CN114109847B - 一种复合材料渣浆泵泵体及其制造方法 - Google Patents
一种复合材料渣浆泵泵体及其制造方法 Download PDFInfo
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Classifications
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Abstract
本发明涉及渣浆泵制造技术领域,公开了一种复合材料渣浆泵泵体及其制造方法,包括外壳和烧结复合陶瓷内胆,外壳由低温结合有机无机复合陶瓷构成,外壳内嵌有金属骨架,外壳一侧设置有吸入口,另一端设置有连接口,连接口处设置有环形密封面,环形密封面与外壳一体成型。本发明具有以下优点和效果:发明采用树脂碳化硅砂制造泵体,树脂碳化硅砂流动性好,易于加工,泵体可以采用模具一体成型,密封性好。改性后的树脂碳化硅层具有较高的韧性和强度,无需加装金属外壳,一方面可提高泵体耐酸碱性能,另一方面可大幅度减少金属用量,降低加工难度,节能减排。
Description
技术领域
本发明涉及渣浆泵制造技术领域,特别涉及一种复合材料渣浆泵泵体及其制造方法。
背景技术
渣浆泵是指讲指通过借助离心力(泵的叶轮的旋转)的作用使固、液混合介质能量增加的一种机械,将电能转换成介质的动能和势能的设备。主要适用于:矿山、电厂、疏浚、冶金、化工、建材及石油等行业领域。
渣浆泵主要用于输送固液混合介质,因此需要有较强的耐磨蚀能力,用于化工行业时,还需要较强的耐酸碱性。目前渣浆泵通常采用不锈钢、合金钢等材质,但是不锈钢、合金钢的耐腐蚀性都难以达到要求,使用寿命较短;碳化硅陶瓷渣浆泵耐腐蚀性较强,但其抗冲击韧性较弱,通常需要在泵体外加装一层金属外壳,然而金属外壳会影响碳化硅陶瓷泵的耐腐蚀效果。
发明内容
本发明的目的是提供一种复合材料渣浆泵泵体及其制造方法,具有耐酸碱腐蚀、加工方便、强度高、耐剥蚀的效果。
本发明的上述技术目的是通过以下技术方案得以实现的:一种复合材料渣浆泵泵体,包括外壳和烧结复合陶瓷内胆,所述外壳由低温结合有机无机复合陶瓷构成,所述外壳一侧设置有吸入口,另一端设置有连接口,所述连接口处设置有环形密封面,所述环形密封面与外壳一体成型。
本发明的进一步设置为:所述外壳内嵌有金属骨架,所述金属骨架为笼式、开式、半开式框架结构中的一种,所述金属骨架上预制有接用的螺纹套,螺纹套形状为圆柱形、方形、多边形中的一种或多种,所述金属骨架由金属片或金属网构成。
本发明的进一步设置为:所述金属骨架上预制有接用的螺纹套,或所述外壳上预设螺纹套,所述螺纹套形状为圆柱形、方形、多边形中的一种或多种。
本发明的进一步设置为:所述外壳上设置有吊环结构和扶手凸台,外壳上设置进口和出口,进口和出口的连接面处设置有用于连接的螺纹套。
本发明的进一步设置为:所述低温结合有机无机复合陶瓷由填充料70~125份、聚氨酯改性环氧树脂6~10份、固化剂1~3份、添加剂1~3份混合而成。
本发明的进一步设置为:所述填充料由碳化硅砂和硅烷偶联剂混合制得。
本发明的进一步设置为:所述填充料还包括碳化硅纤维或碳化硅晶须。
一种复合材料渣浆泵泵体制造方法:包括如下步骤:
S1、以甲苯二异氰酸酯和聚丙二醇为原料,合成聚氨酯预聚体,将聚氨酯预聚体与环氧树脂混合改性,制成聚氨酯改性环氧树脂;
S2、将碳化硅砂70~125份与硅烷偶联剂40~50份混合,并在110~120℃条件下通过机械球磨混合8~10h,然后将混合物真空抽滤,用丙酮抽提12h,除去未反应的硅烷偶联剂,将反应物真空干燥,得到填充料。
S3、将填充料70~125份、碳化硅纤维或碳化硅晶须1~3份、聚氨酯改性环氧树脂6~10份、固化剂1~3份、添加剂1~3份混合均匀,注入渣浆泵外壳的模具内,加热固化,脱模后得到渣浆泵外壳;
S4、在渣浆泵结构件的过流面粘接烧结复合陶瓷;
S5、对渣浆泵外壳和渣浆泵结构件进行组装,得到完整的渣浆泵。
本发明的进一步设置为:所述碳化硅砂包括:
10-24目的碳化硅砂粉体 5-15份;
24-50目的碳化硅砂粉体 25-35份;
50-80目的碳化硅砂粉体 20-30份;
80-200目的碳化硅砂粉体 10-25份;
200目以下的碳化硅砂粉体 10-20份。
本发明的有益效果是:
1.本发明采用树脂碳化硅砂制造泵体,树脂碳化硅砂流动性好,易于加工,泵体外壳可以采用模具一体成型,在泵壳的吸入口处设置密封面,密封面在浇注外壳时一次成型,无需加工,密封性好。改性后的树脂碳化硅层具有较高的韧性和强度,无需加装金属外壳,一方面可提高泵体耐酸碱性能,另一方面可大幅度减少金属用量,降低加工难度,节能减排。
2. 环氧树脂有较高的韧性、耐磨性、粘接性、热稳定性、化学稳定性和较小的收缩率,作为粘接剂与碳化硅制成树脂碳化硅复合材料,可达到较高的强度、耐酸碱性和耐磨性,可用于制作高性能的化工泵。环氧树脂固化后脆性较高,受到外力作用时,容易出现应力集中现象而断裂。通过聚氨酯改性环氧树脂可提高环氧树脂的韧性,聚氨酯预聚体与环氧树脂混合后,聚氨酯分子链和环氧树脂分子链之间相互缠结,聚氨酯可起到良好的分散应力作用,改善环氧树脂力学性能,增强环氧树脂韧性。
3. 采用偶联改性碳化硅,可提高碳化硅的活性和分散性,避免碳化硅砂团聚。本发明中采用的碳化硅颗粒较大,表面活性较低,硅烷偶联剂与碳化硅采用机械球磨混合,机械球磨对碳化硅表面不断进行挤压,可增大碳化硅颗粒表面活性,有利于硅烷偶联剂与碳化硅反应。且通过硅烷偶联剂改性后,硅烷偶联剂上的硅烷基团在高温下与碳化硅表面形成Si-O-Si分子键,硅烷偶联剂与碳化硅砂可紧密结合;另一方面,聚氨酯改性环氧树脂内含有大量的异氰酸酯基团,异氰酸酯基与硅烷偶联剂中的硅烷反应,可生成硅烷封端聚氨酯聚合物,该聚合物具有较高的韧性,硅烷偶联剂可同时与碳化硅和聚氨酯改性环氧树脂反应,通过偶联剂将环氧树脂与碳化硅以化学键联接起来,起到架桥作用,可提高碳化硅砂与聚氨酯改性环氧树脂的相容性,使环氧树脂与碳化硅表面结合更为紧密,提高碳化硅砂层的抗剥蚀强度。
4. 温度变化时,碳化硅砂与环氧树脂的热膨胀系数差别较大,偶联剂可为环氧树脂与碳化硅砂之间提供缓冲,消除结合面产生的内应力,提高泵体的耐候性。
5. 添加一定量的纤维,可进一步提高树脂碳化硅砂层的韧性。
附图说明
为了更清楚地说明本发明实施例中的技术方案,下面将对实施例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是实施例1渣浆泵模具结构示意图。
图2是实施例1渣浆泵外壳结构示意图。
图中,1、吸入口盖板;2、模具; 3、蜗壳;4、托架侧定位板; 5、外壳;6、吸入口;7、连接口;8、密封面。
实施方式
下面将结合具体实施例对本发明的技术方案进行清楚、完整地描述。显然,所描述的实施例仅仅是本发明的一部分实施例,而不是全部的实施例。基于本发明的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例
一种复合材料渣浆泵泵体,包括泵体,泵体包括外壳5和烧结复合陶瓷内胆,外壳5有低温结合有机无机复合陶瓷构成,低温结合有机无机复合陶瓷强度较高,对于小型渣浆泵,如图1所示,可直接采用小型渣浆泵模具浇筑低温结合有机无机复合陶瓷制造泵体外壳5,然后在泵体过流面粘接烧结复合陶瓷,增强过流面耐磨强度。外壳5一侧设置有吸入口6,另一端设置有连接口7,所述连接口7处设置有环形密封面8,所述环形密封面8与外壳一体成型。外壳5上预设有螺纹套,用于与其他装置进行连接。烧结复合陶瓷为碳化硅陶瓷,此处烧结复合陶瓷可不限于碳化硅陶瓷,也可为氮化硅结合碳化硅、无压碳化硅、重结晶碳化硅、氧化铝、氧化锆中的一种。小型渣浆泵模具如图2所示,外壳5模具由模具2、吸入口盖板1、托架侧定位板4组成,蜗壳3嵌在所述模具内。
外壳5上设置有吊环结构和扶手凸台,外壳上设置进口和出口,进口和出口的连接面处设置有用于连接的圆柱型螺纹套。螺纹套材质是碳素结构钢,此处螺纹套9材质不限于碳素结构钢,也可为不锈钢、合金钢中的一种。
一种复合材料渣浆泵泵体制造方法,包括如下步骤:
S1、以甲苯二异氰酸酯和聚丙二醇为原料,合成聚氨酯预聚体,将聚氨酯预聚体与环氧树脂混合改性,制成聚氨酯改性环氧树脂;
S2、将10-24目的碳化硅砂粉体 5份;
24-50目的碳化硅砂粉体 35份;
50-80目的碳化硅砂粉体 20份;
80-200目的碳化硅砂粉体 25份;
200目以下的碳化硅砂粉体 10份与硅烷偶联剂KH-550 40份混合,并在120℃条件下通过机械球磨混合8h,然后将混合物真空抽滤,用丙酮抽提12h,除去未反应的硅烷偶联剂,将反应物真空干燥,得到改性碳化硅砂(填充料);
S3、将填充料即改性碳化硅砂95份、碳化硅晶须1份、聚氨酯改性环氧树脂10份、固化剂1份、硬脂酸0.5份、蜂蜡1份混合均匀,注入渣浆泵外壳的模具内,加热固化,脱模后得到渣浆泵外壳;
S4、在渣浆泵结构件的过流面粘接烧结碳化硅层;
S5、对渣浆泵外壳和渣浆泵结构件进行组装,得到完整的渣浆泵。
实施例
一种复合材料渣浆泵泵体,包括泵体,泵体包括外壳5和烧结复合陶瓷内胆,外壳5由低温结合有机无机复合陶瓷构成,大型渣浆泵的外壳5中嵌有金属骨架,用于增强外壳5强度,外壳5一侧设置有吸入口6,另一端设置有连接口7,所述连接口7处设置有环形密封面8,所述环形密封面8与外壳一体成型,低温结合有机无机复合陶瓷外壳5内嵌有金属骨架,金属骨架为半开式框架结构,金属骨架上预制有方型螺纹套,金属骨架由金属片构成,然后在泵体过流面粘接烧结复合陶瓷内胆,增强过流面耐磨强度。大型渣浆泵模具由模具2、吸入口盖板1、托架侧定位板4组成,蜗壳3嵌在所述模具内。在大型渣浆泵外壳模具内预安装好片状的金属骨架,然后将树脂碳化硅砂浇筑到模具2内,加热固化后即可得到含有金属骨架的泵体外壳5,金属骨架被完全包裹在泵体内,不与过流介质接触,使用寿命长,且采用浇筑形式,使金属骨架与树脂碳化硅砂层一体成型,加工步骤简单,泵体性质稳定。在渣浆泵的模具内还可预埋螺纹连接装置,螺纹连接装置与金属骨架固定连接,便于后续组装。
外壳上设置有吊环结构和扶手凸台,外壳上设置进口和出口,进口和出口的连接面处设置有用于连接的方型螺纹套。螺纹套材质是碳素结构钢,此处螺纹套材质不限于碳素结构钢,也可为不锈钢、合金钢中的一种。
一种复合材料渣浆泵泵体制造方法,包括如下步骤:
S1、以甲苯二异氰酸酯和聚丙二醇为原料,合成聚氨酯预聚体,将聚氨酯预聚体与环氧树脂混合改性,制成聚氨酯改性环氧树脂;
S2、将10-24目的碳化硅砂粉体 15份;
24-50目的碳化硅砂粉体 25份;
50-80目的碳化硅砂粉体 30份;
80-200目的碳化硅砂粉体 10份;
200目以下的碳化硅砂粉体 20份与硅烷偶联剂KH-550 50份混合,并在110℃条件下通过机械球磨混合10h,然后将混合物真空抽滤,用丙酮抽提12h,除去未反应的硅烷偶联剂,将反应物真空干燥,得到改性碳化硅砂;
S3、将改性碳化硅砂100份、碳化硅纤维3份、聚氨酯改性环氧树脂6份、固化剂1份、硬脂酸1份、蜂蜡1份混合均匀,注入渣浆泵外壳的模具内,加热固化,脱模后得到渣浆泵外壳;
S4、在渣浆泵结构件的过流面粘接烧结碳化硅层;
S5、对渣浆泵外壳和渣浆泵结构件进行组装,得到完整的渣浆泵。
实施例
实施例3与实施例2的区别在于省略步骤S1,采用未改性的环氧树脂制备树脂碳化硅层,步骤S3为:将改性碳化硅砂100份、碳化硅纤维3份、未改性环氧树脂6份、固化剂1份、硬脂酸1份、蜂蜡1份混合均匀,注入渣浆泵外壳的模具内,加热固化,脱模后得到渣浆泵外壳坯体。
实施例
实施例4与实施例2的区别在于省略步骤S2,步骤S3为:将未改性碳化硅砂100份、碳化硅纤维3份、改性环氧树脂6份、固化剂1份、硬脂酸1份、蜂蜡1份混合均匀,注入渣浆泵外壳的模具内,加热固化,脱模后得到渣浆泵外壳坯体。
实施例
实施例5与实施例2的区别在于,省略步骤S1和S2,步骤S3为:将未改性碳化硅砂100份、碳化硅纤维3份、未改性环氧树脂6份、固化剂1份、硬脂酸1份、蜂蜡1份混合均匀,注入渣浆泵外壳的模具内,加热固化,脱模后得到渣浆泵外壳坯体。
采用AG-IS-I-IC-EZGraph试验机测定实施例1~5的树脂碳化硅砂材料制作的泵体外壳的弯曲强度、拉伸强度进行测试,采用腐蚀磨损机对树脂碳化硅砂材料制作的泵体外壳的腐蚀磨损性能进行测试,腐蚀磨损机采用石英砂作为磨料,采用稀硫酸溶液调节腐蚀溶液pH值为3,试验转速50r/min,载荷6N,磨蚀磨损率=磨蚀磨损试样的平均失重量/磨蚀磨损试验时间,试验数据见下表1:
由表1可知,通过改性碳化硅砂、聚氨酯改性环氧树脂制造的树脂碳化硅渣浆泵外壳其弯曲强度、拉伸强度远高于未改性的碳化硅砂、未改性环氧树脂制造的树脂碳化硅砂渣浆泵外壳;通过改性碳化硅砂、聚氨酯改性环氧树脂,可大幅度降低树脂碳化硅砂浆泵外壳磨蚀磨损率。
值得注意的是,本申请的实施例为优选方案,本申请填充料优选为碳化硅砂,碳化硅硬度大,耐磨性能好。本申请中的填充料中的碳化硅砂出于降低成本考虑填充料也可替为碳化硅陶瓷破碎砂(碳化硅陶瓷制品废料回收利用)、氧化铝、刚玉。出于进一步提升性能,可在无机填料中加入碳化硼、氮化硼、金刚石、氧化锆等粉体。
环氧树脂可替换为酚醛树脂、聚酯树脂等本领域常规树脂或水泥、玻璃钢等其他结合剂,通过结合剂结合无机填料均可制备成复合材料渣浆泵泵体。
Claims (9)
1.一种复合材料渣浆泵泵体,其特征在于:包括外壳(5)和烧结复合陶瓷内胆,所述外壳(5)由低温结合有机无机复合陶瓷构成,所述外壳(5)一侧设置有吸入口(6),另一端设置有连接口(7),所述连接口(7)处设置有环形密封面(8),所述环形密封面(8)与外壳一体成型;
制造如上述复合材料渣浆泵泵体的方法,包括如下步骤:将低温结合有机无机复合陶瓷填充料混合均匀后,注入渣浆泵注入渣浆泵外壳的模具内,加热固化,脱模后得到渣浆泵外壳;在渣浆泵外壳的过流面粘接烧结复合陶瓷。
2.根据权利要求1所述的一种复合材料渣浆泵泵体,其特征在于:所述外壳(5)内嵌有金属骨架,所述金属骨架为笼式、开式、半开式框架结构中的一种,所述金属骨架由金属片或金属网构成。
3.根据权利要求2所述的一种复合材料渣浆泵泵体,其特征在于:所述金属骨架上预制有接用的螺纹套,或所述外壳上预设螺纹套,所述螺纹套形状为圆柱形、方形、多边形中的一种或多种。
4.根据权利要求1所述的一种复合材料渣浆泵泵体,其特征在于:所述外壳(5)上设置有吊环结构和扶手凸台,外壳(5)上设置进口和出口,进口和出口的连接面处设置有用于连接的螺纹套。
5.根据权利要求1~4任一项所述的一种复合材料渣浆泵泵体,其特征在于:所述低温结合有机无机复合陶瓷由填充料70~125份、聚氨酯改性环氧树脂6~10份、固化剂1~3份、添加剂1~3份混合而成。
6.根据权利要求5所述的一种复合材料渣浆泵泵体,其特征在于:所述填充料由碳化硅砂和硅烷偶联剂混合制得。
7.根据权利要求6所述的一种复合材料渣浆泵泵体,其特征在于:所述填充料还包括碳化硅纤维或碳化硅晶须。
8.根据权利要求6~7任一项所述的一种复合材料渣浆泵泵体制造方法,其特征在于:包括如下步骤:
S1、以甲苯二异氰酸酯和聚丙二醇为原料,合成聚氨酯预聚体,将聚氨酯预聚体与环氧树脂混合改性,制成聚氨酯改性环氧树脂;
S2、将碳化硅砂70~125份与硅烷偶联剂40~50份混合,并在110~120℃条件下通过机械球磨混合8~10h,然后将混合物真空抽滤,用丙酮抽提12h,除去未反应的硅烷偶联剂,将反应物真空干燥,得到填充料;
S3、将填充料70~125份、碳化硅纤维或碳化硅晶须1~3份、聚氨酯改性环氧树脂6~10份、固化剂1~3份、添加剂1~3份混合均匀,注入渣浆泵外壳的模具内,加热固化,脱模后得到渣浆泵外壳;
S4、在渣浆泵外壳的过流面粘接烧结复合陶瓷;
S5、对渣浆泵外壳和渣浆泵结构件进行组装,得到完整的渣浆泵。
9.根据权利要求8所述的一种复合材料渣浆泵泵体制造方法,其特征在于:所述碳化硅砂包括:
10-24目的碳化硅砂粉体 5-15份;
24-50目的碳化硅砂粉体 25-35份;
50-80目的碳化硅砂粉体 20-30份;
80-200目的碳化硅砂粉体 10-25份;
200目以下的碳化硅砂粉体 10-20份。
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