CN107286443A - 一种新型热敏电阻材料的制备方法 - Google Patents
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Abstract
一种新型热敏电阻材料的制备方法,包括以下制备步骤:a、将高分子聚合物、填充聚合物和聚乙烯吡咯烷酮加入密炼机中加热并搅拌,得到混合物一;b、向混合物一中加入交联剂、助剂和导电填料混合,得到混合物二;c、将混合物二用双螺杆挤出机挤出、造粒后,再进行模压成型,得到半成品;d、将半成品热处理,即可得到成品。本发明制备的电阻材料具有高的耐电压耐电流性能,且具有较低的室温电阻率、较高的PTC强度和稳定性。
Description
技术领域
本发明属于电阻材料技术领域,具体涉及一种新型热敏电阻材料的制备方法。
背景技术
具有正温度系数(PTC)的聚合物复合材料广泛应用于计算机及其外部设备、移动电话、电池组、远程通讯和网络装备、变压器、工业控制设备、汽车及其它电子产品中,起到过电流或过温保护的作用。PTC聚合物复合材料是电阻值随温度的升高而上升的一种热敏材料,即材料的电阻或者电阻率在某一定的温度范围内时基本保持不变或仅有微小量的变化,而当温度达到材料的某个特定的转变点温度附近时,材料的电阻率会在几度或十几度狭窄的温度范围内发生突变,电阻率迅速增大103~109数量级。借助于这种电阻率随温度的变化关系,该正温度系数复合材料可实现过电流或过温保护的目的。对于热敏电阻复合材料,一般希望其具有尽可能低的室温电阻率、尽可能高的PTC强度以及足够的稳定性。
目前,国内外研究和应用较为广泛的具有正温度系数(PTC)特性导电复合材料是炭黑填充的复合材料和金属颗粒为导电填料的复合材料。炭黑填充的PTC聚合物复合材料具有在较大范围内可调的导电性能,易于成型,成本低等特点;但存在的问题是室温电阻率偏高,PTC效应稳定性差,致使PTC强度及输出功率衰减过快,保护后漏电流大等。而金属颗粒为导电填料的PTC聚合物复合材料,由于金属颗粒在PTC升温相变过程中始终是刚性颗粒,不发生相变,从而导致继续升温过程中出现较严重的负温度电阻效应(NTC);NTC现象的出现不仅使PTC材料的电性能发生不可逆的变化,而且在材料的使用过程中会因材料温度过高而失效,甚至起火燃烧。因此,如何能有效构筑导电网络,保持较低的室温电阻率,并在稳定性和PTC强度方面也具备良好性能,对热敏电阻材料的实际应用意义重大。
发明内容
本发明的目的是提供一种新型热敏电阻材料的制备方法,本发明制备的电阻材料具有高的耐电压耐电流性能,且具有较低的室温电阻率、较高的PTC强度和稳定性。
本发明提供了如下的技术方案:
一种新型热敏电阻材料的制备方法,包括以下制备步骤:
a、将高分子聚合物、填充聚合物和聚乙烯吡咯烷酮加入密炼机中,在240-280℃下加热并搅拌,搅拌速度为120-150r/min,密炼2-3h,得到混合物一;
b、向混合物一中加入交联剂、助剂和导电填料,在300-450r/min的转速下,继续混合40-50min,得到混合物二;
c、将混合物二用双螺杆挤出机挤出、造粒后,再进行模压成型,得到半成品;
d、将半成品置于80-120℃的温度下,热处理4-5h,即可得到成品。
优选的,所述新型热敏电阻材料包括以下重量份的原料:高分子聚合物34-42份、填充聚合物35-39份、聚乙烯吡咯烷酮24-28份、交联剂18-23份、抗氧剂17-24份、润滑剂12-14份、助剂13-15份和导电填料17-28份。
优选的,所述步骤a的高分子聚合物为聚乙烯、聚丙烯、聚丁烯、聚偏氟乙烯和聚三氯乙烯中的任一种或多种的混合物。
优选的,所述步骤a的填充聚合物为含氟类聚合物和聚四氟乙烯聚合物。
优选的,所述步骤b的助剂为无机绝缘填料、成核剂、抗氧剂和润滑剂中的任一种或多种的混合物。
优选的,所述步骤b的导电填料为镍粉、金粉、铁粉、银粉、碳化钛和氮化钛中的任一种或多种的混合物。
优选的,所述导电填料混合前进行预处理,预处理方法为:在真空或是氮气保护条件下,采用γ射线辐照处理,然后将其研磨粉碎,最后筛选得到粒径在10-15μm。
优选的,所述研磨粉碎的方法为机械球磨、气流粉碎和超声波粉碎中的任一种。
本发明的有益效果是:
本发明制备的电阻材料具有高的耐电压耐电流性能,且具有较低的室温电阻率、较高的PTC强度和稳定性。
本发明的原材料成本低廉,来源广泛,且本发明制备方法简单、易操作、制备流程短,因此适合工业化大规模生产制造。
本发明的制备过程中无二次污染物的产生,且原材料均不会产生环境污染,因此具有一定的节能、环保意义。
具体实施方式
实施例1
一种新型热敏电阻材料的制备方法,包括以下制备步骤:
a、将高分子聚合物、填充聚合物和聚乙烯吡咯烷酮加入密炼机中,在240℃下加热并搅拌,搅拌速度为150r/min,密炼3h,得到混合物一;
b、向混合物一中加入交联剂、助剂和导电填料,在350r/min的转速下,继续混合40min,得到混合物二;
c、将混合物二用双螺杆挤出机挤出、造粒后,再进行模压成型,得到半成品;
d、将半成品置于80℃的温度下,热处理5h,即可得到成品。
新型热敏电阻材料包括以下重量份的原料:高分子聚合物42份、填充聚合物35份、聚乙烯吡咯烷酮28份、交联剂18份、抗氧剂24份、润滑剂12份、助剂13份和导电填料28份。
步骤a的高分子聚合物为聚乙烯、聚丙烯、聚丁烯、聚偏氟乙烯和聚三氯乙烯的混合物。
步骤a的填充聚合物为含氟类聚合物和聚四氟乙烯聚合物。
步骤b的助剂为无机绝缘填料、成核剂、抗氧剂和润滑剂的混合物。
步骤b的导电填料为镍粉、金粉、铁粉、银粉、碳化钛和氮化钛的混合物。
导电填料混合前进行预处理,预处理方法为:在真空或是氮气保护条件下,采用γ射线辐照处理,然后将其研磨粉碎,最后筛选得到粒径在15μm。
研磨粉碎的方法为气流粉碎。
检测本实施例制备的电阻材料的性能:体积电阻率为0.074Ω·㎝,PTC强度大于10。
实施例2
一种新型热敏电阻材料的制备方法,包括以下制备步骤:
a、将高分子聚合物、填充聚合物和聚乙烯吡咯烷酮加入密炼机中,在240℃下加热并搅拌,搅拌速度为120r/min,密炼2h,得到混合物一;
b、向混合物一中加入交联剂、助剂和导电填料,在300r/min的转速下,继续混合40min,得到混合物二;
c、将混合物二用双螺杆挤出机挤出、造粒后,再进行模压成型,得到半成品;
d、将半成品置于80℃的温度下,热处理4h,即可得到成品。
新型热敏电阻材料包括以下重量份的原料:高分子聚合物34份、填充聚合物35份、聚乙烯吡咯烷酮24份、交联剂18份、抗氧剂17份、润滑剂12份、助剂13份和导电填料17份。
步骤a的高分子聚合物为聚乙烯、聚丙烯、聚丁烯、聚偏氟乙烯和聚三氯乙烯的混合物。
步骤a的填充聚合物为含氟类聚合物和聚四氟乙烯聚合物。
步骤b的助剂为无机绝缘填料、成核剂、抗氧剂和润滑剂的混合物。
步骤b的导电填料为镍粉、金粉、铁粉、银粉、碳化钛和氮化钛的混合物。
导电填料混合前进行预处理,预处理方法为:在真空或是氮气保护条件下,采用γ射线辐照处理,然后将其研磨粉碎,最后筛选得到粒径在10μm。
研磨粉碎的方法为超声波粉碎。
检测本实施例制备的电阻材料的性能:体积电阻率为0.078Ω·㎝,PTC强度大于10。
实施例3
一种新型热敏电阻材料的制备方法,包括以下制备步骤:
a、将高分子聚合物、填充聚合物和聚乙烯吡咯烷酮加入密炼机中,在280℃下加热并搅拌,搅拌速度为150r/min,密炼3h,得到混合物一;
b、向混合物一中加入交联剂、助剂和导电填料,在300-450r/min的转速下,继续混合50min,得到混合物二;
c、将混合物二用双螺杆挤出机挤出、造粒后,再进行模压成型,得到半成品;
d、将半成品置于120℃的温度下,热处理5h,即可得到成品。
新型热敏电阻材料包括以下重量份的原料:高分子聚合物42份、填充聚合物39份、聚乙烯吡咯烷酮28份、交联剂23份、抗氧剂24份、润滑剂14份、助剂15份和导电填料28份。
步骤a的高分子聚合物为聚乙烯、聚丙烯、聚丁烯、聚偏氟乙烯和聚三氯乙烯的混合物。
步骤a的填充聚合物为含氟类聚合物和聚四氟乙烯聚合物。
步骤b的助剂为无机绝缘填料、成核剂、抗氧剂和润滑剂的混合物。
步骤b的导电填料为镍粉、金粉、铁粉、银粉、碳化钛和氮化钛的混合物。
导电填料混合前进行预处理,预处理方法为:在真空或是氮气保护条件下,采用γ射线辐照处理,然后将其研磨粉碎,最后筛选得到粒径在15μm。
研磨粉碎的方法为机械球磨。
检测本实施例制备的电阻材料的性能:体积电阻率为0.075Ω·㎝,PTC强度大于10。
以上所述仅为本发明的优选实施例而已,并不用于限制本发明,尽管参照前述实施例对本发明进行了详细的说明,对于本领域的技术人员来说,其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换。凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (8)
1.一种新型热敏电阻材料的制备方法,其特征在于,包括以下制备步骤:
a、将高分子聚合物、填充聚合物和聚乙烯吡咯烷酮加入密炼机中,在240-280℃下加热并搅拌,搅拌速度为120-150r/min,密炼2-3h,得到混合物一;
b、向混合物一中加入交联剂、助剂和导电填料,在300-450r/min的转速下,继续混合40-50min,得到混合物二;
c、将混合物二用双螺杆挤出机挤出、造粒后,再进行模压成型,得到半成品;
d、将半成品置于80-120℃的温度下,热处理4-5h,即可得到成品。
2.根据权利要求1所述的一种新型热敏电阻材料的制备方法,其特征在于,所述新型热敏电阻材料包括以下重量份的原料:高分子聚合物34-42份、填充聚合物35-39份、聚乙烯吡咯烷酮24-28份、交联剂18-23份、抗氧剂17-24份、润滑剂12-14份、助剂13-15份和导电填料17-28份。
3.根据权利要求1所述的一种新型热敏电阻材料的制备方法,其特征在于,所述步骤a的高分子聚合物为聚乙烯、聚丙烯、聚丁烯、聚偏氟乙烯和聚三氯乙烯中的任一种或多种的混合物。
4.根据权利要求1所述的一种新型热敏电阻材料的制备方法,其特征在于,所述步骤a的填充聚合物为含氟类聚合物和聚四氟乙烯聚合物。
5.根据权利要求1所述的一种新型热敏电阻材料的制备方法,其特征在于,所述步骤b的助剂为无机绝缘填料、成核剂、抗氧剂和润滑剂中的任一种或多种的混合物。
6.根据权利要求1所述的一种新型热敏电阻材料的制备方法,其特征在于,所述步骤b的导电填料为镍粉、金粉、铁粉、银粉、碳化钛和氮化钛中的任一种或多种的混合物。
7.根据权利要求6所述的一种新型热敏电阻材料的制备方法,其特征在于,所述导电填料混合前进行预处理,预处理方法为:在真空或是氮气保护条件下,采用γ射线辐照处理,然后将其研磨粉碎,最后筛选得到粒径在10-15μm。
8.根据权利要求7所述的一种新型热敏电阻材料的制备方法,其特征在于,所述研磨粉碎的方法为机械球磨、气流粉碎和超声波粉碎中的任一种。
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