电热带的起泡、脱落及裂纹情况进行观察，发现电热带无任何起泡、脱落和裂纹现象。
在实施例1~3涂覆有涂层的电热带上，用滴管分别滴加6mol/L盐酸溶液、40%氢氧化钠溶液各两滴于不同位置，分别在5min和5h后观察涂层，发现无失光、起泡、脱落和变黄现象。
Claims (3)
1.一种耐高温防腐型电热带涂料，其特征在于：由以下重量份数的原料组成：胶水100~135份、改性酚醛树脂25~27份、硅酸钠35~38份、改性无机填料20~35份、纳米碳化硅5~10份、纳米氮化硼5~10份和二氧化硅10~15份。
2.涂覆如权利要求1所述的一种耐高温防腐型电热带涂料的方法，其特征在于，包括以下步骤：
步骤一、称取有机硅树脂，并在有机硅树脂中加入其重量1.5~2.0倍的无机填料，搅拌得混合物，然后加入重量为混合物总重1~3%的纳米改性剂，并加入相当于混合物1.5~3倍重量的去离子水，搅拌均匀后，球磨、过滤、干燥得粉末，将粉末置于反应釜中，并加入乙醇、丙三醇和表面活性剂，在1.2~1.5个大气压下，将反应釜加热至70~85℃，反应4~5h后，停止加热，静置2~3h后取出物料，利用去离子水洗涤后，干燥，制得改性无机填料，备用；
步骤二、按照1：4：3的重量比，称取纳米微胶囊粉、酚醛树脂和无水乙醇，混合后超声分散30~35min，然后进行抽滤，当不再有乙醇液滴滴落时停止抽滤，取出滤出物，置于烘箱中烘干后，自然冷却至室温，制得改性酚醛树脂，备用；
步骤三、按照权利要求1的重量份数称取各原料，将胶水和硅酸钠混合均匀，然后依次加入步骤二制备的改性酚醛树脂、纳米碳化硅和纳米氮化硼，混合均匀后再加入步骤一制得的改性无机填料和二氧化硅，混合搅拌30~50min，制得涂料，将该涂料盛装在喷枪壶中对电热带进行重复喷涂若干层，然后在200℃下固化24~48h。
3.如权利要求2所述的一种耐高温防腐型电热带涂料的涂覆方法，其特征在于：步骤一中的无机填料由氧化镁、氧化锌和氧化铝组成，氧化镁、氧化锌和氧化铝三者的重量比为10~20：5~7：5~8。
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