CN106486222A - 一种多层复合绝缘材料及其制备方法 - Google Patents
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Abstract
本发明公开了一种多层复合绝缘材料及其制备方法,所述多层复合绝缘材料包括电气用热固性树脂工业硬质层压板层和柔软复合材料层,所述电气用热固性树脂工业硬质层压板层和所述柔软复合材料层交替叠放,所述多层复合绝缘材料的上、下外表面层为电气用热固性树脂工业硬质层压板层,总层数 N≥3。所述绝缘材料的制备方法包括:备料、摆料、热压、冷却脱模四个步骤。本发明所述多层复合绝缘材料兼具优异的机械性能及优异的耐电压性能,制备工艺简单,可以依据实际需要应用于不同领域。
Description
技术领域
本发明涉及绝缘材料领域,尤其涉及一种多层复合绝缘材料及其制备方法。
背景技术
绝缘材料多种多样,层压制品类和柔软复合材料是较为常见的绝缘材料。层压制品类(包括:层压板、管、棒等形式)是由纤维织物增强材料浸渍或涂以树脂胶黏剂,经烘干成预浸料(又称上胶布、纸或称黏结片),而后将预浸料经热压固化成板材或经卷绕成管材或筒材。层压制品类绝缘材料因其较好的的机械性能,通常被作为绝缘结构件使用。但是,层压制品类绝缘材料的击穿强度往往难以超过20kV/mm。
柔软复合材料是由两种或两种以上绝缘材料复合而成,其组分是塑料薄膜和诸如浸渍的或不浸渍的纸、浸渍的或不浸渍的纺织品或非纺织品这样的纤维材料,具有很好的电绝缘性能,例如 0.25mm厚聚酰亚胺薄膜聚芳酰胺纤维纸柔软复合材料击穿强度可达到20kV。但是,柔软复合材料不能作为绝缘结构件使用。
然而,随着科学技术的发展,对绝缘材料也提出了更高的要求——作为绝缘结构件时,其不仅需要具有很好的机械性能,对耐电压性能也有了更高的要求。例如高压箱底面绝缘板击穿强度要求达到30kV/mm。
因此,确有必要设计一种绝缘材料,其应兼具好的耐电压性能和好的机械性能,以适应科学技术发展的需要。
发明内容
鉴于目前的绝缘材料不能兼具好的耐电压性能和好的机械性能的问题,本发明的目的是提供一种多层复合绝缘材料及其制备方法,此种复合绝缘材料兼具高机械性能以及较层压板更好的耐电压性能。
本发明的目的之一在于,提供一种兼具高击穿强度和高机械性能的多层复合绝缘材料。
本发明之多层复合绝缘材料包括:电气用热固性树脂工业硬质层压板层和柔软复合材料层,所述电气用热固性树脂工业硬质层压板层和所述柔软复合材料层交替叠放,所述多层复合绝缘材料的上、下外表面层为电气用热固性树脂工业硬质层压板层,多层复合绝缘材料的总层数 N≥3,可依据性能需要和厚度需要进行设计。
进一步地,本发明所述电气用热固性树脂工业硬质层压板层由如下任意一种热固性树脂预浸料热压固化而成:环氧树脂玻璃布预浸料、三聚氰胺树脂玻璃布预浸料、酚醛树脂玻璃布预浸料、不饱和聚酯树脂玻璃毡预浸料、有机硅树脂玻璃布预浸料、聚酰亚胺树脂玻璃布预浸料、双马来酰亚胺树脂玻璃布预浸料、聚酰胺酰亚胺树脂玻璃布预浸料,所述多层复合绝缘材料包括其中的一种或多种电气用热固性树脂工业硬质层压板层。单层电气用热固性树脂工业硬质层压板层厚度为0.1~20mm。
优选的,所述多层复合绝缘材料包括环氧酚醛树脂玻璃布预浸料热压固化而成的电气用热固性树脂工业硬质层压板层和不饱和聚酯树脂玻璃毡预浸料热压固化而成的电气用热固性树脂工业硬质层压板层,且所述环氧酚醛树脂玻璃布预浸料热压固化而成的电气用热固性树脂工业硬质层压板层与不饱和聚酯树脂玻璃毡预浸料热压固化而成的电气用热固性树脂工业硬质层压板层分别作为多层复合绝缘材料的上、下外表面层。这样的设计更有利于热压成型,而且赋予上下表面不同的性能,也能实现高的性价比。
优选的,本发明所述电气用热固性树脂工业硬质层压板层由如下任意一种热固性树脂预浸料材料热压固化而成:环氧树脂玻璃布预浸料、双马来酰亚胺树脂玻璃布预浸料、聚酰亚胺树脂玻璃布预浸料。单层电气用热固性树脂工业硬质层压板层厚度为0.1~20mm。
进一步地,本发明所述柔软复合材料层的柔软复合材料选自如下任意一种:聚酯薄膜聚酯纤维非织布柔软复合材料、聚酯薄膜聚芳酰胺纤维纸柔软复合材料、聚酰亚胺薄膜聚芳酰胺纤维纸柔软复合材料,所述多层复合绝缘材料包括其中的一种或多种柔软复合材料层。单层柔软复合材料层的总厚度为0.1~ 0.6mm。
更优选的,所述多层复合绝缘材料包括聚酰亚胺薄膜聚芳酰胺纤维纸柔软复合材料层和聚酯薄膜聚芳酰胺纤维纸柔软复合材料层,且聚酰亚胺薄膜聚芳酰胺纤维纸柔软复合材料层与所述电气用热固性树脂工业硬质层压板层交替叠放集中布置,聚酯薄膜聚芳酰胺纤维纸柔软复合材料层与所述电气用热固性树脂工业硬质层压板层交替叠放集中布置;这样的设计更利于热压成型并提高多层复合绝缘材料的性价比。
不同电气用热固性树脂工业硬质层压板层和柔软复合材料层的选择以及层数的搭配,使多层复合绝缘材料根据实际的应用需求可以有多种设计方式。优选的,所述多层复合绝缘材料的油中击穿强度为25~40 kV/mm,弯曲强度170~410MPa,体积电阻率为1×1015~9×1016Ω/cm,介电常数为4.0~5.2。
本发明的另一发明目的是,提供一种多层复合绝缘材料的制备方法。
本发明的多层复合绝缘材料的制备方法,包括以下步骤:
(1)备料:按照尺寸要求,将热固性树脂预浸料进行裁切;按照尺寸要求,对柔软复合材料进行裁切;
(2)摆料:在涂有耐高温硅油脱模剂或放有脱模用的聚酯薄膜的两块钢板之间按照所需层数及压制工艺要求的顺序交替叠放所述预浸料和所述柔软复合材料;
(3)热压:将钢板装入热压机,按照压制工艺升温热压,使所述预浸料固化成电气用热固性树脂工业硬质层压板层,并使所述电气用热固性树脂工业硬质层压板层和所述柔软复合材料粘合;
(4)冷却脱模得到所述多层复合绝缘材料,冷却脱模温度为至50℃以下。
所述多层复合绝缘材料的制备方法的步骤(3)中热压温度为100~250℃;热压压力为10~80Kg/cm2。
本发明采用层压预浸料和柔软复合材料经多层间隔叠制热压成型,可以作为绝缘结构件并具有较传统绝缘材料更优异的击穿强度和机械性能。本发明提供了所述多层复合绝缘材料的制备方法,此方法制备工艺简单,同时可以依据实际需求进行设计应用于不同领域。
附图说明
图1是本发明多层复合绝缘材料的结构示意图。
如图参考:1电气用热固性树脂工业硬质层压板层,2柔软复合材料层。
具体实施方式
为了便于理解本发明,下文将结合较佳的实施例对本发明作更全面、细致地描述,但本发明的保护范围并不限于以下具体的实施例。
除非另有定义,下文中所使用的所有专业术语与本领域技术人员通常理解的含义相同。本文中所使用的专业术语只是为了描述具体实施例的目的,并不是旨在限制本发明的保护范围。
除有特别说明,本发明中用到的各种试剂、原料均为可以从市场上购买的商品或者可以通过公知的方法制得的产品。
实施例1
如图1所示,本实施例之多层复合绝缘材料,上、下表面层为电气用热固性树脂工业硬质层压板层1,其余各层电气用热固性树脂工业硬质层压板层1与柔软复合材料层2交替叠放。具体地,包括:3层经环氧树脂玻璃布预浸料热压固化成的电气用热固性树脂工业硬质层压板层1和2层聚酯薄膜聚芳酰胺纤维纸柔软复合材料层2(材料来自,株洲时代新材料科技股份有限公司 TJ6640-NMN)。多层复合绝缘材料的上、下表面两层为经环氧树脂玻璃布预浸料热压固化成的电气用热固性树脂工业硬质层压板层1,厚度为2mm;中间一层经环氧树脂玻璃布预浸料热压固化成的电气用热固性树脂工业硬质层压板层1置于如图1所示的多层复合绝缘材料从上往下数的第3层,厚度20mm;两层聚酯薄膜聚芳酰胺纤维纸柔软复合材料层2置于如图1所示的多层复合绝缘材料从上往下数的第2、4层,第2层柔软复合材料厚度为0.30mm,第4层柔软复合材料厚度为0.50mm。
本实施例之多层复合绝缘材料的制备:(1)备料:将符合上述厚度要求的环氧树脂玻璃布预浸料和聚酯薄膜聚芳酰胺纤维纸柔软复合材料按照所需尺寸裁切;(2)摆料:在放有脱模用的聚酯薄膜的两块钢板之间,将所述预浸料和柔软复合材料按上述本实施例之多层复合绝缘材料的层次叠放;(3)热压:将摆好料的钢板装入热压机,升温热压。热压温度为100~175℃,热压压力为10~65kg/cm2,热压固化时间为5h;(4)冷却至50℃以下脱模。
该产品对应的技术指标见表1
表1 :实施例1制备的多层复合绝缘材料的技术指标
序号 | 项目 | 单位 | 指标值 |
1 | 体积电阻率 | Ω·cm | 8×1015 |
2 | 油中击穿强度 | kV/mm | 33 |
3 | 介电常数 | --- | 4.8 |
4 | 弯曲强度 | MPa | 450 |
实施例2
如图1所示,本实施例之多层复合绝缘材料,上、下表面层为电气用热固性树脂工业硬质层压板层1,其余各层电气用热固性树脂工业硬质层压板层1与柔软复合材料层2交替叠放。具体地包括:9层由双马来酰亚胺树脂玻璃布预浸料热压固化成的电气用热固性树脂工业硬质层压板层1,4层聚酰亚胺薄膜聚芳酰胺纤维纸柔软复合材料层2(材料来自,株洲时代新材料科技股份有限公司 TJ6650-NHN)和4层聚酯薄膜聚芳酰胺纤维纸柔软复合材料2(材料来自,株洲时代新材料科技股份有限公司 TJ6640-NMN)。其中,所述多层复合绝缘材料的上、下表面两层为由双马来酰亚胺树脂玻璃布预浸料热压固化成的电气用热固性树脂工业硬质层压板层1,厚度为3mm;中间7层由双马来酰亚胺树脂玻璃布预浸料热压固化成的电气用热固性树脂工业硬质层压板层1的厚度为0.5mm,置于如图1所示多层复合绝缘材料的从上往下数之第3、5、7、9、11、13、15层; 聚酰亚胺薄膜聚芳酰胺纤维纸柔软复合材料层2厚度0.15mm,置于如图1所示的多层复合绝缘材料从上往下数之第2、4、6、8层;聚酯薄膜聚芳酰胺纤维纸柔软复合材料层厚度为0.15mm,置于如图1所示的多层复合绝缘材料从上往下数之第10、12、14、16层。
本实施例之多层复合绝缘材料的制备:(1)备料:将符合上述厚度要求的双马来酰亚胺玻璃布预浸料、聚酰亚胺薄膜聚芳酰胺纤维纸柔软复合材料、聚酯薄膜聚芳酰胺纤维纸柔软复合材料按照所需尺寸裁切;(2)摆料:在涂有耐高温硅油脱模剂的两块钢板之间,所述预浸料和柔软复合材料按上述本实施例之多层复合绝缘材料的层次叠放;(3)热压:将摆好料的钢板装入热压机,升温热压。热压温度为100~190℃,热压压力为10~70 Kg/cm2;热压固化时间为3h;(4)冷却至50℃以下脱模。
该产品对应的技术指标见表2
表2: 实施例2制备的多层复合绝缘材料的技术指标:
序号 | 项目 | 单位 | 指标值 |
1 | 体积电阻率 | Ω·cm | 7×1016 |
2 | 弯曲强度 | MPa | 420 |
3 | 油中击穿强度 | kV/mm | 38 |
4 | 介电常数 | --- | 4.7 |
实施例3
如图1所示,本实施例之多层复合绝缘材料,上、下表面层为电气用热固性树脂工业硬质层压板层1,其余各层电气用热固性树脂工业硬质层压板层1与柔软复合材料层2交替叠放。具体地包括:2层环氧酚醛树脂玻璃布预浸料热压固化而成的电气用热固性树脂工业硬质层压板层1和2层不饱和聚酯树脂玻璃毡预浸料热压固化而成的电气用热固性树脂工业硬质层压板层1和3层聚酯薄膜聚酯纤维非织布柔软复合材料层2(材料来自,株洲时代新材生产的TJ6641DMD-F);其中,所述多层复合绝缘材料的上表面为环氧酚醛树脂玻璃布预浸料热压固化而成的电气用热固性树脂工业硬质层压板层1,其厚度分别为5mm;另一层环氧酚醛树脂玻璃布预浸料热压固化而成的电气用热固性树脂工业硬质层压板层置于图1所示多层复合绝缘材料从上往下数之第3层,厚度为1mm;2层不饱和聚酯树脂玻璃毡预浸料热压固化而成的电气用热固性树脂工业硬质层压板层分别置于如图1所示多层复合绝缘材料的从上往下数的第5层和下表面,第5层厚度为1mm,下表面厚度为3mm;聚酯薄膜聚酯纤维非织布柔软复合材料层的厚度0.2mm,置于图1所示多层复合绝缘材料从上往下数之第2、4、6层。
本实施例之多层复合绝缘材料的制备:(1)备料:将符合上述厚度要求环氧酚醛玻璃布预浸料、不饱和聚酯玻璃毡预浸料、聚酯薄膜聚酯纤维非织布柔软复合材料按照所需尺寸裁切;(2)摆铺有聚酯薄膜的两块钢板之间,将预浸料和柔软复合材料按上述本实施例之多层复合绝缘材料的层次叠放;(3)入模热压:将摆好料的钢板装入热压机,升温热压。热压温度为100~170℃,热压压力为10~80 Kg/cm2;热压固化时间为2h;(4)冷却至50℃以下脱模。
该产品对应的技术指标见表3
表3: 实施例3制备的多层复合绝缘材料技术指标:
序号 | 项目 | 单位 | 指标值 |
1 | 体积电阻率 | Ω·cm | 2×1015 |
2 | 弯曲强度 | MPa | 170 |
3 | 油中击穿强度 | kV/mm | 28 |
4 | 介电常数 | --- | 5.2 |
实施例4
如图1所示,本实施例之多层复合绝缘材料,上、下表面层为电气用热固性树脂工业硬质层压板层1,其余各层电气用热固性树脂工业硬质层压板层1与柔软复合材料层2交替叠放。具体地包括:2层聚酰亚胺树脂玻璃布预浸料热压固化而成的电气用热固性树脂工业硬质层压板层1和1层聚酰亚胺薄膜聚芳酰胺纤维纸柔软复合材料层2(材料来自,株洲时代新材料科技股份有限公司 TJ6650-NHN);其中,所述多层复合绝缘材料的上、下表面两层为由聚酰亚胺树脂玻璃布预浸料热压固化而成的电气用热固性树脂工业硬质层压板层1,其厚度分别为10mm和5mm;聚酰亚胺薄膜聚芳酰胺纤维纸柔软复合材料层的厚度0.25mm,置于中间一层。
本实施例之多层复合绝缘材料的制备:(1)备料:将符合上述厚度要求的聚酰亚胺树脂玻璃布预浸料和聚酰亚胺薄膜聚芳酰胺纤维纸柔软复合材料,按照所需尺寸裁切;(2)摆料:在涂有耐高温硅油脱模剂的两块钢板之间,将预浸料和柔软复合材料按上述本实施例之多层复合绝缘材料的层次叠放;(3)热压:将摆好料的钢板装入热压机,升温热压;热压温度为100~230℃,热压压力为10~70 Kg/cm2;热压固化时间为3h;(4)冷却至50℃以下脱模。
该产品对应的技术指标见表4
表4: 实施例4制备的多层复合绝缘材料技术指标:
序号 | 项目 | 单位 | 指标值 |
1 | 体积电阻率 | Ω·cm | 8×1015 |
2 | 弯曲强度 | MPa | 410 |
3 | 油中击穿强度 | kV/mm | 38 |
4 | 介电常数 | --- | 4.1 |
从上面的实施例可以看出,本发明制备的多层复合绝缘材料兼具优异的电性能(尤其是击穿电压)和机械性能。
可以理解,对于本领域技术人员来说,以上实施例只适用于对本发明的进一步说明。本领域技术人员在阅读本发明上述说明的过程中,可以从中做出多种变化和选择。这些变化和选择均在所附诸权利要求的精神和范围之内。
Claims (9)
1.一种多层复合绝缘材料,其特征在于,所述多层复合绝缘材料包括:电气用热固性树脂工业硬质层压板层和柔软复合材料层,所述电气用热固性树脂工业硬质层压板层和所述柔软复合材料层交替叠放,所述多层复合绝缘材料的上、下外表面层为电气用热固性树脂工业硬质层压板层,总层数 N≥3。
2.根据权利要求1所述的多层复合绝缘材料,其特征在于,所述电气用热固性树脂工业硬质层压板层由如下任意一种热固性树脂预浸料热压固化而成:环氧树脂玻璃布预浸料、三聚氰胺树脂玻璃布预浸料、酚醛树脂玻璃布预浸料、不饱和聚酯树脂玻璃毡预浸料、有机硅树脂玻璃布预浸料、聚酰亚胺树脂玻璃布预浸料、双马来酰亚胺树脂玻璃布预浸料、聚酰胺酰亚胺树脂玻璃布预浸料,所述多层复合绝缘材料包括其中的一种或多种电气用热固性树脂工业硬质层压板层;所述电气用热固性树脂工业硬质层压板层单层厚度为0.1~20mm。
3.根据权利要求1所述的多层复合绝缘材料,其特征在于,所述电气用热固性树脂工业硬质层压板层由如下任意一种热固性树脂预浸料热压固化而成:环氧树脂玻璃布预浸料、双马来酰亚胺树脂玻璃布预浸料、聚酰亚胺树脂玻璃布预浸料,所述多层复合绝缘材料包括其中的一种或多种电气用热固性树脂工业硬质层压板层;所述电气用热固性树脂工业硬质层压板层单层厚度为0.1~20mm。
4.根据权利要求1所述的多层复合绝缘材料,其特征在于,所述多层复合绝缘材料包括环氧酚醛树脂玻璃布预浸料热压固化而成的电气用热固性树脂工业硬质层压板层和不饱和聚酯树脂玻璃毡预浸料热压固化而成的电气用热固性树脂工业硬质层压板层,且所述环氧酚醛树脂玻璃布预浸料热压固化而成的电气用热固性树脂工业硬质层压板层与不饱和聚酯树脂玻璃毡预浸料热压固化而成的电气用热固性树脂工业硬质层压板层分别作为多层复合绝缘材料的上、下外表面层。
5.根据权利要求1所述的多层复合绝缘材料,其特征在于,所述柔软复合材料层的柔软复合材料选自如下任意一种:聚酯薄膜聚酯纤维非织布柔软复合材料、聚酯薄膜聚芳酰胺纤维纸柔软复合材料、聚酰亚胺薄膜聚芳酰胺纤维纸柔软复合材料,所述多层复合绝缘材料包括其中的一种或多种柔软复合材料层;所述柔软复合材料的单层厚度为0.1~0.6mm。
6.根据权利要求5所述的多层复合绝缘材料,其特征在于,所述多层复合绝缘材料包括聚酰亚胺薄膜聚芳酰胺纤维纸柔软复合材料层和聚酯薄膜聚芳酰胺纤维纸柔软复合材料层,且聚酰亚胺薄膜聚芳酰胺纤维纸柔软复合材料层与所述电气用热固性树脂工业硬质层压板层交替叠放集中布置,聚酯薄膜聚芳酰胺纤维纸柔软复合材料层与所述电气用热固性树脂工业硬质层压板层交替叠放集中布置。
7.根据权利要求1至6中任一项所述的多层复合绝缘材料,其特征在于,所述多层复合绝缘材料的油中击穿强度为25~40 kV/mm,弯曲强度170~450MPa,体积电阻率为1×1015~9×1016Ω/cm,介电常数为4.0~5.2。
8.一种如权利要求1至7任一项所述的多层复合绝缘材料的制备方法,其特征在于,包括以下步骤:
(1)备料,按照尺寸要求,将热固性树脂预浸料进行裁切;按照尺寸要求,将柔软复合材料进行裁切;
(2)摆料,在涂有耐高温硅油脱模剂或放有聚酯薄膜的两块钢板之间按照所需层数及压制工艺要求的顺序交替叠放所述热固性树脂预浸料和所述柔软复合材料;
(3)热压,将钢板装入热压机,按照压制工艺升温热压,使所述热固性树脂预浸料固化成电气用热固性树脂工业硬质层压板层,并使所述电气用热固性树脂工业硬质层压板层和所述柔软复合材料粘合;
(4)冷却脱模得到所述多层复合绝缘材料,冷却脱模温度为至50℃以下。
9.根据权利要求8所述多层复合绝缘材料的制备方法,其特征在于,所述步骤(3)中热压温度为100~250℃,热压压力为10~80Kg/cm2。
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