CN107310178A - 一种芳纶纤维绝缘拉杆的制备方法 - Google Patents
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Abstract
本发明公开了一种芳纶纤维绝缘拉杆的制备方法,包括芳纶毛坯管的制备、芳纶毛坯管和两端金属接头的加工和粘接。芳纶毛坯管的制备采用芳纶纤维与聚酯纤维混纺成布,芳纶纤维布经过表面处理,卷绕成型,烘干除湿,真空浸渍树脂,一次固化,脱模后再进行二次固化制备成芳纶毛坯管,对芳纶毛坯管的粘接面进行机加工后,将芳纶毛坯管的两端与金属接头进行粘接,从而制备成芳纶纤维绝缘拉杆。利用这种制备方法可解决芳纶纤维绝缘拉杆制备过程中芳纶纤维布与环氧树脂浸润性差,真空浸渍过程中芳纶毛坯管内部产生气孔、分层等现象,金属接头与芳纶毛坯管粘接不牢靠、粘接区易产生气隙等技术缺陷。
Description
技术领域
本发明涉及一种绝缘拉杆的制备方法,尤其是涉及一种芳纶纤维增强环氧树脂复合材料绝缘拉杆的制备方法,属于材料制作技术领域。
背景技术
绝缘拉杆作为高压开关设备中分合闸的关键零部件,要求其具备绝缘性能优异、机械性能高、重量轻及耐SF6气体分解物腐蚀等特点。高压开关断路中绝缘拉杆广泛采用的是将两端接头用环氧树脂浇注成一体,此种浇注工艺生产出来的绝缘拉杆存在重量大、机械性能差、长度较短缺点。
为了改进浇注绝缘拉杆的缺点,国内常见的方法是采用真空压力浸渍玻璃纤维管替代浇注绝缘拉杆,并根据需要在玻璃纤维管两端通过螺纹或胶粘方式连接金属接头,由于玻璃纤维在纺丝过程中易造成内部孔洞,成型过程中无法避免绝缘拉杆内部的气隙,并且玻璃纤维易受SF6气体分解物的腐蚀,所以玻璃纤维绝缘拉杆存在许多质量隐患。
真空浸渍芳纶布绝缘拉杆是将芳纶纤维布与环氧树脂在真空条件下充分浸润再进行固化而得的绝缘管。由于芳纶纤维表面极其规整,与环氧树脂的浸润性差,在成型过程中容易造成浸润不充分、拉杆内部产生气隙、分层等质量缺陷,从而极大的降低了芳纶绝缘拉杆的绝缘性能。此外,绝缘管与两端金属接头在粘接过程中易造成粘接不牢固、不稳定,排气孔堵塞,粘接面产生气隙等缺陷,从而极大的降低芳纶绝缘拉杆的机械性能、操作可靠性和电气性能。
发明内容
本发明要提供一种机械性能和电气性能高,操作可靠性高的芳纶纤维绝缘拉杆的制备方法,从而解决芳纶纤维与环氧树脂浸润性差、树脂适用期短、分层、芳纶毛坯管与接头粘接不牢靠等技术难题。
技术方案:
一种芳纶纤维绝缘拉杆的制备方法,其特征在于,通过芳纶纤维与聚酯纤维混纺成芳纶纤维布,经过表面处理、卷绕成型、烘干除湿、真空浸渍树脂、一次固化、脱模、再进行二次固化的步骤制备成芳纶毛坯管,对芳纶毛坯管的粘接面进行机加工后,将芳纶毛坯管的两端与金属接头进行粘接,制备成芳纶纤维绝缘拉杆。
所述工艺流程的具体步骤是:
1)步骤1:芳纶纤维与聚酯纤维混纺成经纬向的芳纶纤维布,经过表面处理后干燥存放;
2)步骤2:模芯表面抛光及用脱模剂处理,在模芯上缠绕芳纶纤维布,然后将缠有芳纶纤维布的模芯置于烘箱内;
3)步骤3:对烘箱内的芳纶纤维布进行高温干燥,以去除芳纶纤维内部残留的水分;
4)步骤4:根据配比将环氧树脂、固化剂和促进剂在真空浸渍工艺温度条件下搅拌混合得到树脂,然后导入到混料罐中进行真空脱气待用;
5)步骤5:将流程3中得到的烘干芳纶半成品装配至真空罐中,进行加热抽真空除湿;
6)步骤6:待真空罐中的真空度和温度达到工艺要求的条件下,将流程4中得到的脱气待用的树脂真空导入真空罐中;
7)步骤7:在工艺要求的真空度和温度下,将芳纶纤维布浸渍在树脂中,真空保持5~18h,使树脂充分浸润芳纶纤维布;
8)步骤8:树脂导回混料罐中循环利用,取出真空罐中的芳纶半成品,在缠绕机上以工艺要求的缠绕角度和张力缠绕聚酯薄膜,使树脂不溢出;
9)步骤9:将芳纶半成品放入专用烘箱内进行一次固化,固化过程中采用旋转固化,使树脂分布均匀;
10)步骤10:将模具降温,在专用脱模机上进行脱模,将模芯脱出,得到芳纶毛坯管;
11)步骤11:将芳纶毛坯管放入烘箱内进行二次固化,以消除芳纶毛坯管的内应力;
12)步骤12:对芳纶毛坯管的粘接面进行机加工,对接头进行喷砂处理,采用合适的粘接剂,在专用粘接工装上将芳纶毛坯管与接头进行粘接,得到芳纶纤维绝缘拉杆。
优选的,流程2中所述的芳纶纤维布为芳纶纤维与聚酯纤维混纺的布,布的重量为280g/m2;
优选的,流程4中所述的树脂中的环氧树脂、固化剂和促进剂的重量比为100:98:5。
优选的,流程6中所述的真空度为1~20mbar,浸渍温度为30~60℃。
优选的,流程8中的缠绕角度为15°~75°,缠绕张力为15~45N。
优选的,流程12中对芳纶毛坯管进行加工和粘接,包括以下步骤:
1)步骤12-1:将芳纶毛坯管的粘接面头部加工成倾斜角,粘接面加工多个沟槽以增加粘接面积,提高粘接力;毛坯管粘接面的直径比接头的直径大0.05~0.50mm,使得毛坯管与接头形成紧配合;
2)步骤12-2:接头粘接面也加工多个沟槽,采用不锈钢砂粒对粘接面进行喷砂处理,使表面粗糙度达到25um或以上;
3)步骤12-3:用丙酮将步骤12-1加工完的芳纶毛坯管擦拭干净,再放入烘箱内加热2h~5h;
4)步骤12-4:粘接一端接头,将粘接剂均匀涂覆在毛坯管一端和与其接头的粘接面上,使得沟槽内充满粘接剂,再将接头插入毛坯管内,放入烘箱内进行初固化;
5)步骤12-5:粘接另一端接头,将粘接剂均匀涂覆在毛坯管另一端和与其接头的粘接面上,使得沟槽内充满粘接剂,再将毛坯管和接头分别装配至专用粘接工装上,后将另一端接头插入毛坯管内,放入烘箱内进行高温固化,得到芳纶纤维绝缘拉杆。
优选的,步骤12所述的粘接剂为双组分粘接剂,其环氧树脂与固化剂的重量比为100:70~90。
有益效果:
1)采用真空混料罐使树脂内部的气泡充分排出,再利用真空罐与混料罐内的压差,使脱完气的树脂缓慢流入真空罐内的浸胶槽,能使芳纶纤维布与环氧树脂充分浸润;
2)采用专用的聚酯薄膜在半成品外表面缠绕,使环氧树脂固封在芳纶纤维布内部,在固化过程中采用旋转固化,使芳纶毛坯管内部的树脂在固化过程中不溢出,且分布均匀;
3)脱模后对芳纶毛坯管进行二次固化,充分消除其内应力;
4)芳纶毛坯管与铝合金的接头粘接面通过增加沟槽、喷砂处理,及粘接过程中的加温等操作,提高了芳纶毛坯管与接头的粘接强度。
附图说明
图1是本发明中真空浸渍芳纶纤维绝缘管的原理图。
图2是本发明中芳纶毛坯管与铝合金接头粘接的结构图。
图3是本发明中图2的A部放大图。
其中:1为混料罐,2为混料罐真空泵,3为真空罐,4为浸胶槽,5为模具,6为芳纶半成品,7为真空罐真空泵,8为铝合金接头,9为芳纶毛坯管,10为沟槽。
具体实施方式
下面结合附图和具体实施例对本发明进行详细说明:
图1所示为真空浸渍芳纶纤维绝缘管的原理图,其中包括混料罐1、混料罐真空泵2、真空罐3、浸胶槽4、模具5、芳纶半成品6和真空罐真空泵7,混料罐1罐壁内部充满导热油,通过加热丝加热导热油使混料罐内的树脂均匀加热,电动机带动搅拌桨对混料罐内部的树脂进行搅拌,真空泵2与混料罐1相连,通过真空泵2对混料罐内的树脂进行抽真空脱气,模具5卷制好芳纶半成品6干燥除湿后放入浸胶槽4内,再把浸胶槽4整体放入真空罐3内部,通过真空泵7对真空罐3进行抽真空,真空罐3罐壁夹层加入导热油,通过电阻加热丝加热导热油使真空罐罐体内部均匀加热,通过控制真空泵7和真空泵2,使真空罐3和混料罐1形成负压差,混料罐1内部的树脂通过管道缓慢导入真空罐1内部的浸胶槽4中,树脂淹没模具5和芳纶半成品6,这就是真空浸渍的原理。
图2和图3所示为芳纶毛坯管与铝合金接头粘接的结构,芳纶毛坯管9与两端的铝合金接头8,通过加工沟槽10,使二者形成较小的粘接间隙,提高了两者间的粘结强度。
结合图1至图3对芳纶纤维绝缘管的制备方法进行说明,具体制备方法包括以下步骤:
步骤(1):清理模具表面,模具5表面涂覆甲基硅油脱模剂后在烘箱内170℃的温度下保温3h,重复处理3次,打开烘箱门,模具5在烘箱内缓慢降温;
步骤(2):采用卷布机在模具5表面卷制芳纶半成品6,把模具5和芳纶半成品6整体放入烘箱中进行烘干除湿,烘干温度为120℃,烘干时间为24h;
步骤(3):将模具5和芳纶半成品6从烘箱中取出,快速装入浸胶槽4中,再整体装入至真空罐3中,打开真空泵7对真空罐3内部进行抽真空,开启真空罐3的导热油加热功能,真空度保持在1mbar,加热温度设定为60℃;
步骤(4):按照重量比100份环氧树脂、98份固化剂和5份促进剂的配比加入到混料罐1中,打开真空泵2,对混料罐中进行抽真空,同时打开混料罐1内部的搅拌,电机频率设定为30Hz,开启混料罐1的导热油加热功能,真空度设定为1mbar,温度为45℃;
步骤(5):关闭混料罐1的搅拌,关闭真空泵2,将混料罐内的真空度调为10mbar,将真空罐3的加热温度调为45℃,真空度调为2mbar,打开输料阀,利用混料罐1与真空罐3的压力差,将混料罐内的树脂导入真空罐3中的浸胶槽4内,待树脂完全淹没模具5和芳纶半成品6后,关闭输料阀;
步骤(6):芳纶半成品在树脂中真空浸渍真空度为2mbar,浸渍温度为45℃,浸渍时间为8h;
步骤(7):打开真空泵2,将混料罐1的真空度设定为1mbar,关闭真空泵7,将真空罐3的真空度设定为20mbar,开启回料阀,将浸胶槽4内的树脂回送至混料罐1中保存;
步骤(8):在聚酯薄膜专用缠绕机上,在芳纶半成品6表面超绕一层聚酯薄膜,缠绕角度为30°,缠绕张力为20N;
步骤(9):将模具5装配至专用旋转固化工装上,整体放入烘箱内,开启旋转,设定固化程序,对芳纶半成品6进行一次固化;
步骤(10):一次固化结束后,在脱模机上将芳纶半成品6从模具5中脱出,得到芳纶毛坯管;
步骤(11):将芳纶毛坯管放入烘箱,设定二次固化程序,在烘箱内进行二次固化;
步骤(12):对芳纶毛坯管9的粘接位置进行机加工,粘接面的直径公差与铝合金接头8的粘接面直径公差严格控制,保证粘接间隙在0.08~0.18mm范围内;
步骤(13):铝合金接头8的粘接面进行沟槽10的机加工,并且用不锈钢砂粒对粘接面进行喷砂处理,使粘接面的粗糙度大于或等于25um;
步骤(14):清洗根据步骤12加工完的芳纶毛坯管9和根据步骤13加工完的铝合金接头8,然后将芳纶毛坯管9放入烘箱内在80℃温度下加热3~4h,使芳纶毛坯管膨胀;
步骤(15):将胶粘剂均匀涂覆在芳纶毛坯管9和铝合金接头8的粘接面,使沟槽10内均充满胶粘剂;
步骤(16):将涂覆好胶粘剂的铝合金接头8插入芳纶毛坯管9内,再装配至粘接工装,保证绝缘拉杆的尺寸,在室温下初固化2h;
步骤(17):将粘接好的芳纶纤维绝缘拉杆放入烘箱中,在80℃温度下对胶粘剂进行6~8h的高温固化,结束后芳纶纤维绝缘拉杆制备完成。
在上述工艺中芳纶纤维布为芳纶纤维与聚酯纤维沿经纬度方向混纺编织而成,胶粘剂为重量比100份环氧树脂和85份固化剂均匀混合而成。
尽管结合优选方案具体展示和介绍了本发明,但所属领域的技术人员应该明白,在不脱离所附权利要求书所限定的本发明的精神和范围内,在形式上和细节上对本发明做出各种变化,均为本发明的保护范围。
Claims (8)
1.一种芳纶纤维绝缘拉杆的制备方法,其特征在于:通过芳纶纤维与聚酯纤维混纺成芳纶纤维布,经过表面处理、卷绕成型、烘干除湿、真空浸渍树脂、一次固化、脱模、再进行二次固化的步骤制备成芳纶毛坯管,对芳纶毛坯管的粘接面进行机加工后,将芳纶毛坯管的两端与金属接头进行粘接,制备成芳纶纤维绝缘拉杆。
2.根据权利要求1所述的芳纶纤维绝缘拉杆的制备方法,其特征在于:所述工艺流程的具体步骤是:
步骤1:芳纶纤维与聚酯纤维混纺成经纬向的芳纶纤维布,经过表面处理后干燥存放;
步骤2:模芯表面抛光及用脱模剂处理,在模芯上缠绕芳纶纤维布,然后将缠有芳纶纤维布的模芯置于烘箱内;
步骤3:对烘箱内的芳纶纤维布进行高温干燥,以去除芳纶纤维内部残留的水分;
步骤4:根据配比将环氧树脂、固化剂和促进剂在真空浸渍工艺温度条件下搅拌混合得到树脂,然后导入到混料罐中进行真空脱气待用;
步骤5:将流程3中得到的烘干芳纶半成品装配至真空罐中,进行加热抽真空除湿;
步骤6:待真空罐中的真空度和温度达到工艺要求的条件下,将流程4中得到的脱气待用的树脂真空导入真空罐中;
步骤7:在工艺要求的真空度和温度下,将芳纶纤维布浸渍在树脂中,真空保持5~18h,使树脂充分浸润芳纶纤维布;
步骤8:树脂导回混料罐中循环利用,取出真空罐中的芳纶半成品,在缠绕机上以工艺要求的缠绕角度和张力缠绕聚酯薄膜,使树脂不溢出;
步骤9:将芳纶半成品放入专用烘箱内进行一次固化,固化过程中采用旋转固化,使树脂分布均匀;
步骤10:将模具降温,在专用脱模机上进行脱模,将模芯脱出,得到芳纶毛坯管;
步骤11:将芳纶毛坯管放入烘箱内进行二次固化,以消除芳纶毛坯管的内应力;
步骤12:对芳纶毛坯管的粘接面进行机加工,对接头进行喷砂处理,采用合适的粘接剂,在专用粘接工装上将芳纶毛坯管与接头进行粘接,得到芳纶纤维绝缘拉杆。
3.根据权利要求2所述的芳纶纤维绝缘拉杆的制备方法,其特征在于:步骤2中所述的芳纶纤维布为芳纶纤维与聚酯纤维混纺的布,布的重量为280g/m2。
4.根据权利要求2所述的芳纶纤维绝缘拉杆的制备方法,其特征在于:步骤4中所述的树脂中的环氧树脂、固化剂和促进剂的重量比为100:98:5。
5.根据权利要求2所述的芳纶纤维绝缘拉杆的制备方法,其特征在于:步骤6中所述的真空度为1~20mbar,浸渍温度为30~60℃。
6.根据权利要求2所述的芳纶纤维绝缘拉杆的制备方法,其特征在于:步骤8中的缠绕角度为15°~75°,缠绕张力为15~45N。
7.根据权利要求2所述的芳纶纤维绝缘拉杆的制备方法,其特征在于:步骤12中对芳纶毛坯管进行加工和粘接,包括以下步骤:
步骤12-1:将芳纶毛坯管的粘接面头部加工成倾斜角,粘接面加工多个沟槽以增加粘接面积,提高粘接力;毛坯管粘接面的直径比接头的直径大0.05~0.50mm,使得毛坯管与接头形成紧配合;
步骤12-2:接头粘接面也加工多个沟槽,采用不锈钢砂粒对粘接面进行喷砂处理,使表面粗糙度达到25um或以上;
步骤12-3:用丙酮将步骤12-1加工完的芳纶毛坯管擦拭干净,再放入烘箱内加热2h~5h;
步骤12-4:粘接一端接头,将粘接剂均匀涂覆在毛坯管一端和与其接头的粘接面上,使得沟槽内充满粘接剂,再将接头插入毛坯管内,放入烘箱内进行初固化;
步骤12-5:粘接另一端接头,将粘接剂均匀涂覆在毛坯管另一端和与其接头的粘接面上,使得沟槽内充满粘接剂,再将毛坯管和接头分别装配至专用粘接工装上,后将另一端接头插入毛坯管内,放入烘箱内进行高温固化,得到芳纶纤维绝缘拉杆。
8.根据权利要求7所述的芳纶纤维绝缘拉杆的制备方法,其特征在于:所述的粘接剂为双组分粘接剂,其环氧树脂与固化剂的重量比为100:70~90。
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