CN108501473A - 一种超高分子量聚乙烯板材贴覆在钢板表面的方法 - Google Patents
一种超高分子量聚乙烯板材贴覆在钢板表面的方法 Download PDFInfo
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Abstract
一种超高分子量聚乙烯板材贴覆在钢板表面的方法的优点在于,它能大幅减少检修清除附着物的工作量,不需要采用酸碱或机械清理,只用高压水枪冲洗即可。用贴覆了本发明所述复合片的钢板制成的水中行走器表面具有高耐磨性及高抗冲击性,并具有吸收冲击能的作用,耐海水腐蚀能力增强,可提高水中行走器的使用寿命。另外,经检测大于2毫米的超高分子聚乙烯板具有较好的隔离放射性、核辐射的性能及较好的防微波穿透性能等。
Description
技术领域
本发明涉及钢板包覆方法,是一种超高分子量聚乙烯板材贴覆在钢板表面的方法。
背景技术
钢板表面包覆非金属材料具有抗腐蚀等作用。特别是大型轮船、军舰等水中行进器需要表面不结垢、不附着、耐腐蚀及耐冲击等性能,以增加其使用寿命,减少水中行进阻力等。目前,对于水中行走器的外壳提高金属表面光洁度的方法主要是通过使用高性能的金属材料解决上述问题。但是,这种解决方案的不足是造价昂贵,使用寿命相对较难提高到与造价的相应水平。已公开的超高分子量聚乙烯膜片与金属板的粘结方法是目前比较好的方法,这种方法中使用的膜片最大厚度为1.5毫米,大于1.5毫米时无法实现将膜片贴覆在钢板上的目的。同时,在使用中发现存在难以实现的不足,例如将钢板大面积加热,然后贴覆膜片后迅速冷却(不冷却会使膜片变形),在工艺上很难实现,二是两种材料的热胀系数差别较大,遇冷热发生变化,使贴覆牢固度受影响,易出现剥离现象,这种方法无法用于水中行走器金属表面的贴覆。为此,本领域技术人员一直将如何降低水中行走器的行进阻力、提高耐磨、耐冲击、耐腐蚀及降低造价等性能做为重要研究课题。
发明内容
本发明的目的是提供一种超高分子量聚乙烯板材贴覆在钢板表面的方法,它能解决现有技术的不足。
本发明为实现上述目的,采用以下技术方案:一种超高分子量聚乙烯板材贴覆在钢板表面的方法,包括下述步骤:
①将超高分子量聚乙烯带状板材制成宽度为27-35厘米、厚度为2-20毫米,再将上述带状板材裁成正方形或长方形块状备用;
②将步骤①的正方形或长方形超高分子量聚乙烯板材一个表面采用覆膜机热合一薄层塑料薄膜,形成覆膜片;
③取马口铁片制成正方形或长方形块,与步骤①的超高分子量聚乙烯板材尺寸形状相同,马口铁片的厚度为0.3-0.8毫米;
④采用带钢锥模具的冲床在步骤③所述的马口铁片上打出数排通孔,通孔直径为0.1-1毫米,使马口铁片一面是向下凹的通孔,另一面是孔周围的尖锐凸起;
⑤将步骤④打孔后的马口铁片放置在可加热的工作台上,尖锐凸起面向上,启动电源加热工作台将马口铁片加热至200℃-240℃,断开热源;
⑥将步骤②的覆膜片有覆膜的一面向下置于马口铁片向上的尖锐凸起面上,给覆膜片向下的压力,使覆膜片与马口铁片热合成一体,得到热合片;
⑦对热合片用冷却水进行冷却,冷却过程中保持步骤⑥的压力不变,冷却到环境温度后得到复合片;
⑧将钢板表面打磨掉锈迹,露出亮的粗糙表面,将二组分钢材结构胶调成粘合剂,涂覆在钢板粗糙表面上,同时将粘合剂涂覆在步骤⑦复合片的马口铁面上;
⑨将步骤⑧涂粘合剂的马口铁面用电磁铁板压合到涂粘合剂的钢板表面,待粘合剂固结后取下电磁铁板;
⑩重复步骤⑨的操作,将数块复合片逐一贴在钢板上直至贴满整个钢板为止。
步骤②中所述的塑料薄膜材料可以是共聚物底胶或线性低密度聚乙烯。步骤④中所述的尖锐凸起均布在马口铁片上,每两个尖锐凸起间的中心距为10-16毫米,纵向尖锐凸起中心距H和横向尖锐中心距L相等。步骤⑤所述的马口铁片加热温度为240℃。步骤①所述的超高分子量聚乙烯板材的厚度为2-8毫米。步骤⑦中所述的保持压力为0.1MPa-0.2 MPa。步骤⑥所述的给覆膜片向下的压力为0.1MPa-0.2 MPa,保持压力状态5-10分钟。步骤⑨所述电磁铁板给予复合片的压力为0.02 MPa -0.1MPa。
本发明的优点在于,它能够使厚度大于2毫米的超高分子量聚乙烯膜片通过马口铁片贴覆在水中行走器的钢板表面,使表面的光滑度大幅提高,使水中行走器的表面糙率达到0.007,使轮船、军舰及潜水艇等水中行走器明显降低行走阻力;同时,由于水中行走器的超高分子量聚乙烯表面光滑,因而不会被海蛎子等海洋生物附着,大幅减少检修清除附着物的工作量,不需要采用酸碱或机械清理,只用高压水枪冲洗即可。用贴覆了本发明所述复合片的钢板制成的水中行走器表面具有高耐磨性及高抗冲击性,并具有吸收冲击能的作用,耐海水腐蚀能力增强,可提高水中行走器的使用寿命。另外,经检测大于2毫米的超高分子聚乙烯板具有较好的隔离放射性、核辐射的性能及较好的防微波穿透性能等。
附图说明
附图1是本发明方法中所述复合片放置在工作台上的结构示意图,图中1是工作台,2是超高分子量聚乙烯板材,3是马口铁片,4是凸起;附图2是图1中马口铁片3的结构示意图,图中5是通孔;附图3是图2中A-A剖视结构示意图;附图4是复合片的结构示意图;附图5是图4中B-B剖视结构示意图。
具体实施方式
对照附图对本发明做进一步说明。
本发明所述的一种超高分子量聚乙烯板材贴覆在钢板表面的方法,包括下述步骤:
①将超高分子量聚乙烯带状板材制成宽度为27-35厘米、厚度为2-20毫米,再将上述带状板材裁成正方形或长方形块状备用;
②将步骤①的正方形或长方形超高分子量聚乙烯板材一个表面采用覆膜机热合一薄层塑料薄膜,形成覆膜片;
③取马口铁片制成正方形或长方形块,与步骤①的超高分子量聚乙烯板材尺寸形状相同,马口铁片的厚度为0.3-0.8毫米;
④采用带钢锥模具的冲床在步骤③所述的马口铁片上打出数排通孔,通孔直径为0.1-1毫米,使马口铁片一面是向下凹的通孔,另一面是孔周围的尖锐凸起;
⑤将步骤④打孔后的马口铁片放置在可加热的工作台上,尖锐凸起面向上,启动电源加热工作台将马口铁片加热至200℃-240℃,断开热源;
⑥将步骤②的覆膜片有覆膜的一面向下置于马口铁片向上的尖锐凸起面上,给覆膜片向下的压力,使覆膜片与马口铁片热合成一体,得到热合片;
⑦对热合片用冷却水进行冷却,冷却过程中保持步骤⑥的压力不变,冷却到环境温度后得到复合片;
⑧将钢板表面打磨掉锈迹,露出亮的粗糙表面,将二组分钢材结构胶调成粘合剂,涂覆在钢板粗糙表面上,同时将粘合剂涂覆在步骤⑦复合片的马口铁面上;
⑨将步骤⑧涂粘合剂的马口铁面用电磁铁板压合到涂粘合剂的钢板表面,待粘合剂固结后取下电磁铁板;
⑩重复步骤⑨的操作,将数块复合片逐一贴在钢板上直至贴满整个钢板为止。
步骤⑥所述的得到热合片边缘有轻微“鼓浆”现象。
步骤④所述的冲床是公知技术,钢锥模具是根据本发明所述的马口铁片的结构设计。钢锥模具有一个底座,底座上安装数排钢锥,钢锥的排列及钢锥直径的最细端与马口铁片上的通孔直径相一致。本发明所述的采用带钢锥的冲床制作的马口铁片上的尖锐凸起呈规则状。
上述方法中所述的马口铁片的一个表面上开设小孔,该表面呈现的是规则的数个小孔,马口铁片另一表面上小孔的周围是尖锐凸起,该凸起呈尖刺状。马口铁片上的通孔可限制超高分子量聚乙烯板材的膨胀和收缩,使超高分子量聚乙烯板材与马口铁片由于不同的热胀冷缩产生的不良影响大幅降低,使两者能够牢固的贴合在一起,不产生剥离现象。实验统计数据表明,采用本发明方法使超高分子量聚乙烯板材与马口铁片贴合后的剥离强度超过150 N/cm,并且,马口铁片贴合在钢板上的剥离强度超过200 N/cm。所述带状板材可以裁成边长为20厘米、30厘米、32厘米、35厘米或40厘米的正方形,也可以裁成长30厘米、宽28厘米,长35厘米、宽30厘米及长38厘米、宽35厘米的长方形。总之,正方形的边长优选20厘米至40厘米之间,长方形的边长优选为:长20厘米至40厘米,宽18厘米至35厘米之间。这种优选的形状可使超高分子量聚乙烯板材与马口铁片更易贴合,增加其剥离难度,同时,更易于使复合片贴合在钢板上。本发明方法中使用的电磁铁板的尺寸比复合片的各边长大10-12毫米,使复合片表面压力更均匀。
本发明的优选方案是:步骤②中所述的塑料薄膜材料可以是共聚物底胶或线性低密度聚乙烯。使超高分子量聚乙烯板材与马口铁片的结合更牢固。
本发明的优选方案是:步骤④中所述的尖锐凸起均布在马口铁片上,每两个尖锐凸起间的中心距为10-16毫米,纵向尖锐凸起中心距H和横向尖锐中心距L相等。该方案进一步降低超高分子量聚乙烯板材与马口铁片间因热胀冷缩不同产生的贴合牢固低的不足。
本发明进一步的优选方案是:步骤⑤所述的马口铁片加热温度为240℃。加热板工作台的加热可采用电阻丝加热,使整个马口铁片全部贴覆在发热板上均匀受热。
本发明更进一步的优选方案是:步骤①所述的超高分子量聚乙烯板材的厚度为2-8毫米。这是使超高分子量聚乙烯板材和马口铁片更好的贴合、并使复合片更好的与钢板贴合不产生剥离现象的优选方案。
本发明步骤⑦中所述的保持压力为0.1MPa-0.2 MPa,优选0.12 MPa。
本发明步骤⑥所述的给覆膜片向下的压力为0.1MPa-0.2 MPa,保持压力状态5-10分钟。
本发明步骤⑨所述电磁铁板给予复合片的压力为0.02 MPa -0.1MPa,保持该压力状态下23-25小时使粘合剂固结,优选的保持压力的固结时间为24小时,可进一步保证复合片与钢板紧密结合,达到好的牢固度。
Claims (8)
1.一种超高分子量聚乙烯板材贴覆在钢板表面的方法,其特征在于:包括下述步骤:
①将超高分子量聚乙烯带状板材制成宽度为27-35厘米、厚度为2-20毫米,再将上述带状板材裁成正方形或长方形块状备用;
②将步骤①的正方形或长方形超高分子量聚乙烯板材一个表面采用覆膜机热合一薄层塑料薄膜,形成覆膜片;
③取马口铁片制成正方形或长方形块,与步骤①的超高分子量聚乙烯板材尺寸形状相同,马口铁片的厚度为0.3-0.8毫米;
④采用带钢锥模具的冲床在步骤③所述的马口铁片上打出数排通孔,通孔直径为0.1-1毫米,使马口铁片一面是向下凹的通孔,另一面是孔周围的尖锐凸起;
⑤将步骤④打孔后的马口铁片放置在可加热的工作台上,尖锐凸起面向上,启动电源加热工作台将马口铁片加热至200℃-240℃,断开热源;
⑥将步骤②的覆膜片有覆膜的一面向下置于马口铁片向上的尖锐凸起面上,给覆膜片向下的压力,使覆膜片与马口铁片热合成一体,得到热合片;
⑦对热合片用冷却水进行冷却,冷却过程中保持步骤⑥的压力不变,冷却到环境温度后得到复合片;
⑧将钢板表面打磨掉锈迹,露出亮的粗糙表面,将二组分钢材结构胶调成粘合剂,涂覆在钢板粗糙表面上,同时将粘合剂涂覆在步骤⑦复合片的马口铁面上;
⑨将步骤⑧涂粘合剂的马口铁面用电磁铁板压合到涂粘合剂的钢板表面,待粘合剂固结后取下电磁铁板;
⑩重复步骤⑨的操作,将数块复合片逐一贴在钢板上直至贴满整个钢板为止。
2.根据权利要求1所述的一种超高分子量聚乙烯板材贴覆在钢板表面的方法,其特征在于:步骤②中所述的塑料薄膜材料可以是共聚物底胶或线性低密度聚乙烯。
3.根据权利要求1所述的一种超高分子量聚乙烯板材贴覆在钢板表面的方法,其特征在于:步骤④中所述的尖锐凸起均布在马口铁片上,每两个尖锐凸起间的中心距为10-16毫米,纵向尖锐凸起中心距H和横向尖锐中心距L相等。
4.根据权利要求1所述的一种超高分子量聚乙烯板材贴覆在钢板表面的方法,其特征在于:步骤⑤所述的马口铁片加热温度为240℃。
5.根据权利要求1所述的一种超高分子量聚乙烯板材贴覆在钢板表面的方法,其特征在于:步骤①所述的超高分子量聚乙烯板材的厚度为2-8毫米。
6.根据权利要求1所述的一种超高分子量聚乙烯板材贴覆在钢板表面的方法,其特征在于:步骤⑦中所述的保持压力为0.1MPa-0.2 MPa。
7.根据权利要求1所述的一种超高分子量聚乙烯板材贴覆在钢板表面的方法,其特征在于:步骤⑥所述的给覆膜片向下的压力为0.1MPa-0.2 MPa,保持压力状态5-10分钟。
8.根据权利要求1所述的一种超高分子量聚乙烯板材贴覆在钢板表面的方法,其特征在于:步骤⑨所述电磁铁板给予复合片的压力为0.02 MPa -0.1MPa。
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