CN106349494B - 一种聚丙烯金属化薄膜加工工艺 - Google Patents
一种聚丙烯金属化薄膜加工工艺 Download PDFInfo
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Abstract
本发明涉及一种聚丙烯金属化薄膜加工工艺，通过对聚丙烯薄膜的正面依次进行脱碳处理和电晕放电处理，避免聚丙烯薄膜被在发生击穿时，击穿点的面积扩大；即使金属层不设计安全熔丝和空白隔离带，通过在金属层的表面涂覆一层顶涂层，在聚丙烯薄膜的背面涂覆一层底涂层，当金属层发生放电自愈时，自愈会时的高温电弧使得顶涂层、底涂层产生灭弧气体，灭弧气体会及时熄灭电弧，灭弧动作灵敏度高，防止电弧进一步损伤聚丙烯薄膜，避免聚丙烯薄膜发生化学分解和碳化，避免机械性损伤加深，同时还能避免多层聚丙烯薄膜连续击穿造成大面积灼伤的现象。
Description
技术领域
本发明涉及一种聚丙烯金属化薄膜加工工艺，属于电容器技术领域。
背景技术
能源短缺和环境恶化已经成为威胁人类生存的全球化问题，发展新能源是实现人类可持续发展的必经之路，中国应该加快开发利用新能源的步伐，大力发展新能源，逐步实现从常规能源向清洁能源转变。
用新能源逐步取代传统能源进行发电将是今后电力工业发展的趋势，新能源发电主要包括太阳能发电、风力发电、生物质能发电、地热发电、潮汐发电等方面。
城市轨道交通是指具有运量大、速度快、安全、准点、保护环境、节约能源和用地等特点的交通方式，包括地铁、轻轨、磁悬浮、快轨、有轨电车、新交通系统等。因此，在城市轨道交通技术领域中综合利用新能源也成为未来城市轨道交通的发展需求。
新能源汽车是指采用非常规的车用燃料作为动力来源，新能源汽车包括混合动力汽车、纯电动汽车、燃料电池电动汽车、氢发动机汽车、其他新能源（如高效储能器、二甲醚）汽车等各类别产品。
无论是新能源发电、新能源汽车还是城市轨道交通等领域，最终都是要电力设备来驱动、转换或实现，在电力设备中，电容器作为储能元件是其中的重要部件，尤其是在新能源作为非常规能源，在其综合利用过程中，对传统的电力设备尤其是电容器在体积、耐压、耐温、耐电流冲击、可靠性、使用时间上有很高的要求，目前国际上以金属化薄膜电容器最符合其要求，这方面最关键性的材料就是金属化薄膜。
现有金属化薄膜在自愈时容易发生多层介质连续击穿造成大面积灼伤的现象，为避免该情况的发生，通常设计若干规则排列的极板单元，相邻的极板单元之间存在空白隔离带，每一个极板单元通过安全熔丝连接周围的极板单元，其具有的优点是当任一极板单元发生击穿时，即电容器薄膜两极之间发生短路，从而放电并产生电弧，由于安全熔丝区域的载流量较小，因此会优先于极板单元而发生熔断，从而避免金属化薄膜被击穿；但是，该方法由于要设计安全熔丝和与安全熔丝相邻的空白隔离带，加工工艺难度非常高，加工成本高；并且该金属化薄膜在自愈时产生的电弧仍会对绝缘薄膜的表面造成热损伤和电破坏，使得绝缘薄膜发生化学分解和碳化，机械性损伤加深。
发明内容
本发明针对现有技术存在的不足，提供了一种聚丙烯金属化薄膜加工工艺，具体技术方案如下：
一种聚丙烯金属化薄膜加工工艺，包括以下步骤：
步骤一、对聚丙烯薄膜的正面依次进行脱碳处理和电晕放电处理；
步骤二、经步骤一处理的聚丙烯薄膜被送入真空镀膜机中，在真空镀膜机中采用真空蒸镀方式在聚丙烯薄膜的正面形成金属层；
步骤三、在金属层的表面涂覆一层涂料制成顶涂层，在聚丙烯薄膜的背面涂覆一层涂料制成底涂层，所述涂料由聚乙烯蜡、碳酸氢钾、硝酸铵和苯组成。
作为上述技术方案的改进，所述步骤一中脱碳处理工艺为，将聚丙烯薄膜送入烘箱中，烘箱中设置有加热辊，聚丙烯薄膜的正面与加热辊的辊身接触，加热辊辊身的温度为120~125℃，烘箱中持续通入脱碳气，脱碳气的温度为135~140℃，脱碳气由臭氧、氟气和氮气组成，其中，臭氧的体积分数为26%~28%，氟气的体积分数为14%~16%，氮气的体积分数为58%。
作为上述技术方案的改进，所述步骤三中聚乙烯蜡、碳酸氢钾、硝酸铵和苯的质量配比为，聚乙烯蜡为100~110份，碳酸氢钾为12~13份，硝酸铵为3.6~3.8份，苯为120~130份；将聚乙烯蜡加热至120~125℃使得聚乙烯蜡完全熔融成蜡液，将蜡液的温度降至100~105℃，再往蜡液中加入苯，搅拌20~30min制成蜡膏，将蜡膏的温度降至90~95℃，再往蜡膏中加入碳酸氢钾和硝酸铵，搅拌1~2h即制成涂料。
作为上述技术方案的改进，所述步骤三中顶涂层和底涂层的涂布工艺为，利用涂布机在金属层的表面涂覆一层涂料制成顶涂层，涂布机中涂料的温度为90~95℃；利用涂布机在聚丙烯薄膜的背面涂覆一层涂料制成底涂层，涂布机中涂料的温度为90~95℃。
作为上述技术方案的改进，所述聚乙烯蜡的分子量为3500~4000。
本发明的有益效果：通过对聚丙烯薄膜的正面依次进行脱碳处理和电晕放电处理，避免聚丙烯薄膜被在发生击穿时，击穿点的面积扩大；即使金属层不设计安全熔丝和空白隔离带，通过在金属层的表面涂覆一层顶涂层，在聚丙烯薄膜的背面涂覆一层底涂层，当金属层发生放电自愈时，自愈会时的高温电弧使得顶涂层、底涂层产生灭弧气体，灭弧气体会及时熄灭电弧，灭弧动作灵敏度高，防止电弧进一步损伤聚丙烯薄膜，避免聚丙烯薄膜发生化学分解和碳化，避免机械性损伤加深，同时还能避免多层聚丙烯薄膜连续击穿造成大面积灼伤的现象。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。
实施例1
将聚丙烯薄膜送入烘箱中进行脱碳处理，烘箱中设置有加热辊，聚丙烯薄膜的正面与加热辊的辊身接触，加热辊辊身的温度为120℃，烘箱中持续通入脱碳气，脱碳气的温度为135℃，脱碳气由臭氧、氟气和氮气组成，其中，臭氧的体积分数为26%，氟气的体积分数为16%，氮气的体积分数为58%。聚丙烯薄膜的正面进行脱碳处理后再进行电晕放电处理。聚丙烯薄膜经过脱碳处理和电晕放电处理后被送入真空镀膜机中，在真空镀膜机中采用真空蒸镀方式在聚丙烯薄膜的正面形成金属层，金属层为整块的镀层，金属层不存在安全熔丝和空白隔离带。
将100Kg分子量为3500~4000的聚乙烯蜡加热至120℃使得聚乙烯蜡完全熔融成蜡液，将蜡液的温度降至100℃，再往蜡液中加入120Kg苯，搅拌20min制成蜡膏，将蜡膏的温度降至90℃，再往蜡膏中加入12Kg碳酸氢钾和3.6Kg硝酸铵，搅拌1h即制成涂料。利用涂布机在金属层的表面涂覆一层涂料制成顶涂层，涂布机中涂料的温度为90℃，涂料冷却后即形成顶涂层；利用涂布机在聚丙烯薄膜的背面涂覆一层涂料制成底涂层，涂布机中涂料的温度为90℃，涂料冷却后即形成底涂层。
实施例2
将聚丙烯薄膜送入烘箱中进行脱碳处理，烘箱中设置有加热辊，聚丙烯薄膜的正面与加热辊的辊身接触，加热辊辊身的温度为123℃，烘箱中持续通入脱碳气，脱碳气的温度为138℃，脱碳气由臭氧、氟气和氮气组成，其中，臭氧的体积分数为27%，氟气的体积分数为15%，氮气的体积分数为58%。聚丙烯薄膜的正面进行脱碳处理后再进行电晕放电处理。聚丙烯薄膜经过脱碳处理和电晕放电处理后被送入真空镀膜机中，在真空镀膜机中采用真空蒸镀方式在聚丙烯薄膜的正面形成金属层，金属层为整块的镀层，金属层不存在安全熔丝和空白隔离带。
将105Kg分子量为3500~4000的聚乙烯蜡加热至122℃使得聚乙烯蜡完全熔融成蜡液，将蜡液的温度降至102℃，再往蜡液中加入125Kg苯，搅拌25min制成蜡膏，将蜡膏的温度降至92℃，再往蜡膏中加入12.5Kg碳酸氢钾和3.7Kg硝酸铵，搅拌1.5h即制成涂料。利用涂布机在金属层的表面涂覆一层涂料制成顶涂层，涂布机中涂料的温度为92℃，涂料冷却后即形成顶涂层；利用涂布机在聚丙烯薄膜的背面涂覆一层涂料制成底涂层，涂布机中涂料的温度为92℃，涂料冷却后即形成底涂层。
实施例3
将聚丙烯薄膜送入烘箱中进行脱碳处理，烘箱中设置有加热辊，聚丙烯薄膜的正面与加热辊的辊身接触，加热辊辊身的温度为125℃，烘箱中持续通入脱碳气，脱碳气的温度为140℃，脱碳气由臭氧、氟气和氮气组成，其中，臭氧的体积分数为28%，氟气的体积分数为14%，氮气的体积分数为58%。聚丙烯薄膜的正面进行脱碳处理后再进行电晕放电处理。聚丙烯薄膜经过脱碳处理和电晕放电处理后被送入真空镀膜机中，在真空镀膜机中采用真空蒸镀方式在聚丙烯薄膜的正面形成金属层，金属层为整块的镀层，金属层不存在安全熔丝和空白隔离带。
将110Kg分子量为3500~4000的聚乙烯蜡加热至125℃使得聚乙烯蜡完全熔融成蜡液，将蜡液的温度降至105℃，再往蜡液中加入130Kg苯，搅拌30min制成蜡膏，将蜡膏的温度降至95℃，再往蜡膏中加入13Kg碳酸氢钾和3.8Kg硝酸铵，搅拌2h即制成涂料。利用涂布机在金属层的表面涂覆一层涂料制成顶涂层，涂布机中涂料的温度为95℃，涂料冷却后即形成顶涂层；利用涂布机在聚丙烯薄膜的背面涂覆一层涂料制成底涂层，涂布机中涂料的温度为95℃，涂料冷却后即形成底涂层。
通常为了实现良好的自愈，需要降低聚丙烯薄膜表面的分子中碳氢原子含量，并且聚丙烯薄膜表面的分子需含有适量的氧，以便在自愈放电中聚丙烯薄膜分子发生分解时，不产生碳，不发生碳的沉积，以免形成新的导电路径，避免聚丙烯薄膜被进一步击穿。聚丙烯薄膜在脱碳处理过程中，由于臭氧和氟气的氧化性非常强，在高温下，将聚丙烯薄膜表面的分子中碳、氢原子分别氧化成CO2、CO、H2O、HF等气体，使得将聚丙烯薄膜表面的分子中碳、氢原子含量降低，臭氧易提供氧原子被聚丙烯薄膜表面的分子吸附，避免自愈放电中聚丙烯薄膜分子发生分解时产生碳，聚丙烯薄膜发生击穿的面积得到有效控制。由于臭氧易分解，可利用氟气可以进一步提高脱碳气的氧化性，氮气作为载气保护气；聚丙烯薄膜的正面与加热辊的辊身之间热接触，加热辊的辊身可为聚丙烯薄膜的正面持续提供热量，缩短反应时间，提高效率。聚丙烯薄膜的正面进行脱碳处理后再进行电晕放电处理，更利于聚丙烯薄膜正面的表面粗糙度提高。
即使该聚丙烯金属化薄膜的金属层是一整块的镀层，不存在安全熔丝和空白隔离带，由于顶涂层涂覆在金属层的表面，顶涂层的主要成分为聚乙烯蜡、碳酸氢钾和硝酸铵，当金属层上由于存在疵点导致放电自愈时，自愈会产生高温电弧，使得碳酸氢钾分解产生二氧化碳和水蒸气会熄灭电弧；硝酸铵在高温电弧的作用下也会分解产生氨气、一氧化二氮、水蒸气等，都会促使电弧迅速熄灭；硝酸铵热分解速率比碳酸氢钾高得多，通过硝酸铵可缩短电弧产生到灭弧气体（二氧化碳、水蒸气、氨气、一氧化二氮）产生二者之间的时间，灭弧动作灵敏度高，防止电弧进一步损伤聚丙烯薄膜，避免聚丙烯薄膜发生化学分解和碳化，避免机械性损伤加深。其中，碳酸氢钾在100℃时开始分解，200℃时完全分解，生成二氧化碳和水而成碳酸钾。而硝酸铵在110℃左右会分解产生氨气，在185~200℃时会分解产生一氧化二氮和水蒸气，由于硝酸铵在400℃以上时会发生剧烈分解引发爆炸；因此在加入碳酸氢钾和硝酸铵时将蜡膏的温度降至90~95℃，避免碳酸氢钾和硝酸铵分解；苯作为稀释溶解，可以降低蜡膏和后续涂料的粘度，将蜡液的温度降至100~105℃才加入苯，能够最大限定避免苯挥发。由于碳酸氢钾热分解产生的水还可避免硝酸铵剧烈分解，使得硝酸铵在电弧的作用下避免发生剧烈分解；由于硝酸铵热分解速率非常快，含量高易发生爆炸，因此硝酸铵的含量不能过高。涂布机中涂料的温度为90~95℃，不但能保证涂料有足够的粘度，当涂料缓慢冷却时还利于苯挥发。当需要焊接电机或者喷金电极时，由于顶涂层非常薄，其主体成分为聚乙烯蜡，焊接电弧会使得聚乙烯蜡熔化、气化，金属层与电容器引线能够正常电气连接。至于电容器的防爆结构可采用防爆气孔和防爆块配套，避免因灭弧气体的产生导致电容器内部产生高压。
同理，底涂层的主要成分为聚乙烯蜡、碳酸氢钾和硝酸铵，当该聚丙烯金属化薄膜卷绕成电容器芯子时，第N圈聚丙烯金属化薄膜的顶涂层和第N+1圈聚丙烯金属化薄膜的底涂层相接触，N为电容器芯子中聚丙烯金属化薄膜的圈数，底涂层和顶涂层的双重保护结构使得第N圈聚丙烯金属化薄膜的金属区进一步被防护，避免聚丙烯薄膜的损伤加深。
碳酸氢钾和硝酸铵添加在聚乙烯蜡中，还能提高顶涂层和底涂层的耐磨性；通常的金属化薄膜的工作环境为-10~85℃，分子量为3500~4000聚乙烯蜡的熔点为105~120℃（随分子量变化），碳酸氢钾和硝酸铵的热分解温度均高于100℃，聚乙烯蜡的耐寒性、耐热性、耐化学性和耐磨性均非常优良，不影响该聚丙烯金属化薄膜的正常使用。顶涂层和底涂层还能进一步保护该聚丙烯薄膜的金属区和聚丙烯薄膜，避免其在分切、二次卷绕过程中被划伤、损坏，保证产品的合格率。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本发明的保护范围之内。
Claims (1)
1.一种聚丙烯金属化薄膜加工工艺，其特征在于包括以下步骤：
步骤一、对聚丙烯薄膜的正面依次进行脱碳处理和电晕放电处理；
其中，所述脱碳处理工艺为，将聚丙烯薄膜送入烘箱中，烘箱中设置有加热辊，聚丙烯薄膜的正面与加热辊的辊身接触，加热辊辊身的温度为120～125℃，烘箱中持续通入脱碳气，脱碳气的温度为135～140℃，脱碳气由臭氧、氟气和氮气组成，其中，臭氧的体积分数为26％～28％，氟气的体积分数为14％～16％，氮气的体积分数为58％；
步骤二、经步骤一处理的聚丙烯薄膜被送入真空镀膜机中，在真空镀膜机中采用真空蒸镀方式在聚丙烯薄膜的正面形成金属层；
步骤三、在金属层的表面涂覆一层涂料制成顶涂层，在聚丙烯薄膜的背面涂覆一层涂料制成底涂层，所述涂料由聚乙烯蜡、碳酸氢钾、硝酸铵和苯组成；
其中，所述聚乙烯蜡、碳酸氢钾、硝酸铵和苯的质量配比为，聚乙烯蜡为100～110份，碳酸氢钾为12～13份，硝酸铵为3.6～3.8份，苯为120～130份；将聚乙烯蜡加热至120～125℃使得聚乙烯蜡完全熔融成蜡液，将蜡液的温度降至100～105℃，再往蜡液中加入苯，搅拌20～30min制成蜡膏，将蜡膏的温度降至90～95℃，再往蜡膏中加入碳酸氢钾和硝酸铵，搅拌1～2h即制成涂料；
所述顶涂层和底涂层的涂布工艺为，利用涂布机在金属层的表面涂覆一层涂料制成顶涂层，涂布机中涂料的温度为90～95℃；利用涂布机在聚丙烯薄膜的背面涂覆一层涂料制成底涂层，涂布机中涂料的温度为90～95℃；
所述聚乙烯蜡的分子量为3500～4000。
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| CN105597259A (zh) * | 2016-03-04 | 2016-05-25 | 中国船舶重工集团公司第七一〇研究所 | 一种快速高效气溶胶灭火剂及制备方法 |
| CN105869890A (zh) * | 2016-05-23 | 2016-08-17 | 郑州航空工业管理学院 | 一种金属化聚丙烯薄膜介质电容器的蒸镀工艺 |
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