CN112590322A - 一种玄武岩纤维制作成绝缘板的方法 - Google Patents
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Abstract
本发明提供一种玄武岩纤维制作成绝缘板的方法,将单层玄武岩纤维布的正反两面都被混合物充分浸泡,多次浸泡后进行第一次脱水压平,柔软状态变成平硬状态,剪裁成设定长度的布板,布板经过叠放若干层后重压成高密度整板,同时进行加热烘干第二次脱水,对整板再次裁剪并进行双面打磨抛光,送出制板机,排布放置。所述玄武岩纤维制作成绝缘板的方法步骤简单,操作灵活,制作出的绝缘板质量可靠,结实耐用,对高温稳定性、低温稳定性、防潮、变型、整体抗疲劳性能都有明显的优势。
Description
技术领域
本发明涉及一种绝缘板的方法,尤其是涉及一种玄武岩纤维制作成绝缘板的方法。
背景技术
玻璃纤维绝缘板是比较成熟的技术,光玻璃纤维绝缘板的制作方法和配方都有几十种之多,也是现在电路板通用的绝缘板,通常玻璃纤维的材料是由叶腊石、石英砂、石灰石、白云石、硼钙石、硼镁石六种矿石为原料经高温熔制、拉丝、络纱、织布等工艺制造成,十分的复杂。但是,玻璃纤维采用的材料过于复杂,虽然应用广泛,由于采用的材料过于复杂、加工生产费劲、在有些高端领域也不适合,比如新能源车、飞机、航空领域、部分材料比如叶腊石、石灰石、白云石、在耐高温、阻燃方面不如单一纯天然无杂质的玄武岩纤维绝缘板。进一步的,玄武岩纤维绝缘板主要应用于新能源电动车电路板、航空航天、无人飞机、飞机、无线通信等高端电路的绝缘板及绝缘材料。
发明内容
本发明提供了一种玄武岩纤维制作成绝缘板的方法,用于解决将玄武岩石头制作成玄武岩纤维,以及将玄武岩纤维制作成绝缘板的问题,其技术方案如下所述:
一种玄武岩纤维制作成绝缘板的方法,包括以下步骤:
S1:将纺织好的成卷的玄武岩纤维布放入原料轴中,引出玄武岩纤维布开头,顺压布轴送向浸泡池;
S2:所述浸泡池内部和其上方设置有多根转向轴,所述玄武岩纤维布经过转向轴形成蛇形前进路线,使其正反两面都被混合物充分浸泡;
S3:玄武岩纤维布经过多次浸泡后,拖扯移至挤压机中,将带出的多余的混合物均匀挤掉;
S4:玄武岩纤维布进入重压烘干脱水机进行压榨,进行第一次脱水压平,脱水压平后柔软的单层玄武岩纤维布变的平硬;
S5:通过传动轴将平硬状态的玄武岩纤维布的布板送入剪裁机进行第一次剪裁;
S6:剪裁后的布板经过叠放若干层后,重压成高密度整板,同时进行加热烘干第二次脱水;
S7:整板进入打磨机前经过剪裁机进行第二次裁剪,裁剪成设定规格并进行双面打磨抛光,将因重压多出的毛边全部剪裁,送出制板机。
进一步的,步骤S2中,所述混合物包括以下成分:环氧树脂34%~38%、自配方树脂35%~39%、阻燃剂24%~30%。
进一步的,步骤S5中,所述剪裁机将玄武岩纤维布剪裁成宽度为1000mm、长度为2400mm的尺寸。
进一步的,步骤S6中,1.8mm厚度的绝缘板为12层布压制而成,2.1mm厚度的绝缘板为14层布压制而成。
所述玄武岩纤维布通过玄武岩纤维丝线在织布机编织形成。
所述玄武岩纤维丝线通过玄武岩石头制作的步骤如下:
S11:将纯天然无杂质的玄武岩石头破碎为12-20mm颗粒;
S12:用清水将破碎后的玄武岩碎石颗粒洗净并晾干水分;
S13:将玄武岩碎石颗粒放入冶炼熔炉中熔炼成玄武岩汁液,使玄武岩汁液从冶炼熔炉下方的多个细孔流淌出来;
S14:当细孔流淌出的玄武岩汁液接触空气冷却,即可变成玄武岩纤维,这时候不要将其剪断;
S15:用轴压的方法对玄武岩纤维进行捻压,这道捻压工序和把棉花捻成线的工艺相同,同时加捻少量石油浸润在玄武岩纤维表面使其光滑柔软,并能够去除飞毛;
S16:捻成的玄武岩纤维线用线轴将其按照逆时针进行缠绕,缠绕速度按照玄武岩汁液沿细孔流淌的速度即可,每一轴线缠绕纤维线至2.5公斤左右再将其剪断,然后进行后续的第二线轴、第三线轴等进行采集,最终得到多卷合格的电路板专用的玄武岩纤维线。
进一步的,步骤S13中,所述冶炼熔炉下方的多个细孔为漏斗锥形,细孔材质需要用耐高温材料制成,耐高温材料应高于1800度不变型,确保玄武岩汁液漏出流淌的速度和粗细一致。
进一步的,步骤S13中,所述冶炼熔炉采用电炉或燃气炉,温度控制在1425度-1440度之间,漏出的玄武岩汁液及纤维控制在8.5-9.5微米。
所述玄武岩纤维制作成绝缘板的方法步骤简单,操作灵活,制作出的绝缘板质量可靠,结实耐用,对高温稳定性、低温稳定性、防潮、变型、整体抗疲劳性能都有明显的优势。
附图说明
图1是所述玄武岩石头制作玄武岩纤维线的流程示意图;
图2是单层玄武岩纤维布的示意图;
图3是所述玄武岩纤维布制作成绝缘板的方法的流程示意图;
图4是本方法利用的装置示意图。
具体实施方式
本发明提供的玄武岩纤维制作成绝缘板的方法,和现有玻璃纤维绝缘板以及玄武岩纤维绝缘板存在区别,不同的是原材料的不同和加工方法的不同。
本发明用来制作玄武岩纤维绝缘板的主要材料,是单一的纯天然无杂质的玄武岩石头,玄武岩石本身经历了火山爆发千锤百炼,其熔点比叶腊石、石灰石、白云石要高,已具有天然的坚硬、耐高温、抗氧化、耐摩擦、抗腐蚀等优点,是石头中性能比较稳定的一种,是常期被用于高铁、火车轨道地基及桥梁建设使用的主要材料。
如图1所示,利用玄武岩石头制作成玄武岩纤维线,包括以下步骤:
S1:将纯天然无杂质的玄武岩石头破碎为12-20mm颗粒;
S2:用清水将破碎后的玄武岩碎石颗粒洗净并晾干水分;
S3:将玄武岩碎石颗粒放入冶炼熔炉中熔炼成玄武岩汁液(纯玄武岩的岩浆),使玄武岩汁液从冶炼熔炉下方的多个细孔流淌出来;
S4:当细孔流淌出的玄武岩汁液接触空气冷却,即可变成玄武岩纤维,这时候不要将其剪断;
S5:用轴压的方法对玄武岩纤维进行捻压,这道捻压工序和把棉花捻成线的工艺相同,同时加捻少量石油浸润在玄武岩纤维表面使其光滑柔软,并能够去除飞毛;
S6:捻成的玄武岩纤维线用线轴将其按照逆时针进行缠绕,缠绕速度按照玄武岩汁液沿细孔流淌的速度即可,每一轴线缠绕纤维线至2.5公斤左右再将其剪断,然后进行后续的第二线轴、第三线轴等进行采集,最终得到多卷合格的电路板专用的玄武岩纤维线。
在处理过程中,所述冶炼熔炉下方的多个细孔为漏斗锥形,细孔材质需要用耐高温材料制成,耐高温材料应高于1800度不变型,确保玄武岩汁液漏出流淌的速度和粗细一致。
所述冶炼熔炉应采用电炉或燃气炉,这样可以精确对冶炼熔炉进行恒温控制,温度应控制应在1425度-1440度之间,漏出的玄武岩汁液及纤维控制在8.5-9.5微米左右为最佳状态,以上数据可以保障后期织布后,布的柔软度和布的总体厚度为最优状态。
如图2所示的单层玄武岩纤维布,通过上述制作好的玄武岩纤维丝线制作成。玄武岩纤维制布比动物纤维(蚕丝)、聚酯纤维织布的工艺和难度相同,只是工艺要求因为制做高质量的玄武岩纤维绝缘板与普通编织有所不同,用同样的织布机可进行编织,要求织布机可织宽度不得小于1050mm,可织长度不得小于50m,所织布匹必须平整均匀无毛刺。本发明要求采用直纹(平纹)编织,布的均匀厚度不能超过0.16mm,布的宽度尺寸B为1050mm,长度尺寸A不小于50m且不大于1000m,成卷后每卷体积重量不大于550公斤,布的每平米重量200-230克为最佳。
如图3所示,接下来再将织好的玄武岩纤维布安装于制作好的制板机,进行玄武岩纤维绝缘板制作。结合图4所示的制板机装置进行处理,所述制板机从左向右依次设置有原料轴1、浸泡池2、挤压机3、重压烘干脱水机5、剪裁机7和打磨机9,所述浸泡池2的上方和池内设置有转向轴4,所述重压烘干脱水机5通过烘干板6对玄武岩纤维布进行处理。
制作方法包括以下步骤:
S1:将纺织好的成卷的玄武岩纤维布放入原料轴1中,从成卷的玄武岩纤维布引出玄武岩纤维布开头,再将玄武岩纤维布顺原料轴1后端设置的压布轴放入浸泡池2进行穿胶浸泡;
所述压步轴分为上下两轴,其中一端通过电机带动,从而牵引玄武岩纤维布向右侧运动。
S2:在浸泡池2中和浸泡池2的上方设置有多根转向轴4,所述玄武岩纤维布经过转向轴4形成蛇形前进路线,从而使其正反两面都在浸泡池2中的混合物里充分浸泡;
所述浸泡池2中放置有混合物,所述混合物包括以下成分:环氧树脂34%~38%、自配方树脂35%~39%、阻燃剂24%~30%。
S3:玄武岩纤维布在浸泡池2中多次浸泡后,拖扯移至挤压机3中,在挤压机3中,将玄武岩纤维布在浸泡池2带出的多余的混合物均匀挤掉;
所述挤压机3采用上板和对应的下板,通过液压装置提供上板和下板的挤压动力,通过上下两个方向挤压玄武岩纤维布,也能够使得混合物进一步的浸透玄武岩纤维布。
S4:再将浸透的玄武岩纤维布进入重压烘干脱水机5进行压榨,进行第一次脱水压平,脱水压平后柔软的单层玄武岩纤维布会变成又平又硬的布板;
所述重压烘干脱水机5包括上下两块烘干板6,所述烘干板6通过液压装置提供升降动力,通过加热装置提供温度控制,进而实现对单层玄武岩纤维布进行烘干脱水。
S5:所述重压烘干脱水机5右端设置有传动轴,通过传动轴会自动将单层玄武岩纤维布的布板送入剪裁机7进行第一次剪裁,剪裁机7这时只剪裁玄武岩纤维布布板的长度,将布板的长度裁剪成2450mm,裁剪后的布板位于重压床8上。
S6:剪裁后的布板经过叠放12层后,剪裁机7中部设置有重压机,叠放的布板位于重压区域下方的重压床8上,重压机将叠放的布板重压成1.8mm高度的高密度整板,同时重压机的压板也连接有加热装置,在重压时进行加热烘干,对叠放布板进行第二次脱水。
S7:脱水处理到设定的水分达标数值后,剪裁机7对整板进行第二次剪裁,将叠放布板裁剪成宽度为1000mm、长度为2400mm的尺寸,剪裁机7后端的传动轴将整板送入打磨机9中,进行双面打磨抛光,并将整板因重压多出的毛边全部剪裁,送出制板机。
以上操作过程均为全机械化,实现全自动完成,再将压平的整板,以1.8mm厚度的绝缘板为列排布放置。
其中,1.8mm厚度的绝缘板最佳效果为12层布压制而成,2.1mm需要14层进行叠压,以此推算即可。
进一步的,步骤S6中,每单层布加胶压制后最佳效果为0.15mm厚度,宽度不小于1000mm,长度为2400mm,以上数据是通过无数次实验、耗费大量人力财力、经过无数次实验总结后得到的最佳效果数据及数据标准。
本发明制作出的玄武岩纤维与玻璃纤维在拉伸、摩擦性能实验数据对比:
可见,玄武岩纤维不仅可以替代玻璃纤维、还可以增强提高绝缘板抗折强度15%-25%、韧性强度20%-30%,劈裂、抗拉强度16%-30%,可提高抗压强度10.%,对高温稳定性、低温稳定性、防潮、变型、整体抗疲劳性能都有明显的优势。
Claims (9)
1.一种玄武岩纤维制作成绝缘板的方法,包括以下步骤:
S1:将纺织好的成卷的玄武岩纤维布放入原料轴中,引出玄武岩纤维布开头,顺压布轴送向浸泡池;
S2:所述浸泡池内部和其上方设置有多根转向轴,所述玄武岩纤维布经过转向轴形成蛇形前进路线,使其正反两面都被混合物充分浸泡;
S3:玄武岩纤维布经过多次浸泡后,拖扯移至挤压机中,将带出的多余的混合物均匀挤掉;
S4:玄武岩纤维布进入重压烘干脱水机进行压榨,进行第一次脱水压平,脱水压平后柔软的单层玄武岩纤维布变的平硬;
S5:通过传动轴将平硬状态的玄武岩纤维布的布板送入剪裁机进行第一次剪裁;
S6:剪裁后的布板经过叠放若干层后,重压成高密度整板,同时进行加热烘干第二次脱水;
S7:整板进入打磨机前经过剪裁机进行第二次裁剪,裁剪成设定规格并进行双面打磨抛光,将因重压多出的毛边全部剪裁,送出制板机。
2.根据权利要求1所述的玄武岩纤维制作成绝缘板的方法,其特征在于:步骤S2中,所述混合物包括以下成分:环氧树脂34%~38%、自配方树脂35%~39%、阻燃剂24%~30%。
3.根据权利要求1所述的玄武岩纤维制作成绝缘板的方法,其特征在于:步骤S5中,所述剪裁机第一次将玄武岩纤维布剪裁成长度为2450mm的尺寸,用于叠放多层玄武岩纤维布。
4.根据权利要求1所述的玄武岩纤维制作成绝缘板的方法,其特征在于:步骤S7中,所述剪裁机第二次将玄武岩纤维布剪裁成宽度为1000mm、长度为2400mm的尺寸。
5.根据权利要求1所述的玄武岩纤维制作成绝缘板的方法,其特征在于:步骤S6中,1.8mm厚度的绝缘板为12层布压制而成,2.1mm厚度的绝缘板为14层布压制而成。
6.根据权利要求1所述的玄武岩纤维制作成绝缘板的方法,其特征在于:所述玄武岩纤维布通过玄武岩纤维丝线在织布机编织形成。
7.根据权利要求6所述的玄武岩纤维制作成绝缘板的方法,其特征在于:所述玄武岩纤维丝线通过玄武岩石头制作的步骤如下:
S11:将纯天然无杂质的玄武岩石头破碎为12-20mm颗粒;
S12:用清水将破碎后的玄武岩碎石颗粒洗净并晾干水分;
S13:将玄武岩碎石颗粒放入冶炼熔炉中熔炼成玄武岩汁液,使玄武岩汁液从冶炼熔炉下方的多个细孔流淌出来;
S14:当细孔流淌出的玄武岩汁液接触空气冷却,即可变成玄武岩纤维,这时候不要将其剪断;
S15:用轴压的方法对玄武岩纤维进行捻压,这道捻压工序和把棉花捻成线的工艺相同,同时加捻少量石油浸润在玄武岩纤维表面使其光滑柔软,并能够去除飞毛;
S16:捻成的玄武岩纤维线用线轴将其按照逆时针进行缠绕,缠绕速度按照玄武岩汁液沿细孔流淌的速度即可,每一轴线缠绕纤维线至2.5公斤左右再将其剪断,然后进行后续的第二线轴、第三线轴等进行采集,最终得到多卷合格的电路板专用的玄武岩纤维线。
8.根据权利要求7所述的玄武岩纤维制作成绝缘板的方法,其特征在于:步骤S13中,所述冶炼熔炉下方的多个细孔为漏斗锥形,细孔材质需要用耐高温材料制成,耐高温材料应高于1800度不变型,确保玄武岩汁液漏出流淌的速度和粗细一致。
9.根据权利要求7所述的玄武岩纤维制作成绝缘板的方法,其特征在于:步骤S13中,所述冶炼熔炉采用电炉或燃气炉,温度控制在1425度-1440度之间,漏出的玄武岩汁液及纤维控制在8.5-9.5微米。
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