CN116063868A - 一种提高无取向硅钢绝缘性能的环保绝缘涂料、涂层及其涂布工艺 - Google Patents
一种提高无取向硅钢绝缘性能的环保绝缘涂料、涂层及其涂布工艺 Download PDFInfo
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- CN116063868A CN116063868A CN202310061638.5A CN202310061638A CN116063868A CN 116063868 A CN116063868 A CN 116063868A CN 202310061638 A CN202310061638 A CN 202310061638A CN 116063868 A CN116063868 A CN 116063868A
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- C09D1/00—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
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- C09D133/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
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- C09D167/00—Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain; Coating compositions based on derivatives of such polymers
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- 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
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- C08K3/22—Oxides; Hydroxides of metals
- C08K2003/2217—Oxides; Hydroxides of metals of magnesium
- C08K2003/2224—Magnesium hydroxide
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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
- C08K2003/2237—Oxides; Hydroxides of metals of titanium
- C08K2003/2241—Titanium dioxide
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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- C08K3/38—Boron-containing compounds
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- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Chemical Treatment Of Metals (AREA)
Abstract
本发明公开了一种提高无取向硅钢绝缘性能的环保绝缘涂料、涂层及其涂布工艺。该涂料按质量百分比计，包括以下组分：铝溶胶或锆溶胶9‑60％，Ti化合物1‑10％，氢氧化镁0.5‑5％，硼砂1‑5％，有机树脂8‑16％，余量为去离子水；其中铝溶胶或锆溶胶与有机树脂的质量比不小于1。通过调整涂料中成膜物铝溶胶或锆溶胶与有机树脂的质量比能够获得具有优异性能的不同厚度区间涂层，所得涂层绝缘性、耐腐蚀性、耐热性优异，附着性好，原料简单廉价，具有广泛的工业应用价值。
Description
技术领域
本发明属于绝缘涂层技术领域，具体涉及一种提高无取向硅钢绝缘性能的环保涂层料、涂层及其涂布工艺。
背景技术
无取向硅钢广泛应用于电动发动机、发电机、小型变压器等电机的铁芯中。在制造铁芯时，需要连续地将电工钢板冲剪成铁芯形状的坯料，通过焊接将叠好的一定数量的芯片边缘固定。为了减少涡流损失，需要在钢板表面涂覆绝缘涂层，以便使各层片之间彼此绝缘。绝缘涂层不能太厚，太厚一方面会影响无取向硅钢的叠片系数，另一方面会降低钢板的磁性能。然而涂层过薄，将使涂层的绝缘性降低，并且由于应用时，无取向硅钢片需要经750℃去应力退火，退火后绝缘性能更低。
专利US 4844753提出了一种在无取向硅钢片上形成一层绝缘涂层的含水涂料组合物，它包括一种无机铬酸盐成膜组分和一种树脂组分。树脂组分是一种丙烯酸或丙烯酸-笨乙烯乳液和粒度为0.2–1μm的三聚氰胺树脂的混合物。专利US 3793073提供了一种用于涂布表面不平度至少为20微英寸的电工钢的无机/有机绝缘涂层。涂层的有机物是选自丙烯酸树脂或共聚物，无水马来酸，氨基酸树脂，木素磺酸钙，聚乙烯醇，酚树脂，醋酸乙烯酯，聚乙烯醇缩醛，醇酸树脂，氯乙烯和环氧树脂的有机树脂构成的。使用粒度大于2μm的有机颗粒物质来提供表面不平度。涂层的无机物包括磷酸类物质或铬酸类物质中的一种或多种。US 4618377的无机/有机涂料中，有机乳液树脂用一种分散改进剂进行了表面处理的有机树脂颗粒，和一种含有至少一种无机磷酸盐或铬酸盐组分的溶液，经表面处理的树脂颗粒被用于控制固化涂层的表面粗糙度。乳液树脂可以是单独的丙烯酸系、醋酸乙烯酯、苯乙烯、丁二烯，或者是醋酸乙烯酯、苯乙烯和丁二烯中的一种或多种共聚物。无机部分可包括钙、铝、镁和锌的磷酸盐或铬酸盐或重铬酸盐。US 4496399涉及到一种无机/有机磷酸盐绝缘涂层。其无机部分包含100份磷酸铝镁或是33～250份胶体二氧化硅和10～25份铬酐，或是30～250份的一种硅酸铝微粒。其有机部分含15～1350份的一种水悬乳液，含有40～60wt％的一种丙烯酸或醋酸乙烯树脂的固体。专利CN103028531A公开了一种加厚型半有机涂层无取向硅钢生产方法，涂层厚度1.2μm以上，醋酸乙烯树脂含量为8-12％，涂覆后的带钢进入烘烤炉进行烘烤，烘烤炉干燥段加热温度390-550℃，烘烤段分二个温度区段，第一温度区段加热温度415-485℃，第二温度区段加热温度345-410℃，固化段加热温度260-290℃。以上发明的特点是，涂液中含有有毒有害的六价铬，不满足环保需求。
专利CN102634243A公开了一种无取向硅钢用环保绝缘涂料及其涂层制备方法。涂料中含有磷酸二氢盐，氧化镁，硅溶胶，氧化锌，硼酸，钛酸酯偶联剂，硝酸铋，有机溶剂，其他助剂。该涂层经200-400℃烘烤30-60s，形成0.5-4μm的涂层，可耐高温850℃。但该涂层的绝缘性仍较低，层间电阻仅能达到5.5Ω·cm2以上。
专利CN1161434C公开了一种无取向电工钢的无机/有机绝缘涂层。涂液成分包括20-60份的磷酸铝，20-70份的无机硅酸盐微粒和10-25份的丙烯酸树脂和水性有机溶剂。固化后的涂层厚度为0.5-8μm。但该涂层的绝缘性仍较低。
专利CN1177951C公开了一种非取向型电磁钢板，该电磁钢板具有膜性能优良的绝缘膜。所述绝缘膜包含100重量份的金属磷酸盐、5-300份的有机树脂和5-50重量份的水溶性有机化合物。涂布后，该涂层具有较高的冲片性能和滑动性能，但该方法没有考虑涂层的绝缘性能。
专利CN100465337C提供了一种去应力退火后具有高间隙系数、优良冲切性能、膜粘结性能和滑动性能的涂有绝缘膜的非取向型电磁钢板的绝缘膜形成剂，以金属磷酸盐和有机树脂为主要组分，还包含水溶性有机化合物。但该方法没有考虑涂层的绝缘性能。
CN101168642A公开了一种冷轧无取向硅钢用环保型绝缘涂料及其涂层的制备方法，绝缘涂料的组分包括：磷酸盐、钼酸盐、水、有机树脂、硅烷偶联剂、丙三醇。涂覆该涂料后，在150-300℃下烘烤，而后在400-600℃下烧结30-90秒。该涂层具有良好的冲剪加工性、焊接性和耐热性。但该方法获得的涂层绝缘性能仍较低，不超过13.5Ω·cm2。
CN101358096A公开了一种无取向电工钢用的绝缘环保涂料。各组分含量为：磷酸二氢盐20-60％，丙烯酸酯乳液：20-40％，硼酸2-20％，硅溶胶0.5-15％，二甘醇一丁醚0-5％。涂液密度控制在1.0-1.2g/cm3，涂布在无取向电工钢板表面，在250-500℃的干燥炉中30-60秒烘干，涂层涂覆量为0.5-10g/m2。涂层具有润湿性好，便于涂覆及发泡量少的特点。虽然该方法获得的涂层绝缘性能较高，但没有考虑涂层经750℃消除应力退火后的绝缘性能。
专利CN101591495A公开了一种无取向电工钢无铬绝缘环保涂料及其涂层的制备方法。涂料成分包括：0-70％的磷酸二氢盐，5-30％的丙烯酸酯乳液，1-20％的硼酸和0.5％-6％的硅溶胶。该涂液涂布在无取向电工钢表面，在250-500℃的干燥炉中30-60秒烘干，涂层涂覆量为0.5-10g/m2，该方法由于具有较低的游离磷含量，具有较好的防锈性能，但该方法没有关注涂层的绝缘性能。
专利CN101643625A公开了一种用于无取向硅钢的绝缘涂料，涂料成分包含：异丙醇镁5-20％，聚氨酯-丙烯酸酯-环氧乙烷树脂5-25％，磷酸二氢铝5-40％，乙酸锌5-10％，胶体二氧化硅11-30％，非离子表面活性剂1-5％。获得的涂层具有优良的耐热性、焊接性等。但该方法没有关注涂层的绝缘性能。
因此，亟需寻找一种适应于无取向硅钢的绝缘性能优异的环保绝缘涂料。
发明内容
本发明的目的在于提供一种提高无取向硅钢绝缘性能的环保绝缘涂料、涂层及其涂布工艺。
为了实现上述目的，本发明采用了以下技术方案：
提供一种提高无取向硅钢绝缘性能的环保绝缘涂料，按质量百分比计，包括以下组分：铝溶胶或锆溶胶9-60％，Ti化合物1-10％，氢氧化镁0.5-5％，硼砂1-5％，有机树脂8-16％，余量为去离子水；其中铝溶胶或锆溶胶与有机树脂的质量比不小于1。
按上述方案，所述Ti化合物为Ti的碳酸盐和Ti的氧化物中的至少一种。
按上述方案，所述有机树脂是丙烯酸树脂、环氧树脂、氨基酸树脂、酚树脂、醇酸树脂中的一种或二种的混合物。
按上述方案，有机树脂粒径小于0.5μm，优选为0.2-0.4μm，有利于涂层的附着性。
按上述方案，所得绝缘涂料的固含量为20-60％。
按上述方案，所得绝缘涂料pH值为7-8。
本发明中，以铝溶胶或锆溶胶，作为涂层的主要成膜物，并与有机树脂相互交联，在钢板表面形成致密的三维网状结构，强化了涂层的绝缘性能；同时Ti的化合物与氢氧化镁复合，与钢板表面的氧化层反应，进一步提高涂层的附着性和绝缘性。其中：铝溶胶或锆溶胶，作为涂层的主要成膜物，有利于提高涂层的绝缘性、耐腐蚀性、耐热性。Ti的化合物包括Ti的碳酸盐和Ti的氧化物，有利于提高涂层的耐热性和绝缘性。氢氧化镁，一方面可调节涂液的pH值，另一方面有利于涂层的附着性；含量不可过高，过高不利于涂液的涂敷性能；过低，涂层附着性降低。硼砂，较硼酸易溶于水，并且呈弱碱性，有利于调节涂液的pH值，有利于提高涂层的耐热性。
提供一种提高无取向硅钢绝缘性能的环保绝缘涂层，由上述环保绝缘涂料涂布在所述无取向硅钢表面制备得到；其中铝溶胶或锆溶胶与有机树脂的质量比和涂层厚度的关系满足下式(1)：
lnH + 2.3 ≤ X ≤ 0.5×lnH + 3.2 (1)
其中：X为铝溶胶或锆溶胶与有机树脂的质量比，X≥1，H为涂层厚度，μm。
本发明针对不同的涂料配方，特别结合涂料中铝溶胶或锆溶胶与有机树脂的比例调控涂层厚度，能够得到满足要求、性能优异的不同厚度区间的涂层。不同的涂料配方，涂液中不同的铝溶胶或锆溶胶与有机树脂的比例，适应不同厚度区间的涂层，由此可满足不同厚度涂层的生产需求。当涂层较厚时，涂液中有机树脂的含量不可过高，过高容易造成涂层干燥后出现掉粉的现象，降低涂层的绝缘性能。当涂层较薄时，涂液中有机树脂的含量不可过低，过低易降低涂层的附着性和绝缘性能。
按上述方案，所述环保绝缘涂层的厚度为0.3-4μm。
提供一种上述提高无取向硅钢绝缘性能的环保绝缘涂层的涂布工艺，将环保绝缘涂料涂布在所述无取向硅钢表面，经200-280℃的板温烘干；其中涂布过程中，无取向硅钢的移动速度在3-23m/s。
涂布工艺中，板温不可过高，过高易造成有机物碳化，降低涂层的绝缘性。板温不可过低，过低将造成涂层未完全固化，涂层绝缘性降低。本发明中控制板温在200-280℃。
进一步地，涂布获得不同厚度涂层时，钢板的移动速度需要考虑涂液的固化情况。制备较厚涂层时，钢板移动速度不易过快，过快容易使涂层未固化完全；制备较薄涂层时，钢板的移动速度不易过慢，过慢容易造成涂层过固化，会出现涂层掉粉现象，影响绝缘性能。一般而言，涂层较厚时，涂层速度慢，涂层较薄时，涂层速度快。本发明也提供了匹配涂层厚度H的无取向硅钢的移动速度V设定。具体如下：
无取向硅钢的移动速度V与涂层厚度H满足如下关系式:
22/(H+3) ≤ V ≤ 30/(H+1) (2)
其中，V表示钢板的移动速度，m/s；H为涂层厚度，μm。
本发明的有益效果如下：
1.本发明提供了一种提高无取向硅钢绝缘性能的环保绝缘涂料，以铝溶胶或锆溶胶为主要成膜物，与有机树脂相互交联，在钢板表面形成致密的三维网状结构，协同配合Ti的化合物、氢氧化镁和硼砂，能够获得具有优异性能的不同厚度区间涂层，获得的涂层绝缘性、耐腐蚀性、耐热性优异，附着性好，原料简单廉价，具有广泛的工业应用价值。
2.本发明能够得到性能优异、不同厚度区间的涂层。涂液中不同的铝溶胶或锆溶胶与有机树脂的比例，适应不同厚度区间的涂层，可通过涂料配方中成膜物铝溶胶或锆溶胶与有机树脂的质量比的设计，得到适应的不同涂层厚度，有利于提高不同厚度需求的涂层的绝缘性和附着性。
具体实施方式：
下面通过具体实施例进一步对本发明进行解释说明。
实施例1-8
提供一种提高无取向硅钢绝缘性能的环保绝缘涂料，组分包括：铝溶胶或锆溶胶、Ti化合物、氢氧化镁，硼砂、有机树脂和去离子水，其中，各实施例中具体组分选择和配比见表1，计算所得铝溶胶或锆溶胶与有机树脂质量比X见表1。
具体涂布工艺为：
控制无取向硅钢一定的移动速度，将环保绝缘涂料涂料涂布在无取向硅钢上，然后烘干，即得提高无取向硅钢绝缘性能的环保绝缘涂层；其中实施例1-8中烘干所需板温、钢板的移动速度和所得涂层的厚度见表2。
对比例1-2
提供一种环保绝缘涂料，组分包括：铝溶胶或锆溶胶、Ti化合物、氢氧化镁、硼砂、有机树脂和去离子水，其中对比例中具体组分选择和配比见表1，计算所得铝溶胶或锆溶胶与有机树脂质量比X见表1。
具体涂布工艺为：
控制无取向硅钢一定的移动速度，将环保绝缘涂料涂料涂布在无取向硅钢上，然后烘干，即得提高无取向硅钢绝缘性能的环保绝缘涂层；其中对比例1-2中烘干所需板温、钢板的移动速度和所得涂层的厚度见表2。
实施例1-8和对比例1-2中所得环保绝缘涂层的性能结果见表3。
表1.实施例和对比例中的组分及配比
备注：表中X为铝溶胶或锆溶胶与有机树脂比例。
表2.实施例和对比例中的涂布工艺
| 涂层厚度μm | 钢板的移动速度m/s | 板温，℃ | |
| 实施例1 | 0.3 | 7 | 200 |
| 实施例2 | 4 | 3.2 | 280 |
| 实施例3 | 1 | 10 | 220 |
| 实施例4 | 2 | 5 | 230 |
| 实施例5 | 3 | 6 | 240 |
| 实施例6 | 2.5 | 6 | 250 |
| 实施例7 | 0.5 | 15 | 260 |
| 实施例8 | 1.5 | 11 | 270 |
| 对比例1 | 0.3 | 20 | 200 |
| 对比例2 | 4.5 | 5 | 200 |
表3.实施例和对比例中所得环保绝缘涂层的性能结果
备注：耐热性的测试方法为：经750℃，纯氮气下，2小时退火，退火后测钢板层间电阻。
从表1-3中可以看出，在实施例1～8中，按本发明所配制的绝缘涂液涂布在无取向硅钢上，经200-280℃板温烘干后，涂层附着性为A级，钢板叠片系数大于97.0，层间电阻普遍大于30Ω·cm2/片，经750℃，2小时退火后，层间电阻普遍大于10Ω·cm2/片。
对比例1中，成膜物丙烯酸树脂含量过低，最后得到的涂层附着性差，绝缘电阻仅为2.3Ω·cm2/片，经750℃，2小时退火后，层间电阻仅为0.5Ω·cm2/片。
对比例2中，成膜物铝溶胶与有机树脂的比例和涂层厚度的关系不满足本发明提出的公式(1)，涂层附着性差，绝缘电阻仅为4.1Ω·cm2/片，经750℃，2小时退火后，层间电阻仅为0.6Ω·cm2/片。
Claims (9)
1.一种提高无取向硅钢绝缘性能的环保绝缘涂料，其特征在于，按质量百分比计，包括以下组分：铝溶胶或锆溶胶9-60％，Ti化合物1-10％，氢氧化镁0.5-5％，硼砂1-5％，有机树脂8-16％，余量为去离子水；其中铝溶胶或锆溶胶与有机树脂的质量比不小于1。
2.根据权利要求1所述的环保绝缘涂料，其特征在于，所述Ti化合物为Ti的碳酸盐和Ti的氧化物中的至少一种。
3.根据权利要求1所述的环保绝缘涂料，其特征在于，所述有机树脂是丙烯酸树脂、环氧树脂、氨基酸树脂、酚树脂、醇酸树脂中的一种或二种的混合物。
4.根据权利要求1所述的环保绝缘涂料，其特征在于，有机树脂粒径小于0.5μm。
5.根据权利要求1所述的环保绝缘涂料，其特征在于，所得绝缘涂料pH值为7-8。
6.一种提高无取向硅钢绝缘性能的环保绝缘涂层，其特征在于，由权利要求1-5任一项所述的环保绝缘涂料涂布在所述无取向硅钢表面制备得到；其中环保绝缘涂料中铝溶胶或锆溶胶与有机树脂的质量比和涂层厚度的关系满足下式(1)：
lnH + 2.3 ≤ X ≤ 0.5×lnH + 3.2 (1)
其中：X为铝溶胶或锆溶胶与有机树脂的质量比，X≥1，H为涂层厚度，μm。
7.根据权利要求6所述的环保绝缘涂层，其特征在于，所述环保绝缘涂层的厚度为0.3-4μm。
8.一种权利要求6所述的提高无取向硅钢绝缘性能的环保绝缘涂层的涂布工艺，其特征在于，将环保绝缘涂料涂布在所述无取向硅钢表面，经200-280℃的板温烘干；其中涂布过程中，无取向硅钢的移动速度在3-23m/s。
9.根据权利要求8所述的涂布工艺，其特征在于，所述无取向硅钢的移动速度V与涂层厚度H满足如下关系式:
22/(H+3) ≤ V ≤ 30/(H+1) (2)其中，V表示钢板的移动速度，m/s；H为涂层厚度，μm。
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