CN106118326A - 一种纳米防电晕涂层的制备方法 - Google Patents
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Abstract
本发明涉及一种纳米防电晕涂层的制备方法，属于涂层制备技术领域。本发明主要是将异化金属还原菌接种至利用活化后的纳米四氧化三铁、纳米氧化铁等金属氧化物制备的培养基，对其进行培养后，与纳米蒙脱石、去离子水混合进行超声振荡处理，弃去上层菌种，得到吸附了异化金属还原菌的混合物，接着将其与自制的马来酸酐接枝聚乙炔进行搅拌混合，并加入铝锆偶联剂、过氧化二异丙苯，得到纳米防电晕漆，最后将其喷涂清洁的电机线圈上即可形成纳米防电晕涂层。本发明制备的纳米防电晕涂层具有较高的附着力，附着力小于2级，且所需固化时间少，室温固化时间低于22h；防电晕性能好，电晕损失功率小于22.5W/m，起晕电压可升高24～26kV。
Description
技术领域
本发明涉及一种纳米防电晕涂层的制备方法，属于涂层制备技术领域。
背景技术
发电机发展的一个趋势是电压等级越来越高，容量越来越大，尤其是大型空冷机组，这对定子绕组防电晕材料提出了新的要求，不但单根定子线棒起晕电压要求更高，而且定子绕组不能在运行过程中由于电晕作用而端部烧损。要满足这个要求的一种方法就是在成型后线棒端部表面涂刷一层高电阻防电晕漆，以及在定子绕组端部表面喷涂一层高电阻防电晕漆形成涂层。
通常电机线圈槽部的防电晕处理采用两种方法：在线圈表面涂刷低电阻防电晕漆和将低电阻防电晕漆涂在无碱玻璃布上制成低电阻防电晕带，绕包在线圈的直线部分和线圈主绝缘一起进行绝缘处理。低电阻防电晕漆是将碳黑、石墨粉体加入到绝缘漆中而制成的，但这样的防电晕方法，不论是涂刷低电阻防电晕漆还是将低电阻防电晕漆浸涂在玻璃布上制成的低电阻防电晕带，由于碳黑、石墨粉体的颗粒都处在外表面上，在电机运行中会因为线圈的热胀冷缩和振动磨擦，使碳黑、石墨颗粒脱落，改变了防电晕材料的技术参数，降低了防电晕材料的作用，仍会产生电晕造成电机绝缘过早破坏。另一方面，在线圈进行绝缘处理时浸渍漆或主绝缘中的胶互相渗透，破坏了原来的防电晕结构，同样改变了防电晕材料的技术参数，降低了防电晕性能，降低了电机预期的使用寿命。易在定子线棒的装配过程中脱落或在电机运行过程中由于各种腐蚀导致漆基失效分解而使其中所含有的改善端部电位梯度分布的成分脱落，从而最终导致绕组端部因电晕腐蚀烧损。
发明内容
本发明所要解决的技术问题：针对现有的低电阻防电晕漆中处于外部的碳黑、石墨粉体易脱落，影响其防电晕性能，同时其所需要的固化时间长，影响了其附着力的问题，本发明主要是将异化金属还原菌接种至利用纳米四氧化三铁、纳米氧化铁等金属氧化物制备的培养基，对其进行培养后，与纳米蒙脱石，去离子水混合进行超声振荡等处理，得到吸附了异化金属还原菌的混合物，接着将其与自制的马来酸酐接枝聚乙炔进行搅拌混合，并加入铝锆偶联剂、过氧化二异丙苯，得到纳米防电晕漆，最后将其喷涂清洁的电机线圈上即可形成纳米防电晕涂层。本发明制备的纳米防电晕涂层所需固化时间短，附着力高，且其防电晕效果较好。
为解决上述技术问题，本发明采用的技术方案是：
（1）依次称取3～5g纳米四氧化三铁、5～7g纳米氧化铁、2～4g纳米氧化锰、6～8纳米氧化钛、2～4g氧化铝、3～5g氧化硅加入到烧杯中，再加入200～300mL质量浓度为20～30%甲醇溶液，浸泡3～4h，过滤，得到滤渣，将滤渣用去离子水洗涤3～5次，然后将洗涤后的滤渣均匀平铺于培养皿，得培养基，再按接种量为8～12%将异化金属还原菌接种到培养基上，在36～38℃、200～220r/min下，用摇床振荡培养24～36h，得到含有异化金属还原菌菌体的混合物；
（2）将上述含有异化金属还原菌菌体的混合物置于烧杯中，依次加入200～300mL去离子水、10～20g纳米蒙脱石，再将烧杯置于超声波振荡仪中，设定温度为5～10℃，并超声振荡10～20min，静置5～10min，将下层沉淀过滤，得到滤渣，即吸附了异化金属还原菌的混合物，备用；
（3）称取30～40g聚乙炔加入到带有温度计和回流装置的三口烧瓶中，将烧瓶置于水浴锅中，控制温度在70～80℃，向烧杯中加入10～15g马来酸酐，搅拌20～30min，再依次加入0.1～0.3g过氧化月桂酰、0.2～0.4g过氧化二异丙苯，搅拌反应3～4h，得到马来酸酐接枝聚乙炔；
（4）将上述制备的马来酸酐接枝聚乙炔加入到转速为200～300r/min搅拌机中，再加入上述步骤（2）备用的吸附了异化金属还原菌的混合物，搅拌10～20min，再依次加入1～3gTL-5铝锆偶联剂、2～4g过氧化二异丙苯、3～5g空心玻璃微珠，搅拌1～2h，得到纳米防电晕漆；
（5）将上述纳米防电晕漆分次涂刷到已清洁的电机线圈上，涂刷次数为1～3次，每次涂刷厚度为0.2～0.4mm，每层涂刷完毕后在室温下自然晾干1～2h再进行下次涂刷，最后一次涂刷完毕后，在室温下自然晾干6～8h，然后再在80～90℃的条件下烘焙3～5h，然后自然恢复至室温，得到一种纳米防电晕涂层。
本发明的原理：马来酸酐接枝聚乙炔中的共轭双键是电荷转移的通道，纯的马来酸酐接枝聚乙炔无法在分子间架起电荷转移的通道桥梁，电荷只在分子内部移动，而加入吸附了异化金属还原菌的混合物后，将在分子间形成“异化属还原菌网络”， 马来酸酐接枝聚乙炔分子链与“异金属还原菌网络”形成缠结，同时“异金属还原菌网络”连接相邻的高分子链，在分子间形成键接的“桥梁”，因为分子链的电子可以传递到属氧化物上，而异化属还原菌可以将金属氧化物上的电子传递到马来酸酐上类有机物上，从而实现防电晕性能。
本发明制备的纳米防电晕涂层附着力为1级，室温固化时间低于22h，耐热等级达到F级，电晕损失功率小于22.5W/m，起晕电压可升高24～26kV。
本发明与其他方法相比，有益技术效果是：
（1）本发明制备的纳米防电晕涂层具有较高的附着力，附着力小于2级，且所需固化时间少，室温固化时间低于22h；
（2）本发明制备的纳米防电晕涂层防电晕性能好，电晕损失功率小于22.5W/m，起晕电压可升高24～26kV；
（3）本发明制备步骤简单，所需成本低。
具体实施方式
首先依次称取3～5g纳米四氧化三铁、5～7g纳米氧化铁、2～4g纳米氧化锰、6～8纳米氧化钛、2～4g氧化铝、3～5g氧化硅加入到烧杯中，再加入200～300mL质量浓度为20～30%甲醇溶液，浸泡3～4h，过滤，得到滤渣，将滤渣用去离子水洗涤3～5次，然后将洗涤后的滤渣均匀平铺于培养皿，得培养基，再按接种量为8～12%将异化金属还原菌接种到培养基上，在36～38℃、200～220r/min下，用摇床振荡培养24～36h，得到含有异化金属还原菌菌体的混合物；将上述含有异化金属还原菌菌体的混合物置于烧杯中，依次加入200～300mL去离子水、10～20g纳米蒙脱石，再将烧杯置于超声波振荡仪中，设定温度为5～10℃，并超声振荡10～20min，静置5～10min，将下层沉淀过滤，得到滤渣，即吸附了异化金属还原菌的混合物，备用；称取30～40g聚乙炔加入到带有温度计和回流装置的三口烧瓶中，将烧瓶置于水浴锅中，控制温度在70～80℃，向烧杯中加入10～15g马来酸酐，搅拌20～30min，再依次加入0.1～0.3g过氧化月桂酰、0.2～0.4g过氧化二异丙苯，搅拌反应3～4h，得到马来酸酐接枝聚乙炔；将上述制备的马来酸酐接枝聚乙炔加入到转速为200～300r/min搅拌机中，再加入备用的吸附了异化金属还原菌的混合物，搅拌10～20min，再依次加入1～3g TL-5铝锆偶联剂、2～4g过氧化二异丙苯、3～5g空心玻璃微珠，搅拌1～2h，得到纳米防电晕漆；最后将上述纳米防电晕漆分次涂刷到已清洁的电机线圈上，涂刷次数为1～3次，每次涂刷厚度为0.2～0.4mm，每层涂刷完毕后在室温下自然晾干1～2h再进行下次涂刷，最后一次涂刷完毕后，在室温下自然晾干6～8h，然后再在80～90℃的条件下烘焙3～5h，然后自然恢复至室温，得到一种纳米防电晕涂层。
实例1
首先依次称取5g纳米四氧化三铁、7g纳米氧化铁、4g纳米氧化锰、8g纳米氧化钛、4g氧化铝、5g氧化硅加入到烧杯中，再加入300mL质量浓度为30%甲醇溶液，浸泡4h，过滤，得到滤渣，将滤渣用去离子水洗涤5次，然后将洗涤后的滤渣均匀平铺于培养皿，得培养基，再按接种量为8%将异化金属还原菌接种到培养基上，在38℃、220r/min下，用摇床振荡培养36h，得到含有异化金属还原菌菌体的混合物；将上述含有异化金属还原菌菌体的混合物置于烧杯中，依次加入300mL去离子水、20g纳米蒙脱石，再将烧杯置于超声波振荡仪中，设定温度为10℃，并超声振荡20min，静置10min，将下层沉淀过滤，得到滤渣，即吸附了异化金属还原菌的混合物，备用；称取40g聚乙炔加入到带有温度计和回流装置的三口烧瓶中，将烧瓶置于水浴锅中，控制温度在80℃，向烧杯中加入15g马来酸酐，搅拌30min，再依次加入0.3g过氧化月桂酰、0.4g过氧化二异丙苯，搅拌反应4h，得到马来酸酐接枝聚乙炔；将上述制备的马来酸酐接枝聚乙炔加入到转速为300r/min搅拌机中，再加入备用的吸附了异化金属还原菌的混合物，搅拌20min，再依次加入3g TL-5铝锆偶联剂、4g过氧化二异丙苯、5g空心玻璃微珠，搅拌2h，得到纳米防电晕漆；最后将上述纳米防电晕漆分次涂刷到已清洁的电机线圈上，涂刷次数为3次，每次涂刷厚度为0.4mm，每层涂刷完毕后在室温下自然晾干2h再进行下次涂刷，最后一次涂刷完毕后，在室温下自然晾干8h，然后再在90℃的条件下烘焙5h，然后自然恢复至室温，得到一种纳米防电晕涂层。经检测，本发明制备的纳米防电晕涂层附着力为1级，室温固化时间为21h，耐热等级达到F级，电晕损失功率为21.5W/m，起晕电压可升高24kV。
实例2
首先依次称取3g纳米四氧化三铁、5g纳米氧化铁、2g纳米氧化锰、6g纳米氧化钛、2g氧化铝、3g氧化硅加入到烧杯中，再加入200mL质量浓度为20%甲醇溶液，浸泡3h，过滤，得到滤渣，将滤渣用去离子水洗涤3次，然后将洗涤后的滤渣均匀平铺于培养皿，得培养基，再按接种量为10%将异化金属还原菌接种到培养基上，在36℃、200r/min下，用摇床振荡培养24h，得到含有异化金属还原菌菌体的混合物；将上述含有异化金属还原菌菌体的混合物置于烧杯中，依次加入200mL去离子水、10g纳米蒙脱石，再将烧杯置于超声波振荡仪中，设定温度为5℃，并超声振荡10min，静置5min，将下层沉淀过滤，得到滤渣，即吸附了异化金属还原菌的混合物，备用；称取30g聚乙炔加入到带有温度计和回流装置的三口烧瓶中，将烧瓶置于水浴锅中，控制温度在70℃，向烧杯中加入10g马来酸酐，搅拌20min，再依次加入0.1g过氧化月桂酰、0.2g过氧化二异丙苯，搅拌反应3h，得到马来酸酐接枝聚乙炔；将上述制备的马来酸酐接枝聚乙炔加入到转速为200r/min搅拌机中，再加入备用的吸附了异化金属还原菌的混合物，搅拌10min，再依次加入1g TL-5铝锆偶联剂、2g过氧化二异丙苯、3g空心玻璃微珠，搅拌1h，得到纳米防电晕漆；最后将上述纳米防电晕漆分次涂刷到已清洁的电机线圈上，涂刷次数为1次，每次涂刷厚度为0.2mm，每层涂刷完毕后在室温下自然晾干1h再进行下次涂刷，最后一次涂刷完毕后，在室温下自然晾干6h，然后再在80℃的条件下烘焙3h，然后自然恢复至室温，得到一种纳米防电晕涂层。经检测，本发明制备的纳米防电晕涂层附着力为1级，室温固化时间为21h，耐热等级达到F级，电晕损失功率为21.5W/m，起晕电压可升高26kV。
实例3
首先依次称取4g纳米四氧化三铁、6g纳米氧化铁、3g纳米氧化锰、7g纳米氧化钛、3g氧化铝、4g氧化硅加入到烧杯中，再加入250mL质量浓度为25%甲醇溶液，浸泡3h，过滤，得到滤渣，将滤渣用去离子水洗涤4次，然后将洗涤后的滤渣均匀平铺于培养皿，得培养基，再按接种量为12%将异化金属还原菌接种到培养基上，在37℃、210r/min下，用摇床振荡培养30h，得到含有异化金属还原菌菌体的混合物；将上述含有异化金属还原菌菌体的混合物置于烧杯中，依次加入250mL去离子水、15g纳米蒙脱石，再将烧杯置于超声波振荡仪中，设定温度为7℃，并超声振荡15min，静置7min，将下层沉淀过滤，得到滤渣，即吸附了异化金属还原菌的混合物，备用；称取35g聚乙炔加入到带有温度计和回流装置的三口烧瓶中，将烧瓶置于水浴锅中，控制温度在75℃，向烧杯中加入12g马来酸酐，搅拌25min，再依次加入0.2g过氧化月桂酰、0.3g过氧化二异丙苯，搅拌反应3h，得到马来酸酐接枝聚乙炔；将上述制备的马来酸酐接枝聚乙炔加入到转速为250r/min搅拌机中，再加入备用的吸附了异化金属还原菌的混合物，搅拌15min，再依次加入2g TL-5铝锆偶联剂、3g过氧化二异丙苯、4g空心玻璃微珠，搅拌1h，得到纳米防电晕漆；最后将上述纳米防电晕漆分次涂刷到已清洁的电机线圈上，涂刷次数为2次，每次涂刷厚度为0.3mm，每层涂刷完毕后在室温下自然晾干2h再进行下次涂刷，最后一次涂刷完毕后，在室温下自然晾干7h，然后再在85℃的条件下烘焙4h，然后自然恢复至室温，得到一种纳米防电晕涂层。经检测，本发明制备的纳米防电晕涂层附着力为1级，室温固化时间为20h，耐热等级达到F级，电晕损失功率为21.5W/m，起晕电压可升高25kV。
Claims (1)
1.一种纳米防电晕涂层的制备方法，其特征在于具体制备步骤为：
（1）依次称取3～5g纳米四氧化三铁、5～7g纳米氧化铁、2～4g纳米氧化锰、6～8g纳米氧化钛、2～4g氧化铝、3～5g氧化硅加入到烧杯中，再加入200～300mL质量浓度为20～30%甲醇溶液，浸泡3～4h，过滤，得到滤渣，将滤渣用去离子水洗涤3～5次，然后将洗涤后的滤渣均匀平铺于培养皿，得培养基，再按接种量为8～12%将异化金属还原菌接种到培养基上，在36～38℃、200～220r/min下，用摇床振荡培养24～36h，得到含有异化金属还原菌菌体的混合物；
（2）将上述含有异化金属还原菌菌体的混合物置于烧杯中，依次加入200～300mL去离子水、10～20g纳米蒙脱石，再将烧杯置于超声波振荡仪中，设定温度为5～10℃，并超声振荡10～20min，静置5～10min，将下层沉淀过滤，得到滤渣，即吸附了异化金属还原菌的混合物，备用；
（3）称取30～40g聚乙炔加入到带有温度计和回流装置的三口烧瓶中，将烧瓶置于水浴锅中，控制温度在70～80℃，向烧杯中加入10～15g马来酸酐，搅拌20～30min，再依次加入0.1～0.3g过氧化月桂酰、0.2～0.4g过氧化二异丙苯，搅拌反应3～4h，得到马来酸酐接枝聚乙炔；
（4）将上述制备的马来酸酐接枝聚乙炔加入到转速为200～300r/min搅拌机中，再加入上述步骤（2）备用的吸附了异化金属还原菌的混合物，搅拌10～20min，再依次加入1～3gTL-5铝锆偶联剂、2～4g过氧化二异丙苯、3～5g空心玻璃微珠，搅拌1～2h，得到纳米防电晕漆；
（5）将上述纳米防电晕漆分次涂刷到已清洁的电机线圈上，涂刷次数为1～3次，每次涂刷厚度为0.2～0.4mm，每层涂刷完毕后在室温下自然晾干1～2h再进行下次涂刷，最后一次涂刷完毕后，在室温下自然晾干6～8h，然后再在80～90℃的条件下烘焙3～5h，然后自然恢复至室温，得到一种纳米防电晕涂层。
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