CN100402785C - 可控制埋入部分的腐蚀的钢柱 - Google Patents

可控制埋入部分的腐蚀的钢柱 Download PDF

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CN100402785C
CN100402785C CNB2005101373147A CN200510137314A CN100402785C CN 100402785 C CN100402785 C CN 100402785C CN B2005101373147 A CNB2005101373147 A CN B2005101373147A CN 200510137314 A CN200510137314 A CN 200510137314A CN 100402785 C CN100402785 C CN 100402785C
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steel column
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ammonium ion
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山本正弘
山中晋太郎
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Abstract

一种即使在被狗标记领地时其埋入部分的腐蚀可控性也优良的钢柱,即可控制埋入部分的腐蚀的钢柱,其包括具有防腐涂层或锌基镀层防腐材料的钢柱,在该钢柱与埋入的材料互相接触的界面的顶端沿着钢柱外部上至大气侧、下至埋入材料侧至少50mm提供了由对含铵离子的水溶液具有优良耐久性的防腐材料构成的涂层。

Description

可控制埋入部分的腐蚀的钢柱
技术领域
本发明涉及在使用时底部埋在室外的灯柱、标志柱、金属防护网柱或其它钢柱,尤其涉及防止这些钢柱的埋入部分被腐蚀的技术。
背景技术
灯柱、标志柱等由各种材料制成,但是考虑到强度和价格的平衡,经常使用钢材料。它们在使用底部通常埋在室外。在这种情况下,通过一些方法防止钢材料被腐蚀,例如,通过镀锌或涂覆的方法。这些防腐方法设计为通过防护钢材料免受雨、风、浓缩物和其它腐蚀因素的影响来保护高出地面最高达数米的部分。
但是,即使防止了这些部分的腐蚀,已知在刚刚高于钢柱埋入之处的部分也容易被腐蚀(47th Zairyo-to-Kankyo Conference Preprints,195(2000))。在这种情况下,作为一种抑制腐蚀的方法,公开了在高于和低于埋入平面的地方提供防腐层(日本专利公开(A)2001-371372号)。这种防腐方法防止了因埋在混凝土中的部分与刚刚高于它的部分之间的电化学反应引起的腐蚀。但是,沿着人行道、在公园中和人们步行的其它地方安装的钢柱经常被狗用于标记它们的领地。有报道称这引起了腐蚀(25thJapan Road Conference Preprints,06011(2003))。
因此,有人指出经常使用的钢柱被狗用于标记它们的领地,并且有时因为由此导致的腐蚀而倒塌。因此必须使钢柱对于狗的领地标记具有耐久性。
发明内容
本发明的目的是提供一种钢柱,即使在被狗等用于标记它们的领地时,该钢柱埋入部分也具有优良的腐蚀可控性。
本发明人对于因犬尿引起的腐蚀作用进行了详细的实验室研究,并且密切关注由于犬尿引起的腐蚀加速现象。作为多方研究的结果,申请人发现尽管犬尿包含浓度仅为10ppm或者更低的铵离子,但尿被外界环境分解和改变,使铵离子浓度上升超过100倍,并产生了包含大于或等于0.1%的铵离子的溶液,而且还发现这些铵离子是使钢材料和镀锌、焦油环氧涂层和其它钢柱材料常用的防腐涂层变质的主要原因。由此,申请人通过提高对含铵离子的水溶液的耐久性解决了由于狗的领地标记引起的腐蚀问题。也就是说,它们是:
(1)一种可控制埋入部分的腐蚀的钢柱,其包括具有防腐涂层的钢柱,在该钢柱与埋入的材料互相接触的界面的顶端沿着钢柱外部上至大气侧、下至埋入材料侧至少50mm提供了涂覆层,该涂覆层由对含铵离子的水溶液具有优良耐久性的防腐材料构成。
(2)一种可控制埋入部分的腐蚀的钢柱,其包括如下钢柱:在该钢柱与埋入的材料互相接触的界面的顶端沿着钢柱外部上至大气侧、下至埋入材料侧至少50mm具有对含铵离子的水溶液具有优良耐久性的锌基镀层防腐材料。
(3)如(1)或(2)所述的埋入部分具有腐蚀可控性的钢柱,其中所述防腐材料是在钢柱侧具有有机树脂粘结剂层、厚度至少0.1mm的耐腐蚀金属材料。
(4)如(1)或(2)所述的埋入部分具有腐蚀可控性的钢柱,其中所述防腐材料是至少50μm厚的、包含1重量%到30重量%能够中和铵离子的涂料的环氧树脂基涂层。
更具体而言,本发明包括:
(1)一种可控制埋入部分的腐蚀的钢柱,其包括具有防腐涂层的钢柱,在该钢柱与埋入的材料互相接触的界面的顶端沿着钢柱外部上至大气侧、下至埋入材料侧至少50mm提供了由防腐材料构成的涂覆层,所述防腐材料由在钢柱侧具有有机树脂粘结剂层、厚度至少0.1mm的耐腐蚀金属材料构成,对含铵离子的水溶液具有优良耐久性。
(2)一种可控制埋入部分的腐蚀的钢柱,其包括具有防腐涂层的钢柱,在该钢柱与埋入的材料互相接触的界面的顶端沿着钢柱外部上至大气侧、下至埋入材料侧至少50mm提供了由防腐材料构成的涂覆层,所述防腐材料由至少50μm厚的、包含1重量%到30重量%能够中和铵离子的涂料的环氧树脂基涂层构成,对含铵离子的水溶液具有优良耐久性。
(3)如上述(1)或(2)所述的可控制埋入部分的腐蚀的钢柱,其中所述防腐涂层包含锌基镀层。
通过使用根据本发明的钢柱,可以解决埋入部分的腐蚀问题,尤其是因狗标记领地引起的腐蚀问题,而且可以避免柱子倒塌而对行人造成危险或者阻塞交通。而且,可以延长材料寿命,可以延长灯柱等的更换间隔,而且可以减少维护道路、公园等的费用。
附图说明
通过以下通过参考附图对优选实施方案的描述,本发明的这些和其它目的和特点将变得更清楚,其中:
图1是解释本发明结构的视图;和
图2是本发明实例的测试样品结构的示意图。
具体实施方式
下面,将参考附图详细解释本发明。图1是解释本发明结构的视图。如图1所示,本发明提供了具有防腐涂层(Zn镀层)2的钢柱1,在该钢柱1与埋入(地面或混凝土)4的材料互相接触的界面的顶端沿着钢柱外部上至大气侧、下至埋入材料侧至少50mm具有防腐材料3,防腐材料3对含铵离子的水溶液具有优良的耐久性。
对本发明的防腐涂层没有特别限制,只要它是为了保护钢柱免受大气腐蚀而施加的涂层即可,但包括焦油环氧树脂基或者聚酯基涂层材料、聚乙烯或PVC树脂内衬等。而且,在本发明中,钢柱优选具有锌基镀层。也就是说,本发明即使对于上述防腐涂层材料也是有效的,但是如实施例所示,本发明对于使用锌基镀层的钢柱尤其有效。
关于这里所述的锌基镀层,可以使用JIS-H8641所述的镀层。而且,由其中添加Al、Mg或其它合金成分的锌构成的合金镀层具有类似的效果。本发明所述“钢柱”是指由钢和通常是钢管形的核心材料形成的柱,还包括直径逐渐变化的钢管的锥形柱、弯管形、圆柱、钢段等,即对形状没有特别限制,而且还包括复杂设计的形状。
在本发明中,对含铵离子的水溶液具有优良耐久性的防腐材料在钢柱和埋入的材料互相接触的界面的顶端覆盖钢柱外侧上至大气侧、下至埋入材料侧至少50mm。如果在界面的顶端覆盖钢柱上至大气侧、下至埋入材料侧不足50mm,结果是在埋入钢柱时可能发生因电化学反应引起的电化学反应的长度。如果是50mm或更大,这种电化学反应将变得极小,并且不再引起任何实际问题。而且,为了获得完全可以忽略的水平,需要150mm或更大的跨度。覆盖的上限没有特别限制,但是如果考虑到问题高度是狗可以在上面标记其领地的范围,则1000mm是足够的。
而且,在本发明中,对含铵离子的水溶液具有优良耐久性的防腐材料优选是在钢柱侧具有有机树脂粘结剂层、厚度至少为0.1mm的耐腐蚀金属材料。这里所述对铵离子具有耐腐蚀性能的金属包括钛和钛合金、镍和镍合金、高耐腐蚀性不锈钢、金、银、铂等。但是,通常认为具有高耐腐蚀性的铜合金等对铵离子水溶液的耐腐蚀性低,因此不能使用。就实际性能而言,合意的是在浸入PH值为12.5的铵离子水溶液一周后的腐蚀量小于检测极限。
此外,在本发明中,耐腐蚀金属的厚度优选为0.1mm或更大。原则上,使用对铵离子具有耐腐蚀性的金属,厚度的大小是没有关系的,但实际上,在覆盖为了安装而后来埋入的钢柱时,如果小于0.1mm,将形成针孔,而且会从那些位置开始发生腐蚀。为此,需要至少0.1mm的厚度。厚度的上限没有特别限定,但是如果考虑到成本和生产率,小于1mm是合适的。
此外,在本发明中使用的有机树脂粘结剂层优选为能够牢固粘接钢柱和耐腐蚀金属材料、并具有长期耐久性的有机树脂粘结剂层。可以使用涂有环氧树脂基或尿烷基粘结剂或丙烯酸基胶粘剂的丁基橡胶片或聚乙烯泡沫片,或者浸渍了丙烯酸基粘合剂的丁基橡胶片。而且,这些粘结剂的厚度没有特别限制,但是下限(超出该下限,耐腐蚀金属材料和钢柱就不进行电粘合)优选是100μm,而且考虑到成本,上限优选是3mm。
此外,在本发明中,对含铵离子水溶液具有优良耐久性的防腐材料可以是包括1重量%到低于30重量%能够中和铵离子的涂料、厚度为50μm或更高的环氧树脂基涂层。这里所述“能够中和铵离子”是指当溶于含铵离子的水溶液时能够降低PH值。在本发明中,如下所示。
将市售的氨水(28%浓度)稀释5.6倍,以制备5%的含铵离子水溶液。PH值大约12.0。当在其中添加粉状涂料到1%时,即当向100g该水溶液添加1g时,PH值下降1,即下降到11.0或更低。这种情况认为是能够中和铵离子。
具有这种能力的涂料包括化合物钼酸盐、硼酸盐、钒酸盐(vanadinate)、磷酸盐和硫酸盐。其中,适合作为用于涂覆的涂料的物质是在水中具有低溶解度的物质。例如,钙、镁、铝和锌的磷酸盐、硼酸锌、硫酸钙、钒酸铵(ammonium vanadinate)、氧化钒等和它们中两种或多种的混合物提高了中和铵离子的能力。这里,包括含量为1重量%或更高的这种涂料可以充分保证上述性能。如果超过30重量%,涂层本身变脆,因此耐久性反而降低。
本发明中所述的环氧树脂基涂层没有特别限制,但是优选由涂覆材料(其主要由包含环氧基端基的清漆构成)获得、并通过胺、多胺或异氰酸酯固化的涂层。如果需要,还可以添加散装涂料或溶剂、反应助剂、活性稀释剂和非活性稀释剂等。而且,在本发明中,由环氧树脂基涂层构成的防腐材料可以具有50μm或更高的厚度。如果厚度小于50μm,则难以抑制在涂层中形成针孔,针孔会使得下面的钢材料分解,并且因此无法保证耐久性。厚度更优选为150μm或更高,由此提高耐久性。而且,厚度的上限没有特别设定,但是当厚度大于500μm时,不再发现效果提高,而且随该含量提高了成本,因此500μm是优选的。
实施例1
制造图2所示的测试样品。测试样品5(钢柱)外径60.5mm、长200mm、厚3.8mm。测试样品5先涂覆表2所示的防腐涂层,然后进一步覆盖表2所示的金属基防腐材料。该样品埋在直径为100mm的混凝土6中,至其200mm长度的大约一半。另在该混凝土上放置20mm高的PVC框架7。该框架7填充由市售的园艺用土壤和腐烂树叶等的混合物构成的埋入材料8。每日用其成分与表1所示平均犬尿基本上相同的水溶液喷洒一次该测试样品。六个月后,根据出现的腐蚀和任何蚀损斑来评价腐蚀状态。测试材料及其测试结果示于表2。根据本发明的钢柱显然在犬尿和土壤的组合物的溶液中的耐久性优良。
表1
    成分   %组成(重量%)
    尿素     0.67
    尿酸     0.0069
    肌酸酐     0.090
    NaCl     0.28
    KCl     0.22
Figure C20051013731400101
实施例2
在JIS H 8641所述的条件下,外径43mm、长100mm、厚3.5mm的镀锌钢管在外表面刷涂常温固化的环氧树脂涂料,该环氧树脂涂料由含49重量%环氧树脂清漆、30重量%散装涂料(氧化钛)、约2重量%其它添加剂以及6重量%溶剂的溶液构成,并通过13重量%的固化剂聚合,向其中以表3所示的相对于涂料的重量百分比加入所示颜料,从而形成由防腐材料组成的涂层。这里,为了测量各种涂料中和铵的能力,制备含5%铵离子的100g水溶液,以1%的量加入粉状的表中所述涂料,PH值降低1或更多时的量看作是中和铵离子的能力。另外,关于固化剂的类型,将使用异氰酸酯基树脂的固化剂和使用聚酰胺胺基树脂的固化剂用于本测试中。
用切刀在轴向上切割这些测试钢管,向下至Zn镀层,切出宽1mm、长50mm的切口,并在40℃下在3%的NaCl中浸泡一个月,在常温下在0.01mol/kg的NaOH水溶液中浸泡一个月,在常温下在0.01mol/kg的氨水溶液中浸泡一个月,然后用平均值评价切割部分的腐蚀和膨胀。结果也示于表3。可以看出,本发明的实施例对含铵离子水溶液具有优良的耐久性。而且可以看出,具有厚度超过50μm的、包含1到30重量%能够中和铵离子的涂料的涂层具有更为优良的耐久性。
Figure C20051013731400131
Figure C20051013731400141
实施例3
通过JIS H 8641所述的方法对内径150mm、厚6mm、长3m的钢管镀锌,并且用实施例1中所示规格1的防腐材料覆盖从距其表面底端500mm处起的500mm的范围,用实施例1中所示规格7的防腐材料覆盖,或用实施例2的规格26的防腐材料覆盖,并制备不用防腐材料覆盖的钢管作为对比例。将这些钢管埋入混凝土中,使距底端750mm处在混凝土表面露出来。在它们顶部覆盖50mm厚的土,制得测试样品。
每天用具有表1所示成分的溶液喷洒这些测试样品一次。一年后进行检测,发现对比例材料被腐蚀,并且埋入土壤中的部分在镀层处锈成红色,但是本发明实施例的三种钢管完全没有腐蚀。这说明本发明钢柱的耐久性优良。
尽管参考为了说明而选择的具体实施方案描述了本发明,但是,显然,本领域技术人员可以在不偏离本发明的基本内容和保护范围的情况下对其进行多种更改。

Claims (4)

1.一种可控制埋入部分的腐蚀的钢柱,其包括具有防腐涂层的钢柱,在该钢柱与埋入的材料互相接触的界面的顶端沿着钢柱外部上至大气侧、下至埋入材料侧至少50mm提供了由防腐材料构成的涂覆层,所述防腐材料由在钢柱侧具有有机树脂粘结剂层、厚度至少0.1mm的耐腐蚀金属材料构成,对含铵离子的水溶液具有优良耐久性。
2.如权利要求1所述的可控制埋入部分的腐蚀的钢柱,其中所述防腐涂层包含锌基镀层。
3.一种可控制埋入部分的腐蚀的钢柱,其包括具有防腐涂层的钢柱,在该钢柱与埋入的材料互相接触的界面的顶端沿着钢柱外部上至大气侧、下至埋入材料侧至少50mm提供了由防腐材料构成的涂覆层,所述防腐材料由至少50μm厚的、包含1重量%到30重量%能够中和铵离子的涂料的环氧树脂基涂层构成,对含铵离子的水溶液具有优良耐久性。
4.如权利要求3所述的可控制埋入部分的腐蚀的钢柱,其中所述防腐涂层包含锌基镀层。
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