CN105924149A - 一种城市轨道交通过电压保护器用电阻片的制备方法 - Google Patents

一种城市轨道交通过电压保护器用电阻片的制备方法 Download PDF

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CN105924149A
CN105924149A CN201610254737.5A CN201610254737A CN105924149A CN 105924149 A CN105924149 A CN 105924149A CN 201610254737 A CN201610254737 A CN 201610254737A CN 105924149 A CN105924149 A CN 105924149A
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姚政
施利毅
程迁可
张倩
时雯
任鑫
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University of Shanghai for Science and Technology
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Abstract

本发明公开了一种轨道交通过电压保护器用压敏电阻的制备方法，其特征在于，采用ZnO为主要原料，添加剂包括Bi2O3、Co2O3、Cr2O3、Mn3O4、NiO、Sb2O3、Si02、Al(NO3)3、玻璃粉等氧化物及有机添加物，主要包括混合添加剂细化、添加剂与ZnO混合、喷雾造粒、压片、排胶、烧结、热处理、喷铝、凃绝缘层等制备步骤。本发明通过调节添加剂各氧化物的含量以及与主原料ZnO的比例等配方的优化工作以及烧结成瓷工艺、热处理工艺的调整，获得具有良好的方波通流容量及老化性能优异的电阻片，并且具有优良的保护特性，制备工艺简单，能耗低，安全可靠，完全满足用于轨道交通保护牵引电机及电气设备免受过电压的侵害。

Description

一种城市轨道交通过电压保护器用电阻片的制备方法
技术领域
本发明涉及一种轨道交通过电压保护器用电阻片的制备方法，属于功能陶瓷材料制备技术领域。
背景技术
城市轨道交通供电系统在运行过程中会遭受暂态过电压、操作过电压和雷电过电压的侵袭，使系统设备绝缘直接破坏或不断劣化，从而引发事故。在轨道交通供电系统中，用于提供动力牵引、机车电力及相关的电气设备等触网供电系统处于重要的地位，其雷电过电压保护是轨道交通安全运行的重要保证。现有对轨道交通触网的过电压保护所采用的过电压保护器为额定电压2.4kV的直流金属氧化物保护器，其有两种：一种是带串联间隙的直流金属氧化物保护器，另一种是瓷套型带发兰结构的无间隙直流金属氧化物保护器。随着轨道交通行业的迅速发展，保护轨道运行系统免受到运行中所产生的的过电压的损害变得越来越重要，作为轨道交通过电压保护器的核心元件ZnO电阻片由于具有优良的非线性伏安特性和吸收冲击能量的能力，成为了目前轨道交通过电压保护器的重要元器件，由于轨道交通对于安全、车辆动力等因数的特殊要求，其触网供电系统采用直流供电制式，因此直流工作电压要长期作用在保护器的电阻片上，因而电阻片必须具备优异的耐受直流电压下的老化特性，再加上轨道交通系统有很大一部分在地面行驶，自然雷电会随时侵入，机车的频繁启止动等因数会给系统带来巨大的浪涌电压，因此需要电阻片具有良好的通流能力。在电阻片材料配方设计中降低绝缘晶相的生成与导热系数较低的硅酸锌晶相含量。另外本发明与其他专利的不同处是在配方中使用了少量的SiO2用量，使Si与玻璃粉中B成分形成化合物后能使添加剂在晶界上形成部分玻璃网络，阻止填隙锌离子的迁移，从而大幅改善电阻片耐受直流老化性能。另外本发明添加剂制备工艺中，添加剂混合物经球磨后烘干即与主原料ZnO混合成总浆料，从而制备电阻片产品，工艺简单且成本低，有利于产业化的批量实现。
专利CN102390992B中直流系统用ZnO压敏电阻的配方设计包括Bi、Sb、Cr、Mn、Co、Ni、Zr、Al、B、Zn，配方中氧化物种类繁多，制备工艺包括添加剂的煅烧→备料→造粒→压制→排胶、预烧→烧成→研磨→热处理→喷电极→涂覆绝缘层，工艺周期长，其中添加剂煅烧以及预烧过程增加了生产成本并且造成一定的能源消耗。
专利CN200910010647.1公开的直流氧化锌电阻片采用在煅烧之后进行研磨、铋膏涂覆工艺及直流扩散工艺，该工艺需要增设氧化铋浆料制备设备、涂布设备，同时需要较长的扩散时间才能使氧化铋均匀扩散，因此工艺复杂、能源损耗较大、生产成本较高。
专利CN102249666A中将排胶后的电阻片生坯置于具有双层垫料的耐高温陶瓷板上，使生坯密封在陶瓷板与陶瓷坩埚围成的空间进行一次烧结，其工艺虽然省去了直流涂布和直流扩散工艺，但是生产效率低，设计高含铋量的密闭环境会产生氧化铋的浪费，成本增加并且实际操作难度大。
发明内容
本发明的目的是针对上述生产技术的不足，提供一种轨道交通过电压保护器用压敏电阻片的配方及制造方法，采用该配方生产出的轨道交通过电压保护器用压敏电阻片，能够满足轨道交通电力系统对压敏电阻片伏安特性及老化各方面性能的要求，同时降低生产成本，减少能耗。
一种轨道交通过电压保护器用压敏电阻为了达到上述目的，本发明采用了如下技术方案，其特征在于具有以下配方组成：
a，复合添加剂配方（重量百分比）组成： Bi2O3 23.0wt%~30.0wt%；NiO 16.0wt%~20.0wt%；Cr2O3 0.05wt%~2wt%；Sb2O3 30.0wt%~40.0wt%；Mn3O4 5wt%~7.0wt%；Co3O4 8.0wt%~12.0wt%；SiO2 1wt%~5wt%；玻璃粉（含Ag、B） 0.5%～3.0%；
b，主体ZnO与复合添加剂的重量百分配比为：（83%-90%）：（10.0%~17.0%）。
一种轨道交通过电压保护器用压敏电阻片的制备方法，其特征在于具有如下制备过程和步骤：
a，复合添加剂制备：所用添加剂粉料总质量、去离子水质量、磨球质量的比例为1:1:2.5；再加入聚丙烯酸铵型分散剂，分散剂用量为所述添加剂粉料总质量的0.6%~1.0%；装入球磨罐中，用球磨机球磨约40h~50h；将球磨后的添加剂浆料取出，过筛后放入烘箱中烘干，然后用研钵或粉碎机进行粉碎并过筛；由此制得ZnO压敏电阻用复合添加剂粉料；
b，复合添加剂同ZnO混合：添加剂与ZnO混合球磨：将上述制得的复合添加剂与ZnO、Al(NO3)3·9H2O，PVA溶液混合球磨，各物质质量百分比为ZnO 83.0wt%~90.0wt%；复合添加剂 10.0wt%~17.0wt%；另外加入Al(NO3)3·9H2O其重量按照干料量的：0.01wt%~0.04wt%加入； PVA（5%水溶液）重量按照占干料量的比例 18 % -25 %加入；的造粒粉料；
c，喷雾干燥：用于造粒的上述浆料固含量为50%~60%；并加入适量的消泡剂；喷雾干燥后的造粒料含水率控制在1.00%～2.00%；
d，压片：将上述制得的粉料进行压片制得坯体，坯体压制后的密度应控制在3.00g/cm3～3.50g/cm3；
e，排胶：将上述坯体进行，其排胶温度在480℃～530℃，在该温度保温4-5h；
f，烧成：将排胶后的电阻片坯体在1074℃～1200℃温度条件下烧成并保温3-4h；
g，磨片：对烧成后的电阻片进行磨片处理，以保证电阻片两端的平行度和端面的平整度；
h，热处理：将研磨平整的电阻片放在高温电炉中进行热处理，热处理温度：460℃～540℃，热处理保温时间为4～5h；
i，喷铝及绝缘层：对热处理后的电阻片端面进行喷铝电极处理，侧面喷涂绝缘层，最终制得成品电阻片。
与现有技术相比，本发明的突出优点和有益效果如下：
（1） ZnO电阻片的老化系数小于1，同时10kA残压比可以达到1.84以下，为轨道交通的正常运行提供了安全的保障。
（2）与现有的直流系统过电压保护器用压敏电阻相比，本发明采用的添加元素少，不进行涂铋及高温铋处理工艺，热处理温度相对高温铋处理温度较低，具有工艺简单、节能环保及成本低等优点。
（3）能够实现各种不同直流过电压保护器的通用，具有老化系数小，残压比低、容量大等性能优点，能够完全满足各种直流过电压保护器的要求，并且具有足够的安全裕度。
具体实施方式
为了便于理解本发明，现将本发明的具体实施例叙述如下。
实施例1
按质量百分比Bi2O3：28.0wt%、NiO：18.0wt%、Cr2O3：1.0wt%、Sb2O3：33.0wt%、Mn3O4：6.0wt%、Co3O4：11.0wt%、SiO2：2.0wt%、含Ag2O玻璃粉：1.0wt%进行配制ZnO压敏电阻片复合添加剂粉料。按照添加剂粉料总质量、去离子水质量、玛瑙磨球质量的比例为1:1:2.5；加入聚丙烯酸铵型分散剂，其用量为粉料总质量的0.8%，装入10L规格聚氨酯球磨罐中，用罐式球磨机球磨40h，转速设置为415r/min。
添加剂粉料烘干，然后用粉碎机进行粉碎并过筛。
由此便制得了ZnO压敏电阻用添加剂粉料。
将制得的复合添加剂按照添加剂：14.00wt%、ZnO：86.00wt%、另外加入Al(NO3)3·9H2O按照干料量的0.05%的重量比，加入进行混合球磨，另加入PVA（5%水溶液），按照占干料量的22%加入。再经过喷雾造粒、压制成型、排胶、烧结、热处理、喷铝及涂绝缘层等常规压敏电阻片制备过程，制成ZnO压敏电阻。
实施例2
按质量百分比Bi2O3：25.0wt%、NiO：17.0wt%、Cr2O3：1.0wt%、Sb2O3：37.0wt%、Mn3O4：6.0wt%、Co3O4：10.0wt%、SiO2：3.0wt%、含Ag2O玻璃粉：1.0wt%进行配制ZnO压敏电阻片复合添加剂粉料，按照添加剂粉料总质量、去离子水质量、玛瑙磨球质量的比例为1:1:2.5；加入聚丙烯酸铵型分散剂，其用量为粉料总质量的0.8%，装入10L规格聚氨酯球磨罐中，用罐式球磨机球磨40h，转速设置为415r/min。
添加剂烘干，然后用粉碎机进行粉碎并过筛。
由此便制得了ZnO压敏电阻片用复合添加剂粉料。
将制得的复合添加剂按照添加剂：14wt%、ZnO：86.00wt%、另外加入Al(NO3)3·9H2O按照干料量的0.05%的重量比加入进行混合球磨，另加入PVA（5%水溶液）按照占干料量的22%加入。再经过喷雾造粒、压制成型、排胶、烧结、热处理、喷铝及涂绝缘层等常规压敏电阻制备过程，制成ZnO压敏电阻片。
现有对轨道交通触网的过电压保护所采用的过电压保护器为额定电压2.4kV的直流金属氧化物保护器，根据现有轨道交通使用过电压保护器产品YH10WL2-2.4/4.9L产品技术规范与我们开发产品的测试结果如下：
测试指标

Claims (2)

1.一种轨道交通过电压保护器用电阻片，其特征在于具有以下配方组成：
a，复合添加剂配方组成： Bi2O3 23.0wt%~30.0wt%；NiO 16.0wt%~20.0wt%；Cr2O3 0.05wt%~2wt%；Sb2O3 30.0wt%~40.0wt%；Mn3O4 5wt%~7.0wt%；Co3O4 8.0wt%~12.0wt%；SiO2 1wt%~5wt%；玻璃粉（含Ag、B） 0.5%～3.0%；
b，主体ZnO与复合添加剂的重量百分配比为：（83%-90%）：（10.0%~17.0%）。
2.一种轨道交通过电压保护器电阻片的制备方法，其特征在于具有如下制备过程和步骤：
a，复合添加剂制备：所用添加剂粉料总质量、去离子水质量、磨球质量的比例为1:1:2.5；再加入聚丙烯酸铵型分散剂，分散剂用量为粉料总质量的0.6%~1.0%；用球磨机球磨约40h~50h；过筛后放入烘箱中烘干，然后用研钵或粉碎机进行粉碎并过筛；由此制得ZnO压敏电阻用添加剂粉料；
b，添加剂与ZnO混合，添加剂与ZnO混合球磨：将上述制得的添加剂与ZnO、Al(NO3)3、PVA溶液混合球磨，各物质质量百分比为ZnO 83.0wt%~90.0wt%；复合添加剂：10.0wt%~17.0wt%；另外加入Al(NO3)3·9H2O其重量按照干料量的 0.01%~0.04%加入； PVA（5%水溶液），其重量按照占干料量的比例：18 % -25 %加入,得造粒浆料；
c，喷雾干燥：用于造粒的上述总浆料含固率为50%~60%，并加入适量的消泡剂，喷雾干燥后的造粒料的含水率控制在1.00%～2.00%；
d，压片：将上述所得的粒料进行压片压制坯体，坯体压制后的密度应控制在3.20g/cm3～3.35g/cm3；
e， 排胶： 将制得坯体进行排胶，其排胶温度在480℃～530℃，在该温度下保温4-5h；
f，烧成：将排胶后的电阻片坯体在1074℃～1200℃下烧成并保温3-4h；
g，磨片：对烧成后的电阻片进行磨片处理，以保证电阻片两端的平行度和端面的平整度；
h，热处理：将研磨平整的电阻片放在高温电炉中进行热处理，热处理温度：460℃～540℃，热处理保温时间为4～5h；
i，喷铝及绝缘层：对热处理后的电阻片端面进行喷铝电极处理，侧面涂覆绝缘层，最终制得试品电阻片。
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