CN113459624B - 一种防腐蚀保护罩及其制备方法 - Google Patents

一种防腐蚀保护罩及其制备方法 Download PDF

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CN113459624B
CN113459624B CN202111017420.7A CN202111017420A CN113459624B CN 113459624 B CN113459624 B CN 113459624B CN 202111017420 A CN202111017420 A CN 202111017420A CN 113459624 B CN113459624 B CN 113459624B
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fabric
corrosion
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CN113459624A (zh
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蔡欣阳
张大伟
刘李蕾
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Beijing Hengxin Tongwei Technology Development Co ltd
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Abstract

本发明涉及一种防腐蚀保护罩及其制备方法，所述保护罩的结构依次包括表层、中间层和内衬层；所述表层为防水透气性聚酯织物材料，阻隔外部水分的进入，同时透气性结构可以允许材料包装范围内的水汽向外散发，以减少内部水汽的冷凝，可以反射太阳光线，阻挡UV紫外线的伤害；中间层为高阻隔气相防锈膜，隔绝腐蚀物质的接触从而起到防腐蚀的效果，减少保护件腐蚀的发生；内衬层面料选用气相防锈无纺布，不仅对设备漆面和高光洁表面有很好的防护性能，减少漆面及电镀表面破损的产生，具备一定的防滑功能，还能进一步提高耐腐蚀性能。因此，本发明所述防腐蚀保护罩，防水、透气，环保无污染，轻质，耐紫外性好，防腐性能好，强度高。

Description

一种防腐蚀保护罩及其制备方法
技术领域
本发明属于防护包装材料技术领域，具体涉及一种防腐蚀保护罩及其制备方法。
背景技术
我国现役飞机尤其是经常在沿海地区飞行的飞机腐蚀问题比较突出。其原因主要是由于沿海地区湿度大，多海雾，大气中含盐量高，且工业污染加剧了腐蚀。例如，在飞机停放时，机身、机翼下壁距地面较近，地面水蒸汽蒸发凝结于下壁上，使机身-机翼长期处于潮湿环境，水、凝露和水蒸汽进入非密封的铆接缝隙处，从而造成严重腐蚀。
现有技术中，缓蚀剂对飞机上的局部应用从2008年开始，重点是搭接及连接部位，经过多次对试验区域进行检查，发现使用5年后缓蚀剂喷涂部位尚无腐蚀失效现象发生。在未喷涂缓蚀剂的对比区，机身下部长桁与腹板连接部位出现涂层剥落现象，基体金属轻微腐蚀。
缓蚀剂施工方法包括刷涂、浸涂和喷涂等。刷涂适用于小区域涂覆，或者防止周围区域或设备涂覆缓蚀剂的情况；浸涂适用于小型分解部件的缓蚀剂涂覆，应使用材料与缓蚀剂相容的容器进行浸涂；喷涂适用于无限制大面积区域的涂覆，应该根据材料黏度选择合适的喷涂设备。
在外场和机库停放时，为了进一步加强对飞机起落架、进气道和尾喷等部件的防腐蚀保护，延长飞机外场停放时的维护周期，减少腐蚀性维护的工作量，目前应用于海军飞机的防腐蚀保护罩材料多为重型防水遮罩，如防水帆布等，存在不透气、重量大、不柔软且防腐效果差等缺陷。
发明内容
为了解决现有技术存在的上述问题，本发明提供了一种防腐蚀保护罩及其制备方法。本发明所述防腐蚀保护罩，防水、透气，环保无污染，轻质，耐紫外性好，防腐性能好，强度高。
本发明所采用的技术方案为：
一种防腐蚀保护罩，所述保护罩为复合膜结构，所述复合膜结构依次包括表层、中间层和内衬层；
所述表层为防水透气性聚酯织物材料，所述防水透气性聚酯织物材料由外至内依次包括涂层、防水透气膜、高强织物；
所述中间层为高阻隔气相防锈膜；
所述内衬层为气相防锈无纺布。
所述涂层为纳米疏水涂层。本发明直接采购表面具有纳米疏水涂层TPU膜产品，即为涂层/防水透气膜复合产品。
所述防水透气膜的材质为热塑性聚氨酯弹性体。
所述高强织物为锦纶绸。
所述锦纶绸采用如下方法加工而成：
（a）取锦纶长丝，依次进行络筒、加捻、整经、穿筘、织造后，得到织物；
（b）将所述织物进行印花，得到锦纶绸。
步骤（a）中，所述加捻为120捻/米；车速为200转/分钟。
所述高阻隔气相防锈膜采用如下方法制得：
（S1）将苯甲酸钠、钼酸铵、六亚甲基四胺、植酸胺以4-6:1-3:1-3:0.5-1.5的质量比进行复配，充分混匀，得到气相缓蚀剂备用；
（S2）将线型低密度聚乙烯和低密度聚乙烯按照质量比2:1进行混匀，得到载体备用；
（S3）按照质量比3:7取气相缓蚀剂与混匀的载体，加入色母粒，色母粒的质量为母粒与载体总质量的千分之一，充分混匀后，经造粒、挤出吹塑，即得所述高阻隔气相防锈膜。
所述气相防锈无纺布采用如下方法制得：
（SS1）将苯甲酸钠、钼酸铵、六亚甲基四胺、植酸胺以4-6:1-3:1-3:0.5-1.5的质量比进行复配，充分混匀，得到气相缓蚀剂备用；
（SS2）采用浸轧法在超细涤纶纺粘水刺无纺布上添加气相缓蚀剂，即得所述气相防锈无纺布。
所述的防腐蚀保护罩的制备方法，包括以下步骤：
（1）将高阻隔气相防锈膜与气相防锈无纺布贴合成为半成品Ⅰ
对高阻隔气相防锈膜的一个侧面进行上胶，在线电晕；之后采用点贴方式将高阻隔气相防锈膜与气相防锈无纺布进行贴合，固化，即得半成品Ⅰ；
（2）将半成品Ⅰ与高强织物贴合为半成品Ⅱ
将半成品Ⅰ中高阻隔气相防锈膜的另一侧面进行上胶，在线电晕；之后采用点贴方式将半成品Ⅰ中的高阻隔气相防锈膜一侧与高强织物进行贴合，固化，即得半成品Ⅱ；
（3）将半成品Ⅱ与涂层/防水透气膜贴合
在涂层/防水透气膜的防水透气膜的一侧进行上胶，之后采用点贴方式将半成品Ⅱ中的高强织物一侧与涂层/防水透气膜进行贴合，固化，即得所述防腐蚀保护罩。
步骤（1）中，进行贴合时，膜牵引张力为50N，车速5.5m/min，上胶量10-15g/m2，烘干温度为100℃；固化温度为25℃，固化时间为72h，RH60-70%；
步骤（2）中，进行贴合时，膜牵引张力为50N，车速3-4m/min，上胶量10-15g/m2，烘干温度为100℃；固化温度为25℃，固化时间为72h，RH60-70%；
步骤（3）中，进行贴合时，膜牵引张力为30-40N，车速2m/min，上胶量10-15g/m2，烘干温度为100℃；固化温度为25℃，固化时间为72h，RH60-70%。
本发明的有益效果为：
本发明所述的防腐蚀保护罩，所述保护罩为复合膜结构，所述复合膜结构依次包括表层、中间层和内衬层；所述表层为防水透气性聚酯织物材料，100%完全防水，阻隔外部水分的进入，同时透气性结构可以允许材料包装范围内的水汽向外散发，以减少内部水汽的冷凝，表层涂层可以反射太阳光线，阻挡UV紫外线的伤害；中间层为高阻隔气相防锈膜，通过将气相缓蚀剂与树脂基体混合，经过挤出机的两次造粒挤出，最后吹塑而成的高阻隔气相防锈膜，利用气相缓蚀剂（VCI）的挥发性，使其从树脂中渗透到保护件的表面，隔绝腐蚀物质的接触从而起到防腐蚀的效果，减少保护件腐蚀的发生；内衬层面料选用气相防锈无纺布，添加有气相缓释剂成分，从而所述内衬层不仅对设备漆面和高光洁表面有很好的防护性能，减少漆面及电镀表面破损的产生，具备一定的防滑功能，还能进一步提高耐腐蚀性能。因此，本发明所述防腐蚀保护罩，防水、透气，环保无污染，轻质，耐紫外性好，防腐性能好，强度高。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本发明所述防腐蚀保护罩的成型工艺流程图；
图2为本发明所述防腐蚀保护罩的结构示意图。
图中，1-防水透气性聚酯织物材料，2-高阻隔气相防锈膜，3-气相防锈无纺布，4-锦纶绸。
具体实施方式
为使本发明的目的、技术方案和优点更加清楚，下面将对本发明的技术方案进行详细的描述。显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动的前提下所得到的所有其它实施方式，都属于本发明所保护的范围。
实施例1
本实施例提供一种防腐蚀保护罩，所述保护罩为复合膜结构，所述复合膜结构依次包括表层、中间层和内衬层。
如图2所示，所述表层为防水透气性聚酯织物材料1，所述防水透气性聚酯织物材料1由外至内依次包括涂层、防水透气膜、高强织物；所述涂层为纳米疏水涂层。所述防水透气膜的材质为热塑性聚氨酯弹性体（TPU），采购的TPU膜（购自惠州艺都高科新材料有限公司）自身表面涂有纳米疏水涂层。所述高强织物为锦纶绸4。
所述锦纶绸4采用如下方法加工而成：（a）取锦纶长丝，依次进行络筒、加捻、整经、穿筘、织造后，得到织物；其中，所述加捻为120捻/米，车速为200转/分钟；（b）依次经制版、调浆、颜色小样、大机样品后，对所述织物进行印花，得到锦纶绸4。
所述中间层为高阻隔气相防锈膜2；所述高阻隔气相防锈膜2采用如下方法制得：（S1）将苯甲酸钠、钼酸铵、六亚甲基四胺、植酸胺以5:2:2:1的质量比进行复配，充分混匀，得到气相缓蚀剂备用；（S2）将线型低密度聚乙烯和低密度聚乙烯按照质量比2:1进行混匀，得到载体备用；（S3）按照质量比3:7取气相缓蚀剂与混匀的载体，加入色母粒，色母粒的质量为母粒与载体总质量的千分之一，充分混匀后，经造粒、挤出吹塑，即得所述高阻隔气相防锈膜2。
所述内衬层为气相防锈无纺布3，所述气相防锈无纺布3采用如下方法制得：（SS1）将苯甲酸钠、钼酸铵、六亚甲基四胺、植酸胺以5:2:2:1的质量比进行复配，充分混匀，得到气相缓蚀剂备用；（SS2）采用浸轧法在超细涤纶纺粘水刺无纺布上添加气相缓蚀剂，即得所述气相防锈无纺布3。
本实施例还提供防腐蚀保护罩的制备方法，如图1所示，具体包括如下步骤：
（1）将高阻隔气相防锈膜2与气相防锈无纺布3贴合成为半成品Ⅰ
对高阻隔气相防锈膜2的一个侧面进行上胶，在线电晕；之后采用点贴方式将高阻隔气相防锈膜2与气相防锈无纺布3进行贴合，进行贴合时，膜牵引张力为50N，车速5.5m/min，上胶量10-15g/m2，烘干温度为100℃；最后进行固化，固化温度为25℃，固化时间为72h，相对湿度RH60-70%；即得半成品Ⅰ；
（2）将半成品Ⅰ与高强织物贴合为半成品Ⅱ
将半成品Ⅰ中高阻隔气相防锈膜2的另一侧面进行上胶，在线电晕；之后采用点贴方式将半成品Ⅰ中的高阻隔气相防锈膜2一侧与高强织物进行贴合，进行贴合时，膜牵引张力为50N，车速3-4m/min，上胶量10-15g/m2，烘干温度为100℃；最后进行固化，固化温度为25℃，固化时间为72h，相对湿度RH60-70%，即得半成品Ⅱ；
（3）将半成品Ⅱ与涂层/防水透气膜贴合
在涂层/防水透气膜的防水透气膜的一侧进行上胶，之后采用点贴方式将半成品Ⅱ中的高强织物一侧与涂层/防水透气膜进行贴合，进行贴合时，膜牵引张力为30-40N，车速2m/min，上胶量10-15g/m2，烘干温度为100℃；最后进行固化，固化温度为25℃，固化时间为72h，相对湿度RH60-70%，即得所述防腐蚀保护罩。
最后通过排版和划线、裁片工艺、热合工艺、贴条工艺等进行成型加工，完成防腐蚀保护罩成品试制。
实施例2
本实施例提供一种防腐蚀保护罩，与实施例1的区别仅在于：步骤（S1）、步骤（SS1）中，制备气相缓蚀剂时，苯甲酸钠、钼酸铵、六亚甲基四胺、植酸胺的质量比为0.5:0.5:0.5:0.5，其他操作均与实施例1完全相同。
实施例3
本实施例提供一种防腐蚀保护罩，与实施例1的区别仅在于：步骤（S1）、步骤（SS1）中，制备气相缓蚀剂时，苯甲酸钠、钼酸铵、六亚甲基四胺、植酸胺的质量比为1:0.5:0.3:0.2，其他操作均与实施例1完全相同。
实施例4
本实施例提供一种防腐蚀保护罩，与实施例1的区别仅在于：步骤（S1）、步骤（SS1）中，制备气相缓蚀剂时，苯甲酸钠、钼酸铵、六亚甲基四胺、植酸胺的质量比为1:0.6:0.2:0.2，其他操作均与实施例1完全相同。
实施例5
本实施例提供一种防腐蚀保护罩，与实施例1的区别仅在于：步骤（SS2）中，采用涂覆工艺在超细涤纶纺粘水刺无纺布上添加气相缓蚀剂，其他操作均与实施例1完全相同。
实施例6
本实施例提供一种防腐蚀保护罩，与实施例1的区别仅在于：步骤（SS2）中，采用喷涂工艺在超细涤纶纺粘水刺无纺布上添加气相缓蚀剂，其他操作均与实施例1完全相同。
对比例1
本对比例与实施例1的区别在于：步骤（S1）、步骤（SS1）中，制备气相缓蚀剂时，没有加入苯甲酸钠，只加入了钼酸铵、六亚甲基四胺、植酸胺三种组分，且钼酸铵、六亚甲基四胺、植酸胺的质量比为2:2:1。
对比例2
本对比例与实施例1的区别在于：步骤（S1）、步骤（SS1）中，制备气相缓蚀剂时，没有加入苯甲酸钠和植酸胺，只加入了钼酸铵、六亚甲基四胺两种组分，且钼酸铵、六亚甲基四胺的质量比为2:1。
实验例1
1、采用本发明实施例1所述防腐蚀保护罩进行性能检测，检测结果如表1-1、表1-2所示。
表1-1
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表1-2
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从表1-1、表1-2可以看出，采用本发明所述防腐蚀保护罩，综合性能优异，100%防水，具有防水透湿功能，透气性（水蒸气透过率）可达2.3g/m2·24h；拉伸强度可达（横向：70.5Mpa、纵向：92.4Mpa）；撕破强度可达（横向：144N、纵向：181N）；屈服强度可达（横向：64.2Mpa、纵向：91Mpa）；承重强度可达（横向：1940N、纵向：2540N）；伸长率可达（横向：31.5％、纵向：36％）；紫外线阻挡性可达UVB：99.72% ；光泽度（60°角）可达46.4°。因此，经检验验证，产品的各项性能指标都达到了技术协议的规定。防腐蚀保护罩材料易成型，可热合，成型加工工艺稳定可靠，可满足设备封存防护罩体的加工。
2、采用不同方式在超细涤纶纺粘水刺无纺布上添加气相缓蚀剂对防腐蚀保护罩的性能影响
分别检测实施例1（采用浸轧工艺在超细涤纶纺粘水刺无纺布上添加气相缓蚀剂）、实施例5（采用涂覆工艺在超细涤纶纺粘水刺无纺布上添加气相缓蚀剂）、实施例6（采用喷涂工艺在超细涤纶纺粘水刺无纺布上添加气相缓蚀剂）所得防腐蚀保护罩的性能，如表2所示。
表2-三种不同工艺添加气相缓蚀剂的防腐蚀保护罩的性能测试对比表
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从表2可以看出，采用浸轧工艺在超细涤纶纺粘水刺无纺布上添加气相缓蚀剂，最终制得防腐蚀保护罩的重量更小，仅为359g/m2，而采用涂覆、喷涂两种工艺制得防腐蚀保护罩的重量相对要重，分别为371.6g/m2和375g/m2。
3、不同原料配比制得气相缓蚀剂的防锈性能测试
对实施例1-4以及对比例1、2中气相缓蚀剂的防锈性能进行检测，结果如表3所示。
表3-不同原料配比下的防锈效果
Figure 684942DEST_PATH_IMAGE004
根据表3检测结果，只有同时采用苯甲酸钠、钼酸铵、六亚甲基四胺、植酸胺四种组分，并限定上述四种组分质量比为5:2:2:1时，气相缓蚀剂的防锈性能最佳。
以上所述，仅为本发明的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，可轻易想到变化或替换，都应涵盖在本发明的保护范围之内。因此，本发明的保护范围应以所述权利要求的保护范围为准。

Claims (1)

1.一种防腐蚀保护罩，其特征在于，所述保护罩为复合膜结构，所述复合膜结构依次包括表层、中间层和内衬层；
所述表层为防水透气性聚酯织物材料，所述防水透气性聚酯织物材料由外至内依次包括涂层、防水透气膜、高强织物；所述涂层为纳米疏水涂层，所述防水透气膜的材质为热塑性聚氨酯弹性体，所述高强织物为锦纶绸；
所述锦纶绸采用如下方法加工而成：（a）取锦纶长丝，依次进行络筒、加捻、整经、穿筘、织造后，得到织物；其中，所述加捻为120捻/米，车速为200转/分钟；（b）依次经制版、调浆、颜色小样、大机样品后，对所述织物进行印花，得到锦纶绸；
所述中间层为高阻隔气相防锈膜；所述高阻隔气相防锈膜采用如下方法制得：（S1）将苯甲酸钠、钼酸铵、六亚甲基四胺、植酸胺以5:2:2:1的质量比进行复配，充分混匀，得到气相缓蚀剂备用；（S2）将线型低密度聚乙烯和低密度聚乙烯按照质量比2:1进行混匀，得到载体备用；（S3）按照质量比3:7取气相缓蚀剂与混匀的载体，加入色母粒，色母粒的质量为母粒与载体总质量的千分之一，充分混匀后，经造粒、挤出吹塑，即得所述高阻隔气相防锈膜；
所述内衬层为气相防锈无纺布；所述气相防锈无纺布采用如下方法制得：（SS1）将苯甲酸钠、钼酸铵、六亚甲基四胺、植酸胺以5:2:2:1的质量比进行复配，充分混匀，得到气相缓蚀剂备用；（SS2）采用浸轧法在超细涤纶纺粘水刺无纺布上添加气相缓蚀剂，即得所述气相防锈无纺布；
所述防腐蚀保护罩的制备方法，具体包括如下步骤：
（1）将高阻隔气相防锈膜与气相防锈无纺布贴合成为半成品Ⅰ
对高阻隔气相防锈膜的一个侧面进行上胶，在线电晕；之后采用点贴方式将高阻隔气相防锈膜与气相防锈无纺布进行贴合，进行贴合时，膜牵引张力为50N，车速5.5m/min，上胶量10-15g/m2，烘干温度为100℃；最后进行固化，固化温度为25℃，固化时间为72h，相对湿度RH60-70%；即得半成品Ⅰ；
（2）将半成品Ⅰ与高强织物贴合为半成品Ⅱ
将半成品Ⅰ中高阻隔气相防锈膜的另一侧面进行上胶，在线电晕；之后采用点贴方式将半成品Ⅰ中的高阻隔气相防锈膜一侧与高强织物进行贴合，进行贴合时，膜牵引张力为50N，车速3-4m/min，上胶量10-15g/m2，烘干温度为100℃；最后进行固化，固化温度为25℃，固化时间为72h，相对湿度RH60-70%，即得半成品Ⅱ；
（3）将半成品Ⅱ与涂层/防水透气膜贴合
在涂层/防水透气膜的防水透气膜的一侧进行上胶，之后采用点贴方式将半成品Ⅱ中的高强织物一侧与涂层/防水透气膜进行贴合，进行贴合时，膜牵引张力为30-40N，车速2m/min，上胶量10-15g/m2，烘干温度为100℃；最后进行固化，固化温度为25℃，固化时间为72h，相对湿度RH60-70%，即得所述防腐蚀保护罩。
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