CN103041966B - 电工钢表面极厚绝缘涂层的生产方法 - Google Patents

电工钢表面极厚绝缘涂层的生产方法 Download PDF

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CN103041966B
CN103041966B CN201110315303.9A CN201110315303A CN103041966B CN 103041966 B CN103041966 B CN 103041966B CN 201110315303 A CN201110315303 A CN 201110315303A CN 103041966 B CN103041966 B CN 103041966B
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thickness
roller
section
baking
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CN103041966A (zh
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陆永强
吕春国
王志成
陈彬
陈晓
谢世殊
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Baoshan Iron and Steel Co Ltd
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Priority to RU2014119944/05A priority patent/RU2568727C1/ru
Priority to US14/348,357 priority patent/US9406416B2/en
Priority to KR1020147008835A priority patent/KR101602748B1/ko
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Priority to JP2014536090A priority patent/JP5778351B2/ja
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Abstract

电工钢表面极厚绝缘涂层的生产方法，包括如下步骤：1)涂液配制，将涂液进行充分搅拌，搅拌时间0.1～4小时，涂液粘度在10～80S内；2)带钢涂覆，采用二辊或三辊式涂层机，通过调整不同的参数从而可以控制膜厚和均匀性；3)涂层烘烤，采用三段式加热对涂层进行烘烤成膜，三段为干燥段、烘烤段和冷却段，干燥段温度在100～400℃，烘烤段温度在200～370℃；整个干燥段和烘烤段时间为33～144秒，其中湿膜干燥时间为9～39秒，烘烤时间为24～105秒；涂覆后的带钢及在涂层烘烤阶段，带钢传送是采用与带钢不接触的传送方法进行，具体为通过对带钢下表面吹出可调压力的空气，使带钢漂浮传送，气体压力在0～2000Pa；湿膜固化前不与加热炉辊接触，保证湿膜表面完整成膜；4)在线膜厚检测。

Description

电工钢表面极厚绝缘涂层的生产方法
技术领域
本发明涉及带钢表面涂层的涂覆及成膜技术，特别涉及电工钢表面极厚绝缘涂层的生产方法。
背景技术
目前，随着国内工业的迅速发展，对电力需求日益上升，随着环保呼声愈来愈高，国家对核电、水电和太阳能电的投资逐步增大，大型水电、核电发电机等对电工钢的要求越来越高，对绝缘性要求更加严格。因此，需开发一种在带钢表面涂覆极厚环保绝缘涂层的工艺技术。
目前，电工钢表面极厚绝缘涂层主要采用Dupont、Rembrandtin和Kluthe等公司生产的涂料。涂料涂敷过程一般采用上下两辊式涂层机，涂层辊采用刻槽辊，且涂层辊是被动辊，主要靠带钢的速度带动涂层辊的转动，一旦机组速度波动，将对膜厚控制带来不利影响，故该种涂敷方式对涂层厚度控制精度不高，且刻槽辊生产的涂层容易产生涂层不均的缺陷，导致绝缘性能不均匀，且不满足叠片的要求。涂覆后烘烤方式主要有感应加热技术、热风干燥技术、红外加热技术以及近红外加热技术，其中感应加热技术设备安装困难，沿带钢宽度方向上加热不均匀，容易造成涂层性能不均；而红外和近红外加热装置，虽然加热精度高，但设备投资大，工艺复杂，不利于降低生产成本。
发明内容
本发明的目的在于提供一种电工钢表面极厚绝缘涂层的生产方法，电工钢表面具有优异性能的极厚绝缘涂层，涂层膜厚在2～10μm，膜厚均匀，具有优异层间电阻性能，适用于大型水电、核电用。
为达到上述目的，本发明采用如下的技术解决方案：
电工钢表面极厚绝缘涂层的生产方法，其包括如下步骤：
1)涂液配制：
将涂液进行充分搅拌，搅拌时间0.1～4小时，然后对涂液进行加水或溶剂进行稀释，保证粘度在10～80S内(采用DIN4杯测量)。
由于极厚涂层中固含量较高，粘度大(一般超过100S)，为保证涂液的均匀性，先将涂液用气动可调搅拌器(转速约100～1000转/分钟)进行充分搅拌约0.1～4小时，然后对涂液进行稀释，并采用粘度计进行检测。
为保证带钢良好的涂层涂覆与带钢速度匹配，保证涂液的流平性及涂层均匀性，涂液粘度低容易造成涂覆速度快，容易产生气泡对表面质量不利，粘度大不利于涂液的流平性，容易产生条纹和漏涂缺陷，因此，需要选择合理的涂液粘度，本发明粘度范围在10～80S内，另，搅拌过程中注意涂液中不要有大量气泡产生。
本发明极厚涂层涂液主要采用Dupont、Rembrandtin和Kluthe等公司的产品，主要为无机组分和有机组分的混合体，但不同公司产品所含的固体组分不同，主要由BaSO4、CaSO4、CaCO3、TiO2、N-N-二甲基乙醇胺、2-丁氧基乙醇、1-丁氧基-2-丙醇、炭黑、聚异丁烯和正丁醇等中的几种组成。
其中BaSO4、CaSO4和CaCO3含量一般分别在30-70％，TiO2的含量一般分别在5-15％，N-N-二甲基乙醇胺、2-丁氧基乙醇和1-丁氧基-2-丙醇含量一般分别在1-5％，其余有机组分含量一般在0.1-1％之间。
由于具体涂液为外购的现有产品，在此不再赘述。
2)带钢涂覆：
采用两辊式或三辊式涂层机进行涂覆，以此确定可以调节膜厚的方法，如调整辊子的周速比、压力、间隙等参数，实现对膜厚的均匀控制与精度。
如采用三辊式涂层机，通过设定涂层机中三辊的周速比，涂层辊与取液辊之间的压力，取液辊与计量辊之间的间隙便可以对涂层厚度和涂层均匀性进行适时调节。优化的，涂层机涂层辊和取液辊周速比一般为0.2～1.2之间，涂层辊与取液辊压力为0.1～10KPa之间，取液辊与计量辊间隙为60～150μm。
如采用二辊式涂层机，通过设定二辊的周速比，涂层辊与取液辊之间的压力便可以对涂层厚度和涂层均匀性进行适时调节。优化的，取液辊、涂层辊周速比均在0.2-1.5之间，两辊之间的压力为1-50KPa。
3)涂层烘烤：
本发明采用烧嘴加热的方法，加热后的空气通过上下布置的循环风箱循环，对带钢表面湿膜进行干燥和固化成膜，而涂液中的水分蒸发后通过排烟风机到大气中。
根据湿膜成膜特性，涂层烘烤采用三段式加热和冷却方法对涂层进行烘烤成膜。三段主要为干燥段、烘烤段和冷却段，其中干燥段温度在100～400℃，烘烤段温度在200～370℃。整个干燥固化成膜阶段，时间为33～144S，其中湿膜干燥时间为9～39S，烘烤时间为24～105S；最终形成2～10μm膜厚的涂层；
带钢传送：
本发明整个涂层后的干燥段和烘烤段通过与带钢不接触的传送装置进行生产，该传送装置可以吹出可调压力的空气用于漂浮带有湿膜的带钢。涂有湿膜的带钢利用烘烤炉内传送装置的漂浮作用，湿膜固化前不与炉辊接触，保证湿膜表面完整成膜。气体压力在0～2000Pa之间。
进一步，本发明方法还包括步骤4)在线膜厚检测，本发明采用常规在线膜厚检测方法对上下两表面膜厚进行连续检测，并具有膜厚反馈功能。通过在线膜厚的结果与目标膜厚进行比较，从而适时调节涂层机各参数，达到目标膜厚，保证膜厚的稳定性。
采用本发明的生产工艺制备的电工钢表面厚涂层，膜厚均匀，附着性好，抗划擦性强，具有优异的电绝缘性，可以用于大型水电、核电用电工钢涂层。
本发明的主要特点：
1.极厚涂层的涂液粘度范围在10～80S，具有良好的流平性和涂覆性。
2.采用二辊或三辊式涂层机进行涂覆，以此来确定涂层厚度的控制和调节方法，便可实现对膜厚的精确控制。
3.采用明火烧嘴加热和热风循环的方法进行涂层成膜，并设置不同温度的加热段，以获得良好的涂层，固化成膜时间在33～144秒，从而保证了涂层具有优异的附着性和绝缘性。
4.采用非接触式带钢传送装置对带钢进行传送，从而保证了涂层的完整性。
5.对环保涂层膜厚在线反馈控制，从而有效监控膜厚，保证膜厚的均匀性。
6.本发明对大于2μm的涂层产品均可实现连续式生产，从而保证不同厂家对于膜厚的需求及涂层本身性能。
附图说明
图1为本发明一实施例的示意图。
图2为本发明另一实施例的示意图。
具体实施方式
以下结合实施例对本发明的工艺作进一步说明。
1、采用三辊式涂层机生产
如图1所示，经过轧制、退火的电工钢带钢1通过取液辊2、涂层辊3对带钢1上下表面分别涂覆，涂液粘度27S，采用三辊进行涂覆，涂层辊周速比0.45，取液辊2周速比0.41，取液辊2与计量辊4间隙100μm，然后在烘烤炉5内进行成膜，采用三段式加热和冷却方法对涂层进行烘烤成膜，具体为干燥段51、烘烤段52和冷却段53，干燥温度350℃，烘烤温度320℃，固化成膜时间为35S。最终得到上下表面膜厚为5μm，涂层附着性为GT0，层间电阻为900Ω·lam(欧标)，表面质量优良的均匀厚涂层。如超出参数优化范围所制涂层表面质量较差，存在掉粉，附着性差，涂层表面不均匀等问题。
其他实施例见表1所示。
表1
2、采用二辊式涂层机生产
如图2所示，经过轧制、退火的电工钢带钢1通过取液辊2、涂层辊3对带钢1上下表面分别涂覆，涂液粘度30S。采用二辊进行涂覆，涂层辊周速比0.48，取液辊2周速比0.40，涂层辊与取液辊压力为然后在烘烤炉5内进行成膜，采用三段式加热和冷却方法对涂层进行烘烤成膜，具体为干燥段51、烘烤段52和冷却段53，干燥温度100℃，烘烤温度220℃，固化成膜时间为72S。最终得到上下表面膜厚为5μm，涂层附着性为GT0，层间电阻为900Ω·lam(欧标)，表面质量优良的均匀厚涂层。如超出参数优化范围所制涂层表面质量较差，存在掉粉，附着性差，涂层表面不均匀等问题。
其他实施例见表2所示。
表2
本发明可应用于大型水电、核电发电机及其他对绝缘性要求高的电动机等用电工钢表面涂层生产。

Claims (6)

1.电工钢表面极厚绝缘涂层的生产方法，其包括如下步骤：
1)涂液配制
将涂液进行充分搅拌，搅拌时间0.1～4小时，根据涂液原液的初始粘度，对涂液原液加纯水或溶剂进行稀释，保证粘度在10～80S内，采用DIN4杯测量；
2)带钢涂覆
采用二辊式涂层机进行上下表面分别涂覆生产，涂覆方式分为顺涂和逆涂两种方式；
二辊式涂层机取液辊、涂层辊周速比均在0.2～1.5之间，两辊之间的压力为1～50KPa；
3)涂层烘烤
采用烧嘴加热的方法，加热后的空气通过上下布置的循环风箱循环，对带钢表面湿膜进行干燥和固化成膜；
涂层烘烤采用三段式烘烤成膜，即干燥段、烘烤段和冷却段；其中干燥段温度在100～400℃，烘烤段温度在200～370℃；整个干燥段和烘烤段时间为33～144秒，其中干燥段时间为9～39秒，烘烤段时间为24～105秒；最终形成2～10μm膜厚的涂层；
涂覆后的带钢及在涂层烘烤阶段，带钢传送是采用与带钢不接触的传送方法进行，具体为通过对带钢下表面吹出可调压力的空气，使带钢漂浮传送，根据带钢厚度，气体压力在1～2000Pa可调；湿膜固化前不与加热炉辊接触，保证湿膜表面完整成膜。
2.如权利要求1所述的电工钢表面极厚绝缘涂层的生产方法，其特征是，还包括，步骤4)在线膜厚检测，采用常规手段，对带钢上下表面膜厚进行连续在线检测，通过在线膜厚的结果与目标膜厚进行比较，适时调节涂层机，达到目标膜厚，保证膜厚的稳定性。
3.如权利要求1所述的电工钢表面极厚绝缘涂层的生产方法，其特征是，步骤1)涂液配制中，粘度调整的溶剂包括乙二醇丁醚或丁基乙二醇。
4.电工钢表面极厚绝缘涂层的生产方法，其包括如下步骤：
1)涂液配制
将涂液进行充分搅拌，搅拌时间0.1～4小时，根据涂液原液的初始粘度，对涂液原液加纯水或溶剂进行稀释，保证粘度在10～80S内，采用DIN4杯测量；
2)带钢涂覆
采用三辊式涂层机进行上下表面分别涂覆生产，涂覆方式分为顺涂和逆涂两种方式；
三辊式涂层机涂层辊、取液辊的周速比在0.2～1.2之间；涂层辊与取液辊之间的压力为0.1～10KPa；取液辊与计量辊之间的间隙为60～150μm；
3)涂层烘烤
采用烧嘴加热的方法，加热后的空气通过上下布置的循环风箱循环，对带钢表面湿膜进行干燥和固化成膜；
涂层烘烤采用三段式烘烤成膜，即干燥段、烘烤段和冷却段；其中干燥段温度在100～400℃，烘烤段温度在200～370℃；整个干燥段和烘烤段时间为33～144秒，其中干燥段时间为9～39秒，烘烤段时间为24～105秒；最终形成2～10μm膜厚的涂层；
涂覆后的带钢及在涂层烘烤阶段，带钢传送是采用与带钢不接触的传送方法进行，具体为通过对带钢下表面吹出可调压力的空气，使带钢漂浮传送，根据带钢厚度，气体压力在1～2000Pa可调；湿膜固化前不与加热炉辊接触，保证湿膜表面完整成膜。
5.如权利要求4所述的电工钢表面极厚绝缘涂层的生产方法，其特征是，还包括，步骤4)在线膜厚检测，采用常规手段，对带钢上下表面膜厚进行连续在线检测，通过在线膜厚的结果与目标膜厚进行比较，适时调节涂层机，达到目标膜厚，保证膜厚的稳定性。
6.如权利要求4所述的电工钢表面极厚绝缘涂层的生产方法，其特征是，步骤1)涂液配制中，粘度调整的溶剂包括乙二醇丁醚或丁基乙二醇。
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