CN105254989B - 一种抗电击穿永久抗静电型滚塑成型用聚乙烯复合材料 - Google Patents
一种抗电击穿永久抗静电型滚塑成型用聚乙烯复合材料 Download PDFInfo
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Abstract
本发明公开了一种抗电击穿永久抗静电型滚塑成型用聚乙烯复合材料，由以下质量百分比计的组分混合制成：聚乙粉末90‑99.9％，金属粉末0.1‑10.0％。本发明的聚乙烯复合材料，通过滚塑工艺加工出的制品，在保持永久性抗静电效果的同时，具备良好的绝缘性，拓宽了常规单层抗静电材料的应用领域，同时避免了使用多层结构工艺带来的加工复杂性。
Description
技术领域
本发明涉及一种聚乙烯复合材料，特别涉及一种抗电击穿永久抗静电型滚塑成型用聚乙烯复合材料。
背景技术
滚塑成型是一种利用旋转的模具进行加工的塑料加工方式，其加工过程是，将塑料粉末或浆料投入模具，闭合后的模具在设备上进行旋转或摇摆，同时通过明火或热风对模具外部进行加热，塑料粉末或浆料在受热的状态下在模内内部翻转、流动，温度达到软化点后逐步涂布到模具内表面，熔融并凝结，将模具放于自然环境下或通过水、雾、风等介质进行冷却后拆模取出制品。在加热过程中，塑料粉末的温度在模具面指向模具内部方向逐渐降低。
聚乙烯具有较高的电阻，在使用过程中，遇到接触、摩擦、碰撞等情况会在制品的表面积累静电荷，且产生的静电荷难以转移，当积累到一定程度，就会带来安全隐患。通常情况下，技术人员通过在聚乙烯材料中添加抗静电剂、炭黑、金属粉末等低电阻物质，降低聚乙烯材料的表面电阻和体积电阻，达到抗静电效果。但在目前的技术条件下，由于在材料中添加低电阻材料，直接会造成塑料材料介电强度(电击穿强度)的大幅下降，使塑料丧失绝缘性。如CN104262751A《永久性抗静电可弯曲聚乙烯管材专用料》、CN103849024A《一种抗静电阻燃改性聚乙烯粉末及其制备方法》、CN102399431B《永久抗静电PA66/HDPE合金及制备方法》等，均采用螺杆造粒法，将抗静电组分充分分散到基体材料中，形成材质均一的、抗静电效果均一的复合材料。在这种工艺下，无法同时保证材料的绝缘性。
在目前的技术方案中，如CN103172890A《一种有机/无机复合中高温质子导电膜的制备方法》、CN103117403B《由塑料制成的燃料电池排气系统的抗静电涂层》等，为达到制品表面抗静电或导电，同时保持整体制品的绝缘性，均使用了双层或多层的结构，在基体材料上涂布、层积或复合具有抗静电或导电功能的材料。
对于均一性单层材料，尚未发现公布具有抗静电效果，同时又具有较高的介电强度的技术方案，也尚未发现公布内外表面具有不同抗静电能力的技术方案。
发明内容
本发明的目的在于提供一种抗电击穿永久抗静电型滚塑成型用聚乙烯复合材料，通过滚塑工艺加工出的制品，在保持永久性抗静电效果的同时，具备良好的绝缘性，拓宽了常规单层抗静电材料的应用领域，同时避免了使用多层结构工艺带来的加工复杂性。
本发明解决其技术问题所采用的技术方案是：
一种抗电击穿永久抗静电型滚塑成型用聚乙烯复合材料，由以下质量百分比计的组分混合制成：聚乙粉末90-99.9％，金属粉末0.1-10.0％。
作为优选，所述聚乙烯粉末堆积密度为0.250-0.500g/cm3，粉体流动性≤30s/100g，熔体流动速率(190℃,2.16Kg)为1.0-20.0g/10min，粒径分布D98≤600μm，D10≥150μm。
控制聚乙烯粉末的参数如堆积密度、粉体流动性、熔体流动速率、粒径分布的作用主要是1、使用滚塑加工工艺可以顺利成型，制品缺陷少；2、和金属粉末的要求搭配，否则不能顺利成型。
作为优选，所述金属粉末的金属选自银、铜、金、铝、钼、镁、钨、锌、镍、铁、铂、锡、铅中的一种金属或几种金属组成的合金。
作为优选，所述金属粉末形态为球状、片状或纤维状，其导电率≤10-6Ω·m。
导电率和表面电阻相关，和介电强度不相关，本发明中的高介电强度是因为在滚塑过程中金属粉末形成局部聚集，外层塑料粉末层中金属粉末的浓度小于介电击穿的阈值，内层塑料粉末中金属粉末的浓度高于阈值产生。
作为优选，所述金属粉末经过聚丙烯蜡包覆处理，金属粉末与聚丙烯蜡质量配比为：金属粉末95％-99.5％，聚丙烯蜡0.5％-5％，两者总和为100％。作为优选，所述聚丙烯蜡的熔点≥140℃，粘度100-5000CPS，维卡软化点≥145℃。控制聚丙烯蜡熔点、粘度等的目的是：良好地包覆金属粉末，引发金属粉末在塑料粉末中的局部聚集，熔点、粘度和维卡软化点太低，聚集效应不明显。
作为优选，聚丙烯蜡包覆处理的具体方法为：将0.5-5％的聚丙烯蜡和95-99.5％的金属粉末，按比例在高速混合机上进行混合，混合工艺参数为：温度130-150℃，转速≥800rpm，混合时间3-10min，当混合温度超过150℃后，降低转速同时喷入混合物重量0.5％-2％的水雾进行降温，当温度降低到80℃后出料。
当混合温度超过150℃后，聚丙烯蜡开始融化并包覆金属粉末，温度过高包覆好的金属粉末会粘结团聚，影响使用效果，使用水雾冷却，可使包覆的金属粉末聚丙烯蜡层迅速冷却并球化，形成有良好流动性的包覆粉末。
130-150℃是混合的稳定温度，起始温度是室温，当温度上升超过150℃后就喷水雾冷却，根据不同的金属粉末种类和加料量，这个过程大概需要3-10min。
作为优选，所述聚乙粉末为线型低密度聚乙烯粉末。
本发明的有益效果是：
(1)通过滚塑工艺加工出的制品，在保持永久性抗静电效果的同时，具备良好的绝缘性，拓宽了常规单层抗静电材料的应用领域，同时避免了使用多层结构工艺带来的加工复杂性。
(2)本发明材料的制备方法简单，无需复杂设备，易实现工业化操作。
具体实施方式
下面通过具体实施例，对本发明的技术方案作进一步的具体说明。
本发明中，若非特指，所采用的原料和设备等均可从市场购得或是本领域常用的。下述实施例中的方法，如无特别说明，均为本领域的常规方法。
本发明聚乙粉末、金属粉末、聚丙烯蜡都为市售产品。
聚乙烯粉末满足：堆积密度为0.250-0.500g/cm3，粉体流动性≤30s/100g，熔体流动速率(190℃,2.16Kg)为1.0-20.0g/10min，粒径分布D98≤600μm，D10≥150μm。
聚丙烯蜡满足：熔点≥140℃，粘度100-5000CPS，维卡软化点≥145℃。
实施例1
将0.5Kg的聚丙烯蜡和99.5Kg的球状铜粉，按比例在高速混合机上进行混合，混合工艺参数为：温度150℃，转速800rpm，混合时间3min，当混合温度超过150℃后，降低转速同时喷入0.5Kg的水雾进行降温，当温度降低到80℃后出料。将90Kg聚乙烯粉末(线型低密度聚乙烯粉末)和10Kg的包覆后铜粉在低速混合机中充分混合，工艺参数为混合时间20min，转速在3-15rpm。
实施例2
将5Kg的聚丙烯蜡和95Kg的纤维状铁粉，按比例在高速混合机上进行混合，混合工艺参数为：温度130℃，转速1200rpm，混合时间10min，当混合温度超过150℃后，降低转速同时喷入2Kg的水雾进行降温，当温度降低到80℃后出料。将99.9Kg聚乙烯粉末和0.1Kg的包覆后纤维状铁粉在低速混合机中充分混合，工艺参数为混合时间2min，转速在3-15rpm。
实施例3
将2Kg的聚丙烯蜡和98Kg的片状铜锌合金粉，按比例在高速混合机上进行混合，混合工艺参数为：温度150℃，转速800rpm，混合时间5min，当混合温度超过150℃后，降低转速同时喷入1Kg的水雾进行降温，当温度降低到80℃后出料。将99.5Kg聚乙烯粉末和0.5Kg的包覆后片状铜锌合金粉在低速混合机中充分混合，工艺参数为混合时间10min，转速在3-15rpm。
实施例4
将2Kg的聚丙烯蜡和98Kg的片状银粉，按比例在高速混合机上进行混合，混合工艺参数为：温度150℃，转速800rpm，混合时间5min，当混合温度超过150℃后，降低转速同时喷入1Kg的水雾进行降温，当温度降低到80℃后出料。将99.5Kg聚乙烯粉末和0.5Kg的包覆后片状银粉，在低速混合机中充分混合，工艺参数为混合时间10min，转速在3-15rpm。
比较例1
将99.5Kg聚乙烯粉末和0.5Kg的片状铜锌合金粉在低速混合机中充分混合，工艺参数为混合时间20min。
将制得的材料各10Kg，加入包装箱的滚塑模具，在烘箱温度260℃，加热时间30min，主轴转速5rpm，副轴转速9rpm，冷却时间25min的工艺条件下进行滚塑，取出制品进行比较，结果见表1。
表面电阻率和体积电阻率按GB1410-2006《材料体积电阻率和表面电阻率试验方法》进行测试，击穿电压按GB/T 29306.2-2012《绝缘材料在300MHz以上频率下介电性能测定方法第2部分:谐振法》进行测试。从测试数据可以看出，本发明中塑料制品保持了较高的击穿电压和体积电阻率，但内表面有较低的表面电阻率，内外表面的表面电阻率有较大差异。
以上所述的实施例只是本发明的一种较佳的方案，并非对本发明作任何形式上的限制，在不超出权利要求所记载的技术方案的前提下还有其它的变体及改型。
Claims (5)
1.一种抗电击穿永久抗静电型滚塑成型用聚乙烯复合材料，其特征在于：由以下质量百分比计的组分混合制成：聚乙粉末90-99.9%，金属粉末0.1-10.0%；所述金属粉末的金属选自银、铜、金、铝、钼、 镁、钨、锌、镍、铁、铂、锡、铅中的一种金属或几种金属组成的合金；
所述金属粉末经过聚丙烯蜡包覆处理，金属粉末与聚丙烯蜡质量配比为：金属粉末95%-99.5%，聚丙烯蜡0.5%-5%，两者总和为100%；
所述聚丙烯蜡的熔点≥140℃，粘度100-5000CPS，维卡软化点≥145℃。
2.根据权利要求1所述的聚乙烯复合材料，其特征在于：所述聚乙烯粉末堆积密度为0.250-0.500g/cm3，粉体流动性≤30s/100g，熔体流动速率为1.0-20.0g/10min，粒径分布D98≤600µm，D10≥150µm。
3.根据权利要求1所述的聚乙烯复合材料，其特征在于：所述金属粉末形态为球状、片状或纤维状，其导电率≤10-6 Ω·m。
4.根据权利要求1所述的聚乙烯复合材料，其特征在于：聚丙烯蜡包覆处理的具体方法为：将0.5-5%的聚丙烯蜡和95-99.5%的金属粉末，按比例在高速混合机上进行混合，混合工艺参数为：温度130-150℃，转速≥800rpm，混合时间3-10min，当混合温度超过150℃后，降低转速同时喷入混合物重量0.5%-2%的水雾进行降温，当温度降低到80℃后出料。
5.根据权利要求1或2所述的聚乙烯复合材料，其特征在于：所述聚乙粉末为线型低密度聚乙烯粉末。
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