CN111136856A - Double-component mixed epoxy casting dielectric function gradient insulation manufacturing device and method - Google Patents
Double-component mixed epoxy casting dielectric function gradient insulation manufacturing device and method Download PDFInfo
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- CN111136856A CN111136856A CN201911404438.5A CN201911404438A CN111136856A CN 111136856 A CN111136856 A CN 111136856A CN 201911404438 A CN201911404438 A CN 201911404438A CN 111136856 A CN111136856 A CN 111136856A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/03—Injection moulding apparatus
- B29C45/04—Injection moulding apparatus using movable moulds or mould halves
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/1742—Mounting of moulds; Mould supports
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/1756—Handling of moulds or mould parts, e.g. mould exchanging means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/18—Feeding the material into the injection moulding apparatus, i.e. feeding the non-plastified material into the injection unit
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
- B29L2031/3412—Insulators
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Abstract
The invention discloses a dielectric function gradient insulation manufacturing device and method by double-component mixed epoxy pouring, which comprises a double-material feeding system, wherein an extrusion head of the feeding system is arranged on a three-dimensional motion system, the diameter of a nozzle of the extrusion head is adjustable, one end of the extrusion head is positioned in a metal die for epoxy pouring, the three-dimensional motion system is connected with a control system, and the control system and the feeding system are respectively connected with a computer through cables and are used for controlling the supply, mixing and extrusion of raw materials and the position of the extrusion head in X, Y and Z directions to complete the manufacturing of a dielectric constant function gradient insulator. The invention utilizes the online mixing of two epoxy resin composite materials with different dielectric properties, accurately conveys the materials to the designated position in the die through the three-dimensional motion platform, and can prepare the large-size insulator with continuous gradient distribution of the dielectric properties under the condition of not changing other properties of the insulating structure, thereby improving the surface power resistance of the insulator.
Description
Technical Field
The invention belongs to the technical field of high-voltage equipment manufacturing, and particularly relates to a device and a method for manufacturing a bi-component mixed epoxy casting dielectric function gradient insulation.
Background
Due to the excellent comprehensive performance of the epoxy casting insulator, the epoxy casting insulator is widely applied to power equipment such as switch cabinets, metal-enclosed SF6 insulated combined electrical appliances and power transmission lines (GIS and GIL). Since the electrical strength along the surface of the insulator is relatively low compared to the bulk properties, it directly determines the overall performance of the power equipment. In addition, with the development demand of device miniaturization, how to reduce the dimension of the insulating structure is also a critical problem to be solved urgently. Because the traditional epoxy casting insulation structure is a homogeneous material, the problems of uneven electric field distribution and field intensity concentration are particularly prominent, and the electric field intensity born by the areas far exceeds the average field intensity and even reaches several times of the average value. The excessively concentrated electric field strength brings about partial discharge of the insulator, aggravates aging of the insulating material, and further develops breakdown damage, and actually the overall performance of the insulating structure is not fully utilized. At present, the method for solving the problem can reduce the maximum electric field and improve the surface flashover voltage through the optimized design of an insulating structure or the addition of an equalizing ring and the like. The above method is however more limited. On the one hand, the optimization effect of the maximum electric field is limited, and on the other hand, the complexity of the insulation structure is increased.
The advent of "Functionally Graded materials" (FGM) provides a possible idea for solving this problem. By using materials with different properties and an advanced composite process, the material characteristics are enabled to present continuous gradient change at different spatial positions in the material, so that the problem of local stress concentration can be overcome actively. Similarly, if an insulator with a material dielectric property (such as dielectric constant) showing gradient change is manufactured, the dielectric constant gradually increases from the outer electrode to the inner electrode, so that the maximum field strength at the inner electrode can be actively reduced, the local concentration can be weakened, and the purposes of greatly improving the electric strength of the insulator and solving the application dilemma of the existing high-voltage equipment insulator can be achieved. Common methods for preparing dielectric functionally graded insulation can be broadly divided into three categories: lamination, centrifugation, and 3D printing methods. The lamination method is easy to cause interface defects and can only form a gradient with a single dimension. Although the centrifugal method can realize two-dimensional gradient distribution, the controllability is poor, and the size of a sample cannot meet the requirements of practical industrial application. The existing method for realizing the manufacturing of the insulation structure by utilizing the photocuring 3D printing has high controllability and can realize random gradient distribution, but the application of the method for the functional equipment, namely an electrical equipment insulator, is rare; and for the current 3D printing technology, the finished product of the insulator is often provided with more internal bubbles and defects, and is difficult to be used for manufacturing the high-voltage equipment insulator. There are disadvantages such as limited molding dimensions, limited material range, etc.
It can be said that the lack of a precisely controllable molding process and a large-scale mass production method have become bottlenecks that restrict the development of dielectric function gradient insulation.
Disclosure of Invention
The technical problem to be solved by the present invention is to provide a device and a method for manufacturing a bi-component mixed epoxy cast dielectric gradient insulation, aiming at the defects in the prior art, wherein the device and the method utilize the online mixing of two epoxy resin composite materials with different dielectric properties, accurately convey the materials to a specified position in a mold through a three-dimensional motion platform, and can prepare a large-size insulator with continuous dielectric property gradient distribution under the condition of not changing other properties of an insulation structure, so as to improve the surface power resistance of the insulator.
The invention adopts the following technical scheme:
the double-component mixed epoxy pouring dielectric function gradient insulation manufacturing device comprises a double-material feeding system, wherein an extrusion head of the feeding system is arranged on a three-dimensional motion system, the diameter of a nozzle of the extrusion head is adjustable, one end of the extrusion head is positioned in a metal die for epoxy pouring, the three-dimensional motion system is connected with a control system, and the control system and the feeding system are respectively connected with a computer through cables and are used for supplying, mixing and extruding raw materials and controlling the positions of the extrusion head in directions X, Y and Z to complete the manufacturing of a dielectric constant function gradient insulator.
Specifically, feeding system includes first storage tank and second storage tank, and first storage tank is used for storing high dielectric constant/conductivity combined material, and the second storage tank is used for storing low dielectric constant/conductivity combined material, and the upper end of first storage tank and second storage tank is connected with the force pump through the stainless steel interface respectively, and first storage tank and second storage tank connect the blender through the conveying pipeline that is provided with the bleeder valve respectively, and the head is extruded in the connection of the lower extreme of blender.
Specifically, the three-dimensional motion system comprises a Z-axis moving device and an X, Y plane moving device, the extrusion head is assembled on the Z-axis moving device, the X, Y plane moving device is fixed on a workbench, a fixing clamp is arranged on the workbench, and the metal mold is arranged in the fixing clamp.
Specifically, the control system comprises a motion controller and a temperature control system, and the motion controller and the temperature control system are respectively connected with the computer through cables.
The invention also provides a method for manufacturing the two-component mixed epoxy casting dielectric function gradient insulation, which comprises the following steps:
s1, preparing two types of epoxy composite materials with high, low and high dielectric constant/conductivity;
s2, constructing a geometric shape and dielectric constant/conductivity spatial distribution three-dimensional model of the insulator to obtain a motion track of the extrusion head, mixing the two resin raw materials with different dielectric constants in the step S1, and determining the temperature;
s3, driving the extrusion head to perform 3D printing and forming work of the dielectric constant/conductivity functional gradient insulator through a X, Y, Z triaxial moving device;
s4, placing the dielectric function gradient insulator molded in the metal mold into a vacuum oven for curing to obtain the bi-component mixed epoxy cast dielectric function gradient insulator.
Specifically, in step S1, the dielectric constant of the high-k/conductivity composite material is 4 to 100, and the electrical conductivity of the composite material isPermeability of 1X 10-8～1×10-16S/cm-2(ii) a The low dielectric constant/conductivity composite material is prepared by mixing thermosetting bisphenol A epoxy resin with silicon dioxide or alumina low dielectric constant functional filler, the dielectric constant of the low dielectric constant/conductivity composite material is 3-5, and the conductivity is 1 multiplied by 10-15～1×10-16S/cm-2。
Furthermore, the mixing ratio of the two groups of composite materials with high and low dielectric constants/conductivity is (1-0.03): 0.02-1.
Specifically, in step S2, the mixer is at a temperature of 40 to 100 ℃, the extrusion head is at a temperature of 40 to 80 ℃, and the work bench is at a temperature of 25 to 200 ℃.
Specifically, in step S3, the mixed droplets of the raw material are extruded from the extrusion head and dropped to a designated position of the die, and then the extrusion head is moved by using the X-direction and Y-direction moving devices according to the moving trajectory of the extrusion head in a single layer obtained by computer modeling; adjusting the mixing proportion of the raw materials according to the dielectric constant or conductivity distribution of the single-layer material, and extruding the single-point material once to finish the accumulative manufacture of the single-layer material; and finally, moving the extrusion head in the Z direction upwards, and performing accumulation manufacturing of single-layer materials again, repeating the steps to complete multilayer accumulation, thereby realizing the manufacturing of the dielectric function gradient insulator.
Specifically, in step S4, the air pressure in the oven is lower than 0.01Pa, the ambient temperature is 120-150 ℃, and the curing time is 8-15 h.
Compared with the prior art, the invention has at least the following beneficial effects:
the invention relates to a bi-component mixed epoxy casting dielectric function gradient insulation manufacturing device, which utilizes the blending extrusion of two materials in different proportions to manufacture a gradient insulation structure. Compared with lamination or centrifugal manufacturing, the manufacturing of a two-dimensional gradient insulating structure can be realized, and the electric field intensity inside and on the surface of the insulator can be flexibly regulated and controlled. Compared with the traditional 3D printing method for manufacturing gradient insulation, the material system is not changed, and compared with the large-size insulation structure which applies the 3D printing technology to the manufacturing of the dielectric constant gradient insulator, the purpose of improving the breakdown voltage of the insulator is achieved.
Furthermore, the first storage tank and the second storage tank are arranged, so that the extrusion of the material with the continuously variable dielectric constant/conductivity can be conveniently realized through the blending of the two components. The mixer can realize the uniform mixing of the two materials, and the condition of interface defect or phase separation can not occur. The discharge valve is arranged in the conveying pipe, so that the extrusion rate of the material can be regulated and controlled, and meanwhile, the debugging, operation maintenance and repair of operators are facilitated. By mounting the extrusion head on the Z-axis, the extrusion head can be conveniently adjusted to a specified position in the metal mold through the movement of the Z-axis, and the prepared structure is ensured to be the same as an expected result. The X and Y devices are arranged on the workbench, the workbench can be freely moved on a plane through two-dimensional motion control, and compared with the traditional mode of moving the spray head, the spray head moving control complexity can be reduced, and the control precision is improved. The temperature control system can realize real-time monitoring and adjustment of the temperature of each area, thereby ensuring that the rheological property can be effectively regulated and controlled in the material conveying process. The problems of nozzle plugs or excessively high material viscosity and the like can be avoided.
The two-component mixed epoxy casting dielectric function gradient insulation manufacturing method adopts epoxy resin for material compounding, can not change a thermosetting epoxy resin system in the traditional electrical engineering field, has good mechanical and heat-resistant properties, and can meet the actual industrial application requirements. By preparing the resin composite material with high and low dielectric constants/conductivities in advance, the regulation and control range of the dielectric constant/conductivity can be determined in advance and matched with the regulation and control range of actual requirements. Through the construction of the three-dimensional model, the optimal spatial distribution of the dielectric constant/conductivity can be found in a simulation mode. The composite material with formulated material characteristics can be conveyed to the specified position in the geometric shape of the insulator through modeling of the movement track of the extrusion head, so that the manufactured gradient insulator and the simulation model can be consistent, the rheological characteristics of the fluid can be regulated and controlled through setting the temperature of each area, and the smoothness of the manufacturing process is ensured. The dielectric function gradient insulator formed in the metal mold is placed in a vacuum oven for curing, so that air bubbles in insulation can be eliminated, and manufacturing defects are reduced.
Further in accordance withAs a result of model optimization, when the dielectric constant of the material can be changed between 4 and 100, or the conductivity can be 1 multiplied by 10-8～1×10-16S/cm-2When any change is made; the surface electric field of the insulating structure can be obviously homogenized, and the maximum field intensity can be greatly reduced. Meanwhile, the range of the material characteristics can be easily realized by a material compounding mode, and the method is simple and easy to implement and convenient to operate.
Furthermore, the carbon fluoride nanotubes are adopted to prepare the high-dielectric-constant composite material, so that the high dielectric constant can be realized, the extremely low dielectric loss can be ensured, and the problem of local overheating of the dielectric material in the running state can be effectively solved.
Furthermore, the temperature of the mixer is set to be 40-100 ℃, the temperature of the extrusion head is set to be 40-80 ℃, rheological properties of the mixed material can be controlled, the set temperature is high when the filling amount is high, the viscosity is reduced, and the set temperature is reduced when the filling amount is low, so that the viscosity properties of the composite material are basically unchanged, and the stability of the material foundation is ensured. The temperature of the workbench is 25-200 ℃, so that the shape of the mixed insulating structure can be maintained, and the infiltration and mutual pollution of materials at the interface can be inhibited.
Furthermore, the movement of the extrusion head in the metal mold is controlled through the three-dimensional motion platform, and liquid drops with formulated material characteristics can be sent to the designated position of the mold, so that the dielectric gradient insulation of the preparation is ensured, and the consistency with a preset structure can be kept. Meanwhile, the three-dimensional motion control can not only realize the regulation and control of Z-axis material characteristics, but also prepare a three-dimensional gradient distribution dielectric function gradient insulator.
Furthermore, when the air pressure in the oven is lower than 0.01Pa, the air bubbles in the composite material can be ensured to be quickly removed before curing, and the defect of bubbles in the composite material is prevented. The environment temperature is 120-150 ℃, the opening of epoxy groups in the composite material can be guaranteed, so that a three-dimensional cross-linked network is generated, the mechanical property of a cured workpiece is improved, the curing time is 8-15 hours, bubbles can be fully removed, and the curing degree is high.
In conclusion, the bi-component mixed epoxy casting dielectric function gradient insulation manufacturing device provided by the invention can realize uniform mixing of two epoxy composite materials with different dielectric constants/conductivities in any proportion; and then conveying the composite material with preset dielectric constant/conductivity to a specified position in a metal mold through a three-dimensional motion platform. The preparation method can realize the manufacture of large-size epoxy casting gradient insulation without changing the condition of the traditional thermosetting manufacturing process, the prepared insulation structure has high electrical resistance, the mechanical and thermal properties can still be maintained, and the actual industrial application requirements can be met, so that the reliability of the insulation structure is improved, and the usage amount of greenhouse gas SF6 is reduced.
The technical solution of the present invention is further described in detail by the accompanying drawings and embodiments.
Drawings
FIG. 1 is a schematic structural view of a manufacturing apparatus according to the present invention;
FIG. 2 is a flow chart of the manufacturing method of the large-size epoxy casting gradient insulation of the present invention.
Wherein: 1. a first material storage tank; 2. a second material storage tank; 3. a pressure pump; 4. a discharge valve; 5. a delivery pipe; 6. a mixer; 7. an extrusion head; 8. a metal mold; a Z-axis moving device; 10. a planar moving device; 11. fixing the clamp; 12. a work table; 13. a motion controller; 14. a cable wire; 15. and (4) a computer.
Detailed Description
In the description of the present invention, it is to be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "one side", "one end", "one side", and the like indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience of description and simplicity of description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed in a particular orientation, and be operated, and thus, are not to be construed as limiting the present invention. Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless otherwise specified.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Referring to fig. 1, the present invention provides a gradient insulation manufacturing apparatus with dielectric function by two-component mixed epoxy casting, which comprises a feeding system, a three-dimensional motion system and a control system; an extrusion head 7 of the feeding system is arranged on the three-dimensional motion system, the control system drives the extrusion head 7 through the three-dimensional motion system, when the extrusion head 7 works, the extrusion head 7 is located inside an epoxy casting metal mold 8, the control system and the feeding system are respectively connected with a computer 15 through cables 14, raw material supply, mixing and extrusion are carried out through control equipment, the extrusion head 7 is controlled in X, Y and Z-direction positions, and finally the accumulative manufacturing of the dielectric constant functional gradient insulator is completed.
The feeding system comprises a first storage tank 1, a second storage tank 2, a pressure pump 3, discharge valves 4, material conveying pipes 5, a mixer 6 and an extrusion head 7, wherein the upper ends of the first storage tank 1 and the second storage tank 2 are connected with the pressure pump 3 through stainless steel interfaces, the first storage tank 1 and the second storage tank 2 are respectively connected with the mixer 6 through the material conveying pipes 5, the discharge valves 4 are respectively arranged on the two material conveying pipes 5, and an active mixing and stirring device is arranged in the mixer 6, so that the two materials can be quickly and uniformly mixed in a short time; the lower end of the mixer 6 is connected with an extrusion head 7 with adjustable nozzle diameter, the extrusion head 7 can be switched according to requirements, the extrusion head 7 is positioned inside an epoxy casting metal mold 8, and the discharge valve 4 is connected with a computer 15.
The first storage tank 1 and the second storage tank 2 are made of stainless steel, the diameter of the first storage tank 1 is 300mm, the height of the first storage tank 2 is 500mm, the first storage tank 1 is used for storing high dielectric constant/conductivity composite materials, the second storage tank 2 is used for storing low dielectric constant/conductivity composite materials, and enough space is reserved for storing epoxy resin composite materials.
The pressure pump 3 is an electric pump driven by an air compressor or a servo motor, the pressure pump 3 is connected with a computer 15 through a cable 14, and the extrusion rate of the two composite materials is adjusted by adjusting the power of the pressure pump 3.
The metal mold 8 can be replaced according to the requirements of different shapes and sizes.
The three-dimensional motion system comprises a Z-axis moving device 9, a X, Y plane moving device 10, a fixing clamp 11 and a workbench 12, wherein the mixer 6 and the extrusion head 7 are assembled on the Z-axis moving device 9 to realize the up-and-down movement in the Z-axis direction, the X, Y plane moving device 10 is fixed on the workbench 12, the fixing clamp 11 is arranged on the workbench 12, and the metal mold 8 is arranged in the fixing clamp 11.
X, Y the metal plate with thickness of 2cm is arranged on the plane moving device 10 for fixing the clamp and the working platform, the metal plate has strong bearing capacity and can bear large-size metal molds, and the heating resistance wire is arranged in the metal plate and can be adjusted by the temperature control system. The set temperature can ensure that the epoxy resin composite material in the metal mold can realize pre-curing, thereby maintaining the spatial distribution of the dielectric property. .
The control system comprises a motion controller 13 and a temperature control system, and the motion controller and the temperature control system are respectively connected with a computer 15 through cables 14.
Referring to fig. 2, the present invention provides a method for manufacturing a two-component mixed epoxy cast dielectric gradient insulation, comprising the following steps:
s1, preparing a high-low high dielectric constant/conductivity composite material;
preparing thermosetting bisphenol A epoxy resin mixed with high dielectric constant inorganic filler or conductive filler, wherein the dielectric constant of the composite material is 4-100, and the conductivity is 1 multiplied by 10-8S/cm-2～1×10-16S/cm-2(ii) a The epoxy resin composite material with low dielectric constant/conductivity is prepared by mixing thermosetting bisphenol A epoxy resin with low-dielectric-constant functional fillers such as silicon dioxide or aluminum oxide and the like, the dielectric constant range of the composite material is 3-5, and the conductivity range is 1 multiplied by 10-15S/cm-2～1×10-16S/c m-2The mixing ratio of the two sets of composite materials with high and low dielectric constants/conductivity is (1-0.03): 0.02-1.
S2, modeling by a computer, mixing double materials and setting temperature;
the computer modeling means that CAD software is used, a three-dimensional model of geometric shape and dielectric constant spatial distribution of the insulator is constructed according to the mechanical performance and the power resistance requirement of an actual electrical insulation structure, the three-dimensional model of the geometric shape is divided into different layers according to preset layer thickness simulation, the moving track of each layer and the dielectric constant value of a single-point material in each layer are obtained through calculation, and finally a file of the moving track of the extrusion head is obtained.
The raw materials are mixed by using a mixer, and two resin raw materials with different dielectric constants are mixed according to dielectric constant or conductivity value required by the single-point material obtained by computer modeling.
The specific working process comprises the following steps: the feeding pump is arranged at the bottom of the material storage tank, raw materials enter the mixing cavity of the 3D printing head mixing device from the two feeding ports through the feeding pump, and the control pump is connected with the control equipment and can control the flow rate (mixing ratio) of the two resins during point-by-point printing so as to achieve the purpose of changing the dielectric constant of the mixture; in the mixing arrangement, the raw materials that get into the material mixing chamber pass through stirring screw rod misce bene to the temperature of mixture is regulated and control through heater and temperature sensor, in order to guarantee that it has suitable viscosity in order to print.
The temperature setting refers to setting the mixer, the extrusion head and the workbench at working temperature through a heating resistance wire, specifically, the temperature of the mixer is 40-100 ℃, the temperature of the extrusion head is 40-80 ℃, and the temperature of the workbench is 25-200 ℃.
S3, cumulative extrusion;
accumulative extrusion refers to that a printing head is driven to perform 3D printing and forming work of the insulator with the dielectric constant functional gradient through an X, Y, Z triaxial moving device, and the specific work flow is as follows: firstly, extruding mixed raw material liquid drops from an extrusion head, dropping the raw material liquid drops to a specified position of a mould, and then moving the extrusion head by using a moving device in the X direction and the Y direction according to a moving track of the extrusion head in a single layer obtained by computer modeling; and adjusting the mixing proportion of the raw materials according to the dielectric constant or conductivity distribution of the single-layer material, and extruding the single-point material once again to finish the cumulative manufacture of the single-layer material. And finally, moving the extrusion head in the Z direction upwards, and performing accumulation manufacturing of single-layer materials again, repeating the steps to complete multilayer accumulation, and finally realizing the manufacturing of the dielectric function gradient insulator.
And S4, thermal curing.
The thermal curing refers to placing the formed dielectric function gradient insulator and a metal mold in a vacuum oven together, wherein the air pressure in the oven is lower than 0.01Pa, the ambient temperature is 120-150 ℃, and the curing time is 8-15 h.
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. The components of the embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the present invention, presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In the epoxy casting dielectric function gradient insulation manufacturing device based on bi-component online mixing, a feeding system comprises a first storage tank 1, an extrusion pump 3 at the upper end of a second storage tank 2 and two feeding valves, wherein the first storage tank 1 and the second storage tank 2 are made of stainless steel and are in a cylindrical shape with a cover, the inner diameter of a cylinder of the first storage tank is 100mm, the height of the cylinder is 150mm, the two storage tanks are fixed on the outer side of a box body 1, and the upper ends of the two storage tanks are respectively connected with a feeding valve 4 and a feeding pipe 5 through stainless steel pipes and are used for supplying resin raw materials from the outside of the device. Two feed pipes 5 are connected to the mixer 6 of the extrusion head for the supply of the extrusion head raw material.
The fixed clamp 11 is used for fixing the metal mould 8 on the workbench 10, one end of the extrusion head 7 is positioned in the metal mould 8, and the mixer 6 comprises an aluminum mixing cavity, an aluminum stirring screw rod, an aluminum heater and a semiconductor temperature sensor; the mixer 6 is fixed on a Z-axis moving device 9 and can move up and down along with the movement of the Z-axis moving device 9, an extrusion head 7 is connected below the mixer 6, and the extrusion head 7 consists of a nozzle and a driving device;
specifically, in the manufacturing device of epoxy casting dielectric function gradient insulation based on two-component online mixing, three-dimensional motion is completed by an X, Y, Z three-axis moving device, a workbench 10, a Z-axis moving device 9 and a set of Z-axis transmission device 9 are connected with a portal frame, and a X, Y-axis plane moving device 10 is positioned at the bottom of the device.
The X-axis plane moving device is composed of a gear transmission mechanism, is connected with an X-axis motor at the upper part through a transmission shaft, and is supported by two X-axis guide rails penetrating through the X-axis motor from left to right, wherein the guide rails are provided with racks, and the plane moving device completes the plane moving under the driving of the motor.
The transmission in the Z direction is also completed by a gear-rack transmission mechanism consisting of a motor, a transmission device and a guide rail: two ends of the X-axis guide rail are connected with two sets of Z-axis transmission devices, and for the Z-axis transmission device on the right side, the right side is connected with a Z-axis motor; the four Z-axis upright posts are divided into a left group and a right group, each group of two Z-axis upright posts penetrates through the two Z-axis transmission devices from top to bottom respectively, the top ends of the two Z-axis upright posts are connected with a fixed support, and the bottom ends of the two Z-axis upright posts are connected with the two sets of Y-axis transmission devices respectively.
The transmission in the Y direction is also completed by a gear-rack transmission mechanism: for the left Y-axis transmission device, the left end of the left Y-axis transmission device is connected with a Y-axis motor, two sets of Y-axis transmission devices are connected through a Y-axis connecting rod, two Y-axis guide rails respectively penetrate through the two Y-axis transmission devices from front to back, two ends of each guide rail are respectively connected with two fixing supports, and the two fixing supports are both fixed on a box body bottom plate.
The working table 10 is located between two fixed brackets, and is also fixed on the bottom plate of the box body for placing the metal mold.
The temperature control and motion control device 13 is constructed by a single chip microcomputer system and is responsible for receiving control information generated by an operator through computer modeling and converting the control information into a control signal for outputting, and an output interface of the control signal is respectively connected with the motion controller 13, the workbench 12 and the pressure pump 3 through cables.
The invention relates to a method for preparing dielectric gradient insulation by double-component mixed epoxy casting, which uses SrTiO3The method for preparing the dielectric constant gradient insulator by using the functional filler and the method for preparing the conductivity gradient insulator by using the carbon fluoride nanotube as the functional filler are taken as examples, and the operation method and the steps of the invention are explained.
With SrTiO3The manufacturing method for preparing the dielectric constant gradient insulator comprises the following steps:
s101, preparing a high dielectric constant composite material and a low dielectric constant composite material; high dielectric constant/composite material made of dielectric filler SrTiO3And the epoxy resin is uniformly mixed with the epoxy resin according to the mass fraction of 1: 1.2. The low dielectric constant/conductivity composite material is prepared from functional filler Al2O3Uniformly mixing the epoxy resin and the epoxy resin according to the mass fraction of 1: 1.2; SrTiO3Has a particle diameter of 10 μm, Al2O3The particle diameter of the coupling agent KH550 is 20 mu m, and the coupling agent KH are subjected to surface treatment;
s102, optimizing electric field distribution according to the geometric shape of an actual electric insulation structure, constructing an insulator dielectric constant spatial distribution three-dimensional model according to the optimized dielectric constant distribution, dividing the three-dimensional model into different layers according to preset layer thickness simulation, and calculating to obtain a printing track of each layer and a dielectric constant value of a single-point material in each layer;
s103, designing the mixing ratio of the two composite materials in the step S101 according to the specific numerical value of the dielectric constant in the step S102, and achieving the purpose of changing the dielectric constant of the mixed material by adjusting the mixing ratio of the two raw materials. The pressure of the extrusion pump is determined through theoretical calculation, and the two materials can be conveyed into the mixer 6 according to a set proportion;
and S104, controlling the temperature of the mixer, the extrusion head and the die in a required range through a temperature control system according to the temperature requirement of each part, so as to ensure that the viscosity of the composite material meets the printing requirement. Then, mixing the resin raw materials in the two storage tanks by using a mixing device 11; the material in the mixer 6 is extruded from the extrusion head 7 after being mixed for a plurality of times;
s105, extruding the mixed composite material into a stainless steel metal die 8 by using an extrusion head 7, and moving the printing head in the X direction and the Y direction in a plane by using an X-axis and Y-axis moving device according to the moving track of the printing head in the single layer and the dielectric constant distribution of the single layer material obtained in the step S102 to finish the printing of the single layer surface;
s106, after the printing of the single layer surface is finished, moving the extrusion head upwards in the Z direction, and repeating the operation of the step S105 to finish the printing of the next layer surface;
s107, performing traditional thermosetting on the insulator manufactured in the step S106, and pumping the vacuum degree in an oven to be lower than 0.01Pa, the ambient temperature to be 120-150 ℃, and the curing time to be 8-15 h to obtain the insulator with the dielectric constant function gradient.
The manufacturing method of the conductivity gradient insulator comprises the following steps:
s201, preparing a high-conductivity composite material and a low-conductivity composite material; the high-conductivity composite material is prepared by uniformly mixing dielectric filler carbon fluoride nanotubes and epoxy resin according to the mass fraction of 1: 20. The low-conductivity composite material is prepared from functional filler Al2O3Uniformly mixing the epoxy resin with the epoxy resin according to the mass fraction of 1:1.2Preparing; the particle size of the alumina is 10 μm, and the surface of the alumina is treated by a coupling agent KH 550;
s202, optimizing electric field distribution according to the geometric shape of an actual electric insulation structure, constructing an insulator dielectric constant spatial distribution three-dimensional model according to the optimized dielectric conductivity distribution, dividing the three-dimensional model into different layers according to preset layer thickness simulation, and calculating to obtain a printing track of each layer and a conductivity value of a single-point material in each layer;
s203, designing the mixing ratio of the two composite materials in the step S201 according to the specific value of the conductivity in the step S202, and achieving the purpose of changing the conductivity of the mixture by adjusting the mixing ratio of the two raw materials. The pressure of the extrusion pump is determined through theoretical calculation, and the two materials can be conveyed into the mixer 6 according to a set proportion;
and S204, controlling the temperature of the mixer, the extrusion head and the mould within a required range through a temperature control system according to the temperature requirement of each part, thereby ensuring that the viscosity of the composite material meets the printing requirement. Then, mixing the resin raw materials in the two storage tanks by using a mixing device 11; the material in the mixer 6 is extruded from the extrusion head 7 after being mixed for a plurality of times;
s205, extruding the mixed composite material into a stainless steel metal die 8 by using an extrusion head 7, and moving the printing head in the X direction and the Y direction in a plane by using an X-axis and Y-axis moving device according to the moving track of the printing head in the single layer and the conductivity distribution of the single layer material obtained in the step S202 to finish the printing of the single layer surface;
s206, after the printing of the single layer surface is finished, moving the extrusion head upwards in the Z direction, and repeating the operation of the step S205 to finish the printing of the next layer surface;
and S207, performing traditional thermosetting on the insulator manufactured in the step S206, and pumping the vacuum degree in an oven to be lower than 0.01Pa, the ambient temperature to be 120-150 ℃, and the curing time to be 8-15 h to obtain the insulator with the dielectric constant function gradient.
In conclusion, the bi-component mixed epoxy casting dielectric function gradient insulation manufacturing device provided by the invention can realize uniform mixing of two epoxy composite materials with different dielectric constants/conductivities in any proportion. And then conveying the composite material with preset dielectric constant/conductivity to a specified position in a metal mold through a three-dimensional motion platform. The preparation method can realize the manufacture of large-size epoxy casting gradient insulation without changing the condition of the traditional thermosetting manufacturing process, the prepared insulation structure has high electrical resistance, the mechanical and thermal properties can still be maintained, and the actual industrial application requirements can be met, so that the reliability of the insulation structure is improved, and the usage amount of greenhouse gas SF6 is reduced.
The above-mentioned contents are only for illustrating the technical idea of the present invention, and the protection scope of the present invention is not limited thereby, and any modification made on the basis of the technical idea of the present invention falls within the protection scope of the claims of the present invention.
Claims (10)
1. The device for manufacturing the dielectric function gradient insulation by pouring the double-component mixed epoxy is characterized by comprising a double-material feeding system, wherein an extrusion head (7) of the feeding system is arranged on a three-dimensional motion system, the diameter of a nozzle of the extrusion head (7) is adjustable, one end of the extrusion head is positioned in a metal die (8) for epoxy pouring, the three-dimensional motion system is connected with a control system, and the control system and the feeding system are respectively connected with a computer (15) through cables (14) and are used for controlling the supply, mixing and extrusion of raw materials and the position of the extrusion head (7) in X, Y directions and Z directions to complete the manufacture of the dielectric constant function gradient insulator.
2. The dielectric gradient insulation manufacturing device for casting of two-component mixed epoxy according to claim 1, characterized in that the feeding system comprises a first storage tank (1) and a second storage tank (2), the first storage tank (1) is used for storing high dielectric constant/conductivity composite material, the second storage tank (2) is used for storing low dielectric constant/conductivity composite material, the upper ends of the first storage tank (1) and the second storage tank (2) are respectively connected with the pressure pump (3) through stainless steel interfaces, the first storage tank (1) and the second storage tank (2) are respectively connected with the mixer (6) through a material conveying pipe (5) provided with a discharge valve (4), and the lower end of the mixer (6) is connected with the extrusion head (7).
3. The apparatus for producing dielectric gradient insulation according to claim 1, wherein the three-dimensional motion system comprises a Z-axis moving device (9) and a X, Y plane moving device (10), the extrusion head (7) is mounted on the Z-axis moving device (9), the X, Y plane moving device (10) is fixed on a worktable (12), a fixing clamp (11) is provided on the worktable (12), and the metal mold (8) is disposed in the fixing clamp (11).
4. The apparatus for producing a two-component hybrid epoxy cast dielectric functionally graded insulation according to claim 1 wherein the control system comprises a motion controller (13) and a temperature control system, the motion controller and the temperature control system being connected to a computer (15) via cables (14), respectively.
5. A method for manufacturing a two-component mixed epoxy casting dielectric function gradient insulation is characterized by comprising the following steps:
s1, preparing two types of epoxy composite materials with high, low and high dielectric constant/conductivity;
s2, constructing a geometric shape and dielectric constant/conductivity spatial distribution three-dimensional model of the insulator to obtain a motion track of the extrusion head, mixing the two resin raw materials with different dielectric constants in the step S1, and determining the temperature;
s3, driving the extrusion head to perform 3D printing and forming work of the dielectric constant/conductivity functional gradient insulator through a X, Y, Z triaxial moving device;
s4, placing the dielectric function gradient insulator molded in the metal mold into a vacuum oven for curing to obtain the bi-component mixed epoxy cast dielectric function gradient insulator.
6. The apparatus and method for manufacturing a two-component epoxy-mixed casting dielectric gradient insulation as claimed in claim 5, wherein in step S1, the dielectric constant of the high-k/conductivity composite material is 4-100, conductivity 1X 10-8～1×10-16S/cm-2(ii) a The low dielectric constant/conductivity composite material is prepared by mixing thermosetting bisphenol A epoxy resin with silicon dioxide or alumina low dielectric constant functional filler, the dielectric constant of the low dielectric constant/conductivity composite material is 3-5, and the conductivity is 1 multiplied by 10-15～1×10-16S/cm-2。
7. The apparatus and method for manufacturing two-component epoxy-mixed casting dielectric gradient insulation as claimed in claim 6, wherein the mixing ratio of the two sets of composite materials with high and low dielectric constants/conductivities is (1-0.03): (0.02-1).
8. The apparatus and method for manufacturing a dielectric gradient insulation according to claim 5, wherein the mixer is at a temperature of 40-100 ℃, the extrusion head is at a temperature of 40-80 ℃, and the work bench is at a temperature of 25-200 ℃ in step S2.
9. The apparatus and method for manufacturing a dielectric gradient insulation according to claim 5, wherein in step S3, the mixed droplets of the raw material are extruded from the extrusion head and dropped to a predetermined position of the mold, and then the extrusion head is moved by using the X-direction and Y-direction moving means according to the moving trajectory of the extrusion head in a single layer obtained by computer modeling; adjusting the mixing proportion of the raw materials according to the dielectric constant or conductivity distribution of the single-layer material, and extruding the single-point material once to finish the accumulative manufacture of the single-layer material; and finally, moving the extrusion head in the Z direction upwards, and performing accumulation manufacturing of single-layer materials again, repeating the steps to complete multilayer accumulation, thereby realizing the manufacturing of the dielectric function gradient insulator.
10. The apparatus and method for manufacturing a two-component mixed epoxy cast dielectric gradient insulation according to claim 5, wherein in step S4, the air pressure in the oven is lower than 0.01Pa, the ambient temperature is 120-150 ℃, and the curing time is 8-15 h.
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