CN109899363B - 用于螺钉的涂层剂 - Google Patents
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Abstract
用于紧固件,尤其是自攻螺钉和自攻丝螺钉的涂层剂用于改进手工操作安全性和可靠性。试剂为此包含至少两种不同的固态润滑剂,其中第一固态润滑剂为塑料或蜡并且第二固态润滑剂为至少一种另外的塑料。优选地,该固态润滑剂存在于溶液中,例如基于水,基于醇或另一种、尤其是有机溶剂的溶液中。固态润滑剂优选作为微颗粒存在,这实现了在涂层中的更佳的分布并且因此实现了在使用情况下的固态润滑剂的更佳的可用性。用这样的涂层剂涂布这样的紧固件的方法同样是本发明的主题。
Description
技术领域
本发明涉及用于螺钉,尤其是自攻丝的、螺纹成型的或者螺纹切削的螺钉的涂层剂,其可以明显减轻拧螺旋过程。
背景技术
在连接技术中始终寻求关于手工操作、经济性和安全性的改进。尤其是在金属结构中,在建筑业中的安装时,重要的是将各种各样的元件快速和安全地彼此连接。主要花费在此典型地是待连接的建筑构件的预钻孔。这些必须临时固定,钻孔,清理钻孔,以及插入并且固定连接件或者紧固件。
在这方面,具有自身的钻头的自攻丝的螺钉是有利的,因为它们极大地简化了这种多阶段过程。然而在此的一个基本问题在于,虽然这种钻头仅使用一次,但仍然必须相应地设计,特别是在用于金属建筑构件时。这明显提高了这样的紧固件的制造成本。同样,自攻丝螺钉的螺纹必须设计成在钻孔过程之后立即在周围材料中成型配合螺纹,这确保了放置的紧固件的高拉出力。在使用纯钻头,铣刀或其他切削工具时,可以通过高价值的材料选择和耗费的表面调质(氮化铝、Cr-Al-氮化物、碳化物,类金刚石碳DLC)优化应用。出于成本原因在自攻螺钉或者螺纹成型的螺钉时不考虑该手段。
特别是在自攻丝的螺钉的情况下,由于钻孔过程产生所有部件的极大的热负荷。这是由于自攻螺钉在钻孔中的摩擦-这尤其涉及钻头边缘。当材料变得如此热以至于发生钻头的塑性变形时,它们的使用寿命急剧下降。通常螺钉在此时失效,因为例如螺钉断裂或钻头边缘丧失其完整性。
热能的另一来源是当钻头边缘形成切屑时,插入钻孔的建筑构件中的变形能量。该能量的大部分留在钻屑中,这是为什么重要的是能够连续地和无障碍地去除钻屑。
对于上述应用情况的热传输过程非常复杂,高度依赖于几何形状和材料,并且因此不能描述为单个线性过程。
在现有技术中已知,能够涂布自攻螺钉和螺纹成型的螺钉并且还提出了多种方法和涂层剂,以达到实现前述应用目的。在此部分地讲到润滑剂,因为通过减少的摩擦减少了热能进入材料。通过借助浸涂法、喷涂法或离心法将涂层剂施加在未处理的紧固件上,然后例如干燥和UV固化,并且如此直至固定在表面上而使用,能够实现干燥的滑动膜。镀层可以相应地显示为坚硬,蜡质,易碎或弹性地。
例如已知的是,对于在螺钉上使用,使用微分散的固态润滑剂在水溶液中的悬浮液,其在室温干燥后有助于在之后的使用中降低摩擦系数。在此包括例如microGLEIT公司的产品DF 911和DF 921。
作为用于涂漆、抹灰的骨料或用于涂布服装,已知微包囊的PCM(相变材料),其能够可逆地储存和重新释放潜热。所述骨料作为溶液(盐水合物,在此未观察到)或微包囊的形式存在。其作为热缓冲剂使用。
文献EP 2 000 680另外描述了用于螺纹成型的螺钉的涂层剂,其具有褐煤酸钙和褐煤酸在热塑性树脂乳液中的混合物。
WO 2016/023855描述了具有电镀施加的硬涂层的由奥氏体或不锈钢组成的自攻螺钉,在所述硬涂层上又施加由润滑性或者散热性物质组成的涂层。
发明内容
测试已表明,商业上可得的或者由现有技术已知的手段和方法尽管可以增加钻孔或内螺纹滚压的产量,但并不能满足当今安装性能的要求。本发明的目的因此在于描述涂层剂,其允许这样的与类型相适应的螺钉的明显更佳的钻削、更小的造型力矩(Einformmomente)和改进的手工操作。
在下文通常将术语“紧固件”理解为建筑构件,其用于可拆卸地或不可拆卸地彼此连接另外的建筑元件。尤其是在本发明的上下文中,将术语“紧固件”理解为螺钉,尤其是自攻丝的螺钉和内螺纹滚压的螺钉。具有排挤尖端或点状尖端的其它紧固件,例如螺钉,以及螺栓、钉子、铆钉诸如此类也可以从根据本发明的涂层或者根据本发明的涂层剂获得好处。
“涂层”在下文在广义上被理解为在表面上的镀层、层、覆层。在这种情况下不仅仅意味着厚度均匀的封闭涂层,而且还意味着那些仅施加在紧固件表面的一部分上并且可以在施加厚度上变化的涂层。涂层的性状可以是固体,革质,蜡状,玻璃状或粘性的。
“涂层剂”在本发明的上下文中全部意味着试剂,采用所述试剂实现涂层。涂层剂的性状可以为液态、固态、粉末状或气态。涂层剂在作为涂料施加在紧固件上时可以具有减摩擦的以及(主动)冷却的作用。
关于涂布方法,提及所有措施,采用所述措施可以实现涂布。这可以意味着在液体中的浸涂法、喷涂、蒸镀、由气相冷凝、撒粉或通过涂抹施加。涂布方法还包括用于以下的过程步骤:a)改进所施加的涂层剂的平面分布,如旋转、在射流中摇动、离心,例如在浸涂过程之后;还有遮盖紧固件的部分,以避免在紧固件的特定部分表面上(例如在头部上)的涂层或者正好相反地改进(种子层)。此外包括b)将施加的涂层剂牢固地连接在待涂布的表面上的过程步骤;这可以取决于涂层剂:干燥法(被动地蒸发溶剂到环境中,在真空下,在干燥箱中,在通风下);焙烧法(热的、UV);化学反应(凝结),可能与紧固件的表面或周围气氛;借助辐射或活化剂交联涂层剂以形成涂层。
在本发明的上下文中将术语“溶液”理解为液体,其在化学意义上可以为由至少两种化学物质组成的均匀的混合物,但也可以作为非均相的物质混合物、乳液或悬浮液存在;还如泥浆或淤泥那样粘性。
在本发明的意义上“固态润滑剂”为作为可与溶液区分的成分而存在于溶液中的润滑剂,例如微颗粒。由此还明确地理解,液体或蜡状润滑剂存在于微胶囊中。
直至典型地约3mm的厚度,可以在没有预钻孔的钢板或者板叠的情况下使用螺纹成型的螺钉,其由冷变形的碳钢制成并且具有顶角为20-30°的非常细的尖端。因此才在没有钻头的螺纹成型的螺钉的失效处使用自攻螺钉。由试验中已知的是,根据现有技术的具有涂层,例如具有DF921的自攻螺钉在将其以300N的给进力在1800U/min的钻孔测试状态使用的情况下具有达20s的使用寿命。作为测试材料,在此一次使用由在10mm钢S500(应用1)或者单板13mm钢S355(应用2)上的2mm钢S355组成的板叠。采用根据现有技术的涂层,记录介于20%(应用1)与70%(应用1)之间的故障率。对于用户而言,这在实际上是很有问题的,因为这样的失败的放置过程是耗时并且高成本的。
因此,在本发明的上下文中进行的试验因此基于应用的典型情况,在通常的工业应用领域中的自攻螺钉的放置过程是持续5至20秒范围的过程。在较软的材料的情况下,可以实现比在较硬的钢的情况下更高的穿透性能,但是放置工具随时间推移的性能基本上与材料无关。
技术物理过程因此在非常窄的时间窗口内进行。然而令发明人惊讶的是,通过将仅具有一种固态润滑剂类型的现有技术中已知的溶液用具有至少两种固态润滑剂类型的溶液替代,已经可以实现极大的钻削能力提高。本发明揭示了这样的认识,即固态润滑剂的润滑或冷却作用尤其对使用结束至关重要,并且两种固态润滑剂的组合使得该应用情况的失效时间点比预期的明显进一步推迟。
所描述的固态润滑剂在应用情况下经历各种热致相变。在最简单的情况下,这是熔化过程和蒸发过程。在两种不同的固态润滑剂的情况下,随时间推移发生多达四个相转换,其各自延迟热负荷的升高。
具体实施方式
因此能够如下划分本发明:
根据本发明的涂层剂包含至少两种不同的固态润滑剂,其中第一固态润滑剂为塑料或蜡并且第二固态润滑剂为至少一种另外的塑料。优选地,但非强制性地,这些固态润滑剂存在于溶液中,几乎在载体液体中。但也考虑将物质以干燥混合物使用。
如果使用溶液,则优选作为基于水,基于醇或另一种、尤其是有机溶剂或者前述成分的混合物的溶液使用。出于程序观点以及安全性和环境方面优选的是水溶液。
在固态润滑剂作为微颗粒存在时实现特别好的结果,优选地标称尺寸介于5和20μm之间。由此一方面实现了涂层中的更好的分布并且因此在使用情况下实现了固态润滑剂的更好的可用性。
如果选择塑料作为第一或者第二固态润滑剂,则热塑性塑料在每种情况下都是优选的塑料。如上所述,第一或者第二固态润滑剂是不同的。因此,证实聚乙烯(PE)适合作为第一固态润滑剂的成分,热塑性塑料聚氯乙烯(PVC)和/或聚乙烯醇缩丁醛(PVB)适合作为第二固态润滑剂的成分。
作为第一固态润滑剂的热塑性塑料的替代,还可以使用蜡,在此尤其是石蜡、硬脂精或其混合物。如上文所述,可以将蜡作为颗粒或微胶囊使用。在后一种情况下,石蜡也可以作为液体存在于胶囊膜中,并且如上所述,应该被认为是宏观固态润滑剂。尤其出人意料地证明可用作热缓冲剂的PCM是良好地可用的并且有效的固态润滑剂。根据本发明的使用放弃了可逆性;大概是所使用的蜡组分和将微胶囊良好地分布在紧固件上的能力是改进的效果的原因。
第一与第二固态润滑剂之间的混合比例优选为介于5:1与1:1之间(基于重量计)。
在替代性思路中,本发明还可以视为至少两种不同的物质的混合物作为固态润滑剂的用途,其中第一物质为塑料或蜡并且第二物质为至少一种另外的塑料。上述所有其它材料和功能解释和陈述类似地适用于该思路。
原则上能够采用以下步骤描述用于涂布紧固件的方法:
提供待涂布的紧固件,
施加如上文描述的涂层剂,
使所施加的涂层剂凝固。
取决于待涂布的紧固件的起始状态,可以在实际施加步骤之前进行预处理,所述预处理根据需要可以由单个步骤、一系列步骤或者一个或更多个步骤的循环重复组成。“预处理”可以意味着清洁步骤、覆盖零件表面、预处理零件表面以改进涂层剂的接受能力。紧固件的该润湿还可以用于例如使某些区域(凹陷、毛刺)能够特别容易地接受涂层的目的。相反地,也可以采取方法步骤以排除涂层的某些表面区域,表面部分区域,例如以在经颜色处理的头部上制造这种涂层或者使力的作用无效。
涂层剂的实际施加基本上由涂层剂的特性(固体、溶液)确定。在需要的情况下可以考虑单次或重复应用单个或一系列过程步骤,如
浸涂法,
喷涂法,
蒸镀法,
离心法,
粉末涂布。
在浸涂法的情况下,将紧固件完全或部分地浸入涂层剂中。在喷涂法中,喷涂紧固件而不是浸没,在蒸镀法的情况下,暴露至(涂层剂)蒸气源。在所有情况下可以单独作为篮中的散装零件布置紧固件,或装载在支架或者带孔金属板上。离心法为其中首先浸没位于篮中的紧固件,然后离心分离过量涂层剂的浸涂法。同样可想到,将固态润滑剂的干混合物施加在带静电的紧固件上,类似于粉末涂层。
所施加的涂层剂的“凝固”步骤汇总了各种各样的下游过程,其用于固定所施加的涂层剂。这取决于施加方法和所使用的涂层剂可以为:干燥、UV固化、焙烧、交联。为此的常规技术辅助手段为烘箱、照射设备、真空干燥或堆置场,用于进行化学反应。取决于使用特性,这些凝固步骤可以多次和/或按序列实施。
在本方法中提到的紧固件如上文所述优选为螺钉、自攻丝的和/或螺纹成型的螺钉、铆钉或者钉子。在所描述的紧固件上的涂层剂、方法的适用性在此不应被理解为限制性的,所述适用性可转移到类似应用情况中。
作为优选的应用变型,在此证实将商业上制造的涂层剂补充每种根据本发明缺失的组分。这也允许可以将已建立的涂布方法进一步用于这样的试剂。因此完全在本发明的意义上,具有微包囊的蜡的水溶液可以用微粒化的热塑性塑料或热塑性塑料混合物补充。
实验表明,在如上文描述的实验布置(布置1或2)的情况下,采用根据现有技术的涂层出现了超过50%的故障率。具有2种热塑性塑料的混合物的涂层将故障率降低至10%以下。值得注意的是,在具有由在10mm钢S500上的50mm矿物棉组成的夹心结构的试验布置的情况下甚至记录故障为减少至9分之一。
Claims (10)
1.具有涂层剂的自攻丝螺钉,所述涂层剂由至少两种不同的固态润滑剂组成,其特征在于,第一固态润滑剂为热塑性塑料或蜡并且第二固态润滑剂为至少一种另外的热塑性塑料,即聚乙烯(PE)、聚氯乙烯(PVC)或聚乙烯醇缩丁醛(PVB),并且
其中所述第一和第二固态润滑剂存在于溶液中或以干燥混合物使用,并且当存在于溶液中时所述溶液基于水、基于醇或基于有机溶剂或者前述成分的混合物。
2.根据权利要求1所述的具有涂层剂的自攻丝螺钉,其特征在于,第一和第二固态润滑剂作为微颗粒存在,并具有介于5至20μm之间的标称尺寸。
3.根据权利要求1或2所述的具有涂层剂的自攻丝螺钉,其特征在于,所述第一固态润滑剂为蜡,并且包括石蜡、硬脂精或其混合物。
4.用于涂布自攻丝螺钉的方法,其具有以下步骤:
提供待涂布的螺钉,
施加由至少两种不同的固体润滑剂组成的溶液,其中第一固态润滑剂为热塑性塑料或蜡并且第二固态润滑剂为至少一种另外的热塑性塑料,
使所施加的涂层剂凝固。
5.根据权利要求4的方法,其特征在于,所述热塑性塑料是聚乙烯(PE)、聚氯乙烯(PVC)或聚乙烯醇缩丁醛(PVB)。
6.根据权利要求5所述的方法,其特征在于,在施加涂层剂的步骤之前进行预处理,以改进涂层剂的接受能力。
7.根据权利要求6所述的方法,其特征在于,所述预处理包括选自如下的一个或多个方法步骤:清洁零件表面,覆盖零件表面或预处理零件表面。
8.根据权利要求4至7任一项所述的方法,其特征在于,涂层剂的施加通过单次或重复应用选自以下的单个或一系列过程步骤进行:
浸涂法,
喷涂法,
蒸镀法,
离心法,
粉末涂布。
9.根据权利要求4至7任一项所述的方法,其特征在于,所施加的涂层剂的凝固通过单次或重复应用选自以下的单个或一系列过程步骤进行:
干燥,
UV固化或者IR固化,
焙烧,
交联。
10.根据权利要求9所述的方法,其特征在于,所述干燥为真空干燥。
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