CN106147944A - 一种制备低噪音润滑脂的新工艺 - Google Patents
一种制备低噪音润滑脂的新工艺 Download PDFInfo
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Abstract
本发明涉及低噪音润滑脂及其制备新工艺。本发明的低噪音润滑脂按照重量份数计算,其包括以下原料:3‑5重量份的单水氢氧化锂、5‑15重量份的稠化剂、70‑90重量份的基础油,3‑5重量份的添加剂。本发明的低噪音润滑脂的制备工艺使用具有300‑400目不锈钢钢网的逐级过滤器对皂进行分散剪切,所得具有优良的耐温性、防锈性、抗氧化性和抗剪切性,能够明显稳定降低轴承的噪音,值得在轴承产业中推广和应用。
Description
技术领域
本发明涉及润滑脂领域,具体涉及制备低噪音润滑脂的新工艺。
背景技术
现代制造工业,尤其是办公自动化设备、机动车和家用电器中的电机,要求提供低噪音和低振动的轴承。近年来,由于轴承加工技术的进步,轴承的制造精度有了很大提高,噪音显著降低。然而润滑脂的使用仍然是降低噪音的最为便捷的方法之一。目前约有80%的滚动轴承以及20%的滑动轴承均使用润滑脂润滑,润滑脂已被认为是轴承内圈、外圈、滚动体和保持架之后不可缺少的第五大“元件”,成为影响轴承噪音的主要因素。
润滑脂属于非牛顿流体,具有独特的流变特性,与润滑油相比,润滑脂具有使用寿命长、适于高温润滑、承载能力好、阻尼性能佳、粘附性增强等不可替代的优点。而低噪音润滑脂除了具有上述特性之外,还能有效降低轴承的噪音,从而延长了轴承寿命,改善了环境质量。因此,低噪音润滑脂具有巨大的经济效益,其研究、生产和使用已经成为国内外润滑脂行业关注的热点。
稠化剂是润滑脂的骨架,含量占润滑脂总量的5%~30%,稠化剂在润滑脂中的主要作用是稳固基础油,降低基础油的流动性。稠化剂通常可分为皂基、烃基、有机以及无机稠化剂,稠化剂的结构与性能对润滑脂的使用寿命有较大影响。目前大多轴承润滑脂采用较多的稠化剂仍为皂基稠化剂。一直以来,在低噪音润滑脂制备中,润滑脂的杂质问题常常被认为是影响低噪音润滑脂性能的重要因素,认为只要控制好润滑脂的杂质就能降低轴承的噪音,杂质越多,噪音就越大。然而随着低噪音润滑脂生产工艺的改良和发展,许多研究者发现,润滑脂的稠化剂、皂纤维的结构和分散好坏也会影响到轴承的噪音。皂纤维分散得好,能在润滑脂中形成均匀的,纤维匀称的结构,噪音就小,且稳定;反之,润滑脂中有未分散好的皂团,皂纤维分散不均匀,噪音就大。因此,有必要开发出新的能够形成分散均匀的皂结构的低噪音润滑脂制备工艺,以增强润滑脂的降噪性能,满足轴承产业和工业机械的润滑需要。
发明内容
本发明的目的是生产降噪音性能增强的低噪音润滑脂。
为了实现本发明的目的,在一个方面中,本发明提供了一种低噪音润滑脂,按照重量份数计算,其包括以下原料:1-5重量份的单水氢氧化锂、5-15重量份的稠化剂、70-90重量份的基础油,3-5重量份的添加剂,并在生产工艺中增加一道逐级分散剪切工序。
在一个实施方案中,所述稠化剂优选是脂肪类化合物,更优选是十二羟基硬脂酸和硬脂酸的混合物,其中十二羟基硬脂酸和硬脂酸的比率在8:2至7:3之间。
根据本发明的一个实施方案,在本发明的低噪音润滑脂中,所述基础油是500SN、环烷基基础油和K10B中的一种或几种。优选基础油是500SN、环烷基基础油和K10B的混合物。更优选其中所述500SN的100℃运动粘度为8-10mm2,倾点低于-9℃,占混合物总量的20%-40%;环烷基基础油的100℃运动粘度为14-16mm2,倾点低于-15℃,占混合物总量的30%-50%;K10B的100℃运动粘度为8-12mm2,倾点低于5℃,占混合物总量的20%-30%。
在一个实施方案中,本发明组合物中的添加剂可以是抗氧剂、防锈剂和粘附剂中的一种或多种。在一个优选的实施方案中,所述添加剂是抗氧剂、防锈剂和粘附剂的组合。
在一个实施方案中,所述抗氧剂可以是胺型或酚型抗氧剂,优选选自二苯胺、二异辛基二苯胺、2,6二叔丁基酚中的一种或多种,更优选是二苯胺。
在一个实施方案中,所述防锈剂可以同时包含针对黑色金属的防锈剂和针对有色金属的防锈剂二者。更具体地,针对黑色金属的防锈剂选自石油磺酸钡、二壬基萘磺酸钡、环烷酸锌、羊毛脂金属皂中的一种或多种,优选是石油磺酸钡,而针对有色金属的防锈剂例如苯并三唑。
在一个实施方案中,所述粘附剂为高粘度聚丁烯或乙丙胶,优选是高粘度聚丁烯。
在一个实施方案中,本发明的低噪音润滑脂,所述的低噪音润滑脂,按照重量份数计算,其包括以下原料:1重量份的单水氢氧化锂、10重量份的稠化剂、70-90重量份的基础油、0.8重量份的二苯胺、2重量份的石油磺酸钡和1.2重量份的聚丁烯。
在又一个方面中,本发明提供了一种制备低噪音润滑脂的新工艺,其包括以下步骤:
(1)公用工程的确认:生产前先检查水、电、汽、空气等公用工程,并确认其正常供应;
(2)热媒炉运转:检查确认泵润滑油贮罐内油的液位达到规定液位后,启动热媒油泵,其中将热媒油温度设定为250℃,喷嘴点火,使热煤加热炉开始运转;
(3)反应釜投料:釜中加入经1-2μm滤布筒式过滤器过滤的部分基础油作为底油,启动搅拌运转,将十二羟基硬脂酸、硬脂酸投入进行熔融,温度不超过90℃,后经1-2μm过滤器过滤,进入反应釜,随后投入经250目不锈钢网过滤的氢氧化锂水溶液;
(4)皂化:将反应釜各阀门关闭,2小时内升温至150℃,随后逐步打开放空阀;
(5)稠化:确认料温为160-180℃,加余油,取样测皂基游离碱并进行调整,搅拌冷却;
(6)移送:使反应釜继续升温,至料温达到210~212℃,保持2分钟后,打开反应釜出脂阀,将脂泵入冷却釜,同时通过加入了急冷油的急冷器,待脂全部移入冷却釜后,加反应釜洗油,反应釜停止运转,将热媒加热炉熄火,待热媒油冷却至100℃以下后,热油泵停止运转;
(7)皂分散剪切:利用泵使料通过循环管线,经逐级过滤器,用300-400目不锈钢网循环剪切过滤2h;剪切压力为0.4-0.6Mpa;
(8)均化:使料温降至110~120℃时,将脂泵入均化器,在20MPa的压力下,均化后移入调和釜;
(9)加入添加剂:开动搅拌,90℃以下加入经300目过滤的二苯胺、石油磺酸钡和聚丁烯;
(10)调整锥入度:回流搅拌30分钟后,取样测锥入度,并进行调整;
(11)脱气:将产品泵入脱气釜进行脱气;
(12)过滤包装:利用出脂泵,经400目过滤后充填包装,取样作全检。
现有的低噪音润滑脂制备中使用1-2μm滤布筒式过滤器对原料进行过滤,仅能降低轴承噪音约2-3个分贝。而本发明的低噪音润滑脂的制备工艺使用具有300-400目不锈钢钢网的逐级过滤器对皂进行分散剪切。所得润滑脂产品经客户使用和检测,轴承的噪音可降低5-8个分贝,且性能稳定。本发明的低噪音润滑脂具有优良的耐温性、防锈性、抗氧化性和抗剪切性,能够明显降低轴承的噪音,使用温度范围广(-20~120℃),值得在轴承产业中推广和应用。
具体实施方式
以下通过具体实施方式的描述对本发明作进一步说明,但这并非是对本发明的限制,本领域技术人员根据本发明的基本思想,可以做出各种修改或改进,但是只要不脱离本发明的基本思想,均在本发明的范围之内。
实施例1:本发明的低噪音润滑脂的制备
按照以下质量比例配制760kg基础油:30%500SN、40%环烷基基础油和30%K10B。
将10kg单水氢氧化锂溶于水中,制备碱溶液;随后按照以下方法制备本发明的低噪音润滑脂:
(1)公用工程的确认:生产前先检查水、电、汽、空气等公用工程,并确认其正常供应;
(2)热媒炉运转:检查确认泵润滑油贮罐内油的液位达到规定液位后,启动热媒油泵,其中将热媒油温度设定为250℃,喷嘴点火,使热煤加热炉开始运转;
(3)反应釜投料:釜中加入经2μm滤布筒式过滤器过滤的600kg基础油作为底油,启动搅拌运转,将80kg十二羟基硬脂酸、20kg硬脂酸投入进行熔融,温度不超过90℃,后经1-2μm过滤器过滤,进入反应釜,随后投入经250目不锈钢网过滤的单水氢氧化锂水溶液;
(4)皂化:将反应釜各阀门关闭,2小时内升温至150℃,随后逐步打开放空阀;
(5)稠化:确认料温为170℃,加余油,取样测皂基游离碱并进行调整,搅拌冷却;
(6)移送:使反应釜继续升温,至料温达到210℃,保持2分钟后,打开反应釜出脂阀,将脂泵入冷却釜,同时通过加入急冷油的急冷器,待脂全部移入冷却釜后,加反应釜洗油50公斤,反应釜停止运转,将热媒加热炉熄火,待热媒油冷却至100℃以下后,热油泵停止运转;
(7)皂分散剪切:利用泵使料通过循环管线,经逐级过滤器,用300目不锈钢网循环剪切过滤2h;剪切压力为0.6Mpa;
(8)均化:使料温降至120℃时,将脂泵入均化器,在20MPa的压力下,均化后移入调和釜;
(9)加入添加剂:开动搅拌,90℃以下加入经300目过滤的8kg二苯胺、20kg石油磺酸钡和12kg聚丁烯;
(10)调整锥入度:回流搅拌30分钟后,取样测锥入度,并进行调整;
(11)脱气:将产品泵入脱气釜进行脱气;
(12)过滤包装:利用出脂泵,经400目过滤后充填包装,取样作全检。
实施例2:本发明的低噪音润滑脂质量指标的测定
经测定,本发明的低噪音润滑脂各项质量指标如表1所示。
表1.质量指标表
检测结果显示,本发明的低噪音润滑脂具有优良的耐温性、防锈性、抗氧化性和抗剪切性,表明本发明低噪音润滑脂的配方合理,制备工艺效果佳,已在浙江,山东等地的轴承产业上大规模使用。
Claims (7)
1.一种低噪音润滑脂,按照重量份数计算,其包括以下原料:1-5重量份的单水氢氧化锂、5-15重量份的稠化剂、70-90重量份的基础油,3-5重量份的添加剂。
2.根据权利要求1所述的低噪音润滑脂,其中所述添加剂是抗氧剂、防锈剂和粘附剂的组合。
3.根据权利要求1或2所述的低噪音润滑脂,其中所述稠化剂是十二羟基硬脂酸和硬脂酸的混合物。
4.根据权利要求3所述的低噪音润滑脂,其中所述十二羟基硬脂酸和所述硬脂酸的比率在8:2至7:3之间。
5.根据权利要求1或2所述的低噪音润滑脂,其中所述基础油是500SN、环烷基基础油和K10B中的一种或几种。
6.根据权利要求1或2所述的低噪音润滑脂,按照重量份数计算,其包括以下原料:1重量份的单水氢氧化锂、10重量份的稠化剂、70-90重量份的基础油、0.8重量份的抗氧剂、2重量份的防锈剂和1.2重量份的粘附剂。
7.一种制备低噪音润滑脂的工艺,其包括以下步骤:
(1)公用工程的确认:生产前先检查水、电、汽、空气等公用工程,并确认其正常供应;
(2)热媒炉运转:检查确认泵润滑油贮罐内油的液位达到规定液位后,启动热媒油泵,其中将热媒油温度设定为250℃,喷嘴点火,使热煤加热炉开始运转;
(3)反应釜投料:釜中加入经1-2μm滤布筒式过滤器过滤的部分基础油作为底油,启动搅拌运转,将十二羟基硬脂酸、硬脂酸投入进行熔融,温度不超过90℃,后经1-2μm过滤器过滤,进入反应釜,随后投入经250目不锈钢网过滤的氢氧化锂水溶液;
(4)皂化:将反应釜各阀门关闭,2小时内升温至150℃,随后逐步打开放空阀;
(5)稠化:确认料温为160-180℃,加余油,取样测皂基游离碱并进行调整,搅拌冷却;
(6)移送:使反应釜继续升温,至料温达到210~212℃,保持2分钟后,打开反应釜出脂阀,将脂泵入冷却釜,同时通过加入了急冷油的急冷器,待脂全部移入冷却釜后,加反应釜洗油,反应釜停止运转,将热媒加热炉熄火,待热媒油冷却至100℃以下后,热油泵停止运转;
(7)皂分散剪切:利用泵使料通过循环管线,经逐级过滤器,用300-400目不锈钢网循环剪切过滤2h;剪切压力为0.4-0.6Mpa;
(8)均化:使料温降至110~120℃时,将脂泵入均化器,在20MPa的压力下,均化后移入调和釜;
(9)加入添加剂:开动搅拌,90℃以下加入经300目过滤的二苯胺、石油磺酸钡和聚丁烯;
(10)调整锥入度:回流搅拌30分钟后,取样测锥入度,并进行调整;
(11)脱气:将产品泵入脱气釜进行脱气;
(12)过滤包装:利用出脂泵,经400目过滤后充填包装,取样作全检。
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CN111704951A (zh) * | 2020-06-29 | 2020-09-25 | 金鹰润滑材料(金湖)有限公司 | 一种超低温静音轴承润滑脂及其制备工艺 |
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