CN114854295A - Polyurethane-based wear-resistant composite material and construction process - Google Patents
Polyurethane-based wear-resistant composite material and construction process Download PDFInfo
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- CN114854295A CN114854295A CN202210394796.8A CN202210394796A CN114854295A CN 114854295 A CN114854295 A CN 114854295A CN 202210394796 A CN202210394796 A CN 202210394796A CN 114854295 A CN114854295 A CN 114854295A
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Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D175/00—Coating compositions based on polyureas or polyurethanes; Coating compositions based on derivatives of such polymers
- C09D175/04—Polyurethanes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
- B05D5/08—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain an anti-friction or anti-adhesive surface
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/24—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials for applying particular liquids or other fluent materials
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
- C09D7/40—Additives
- C09D7/60—Additives non-macromolecular
- C09D7/61—Additives non-macromolecular inorganic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2503/00—Polyurethanes
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
- C08K2003/2227—Oxides; Hydroxides of metals of aluminium
Abstract
The invention relates to the field of polyurethane wear-resistant composite materials and the field of wear repair and remanufacture of heavy-duty rubber conveyor belts, in particular to a polyurethane-based wear-resistant composite material and a construction process; compared with the prior art, the obvious differences in novelty, creativity and practicability are as follows: different antiwear principles, different material attributes, different product production processes, different key technologies of product quality, different product senses, different construction material preparation steps and different application effects, and the embodiment shows that: the invention relates to a polyurethane-based wear-resistant composite material and a construction process, which are high-quality schemes for solving the problem of large-area wear repair of heavy-duty conveyor belts.
Description
Technical Field
The invention relates to the field of polyurethane wear-resistant composite materials and the field of wear repair and remanufacture of heavy-duty rubber conveyer belts, in particular to a polyurethane-based wear-resistant composite material, and relates to a construction process for quickly repairing the wear of heavy-duty rubber conveyer belts on line.
Background
The heavy-duty rubber conveyer belt is key equipment for large bulk material transportation enterprises, and the types of the heavy-duty rubber conveyer belt comprise a steel wire belt, a fiber belt, a tubular belt, a skirt side belt and the like; the short length is hundreds of meters, the long length is thousands of meters, most of the products run continuously for a long time, and the products are widely applied to industries such as mines, cement, electric power, steel, wharfs and the like. The long-distance large-area abrasion of the conveying belt is one of the main reasons for scrapping the conveying belt, and the passive shutdown caused by the abrasion of the conveying belt often causes passive production and economic loss to enterprises; the method is expected by enterprises to find a new material, a new process and a new technology for rapidly repairing the abrasion of the conveying belt on line.
The main reasons for abrasion of the conveying belt are as follows:
the running system of the heavy-duty rubber conveyer belt is generally provided with additional devices such as a sweeper, a material baffle plate, a material distributing plate and the like (such as figures 1 and 2), and the additional devices are usually tightly attached to the conveyer belt.
The first reason is as follows: when the conveyor belt rotates, the attachment necessarily rubs against the conveyor belt, and the harder attachment necessarily causes frictional wear to the softer conveyor belt.
The second reason is that: when the conveyer belt rotates, tiny material particles are continuously embedded into the gap between the additional device and the conveyer belt, the hardness levels of the material particles are far larger than those of the material particles with corners, when the material particles are embedded into the gap between the additional device and the conveyer belt, strong friction is inevitably generated between the material particles and the conveyer belt, and friction and abrasion are also inevitably caused on the softer conveyer belt.
Because the conveyer belt receives the dual frictional wear of hard material granule and additional device, wearing and tearing deepen the expansion for a long time, expose steel wire or fibre gradually, then rubs off steel wire or fibre, and the conveyer belt is scrapped.
Secondly, the prior technical scheme for repairing the abrasion of the conveyer belt is as follows:
the first existing scheme is vulcanization repair. The rubber vulcanization repair is a traditional process, theoretically a method, but due to low efficiency and high labor intensity, the method is almost used by no people in the field of abrasion repair.
In the existing scheme II, repairing glue is used for repairing. The repair rubber is also called a rubber repair agent, a conveyer belt repair rubber and the like, is usually used for emergency repair of general damages of conveyer belts, and has few favorable cases in the aspect of large-area abrasion repair application. The types of repair adhesives at home and abroad are more, finished products are in a two-component supply state, material systems of the repair adhesives are all casting polyurethane elastomers, and the wear-resistant mechanism of the repair adhesives depends on the physical properties of polyurethane polymers. The repair adhesive construction process flow comprises the following steps: polishing the worn part, brushing primer, synchronously preparing glue by two components, gluing, curing and finishing repair.
And in the prior scheme III, polyurea spraying is adopted. The finished product of polyurea is in a two-component supply state, the material property is similar to that of polyurethane, and the anti-wear mechanism of polyurea also depends on the physical property of the polymer. The polyurea has high curing speed and excellent wear resistance, and the spraying construction is occasionally applied to the wear maintenance of the conveyer belt in recent years, and the effect of the polyurea is better than that of the repair adhesive, but the polyurea is finally commendable and disproved. Polyurea spraying process flow: and (3) polishing the worn part, brushing a primer, loading polyurea on a spraying gun or a special spraying machine, mixing heated or normal-temperature two-component polyurea under the action of high-pressure air, spraying the mixed polyurea on the surface of the conveyor belt, and starting up after curing.
At present, no good public technical scheme exists for repairing large-area abrasion of the conveying belt at home and abroad.
Disclosure of Invention
The invention aims to provide a polyurethane-based wear-resistant composite material and a construction process, wherein the polyurethane-based wear-resistant composite material has the advantages of high cost performance, excellent wear resistance, simplicity and convenience in construction, capability of repairing large-area wear of a conveyor belt on line and long service life after repair.
Firstly, in order to achieve the purpose of the invention, the anti-wear technical theory researched by the invention is as follows:
1. the main reason for the wear of the conveyor belt is that its hardness is much lower than that of the material particles.
Table 1 lists the hardness of the different items that the conveyor belt system rubs against each other. As can be seen from Table 1, in the belt friction system, the hardness of the belt members (rubber, steel wires, polyester fibers) is lower than or equal to that of the wearing part attachment devices; the hardness of the conveyor belt objects (rubber, steel wires and polyester fibers) is far less than that of the mineral particle and hard alloy sweeper; the hardness of the existing repair material is similar to that of the rubber of the conveying belt. It follows that the main cause of wear of the conveyor belt is the hardness of the material particles being much greater than the hardness of the conveyor belt articles, whereas the prior art is well-behaved because the hardness is much less than the hardness of the material particles.
Table 1: hardness meter for different articles of conveyer belt friction system
2. The antiwear mechanism of the composite material is that the hardness of the reinforcing phase is far greater than that of the material particles.
To further understand the rationality of the anti-wear formulation design and its anti-wear effect of the composites of the present invention, table 2 lists the hardness of the reinforcing inorganic aggregate of the composites of the present invention with various parts of the belt friction system. As can be seen from table 2, the hardness of the inorganic aggregate (hard particles) of the reinforcing phase of the composite material of the present invention is significantly higher than that of the rubber striker plate, the polyurethane cleaner and the hard alloy cleaner of the conveyor belt attachment device, and also significantly higher than that of the mineral particles. Thus, it can be seen that: the composite material is coated on the surface of the conveyer belt, so that the hardness of particles on the surface of the conveyer belt can be obviously improved, and the abrasion resistance of the surface of the conveyer belt can be obviously improved, so that the conveyer belt is lifted from a weak side of a friction system to an advantageous side of the friction system of the conveyer belt, and the aims of effectively repairing the abrasion of the conveyer belt and prolonging the service life of the conveyer belt are fulfilled.
Table 2: hardness meter for different articles of reinforced phase and conveyer belt friction system
Secondly, in order to realize the purpose of the invention, the technical route is as follows:
1. the invention provides a polyurethane-based wear-resistant composite material, wherein a matrix phase of the polyurethane-based wear-resistant composite material is a generalized casting polyurethane elastomer (comprising a component A prepolymer, a component B curing agent and a component C catalyst), and a reinforcing phase (a component D) of the polyurethane-based wear-resistant composite material is high-hardness inorganic aggregate (comprising silicon carbide (SiC) and ceramic Al 2 O 3 Quartz SiO 2 The monomer or mixture of (a) and (b) the base formulation is: matrix phase: reinforcing phase 100: 80 to 130.
Compared with the prior art, the formula has the advantages that: the high-hardness inorganic aggregate is added into the polyurethane in a large proportion, so that the wear-resisting mechanism is changed from the mode of only depending on the physical properties of the organic polymer to the mode of mainly depending on the high-hardness inorganic aggregate with the hardness remarkably higher than that of material particles.
2. As a further preferred embodiment of the present invention, the physical properties of the cast polyurethane polymer in its broad base phase are shown in Table 3:
table 3: range of physical Properties of matrix phase cast polyurethane
3. As a further optimized embodiment of the invention, the reinforcing phase inorganic aggregate is quartz SiO with Mohs hardness of 6-9.5 2 Ceramic Al 2 O 3 High-alumina ceramic Al 2 O 3 And silicon carbide SiC and a mixture thereof, wherein the reinforcing phase inorganic aggregate is in the form of powder or spherical body with a size of 3mm or less.
4. As a further optimized embodiment of the invention, the surface activation treatment process of the reinforcing phase inorganic aggregate is low-temperature plasma treatment or treatment with an amino coupling agent.
5. As a further optimized embodiment of the invention, when the polyurethane-based wear-resistant composite material is produced and manufactured, a matrix phase and a reinforcing phase are produced into a split-type packaging state in a non-mixing prefabrication mode, wherein the component A is a casting polyurethane prepolymer of the matrix phase, the component B is a curing agent of the matrix phase, the component C is a catalyst of the matrix phase or a mixture of the catalyst and a pigment or a flame retardant, and the component D is a monomer or a mixture of inorganic aggregate of the reinforcing phase or a mixture of the inorganic aggregate and the pigment or the flame retardant. Compared with the 'mixed prefabrication', the 'non-mixed prefabrication' production scheme has the advantages that: "non-hybrid pre-fabrication" enables long-term storage of the composite material of the invention.
6. As a further optimized embodiment of the invention, under the constraint of a reference formula (matrix phase: reinforcing phase: 100: 80-130), in order to meet the requirements of different conveyor belt cost performance, the requirements of matrix phase raw material sources, the requirements of different production management and the requirements of different construction working conditions, the physical properties of the matrix phase can be selected differently, the proportion of the components of the matrix phase can be selected differently, the proportion of the reinforcing phase can be selected differently, and the composite material can be composed of A, B, D three components, also can be composed of A, B, C, D four components, and can be selected differently according to the operable time and the curing speed of the composite material and the application and positioning of products.
7. As a further optimized implementation scheme, the invention provides the following steps of the conventional construction process and the ingredients:
8. as a further preferred embodiment of the present invention, during the actual construction, the composite materials of different types or different curing speeds should be selected as appropriate according to the specific conditions of the wear characteristics of the conveyer belt, the available downtime, the environmental temperature, the actual workload, etc., the composite materials or the conveyer belt should be preheated as appropriate, the stirring time and the blade coating time should be controlled as appropriate, and the normal temperature curing or the heating curing should be selected as appropriate.
Compared with the prior art, the invention has the following main differences and beneficial effects:
compared with the repair adhesive and polyurea spraying in the prior art, the repair adhesive has the obvious differences in novelty, creativity and practicability that:
1. the material properties are different. The material property of the prior art is organic polymer, while the material property of the present invention is a composite of organic polymer and inorganic substance.
2. The principle of wear resistance is different. The abrasion resistance of the prior art depends on the physical properties of organic polymers, while the abrasion resistance of the composite material of the invention depends on high-hardness inorganic aggregates.
3. Key technologies for product quality vary. The quality of the existing repair adhesive and polyurea material depends on the quality of raw materials of each component in the formula and the physical properties of the polymer, while the quality of the material of the invention depends on the adoption of high-density high-hardness inorganic aggregate in the formula;
4. the production process of the product is different. The core process for producing the repair adhesive and the polyurea is the synthesis reaction of organic polymers, while the core process for producing the composite material of the invention is the surface coupling treatment, dehydration and crushing of inorganic aggregate, and the matrix phase and the reinforcing phase of the composite material of the invention adopt 'unmixed prefabrication' and split packaging.
5. The construction and batching steps are different. The repair glue and polyurea spraying are two-component synchronous ingredients, and the ingredients of the invention are multi-component ingredients according to the specified steps.
6. The product has different sense. The cured product of the prior art has the organoleptic characteristics of a monomeric polymer elastomer, while the cured product of the invention has the organoleptic characteristics of high-density hard particles dispersed in a flexible matrix, as shown in figures 3 and 4.
7. The use effect is different. The invention has stable and reliable quality in the large-area abrasion repairing application of low-temperature environment, short halt, high-speed operation and high load transportation capacity, the degumming-free rate of 180 days is more than 99.5 percent, the abrasion rate is less than 20 percent, and the prior art can not reach the application.
Drawings
FIG. 1 is an attachment polyurethane sweeper;
FIG. 2 is an attachment cemented carbide sweeper;
FIG. 3 is a graph of the coating of the composite material of the present invention (2.5mm quartz SiO) 2 130% by weight of beads);
FIG. 4 is a graph of the coating of the composite material of the present invention (0.5mm ceramic Al) 2 O 3 Beads weight ratio 125%);
FIG. 5 shows a state before repair in the application example 8;
FIG. 6 shows a state in repair in application example 8;
FIG. 7 shows a state after repair in application example 8;
FIG. 8 shows a state in repair in application example 9;
FIG. 9 shows a state before repair in the application example 10;
fig. 10 shows a state after repair in example 10.
Examples of the preferred embodiments
In order to make the advantages of the invention more clear, the following test examples and application examples are demonstrated as follows:
first, test examples
Example 1 selection and optimization of matrix phase cast polyurethane properties:
the matrix phase of the composite material and the material of the existing repair adhesive belong to casting polyurethane. The material has mature technology, more varieties and wide selectable range. The matrix phase of the composite material of the present invention is selected with a primary focus on the physical properties and curing characteristics of the cast polyurethane. The physical properties of the matrix phase cast polyurethane useful in the composite of the present invention are shown in Table 4, and the curing characteristics of the matrix phase cast polyurethane useful in the composite of the present invention are shown in Table 5.
Table 4: physical properties of matrix phase casting polyurethane
Table 5: matrix phase casting type polyurethane normal temperature curing characteristic
In practical application, the proper physical performance and curing characteristic of polyurethane should be optimally selected according to the working condition characteristics of the conveyer belt, the matrix phase source and the commercial positioning of products. The embodiment of the composite material aims at a heavy-load conveyer belt which is constructed in an environment of 5 ℃ and 30 ℃ and is started up 20 minutes after being repaired, has high friction frequency and higher manufacturing cost; in order to show the excellent quality of the composite material of the present invention under severe working conditions, two casting type polyurethane base materials of "fast curing, medium hardness, high strength" and "slow curing, medium hardness, high strength" are optimally selected from tables 4 and 5 for the matrix phase of the present embodiment, and are divided into two types of "fast curing 222" and "slow curing 333", the physical properties of the optimized matrix phase are shown in table 6, and the curing characteristics are shown in table 7.
Table 6: examples matrix phase physical Properties
Table 7: examples ordinary temperature curing Properties of matrix phase
When the matrix phase of the composite material is selected, the main consideration is that no matter in a low-temperature or high-temperature environment, the curing speed of the composite material is higher, the operation time is shorter, and the operation time is better, so that the requirements of short stop time and large repair workload of the heavy-load conveyer belt can be met. Because the curing speed of the cast polyurethane is very sensitive to the ambient temperature, the formula of low-temperature quick curing has insufficient high-temperature inevitable operable time, the formula of low-temperature slow curing can be quickly cured at high temperature, and the formula of high-temperature quick curing can be slowly cured at low temperature; in order to meet the requirement of rapid curing in both a low-temperature environment and a high-temperature environment and solve the contradiction between rapid curing and insufficient operable time, the embodiment of the invention optimally selects two types of matrix phases, namely 'rapid curing 222' and 'slow curing 333', uses the rapid curing 222 during normal-temperature or low-temperature operation, and uses the slow curing 333 during high-temperature operation (the related technology of the matrix phase is well known by professionals in the field and is not required by the patent claim, and is not described herein in detail).
Example 2 test of adhesion strength between matrix phase and rubber:
one of the quality indexes of the composite material of the present invention is that the bonding strength of the composite material of the present invention and the rubber of the conveyor belt should meet the use requirement of no degumming with large probability (the technology and the process for bonding the matrix phase and the rubber belong to the common knowledge of professionals in the field, and are not the patent claims, and are not repeated herein). In order to make the advantages of the present invention more clear, the present example focuses on the adhesion test method and the actual adhesion strength.
The test method comprises the following steps: 180 degree tensile peel test, non-calibration test.
Taking 1 block of 50 cm square conveyor belt rubber plate, polishing the surface to obtain an original rubber interface by using a steel wire wheel, brushing a V210 rubber treating agent of the company for 2 times, coating the prepared fast curing 222 polyurethane material or slow curing 333 polyurethane material on the surface, wherein the coating width is about 3 cm, the coating thickness is about 3mm, the coating length is about 15 cm, a group of blocks is cured at normal temperature for 5-8 hours, and a group of blocks is cooled after being heated to 150 ℃ for curing for 15 minutes. And (3) fixing a rubber plate at one end of a self-made peeling test platform, clamping a polyurethane test piece at the other end of the self-made peeling test platform, slowly tensioning, continuously stretching, performing a 180-degree stretching peeling test, observing and recording the position of bonding cracking and the position of a fracture, and evaluating the bonding strength value. The results of the test of the adhesive strength between the matrix phase of the composite material and the rubber of the conveyer belt are shown in Table 8.
Table 8: matrix phase and conveyer belt rubber bonding strength test value
Example 3 selection and optimization of the material of the reinforcing phase inorganic aggregate:
one of the quality indexes of the composite material is that the composite material has excellent wear resistance. In order to achieve the aim, the invention researches and compares the material and hardness characteristics of each friction object of a conveyor belt running system (see tables 1 and 2), proposes and adopts a formula design concept that the hardness of a reinforcing phase is obviously higher than that of material particles and additional devices, and preferably selects the type of the composite material reinforcing phase as high-hardness quartz SiO 2 Ceramic Al 2 O 3 And the hardness value of the reinforced phase is optimized to 6-9.5 Mohs by using the silicon carbide SiC and other monomers or mixtures, so that the hardness of the reinforced phase is far greater than the hardness of material particles and additional devices, and a theoretical basis is laid for realizing excellent wear resistance of the composite material.
Example 4 reinforcing phase inorganic aggregate adhesion strength test:
one of the quality indexes of the composite material is that the bonding strength of the matrix phase and the reinforcing phase needs to meet the use requirement of no falling off in a large probability. The reinforcing phase comprises two types of powder and particles, in order to realize high-strength bonding, the powder needs to be subjected to low-temperature plasma surface treatment, and the particles need to be subjected to amino coupling agent surface treatment (amino coupling treatment or low-temperature plasma treatment technology and process, which are well known to persons skilled in the art and are not in the patent claims, and are not described herein again). In order to make the advantages of the present invention more clear, the present example focuses on the adhesion test method and the actual adhesion strength.
The test method comprises the following steps: 180 degree tensile peel test, non-calibration test.
Taking quartz SiO with the same material as the inorganic aggregate 2 Glass plate with 92% Al 2 O 3 Ceramic plate, specimen size: the length is 20 cm, the width is 10 cm, the thickness is 5mm, the amino coupling solution is soaked in the prepared amino coupling solution for 5 minutes, and the amino coupling solution is taken out and dried; and then coating the prepared matrix fast curing 222 or slow curing 333 on the surface of a test piece, wherein the coating width is about 3 cm, the coating thickness is about 3mm, the coating length is about 10 cm, one group is cured at normal temperature for 5-8 hours, and the other group is heated to 150 ℃ for curing for 15 minutes and cooled. And (3) fixing a test plate at one end of a self-made stripping test platform, clamping a polyurethane test piece at the other end of the self-made stripping test platform, slowly tensioning, continuously stretching, performing a 180-degree stretching stripping test, observing and recording the elongation and the resilience of the polymer, and evaluating the bonding strength value. The adhesion strength value is classified into 5 grades, and the maximum value is 5 grades. The bonding strength of the inorganic aggregate quartz after the coupling treatment is shown in Table 9, and the bonding strength of the inorganic aggregate ceramic is shown in Table 10.
Table 9: test value of bonding strength of inorganic aggregate quartz
Table 10: test value of bonding strength of inorganic aggregate ceramic
Example 5, reinforcing phase inorganic aggregate shape and specification selection test:
one of the quality indexes of the composite material is that the coating layer of the composite material has excellent low-temperature fatigue cracking resistance, and meets the requirement that the coating layer does not fall off when the composite material is operated at a high speed at a low temperature in winter and scraped by a sweeper.
The shape and specification of the inorganic aggregate are related to the interface stress of the reinforced phase of the composite material and the low-temperature fatigue strength of the composite material, the concentration degree of the interface stress is high, the probability of degumming of the aggregate is high, and otherwise, the probability of degumming is low.
The test method comprises the following steps: and (3) performing a 360-degree folding test and a non-standard quantitative test.
Selecting SiO with the size of 0.5mm, 1.5 mm and 3mm 2 One group of particles are regular spheres, and the other group of particles are angular and naturally broken irregular particles, and are subjected to coupling treatment according to a matrix phase: the reinforcing phase is matched with the fast curing 222 matrix phase according to the proportion of 1:1, the mixture is uniformly stirred, and is shoal on a plane, the thickness of the shoal is 3mm, the width of the shoal is 3 cm, the length of the shoal is 15 cm, and the curing is carried out for 48 hours at normal temperature. Cutting the test piece by a blade in the width direction, wherein the depth of a cut is about 0.5 mm; and folding the coating layer in 360 degrees at about minus 5 ℃ by taking the notch as a central line, folding for 1000 times, observing whether the interface cracking degumming or crack extension expansion exists at the notch part 'the interface between the aggregate and the polyurethane base', and evaluating the influence of the shape and specification of the aggregate on degumming or cracking. The test results are shown in Table 11.
Table 11: inorganic aggregate shape specification cracking tendency test
Example 6, inorganic aggregate content optimization test:
one of the outstanding quality indexes of the composite material is to maximize the density of the reinforcing phase of the composite material so as to achieve the aim of optimizing the wear resistance of the composite material. This is achieved in relation to the hardness of the inorganic aggregate, in relation to the particle size of the aggregate, in relation to the content and density of the inorganic aggregate. When the hardness is constant, the smaller the particle size is, the larger the allowable content and density is, and the larger the particle size is, the smaller the allowable content and density is. Example 6 using 50% of 0.5mm particle size and 50% of 2.5mm particle size, the content test is as follows.
The test method comprises the following steps: and (3) performing a 360-degree folding test and a non-standard quantitative test.
Taking the fast solidification 222 as a matrix phase, and taking 92% Al of the size 2 O 3 The ceramic beads are treated by the amino coupling agent, then mixed with the substrate of the fast curing 222 and uniformly stirred, the beaches are on the plane, the thickness of the beaches is 3mm, the width of the beaches is 3 cm, the length of the beaches is 15 cm, and the curing is carried out for 48 hours; cutting the test piece by a blade in the width direction of the middle part of the test piece, wherein the depth of a cut is about 0.5 mm; clamping the sample on a bending fatigue testing machine, folding the sample in half at 360 degrees by taking the notch as a central line at the temperature of about minus 5 ℃, and folding the sample for 1000 times; and observing whether interface cracking degumming or crack extension expansion exists at the 'aggregate and polyurethane interface' of the notch part, and simultaneously referring to the corresponding abrasion value to evaluate and accept or reject the reasonable content of the aggregate. The results of the test are shown in Table 12.
Table 12: selection and optimization of inorganic aggregate content
Example 7 composite curing process test of the invention:
one of the quality indexes of the composite material is that the composite material can be quickly cured and started up as soon as possible no matter the composite material is constructed at low temperature or high temperature. In order to achieve the aim, the invention has the measures that two product formulas of the fast curing 222 and the slow curing 333 are selected to adapt to different construction temperatures, and a special auxiliary heating tool is equipped. The curing process for different ambient temperatures and start-up times is shown in table 13.
Table 13: curing process under different conditions
Example 8, production packaging optimization test:
one of the outstanding quality indexes of the composite material is that the storage life of the composite material is more than 6 months. Because the main component of the casting polyurethane prepolymer is isocyanate which is a sensitive hydrophobic material, if the matrix phase polyurethane prepolymer and the reinforcing phase inorganic aggregate are mixed and prefabricated together during production, the gel failure is easy to occur, and the storage period is short. The matrix phase and the reinforcing phase of the composite material are produced by adopting a non-mixing prefabrication method, and the A-component prepolymer, the B-component curing agent, the C-component catalyst and the D-component inorganic aggregate are respectively and independently packaged in a product supply state, so that the difficult problems of production and storage of the casting type polyurethane-based composite material in a mixing prefabrication mode can be properly solved in a low-cost mode, and the invention can be used for realizing commercialization and online repair of a conveyor belt to be feasible.
The test method comprises the following steps: in the environment humidity of 65-78%, ceramic beads subjected to coupling treatment and air drying are mixed in a polyurethane prepolymer according to the weight ratio of 1:1, the mixture is filled in a vacuum sealing tank with the volume of 70%, and the vacuum sealing tank is placed in a cool and dry place for aging observation.
The shelf life test conclusions for "Mixed Prefabrications" and "non-mixed preffabrications" are shown in Table 14.
Table 14: conclusion of the shelf life test
Second, application example
Example 9 low temperature environment repair steel belt wear:
case characteristics: the daily transportation capacity of a steel wire conveying belt of a certain oversize coal washing plant is 9 ten thousand tons, steel wires are exposed at the position of an anti-overflow baffle plate of the conveying belt due to abrasion, a plurality of steel wires are broken, the production stop time for replacing the conveying belt is long, and great economic loss is caused. The polyurea spraying and repairing glue and other schemes are used for maintenance once, and the effect is poor. Example 9 adopting the 'fast curing 222' polyurethane-based wear-resistant composite material and the construction process of the invention, the environmental temperature is 4-9 ℃, and the construction process and the batching steps are as follows:
1. polishing the repaired part by the steel wire wheel to expose the clean surface;
2. brushing the V210 rubber treating agent for 2 times;
3. the proportion of each component is shown in the table 15:
table 15: example 9 formulation
4. The material preparation step:
4.1 pouring the inorganic aggregate of the component D into the polyurethane prepolymer of the component A, and electrically stirring uniformly;
4.2 pouring the component B curing agent into the AD mixed solution, and electrically and rapidly stirring for 25 seconds;
5. quickly mudflat the stirred mixture on the surface of the conveyor belt treated by V210, quickly scraping the mixture by a scraper within 1 minute, and coating the mixture with the thickness of 2-5 mm;
6. and (3) performing primary curing for 15 minutes after coating, heating the coating layer by using a special heater at 150 ℃, performing heat preservation curing for 10 minutes, and starting up to run.
The total restoration length of the embodiment is 350 m, the construction downtime is 2-4 hours each time, and the restoration is completed after a plurality of construction operations. The conveyor belt system is provided with 3 rollers, 2 polyurethane cleaners and 1 alloy steel cleaner, the conveyor belt system is used for 8 months after being repaired, the fatigue cycle of the conveyor belt system is more than 64 ten thousand times after being repaired, the non-degumming rate is more than 99.9 percent, the average abrasion loss is less than 0.5mm, the coating thickness is not more than 20 percent, the expected abrasion life can reach more than 5 years, and the satisfactory effect is achieved. See fig. 5, 6, 7.
EXAMPLE 10 high temperature Environment repair of fibrous Belt fraying
Case characteristics: the blanking area of the fiber conveying belt for batching in an aluminum plant is worn, 5 layers of fibers are worn to form three layers, safety production is directly influenced, and the belt replacement workload is large, and the production loss is large in long-term shutdown. The enterprise uses the repair adhesive scheme to repair the problems for many times, and the repaired product has lower wear resistance and shorter service life. The invention relates to a slow curing 333 polyurethane-based wear-resistant composite material and a construction process for repairing, wherein the slow curing 333 polyurethane-based wear-resistant composite material is used in summer at the construction environment temperature of 32 ℃, and the construction process and the material preparation steps are as follows:
1. polishing the repaired part by the steel wire wheel to expose the clean surface;
2. brushing the V210 rubber treating agent for 2 times;
3. the proportions of the components are shown in Table 16.
Table 16: example 10 formulation
4. The material preparation step:
4.1 pouring the catalyst of the component C into the prepolymer of the polyurethane of the component A, and electrically stirring the mixture evenly;
4.2 pouring the inorganic aggregate of the component D into the AC mixed solution, and electrically and rapidly stirring for 30 seconds;
4.3 pouring the component B curing agent into the ACD mixed solution, and electrically and rapidly stirring for 30 seconds;
5. the stirred mixture is shouldered on the surface of a conveying belt to be repaired, the mixture is quickly scraped by a scraper within 3 minutes, and the coating thickness is 2-5 mm;
6. after coating, the coating is cured for 60 minutes at room temperature, and the machine is started to run.
After 5 months of operation after repair, the abrasion is very little, and a satisfactory effect is obtained, as shown in figure 8.
EXAMPLE 11 Low temperature repair of skirt band edge fraying
Case characteristics: the edge of the skirt belt of a sintering plant of a certain large steel company is worn, the average service life is less than 2 months, the belt is replaced due to the reduction of strength, the replacement workload is large, and the loss is large after the production is stopped for 24 hours. The machine can be stopped for 1 hour every day, and the repairing effect is not ideal after the repairing glue is used. The construction temperature is 5 ℃, the polyurethane-based wear-resistant composite material 'fast curing 222' is adopted for repair, and the construction process is as follows:
1. polishing the repaired part by the steel wire wheel to expose the clean surface;
2. brushing the V210 rubber treating agent for 2 times;
3. the dosage of each component is weighed according to the proportion in the table 17:
table 17: example 10 formulation
4. The material preparation step:
4.1 pouring the inorganic aggregate of the component D into the polyurethane prepolymer of the component A, and electrically stirring uniformly;
4.2 pouring the component B curing agent into the AD mixed solution, and electrically and rapidly stirring for 25 seconds;
5. quickly mudflat the stirred mixture on the surface of the conveyor belt treated by V210, quickly scraping the mixture by a scraper within 1 minute, and coating the mixture with the thickness of 2-5 mm;
6. and (3) performing primary curing for 15 minutes after coating, heating the coating layer by using a special heater at 150 ℃, performing heat preservation curing for 10 minutes, and starting up to run.
This embodiment utilizes interim brief down time construction, divides the multiple operation to accomplish the restoration, removes to change the long-time shutdown of belt from, and the life after the repair is still permanent than new belt, and it is respond well to obtain. See fig. 9, 10.
And (4) conclusion:
compared with the wear-resistant mechanism, formula design, production technology and application effect in the prior art, the polyurethane-based wear-resistant composite material and the construction process are completely different and make qualitative change progress; the invention fills the blank of polyurethane-based wear-resistant composite material in the field of wear repair and remanufacture of heavy-duty rubber conveyer belts, is a novel material, a novel process and a novel technology with novelty, creativity and practicability, and realizes the purposes of on-line quick repair of conveyer belt wear and prolonging the service life.
Claims (4)
1. A polyurethane-based wear-resistant composite material, characterized in that: high-hardness inorganic aggregate with Mohs hardness of 6-9.5 is added into a flexible casting polyurethane matrix in a large proportion, and the hardness of the inorganic aggregate is far greater than that of an additional device of a conveyer belt and that of material particles, so that the conveyer belt is changed from a weak side to a dominant side in a friction system, the abrasion of the conveyer belt is reduced, and the abrasion resistance of the conveyer belt is improved; the formula of the polyurethane-based wear-resistant composite material is characterized in that: the matrix phase of the composite material is a generalized cast polyurethane elastomer comprising: the component A is prepolymer, the component B is curing agent and the component C is catalyst; the reinforcing phase of the composite material is D component high-hardness inorganic aggregate, and comprises: SiC or Al ceramics 2 O 3 Quartz SiO 2 A monomer or mixture of (a); the basic formula is as follows: matrix phase: reinforcing phase 100: 80 to 130.
2. A polyurethane-based wear-resistant composite material according to claim 1, wherein: the composite material is produced in a split packaging state by using a matrix phase and a reinforcing phase in a non-mixing prefabrication mode, wherein the component A is a matrix phase casting polyurethane prepolymer, the component B is a matrix phase curing agent, the component C is a matrix phase catalyst or a mixture of the catalyst and a pigment or a flame retardant, and the component D is a monomer or a mixture of a reinforcing phase inorganic aggregate or a mixture of the inorganic aggregate and the pigment or the flame retardant.
3. A polyurethane-based wear-resistant composite material according to claim 1 or 2, characterized in that: base formula matrix phase: reinforcing phase 100: 80-130, in order to meet the requirements of different conveyor belt cost performance, the requirements of matrix phase raw material sources, the requirements of different production management and the requirements of different construction working conditions, the physical properties of the matrix phase and the proportion of each component of the matrix phase can be different, and the proportion of different inorganic aggregates of the reinforcing phase can also be different, the composite material disclosed by the invention not only can be composed of the A, B, D three components, but also can be composed of the A, B, C, D four components, and the operable time and the curing speed of the composite material can also be selected differently.
4. The construction process and the material compounding steps of the polyurethane-based wear-resistant composite material are as follows:
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