EP2671232A1 - Method for coating an insulation component and insulation component - Google Patents

Method for coating an insulation component and insulation component

Info

Publication number
EP2671232A1
EP2671232A1 EP12742833.2A EP12742833A EP2671232A1 EP 2671232 A1 EP2671232 A1 EP 2671232A1 EP 12742833 A EP12742833 A EP 12742833A EP 2671232 A1 EP2671232 A1 EP 2671232A1
Authority
EP
European Patent Office
Prior art keywords
protective layer
component
heating cable
insulation
insulating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP12742833.2A
Other languages
German (de)
French (fr)
Inventor
Andreas Koch
Eberhard Lenz
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Siemens AG
Original Assignee
Siemens AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Siemens AG filed Critical Siemens AG
Publication of EP2671232A1 publication Critical patent/EP2671232A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B19/00—Apparatus or processes specially adapted for manufacturing insulators or insulating bodies
    • H01B19/04—Treating the surfaces, e.g. applying coatings
    • 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
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/36—Successively applying liquids or other fluent materials, e.g. without intermediate treatment
    • 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
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
    • B05D3/0254—After-treatment
    • 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
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/14—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by electrical means
    • B05D3/141—Plasma treatment
    • B05D3/142—Pretreatment
    • B05D3/144—Pretreatment of polymeric substrates
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
    • C23C18/04—Pretreatment of the material to be coated
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
    • C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
    • C23C18/1204—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material inorganic material, e.g. non-oxide and non-metallic such as sulfides, nitrides based compounds
    • C23C18/1208—Oxides, e.g. ceramics
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
    • C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
    • C23C18/1204—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material inorganic material, e.g. non-oxide and non-metallic such as sulfides, nitrides based compounds
    • C23C18/1208—Oxides, e.g. ceramics
    • C23C18/1212—Zeolites, glasses
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
    • C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
    • C23C18/1204—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material inorganic material, e.g. non-oxide and non-metallic such as sulfides, nitrides based compounds
    • C23C18/1208—Oxides, e.g. ceramics
    • C23C18/1216—Metal oxides
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
    • C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
    • C23C18/1225—Deposition of multilayers of inorganic material
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
    • C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
    • C23C18/1229—Composition of the substrate
    • C23C18/1233—Organic substrates
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
    • C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
    • C23C18/125—Process of deposition of the inorganic material
    • C23C18/1254—Sol or sol-gel processing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/42—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes polyesters; polyethers; polyacetals
    • H01B3/427—Polyethers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/29—Protection against damage caused by extremes of temperature or by flame
    • H01B7/292—Protection against damage caused by extremes of temperature or by flame using material resistant to heat
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/10—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor
    • H05B3/18—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor the conductor being embedded in an insulating material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers

Definitions

  • the present invention relates to a method for the coating of an insulation component, comprising PEEK, for the insulation of an electrically conductive heating cable. Furthermore, the present invention relates to an insulation component, comprising PEEK, for the insulation of an electrically conductive heating cable and such an insulated electrically conductive heating cable.
  • oil extraction sites can also be used to extract oil, in which the oil must be separated from the sand in a separation process.
  • the oil is usually extracted by heating the oil sands.
  • the viscosity of the bound oil is reduced so that it can be pumped off in a conventional manner.
  • heated steam, heated air or similar hot gases are used to heat the oil sands.
  • This has the disadvantage that in a very complex way, a possibility must be created to transport the gases to the desired position in the ground, namely to the storage location of the oil sands.
  • due to the fact that deposits are sometimes very deep and extensive a great deal of effort has to be made with regard to the resulting pressure loss when introducing the gases / vapors.
  • induction can be used as a physical principle.
  • induction cables ie electrically conductive heating cables
  • electrically conductive heating cables for the above-described extraction of oil from oil sands deposits, a highly aggressive environment exercise prevails.
  • the heating cable must withstand temperatures of permanently over 250 ° C, which prevail under a steam atmosphere and a H 2 S steam atmosphere at an overpressure of 15 bar.
  • a simple electrically conductive heating cable such as a
  • Copper cable would not adequately withstand such an environment.
  • the isolation of such heating cables also presents the environment with extraordinary problems.
  • Even highly resistant plastics, in particular plastic PEEK, are not sufficiently resistant to be permanently used in such atmospheres.
  • a heating cable is also to be understood as meaning an inductor for the extraction of oil sand, in which, during operation, the surrounding soil is excited by means of induction, so that an increase in temperature occurs.
  • Object of the present invention to provide a method that makes it possible to provide an insulation of electrically conductive heating cables that allows their use under the above-described aggressive environmental conditions. It is also an object of the present invention to provide a corresponding insulation component as well as an electrically conductive heating cable insulated therewith.
  • the above object is achieved by a method having the features of independent claim 1. Further features and details of the invention will become apparent from the dependent claims, the description and the drawings. In this case, features and details which are described in connection with the insulation component according to the invention and the electrically conductive heating cable according to the invention apply, of course also in connection with the method according to the invention and in each case vice versa, so that the revelation of the individual aspects of the invention is always or may be referred to alternately.
  • this insulation component has PEEK.
  • PEEK polyether ether ketone
  • the insulation component is made entirely or substantially entirely of PEEK.
  • the insulating component is used to insulate an electrically conductive heating cable.
  • the insulating component has a geometric shape so that it can be placed around the heating cable for the insulation.
  • the insulating member is designed as a hollow cylindrical shape having a length which is smaller than the length of the electrically conductive heating cable.
  • electrically conductive heating cables with lengths of several kilometers, for example two kilometers, are used.
  • Corresponding insulation components in the form of a hollow cylinder are dimensioned with a few meters, for example, about 9 meters.
  • the method according to the invention can be carried out on relatively small units, namely the insulating component, and nevertheless a very large electrically conductive heating cable can also be insulated in accordance with the invention by an insulation component coated according to the invention.
  • a method according to the invention has the following steps for coating the insulation component:
  • the problem with the PEEK material is that it also has high resistance to reactivity due to its high resistance to aggressive environments. Thus, it can be described as "inert”, which prevents the adhesion from being able to occur in a conventional manner via a bonding process with a protective layer and the material of the insulating component Be activated surface of the insulating component, so that this surface is chemically capable of overcoming the material's own inertia and to enter into a corresponding frictional connection with the protective layer, It should be noted that by the plasma flame, which, for example, with A particularly good activation takes place in this way, the material PEEK becomes surface-active and can enter into a viable connection or a reaction with other chemicals in an economically justifiable time.
  • the activation process by means of a cold plasma process is relatively inexpensive to carry out.
  • a temporary change in the chemical properties of the insulating component is carried out on its surface by the plasma flame, so that subsequently the protective layer can adhere.
  • the adhesion of the protective layer is important because during the introduction of a corresponding electrically conductive heating cable with such insulation in areas for oil sands a necessary elongation of up to 1% and more is necessary for the protective layer. Failure to provide a bond between the PEEK insulating layer and the PEEK insulation component would result in cracks in the protective layer and, thus, the aggressive environmental environment could cause premature corrosion of the PEEK material and premature failure of the heating cable would bring with it.
  • a further advantage of a method according to the invention is that, due to the plasma activation of the surface of the insulation component, this activation lasts for a relatively long time. In particular, this activation remains active for several days, so that the step of treating the surface with the plasma flame can be configured temporally and spatially separately from the step of applying at least one protective layer.
  • the protective layer it is possible for the protective layer to be carried out only after the assembly of the respective insulation component on the electrically conductive heating cable. This has the advantage that the protective layer can form a closed protective layer even at the abutting areas of individual insulation components in the longitudinal direction of the electrically conductive heating cable. In this way, even further improved shielding against the harsh environmental conditions can be achieved.
  • treating the surface of the insulating component with at least one cold plasma flame in sections means that at least the portions of the surface of the insulating component are appropriately treated and coated after the insulating component has been attached to the electrically conductive heating cable to show its isolation to the outside and would accordingly come in contact with the aggressive environmental conditions.
  • the electric conductive heating cable is in the frame
  • the present invention preferably a copper cable with about 100 to 160 mm in diameter.
  • a method according to the invention can be carried out, for example, by means of a ring in which one or more cold plasma flames point to the center of this ring.
  • continuous treatment of the surface of the insulating component can take place.
  • an alternating voltage is preferably applied to the ring and fed via gas connections oxygen, nitrogen and C 3 H 8 the ring and thus the plasma flame for their production.
  • a further advantage is the particularly environmentally friendly activation in that during the plasma process no unnecessary exhaust gases are produced, which could be perceived as environmental pollution.
  • the protective layer can be different formations.
  • At least one protective layer is applied as a sol-gel layer by a sol-gel method.
  • the sol-gel process is used by spraying the activated surface with, for example, a sol-gel solution.
  • This solution has a solvent, for example an alcohol. It vaporizes very quickly or instantly and leaves a thin film with oxidic and pre-oxidic nanoparticles through evaporation.
  • the application and evaporation of the solvent can ensure that a substantially or completely sealed film surrounds the material of the insulating component. In this way, so to speak, creates a dense, glassy oxide layer.
  • this oxide layer has the advantage that it protects the material of the insulating component, in particular the PEEK, from the aggressive environmental conditions in the desired manner.
  • the oxide layer is able to form a good adhesion with the surface of the material of the insulating component.
  • This makes it possible that a material expansion of more than 1% of the protective layer can be sustained. This is due to the fact that a material, the thinner it is, the more length deformation can endure without showing a cracking. In this way it is ensured that the desired shielding against the aggressive environmental conditions not only after carrying out the method according to the invention, but also when introducing into the desired position in the earth's interior for heating oil sands.
  • the protective layer is applied in such a way. conditions that a layer thickness of at least 2 ⁇ is achieved. Preferably, a layer thickness of between 2 and 5 ⁇ .
  • the protective layer can also consist of individual protective layer films, which can store one another achieve a correspondingly greater protective layer thickness of in particular up to 30 ⁇ .
  • Under 2 ⁇ is a minimum layer thickness to understand to avoid open spots and continuous cracks in the protective layer. Such a continuous crack is to refer to the radial orientation of the insulating component. This would lead to a leakage through which the material of the insulating component, ie in particular the PEEK, would be exposed directly to the aggressive environmental conditions.
  • the step of applying the protective layer is carried out at least twice.
  • the layer thickness of the protective layer is increased.
  • the layer thickness is increased to about 30 ⁇ m, so that even better protection against corrosion leakage can be achieved.
  • the individual steps of applying the protective layer are carried out such that between the individual application steps only partially or not at all a drying or curing of the previously applied
  • Protective layer could take place. This has the advantage that, at the time of application of the next protective layer, the underlying protective layer is still able to form a non-positive connection, for example play by material reason to enter.
  • both a same protective layer, as well as different protective layers can be used.
  • different protective layers can be stored one above the other in order to combine their quality of protection with different focal points to form a common and accordingly higher-grade protective layer.
  • a method according to the invention is followed by at least one drying step for the protective layer. This drying step is carried out at a temperature above room temperature, in particular between 100 ° C and 200 ° C.
  • a temperature range between 120 ° C and 180 ° C is preferred. In this way, the speed of implementation of the method can be accelerated.
  • the drying step serves to accelerate the curing of the applied protective layer. It should be noted that when using several protective layer films which are applied to one another, the drying step is to be carried out finally, ie after the last application of a protective layer film. In this way, the individual protective layers can be applied one after the other in a relatively rapid manner one after another, and finally a rapid completion of the insulating component by a method according to the invention can be ensured via the drying step.
  • the drying step may take place, for example, by heating the insulation components together in an oven prior to mounting on the heating cable.
  • a method according to the invention is carried out in a single production line, so that substantially continuously activating the
  • Isolation component, a coating of the insulating component and then, in particular, a drying of the insulating component can take place in a continuous process.
  • at least one protective layer is applied as an adhesive, in particular directly on the surface of the insulating component.
  • the advantage is achieved that the frictional connection between an adhesive and the material of the insulating component, ie in particular the PEEK, can be made particularly strong.
  • the adhesive itself may already represent the final protective layer or only a part of this protective layer, which in turn is provided with an additional protective layer attached thereto.
  • the adhesive is to be understood in particular as a primer, for example, for a sol-gel method in this embodiment.
  • a phenol novolac cyanate ester can be used.
  • a ring brush is used, which is arranged such that the insulation component is guided by this ring brush during application in such a way that after application, the applied adhesive material in still liquid on the insulation component along direction ring brush through the Gravity moves down. In this way, a substantially constant and above all closed protective layer can be formed. In addition, it is avoided that thickness jumps arise with regard to the layer thickness of the protective layer.
  • a single protective layer or protective layer film is formed as an adhesive or as a sol-gel layer, that is to say as a vitreous oxide layer.
  • a sol-gel layer that is to say as a vitreous oxide layer.
  • Several layers of adhesive or sol-gel layer are also conceivable within the scope of the present invention. bar.
  • a combination of an adhesive and a sol-gel layer is conceivable, wherein in particular the adhesive has been applied directly to the surface of the insulating component.
  • a method according to the invention can be further developed such that after the application of the protective layer in the form of the adhesive, a curing step is carried out in such a way that the adhesive becomes dimensionally stable without already completely curing. This leads to the fact that also further protective layers can be applied.
  • the further application can take place, for example, in a next process step by spraying the surface with an alcoholic sol-gel mixture.
  • the curing step preferably takes place with a greater distance when operating with flames or with heat radiators.
  • the adhesive preferably exhibits a thermal decomposition point of 400 to 420 ° Celsius after its curing. Accordingly, the adhesive itself can already have a protective effect, and be understood as a protective layer in the context of the present method.
  • this is designed for coating an insulating component with a hollow-cylindrical shape, which in particular has a length which is smaller than the length of the electric heating cable.
  • a compact unit of the insulation component having a length of, for example, less than approximately 10 m in large quantities can be treated and coated in accordance with the invention.
  • the application can be done by combining a variety of insulation components even with much longer electrical heating cables by the individual insulation components are used adjacent to each other. This reduces not only the production costs but also the expense of storing and transporting the insulation components.
  • a further advantage is achieved if, in a method according to the invention, after the surface of the insulating component has been treated with at least one cold plasma flame and before the at least one protective layer is applied to the treated surface of the insulating component, an assembly is carried out on the electrical heating cable ,
  • a particularly effective protective effect can be achieved by the coating. This is based, in particular, on the fact that in the case of a coating carried out after assembly with the protective layer, the joints between individual adjoining insulating components are treated and coated in accordance with the invention. This results in a continuous or substantially continuous protective layer over the course of the entire electrical heating cable, regardless of the number of used and adjoining insulation components.
  • the treatment of the surface of the insulating component can be carried out with at least one cold plasma flame with a ring surrounding the insulating component.
  • a ring is particularly advantageous in the production of a circumferential protective layer, as has been described in the preceding paragraph. This can be a cost-effective production, in particular in a continuous or semikontinuierli - tend manner to be performed.
  • At least two protective layers in particular particular all protective layers consist of the same or substantially the same material. Large layer thicknesses can thus be applied in layers without material differences, such as different thermal expansions or the like, that could lead to mechanical or electrical or thermal problems.
  • Another object of the present invention is an insulation component, comprising PEEK, for the isolation of an electrically conductive heating cable.
  • This insulating component is characterized in that the surface of the insulating component is at least partially provided with a protective layer.
  • an insulation component according to the invention is designed such that it can be produced by a method according to the invention. Accordingly, an insulation component according to the invention has the same advantages as have been explained in detail with reference to a method according to the invention.
  • Another object of the present invention is an electrically conductive heating cable, which has been isolated by at least one insulation component according to the invention, having the features of the present invention. Accordingly, a correspondingly electrically conductive heating cable has the same advantages as have been explained in detail with regard to an insulation component according to the invention or with regard to a method according to the invention.
  • Figure 1 is a schematic view of a way the
  • FIG. 2 shows an embodiment of an insulating component produced in accordance with the invention
  • FIG. 3 shows a further exemplary embodiment of an insulating component produced according to the invention
  • FIG. 4 shows a further exemplary embodiment of an insulation component produced according to the invention
  • FIG. 5 shows a further exemplary embodiment of an insulation component produced according to the invention
  • FIG. 6 shows a further exemplary embodiment of an insulation component produced according to the invention.
  • FIG. 7 shows another embodiment of an insulation component according to the invention.
  • a plasma flame ring is provided, which is shown schematically in FIG. 1 and can be charged with C 3 H 8 .
  • a connection for an AC voltage is provided at the bottom of the ring to produce the plasma in the desired manner.
  • the ring in particular in a rotating manner, is moved along the axis of the insulation component 10.
  • the surface of the insulation component 10 is activated. This activation overcomes the inertness of the reaction and thus enables a frictional connection with the insulating component.
  • a protective layer 20 is the application of a protective layer 20. The result of such a production step is shown in FIG. FIG.
  • FIG. 2 shows, by way of example, a schematic cross section of an embodiment of an insulation component 10. This is provided with a protective layer 20.
  • the protective layer 20 is in this embodiment, a sol-gel layer 22, with a thickness D, which is greater than or equal to 2 ⁇ .
  • the sol-gel process has preferably been carried out in such a way that the desired film having a desired layer thickness has been produced by evaporation of a solvent. Subsequently, a curing process was performed which left a glassy oxide layer of nanoparticles.
  • FIG. 3 shows the insulation situation with an insulation component 10 according to the invention according to FIG. 2.
  • the insulation component 10 can be wrapped around the electrically conductive heating cable 100 in an insulated manner.
  • the heating cable can be used in the aggressive environmental condition, for example in the extraction of oil sands used for heating the same.
  • FIGS. 4, 5, 6 and 7 show alternative embodiments of an insulation component 10 according to the invention by a method according to the invention. These differ by different Schichtdickenart and different number of layer thicknesses.
  • FIG. 4 shows an embodiment in which five protective layers result in a common protective layer 20. In this case, five films of a sol-gel solution were produced one above the other as respective sol-gel layer 22. In this way, the layer thickness D could be increased, in particular be increased to a range of 30 ⁇ .
  • FIG. 5 shows the possibility of combining different materials for the protective layer 20.
  • the lation component 10 of this embodiment has first been coated with an adhesive 24.
  • This adhesive 24 was only partially cured in a curing process, so that it remained dimensionally stable but still viscous.
  • a sol-gel layer 22 was applied to the adhesive 24 in a sol-gel process.
  • a frictional connection between the insulating member 10 and the adhesive 24 and between the adhesive 24 and the sol-gel layer 22 could be achieved.
  • the chemical composition properties and thus the protective mechanisms of the adhesive layer 24 and the sol-gel layer 22 could be combined with one another in order to even better resist the aggressive environmental conditions with regard to the protection of the insulating component 10 during its use.
  • FIG. 6 shows an alternative embodiment of the insulation component 10.
  • the protective layer 20 in this embodiment consists of an adhesive 24. This is likewise applied in a manner prescribed by a method according to the invention, that is to say after the plasma activation of the surface of the insulating component 10.
  • FIG. 7 shows that the adhesive as adhesive layer 24 can also be double or even multiple.
  • the layer thickness D is also increased, so that the shielding effect is increased against the aggressive environmental conditions.
  • a further advantage of increased layer thicknesses D is that in this way the mechanical stability of the protective layer 20 can be enhanced. During use, cracks can be further minimized in this way, so that the long-term stability of the correspondingly insulated electrically conductive heating cable 100 has been increased even further.

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Abstract

The invention relates to a method for coating an insulation component (10), having PEEK, for insulating an electrically conductive heating cable (100) comprising the following steps: 1.) at least sectionally treating the surface of the insulation component (10) with at least one cold plasma flame, and 2.) applying at least one protective layer (20) to the treated surface of the insulation component (10).

Description

Beschreibung description
Verfahren für die Beschichtung eines Isolationsbauteils und Isolationsbauteil Process for coating an insulation component and insulation component
Die vorliegende Erfindung betrifft ein Verfahren für die Beschichtung eines Isolationsbauteils, aufweisend PEEK, zur Isolierung eines elektrisch leitfähigen Heizkabels. Weiter betrifft die vorliegende Erfindung ein Isolations- bauteil, aufweisend PEEK, für die Isolierung eines elektrisch leitfähigen Heizkabels sowie ein derartig isoliertes elektrisch leitfähiges Heizkabel . The present invention relates to a method for the coating of an insulation component, comprising PEEK, for the insulation of an electrically conductive heating cable. Furthermore, the present invention relates to an insulation component, comprising PEEK, for the insulation of an electrically conductive heating cable and such an insulated electrically conductive heating cable.
Es ist bekannt, dass zur Förderung von Öl auch Öllager- Stätten infrage kommen, in welchen das Öl in einem Trenn- prozess vom Sand abgeschieden werden muss. In Lagerstätten, in welchen der Ölsand jedoch nicht im Tagebau zugänglich ist, erfolgt üblicherweise eine Förderung des Öls durch das Erhitzen des Ölsandes. Hierdurch wird die Visko- sität des gebundenen Öls derart reduziert, dass es in konventioneller Weise abgepumpt werden kann. Bei bekannten Verfahren wird für das Erhitzen des Ölsandes erhitzter Dampf, erhitzte Luft oder ähnliche heiße Gase eingesetzt. Dies bringt den Nachteil mit sich, dass in sehr aufwendi- ger Weise eine Möglichkeit geschaffen werden muss, um die Gase in die gewünschte Position im Erdreich, nämlich zu dem Lagerort des Ölsandes, zu transportieren. Darüber hinaus ist aufgrund teilweise sehr tiefer und weit ausgedehnter Lagerstätten ein hoher Aufwand hinsichtlich des ent- stehenden Druckverlustes beim Einbringen der Gase / Dämpfe zu beachten. It is well known that oil extraction sites can also be used to extract oil, in which the oil must be separated from the sand in a separation process. However, in reservoirs where the oil sands are not open pit open, the oil is usually extracted by heating the oil sands. As a result, the viscosity of the bound oil is reduced so that it can be pumped off in a conventional manner. In known processes, heated steam, heated air or similar hot gases are used to heat the oil sands. This has the disadvantage that in a very complex way, a possibility must be created to transport the gases to the desired position in the ground, namely to the storage location of the oil sands. In addition, due to the fact that deposits are sometimes very deep and extensive, a great deal of effort has to be made with regard to the resulting pressure loss when introducing the gases / vapors.
Auch ist es bekannt, dass zum Erwärmen von Materialien Induktion als physikalisches Prinzip zum Einsatz kommen kann. Jedoch besteht dabei das Problem, dass bei der Verwendung von Induktionskabeln, also elektrisch leitfähigen Heizkabeln, für die voranstehend beschriebene Förderung von Öl aus Ölsandlagerstätten, eine hoch aggressive Umge- bung vorherrscht. Insbesondere müssen die Heizkabel Temperaturwerte von dauerhaft über 250°C aushalten, die unter einer Wasserdampfatmosphäre und einer H2S Dampfatmosphäre bei einem Überdruck von 15 bar herrschen. Ein einfaches elektrisch leitfähiges Heizkabel, wie zum Beispiel einIt is also known that for heating materials induction can be used as a physical principle. However, there is the problem that when using induction cables, ie electrically conductive heating cables, for the above-described extraction of oil from oil sands deposits, a highly aggressive environment exercise prevails. In particular, the heating cable must withstand temperatures of permanently over 250 ° C, which prevail under a steam atmosphere and a H 2 S steam atmosphere at an overpressure of 15 bar. A simple electrically conductive heating cable, such as a
Kupferkabel, würde einer solchen Umgebung nicht in ausreichender Weise standhalten. Auch die Isolierung solcher Heizkabel stellt die Umgebungssituation vor außerordentliche Probleme. Selbst hochresistente Kunststoffe wie insbe- sondere der Kunststoff PEEK, sind nicht ausreichend resistent, um dauerstabil in solchen Atmosphären eingesetzt zu werden . Copper cable would not adequately withstand such an environment. The isolation of such heating cables also presents the environment with extraordinary problems. Even highly resistant plastics, in particular plastic PEEK, are not sufficiently resistant to be permanently used in such atmospheres.
Als Heizkabel ist auch ein Induktor für die Ölsandförde- rung zu verstehen, bei dem im Betrieb mittels Induktion der umgebende Erdboden angeregt wird, so dass es zu einer Temperaturerhöhung kommt . A heating cable is also to be understood as meaning an inductor for the extraction of oil sand, in which, during operation, the surrounding soil is excited by means of induction, so that an increase in temperature occurs.
Es ist Aufgabe der vorliegenden Erfindung die voranstehend beschriebenen Probleme zu beheben. Insbesondere ist esIt is an object of the present invention to overcome the problems described above. In particular it is
Aufgabe der vorliegenden Erfindung, ein Verfahren zur Verfügung zu stellen, das es ermöglicht, eine Isolierung von elektrisch leitfähigen Heizkabeln zur Verfügung zu stellen, die deren Einsatz unter den voranstehend beschriebe- nen aggressiven Umgebungsbedingungen ermöglicht. Ebenfalls Aufgabe der vorliegenden Erfindung ist es, ein entsprechendes Isolationsbauteil sowie ein damit isoliertes elektrisch leitfähiges Heizkabel zur Verfügung zu stellen. Voranstehende Aufgabe wird gelöst durch ein Verfahren mit den Merkmalen des unabhängigen Anspruchs 1. Weitere Merkmale und Details der Erfindung ergeben sich aus den Unteransprüchen, der Beschreibung und den Zeichnungen. Dabei gelten Merkmale und Details, die im Zusammenhang mit dem erfindungsgemäßen Isolationsbauteil und dem erfindungsgemäßen elektrisch leitfähigen Heizkabel beschrieben werden, selbstverständlich auch im Zusammenhang mit dem erfindungsgemäßen Verfahren und jeweils umgekehrt, so dass be- züglich der Offenbarung zu den einzelnen Erfindungsaspekten stets wechselseitig Bezug genommen wird beziehungsweise werden kann. Bei einem erfindungsgemäßen Verfahren für die Beschichtung eines Isolationsbauteils zur Isolierung eines elektrisch leitfähigen Heizkabels weist dieses Isolationsbauteil PEEK auf. Das bedeutet, dass PEEK (Polyetheretherketon) als Material für die Fertigung des Isolationsbauteils zum Ein- satz gekommen ist. Insbesondere ist das Isolationsbauteil vollständig oder im Wesentlichen vollständig aus PEEK hergestellt. Das Isolationsbauteil dient zur Isolierung eines elektrisch leitfähigen Heizkabels. Hierzu weist das Isolationsbauteil die eine geometrische Form auf, so dass es um das Heizkabel für die Isolierung gelegt werden kann. Insbesondere ist das Isolationsbauteil als hohlzylindrische Form ausgeführt, die eine Länge hat, die kleiner als die Länge des elektrisch leitfähigen Heizkabels ist. Häufig werden elektrisch leitfähige Heizkabel mit Längen von meh- reren Kilometern, zum Beispiel zwei Kilometern, eingesetzt. Entsprechende Isolationsbauteile in Form eines Hohlzylinders sind dabei mit einigen Metern dimensioniert, zum Beispiel ca. 9 Metern. Auf diese Weise kann das erfindungsgemäße Verfahren an relativ kleinen Einheiten, näm- lieh dem Isolationsbauteil, durchgeführt werden und trotzdem auch ein sehr groß dimensioniertes elektrisch leitfähiges Heizkabel in erfindungsgemäßer Weise durch ein erfindungsgemäß beschichtetes Isolationsbauteil isoliert werden . Object of the present invention to provide a method that makes it possible to provide an insulation of electrically conductive heating cables that allows their use under the above-described aggressive environmental conditions. It is also an object of the present invention to provide a corresponding insulation component as well as an electrically conductive heating cable insulated therewith. The above object is achieved by a method having the features of independent claim 1. Further features and details of the invention will become apparent from the dependent claims, the description and the drawings. In this case, features and details which are described in connection with the insulation component according to the invention and the electrically conductive heating cable according to the invention apply, of course also in connection with the method according to the invention and in each case vice versa, so that the revelation of the individual aspects of the invention is always or may be referred to alternately. In a method according to the invention for coating an insulation component for insulating an electrically conductive heating cable, this insulation component has PEEK. This means that PEEK (polyether ether ketone) has been used as material for the production of the insulation component. In particular, the insulation component is made entirely or substantially entirely of PEEK. The insulating component is used to insulate an electrically conductive heating cable. For this purpose, the insulating component has a geometric shape so that it can be placed around the heating cable for the insulation. In particular, the insulating member is designed as a hollow cylindrical shape having a length which is smaller than the length of the electrically conductive heating cable. Frequently, electrically conductive heating cables with lengths of several kilometers, for example two kilometers, are used. Corresponding insulation components in the form of a hollow cylinder are dimensioned with a few meters, for example, about 9 meters. In this way, the method according to the invention can be carried out on relatively small units, namely the insulating component, and nevertheless a very large electrically conductive heating cable can also be insulated in accordance with the invention by an insulation component coated according to the invention.
Ein erfindungsgemäßes Verfahren weist für die Beschichtung des Isolationsbauteils die folgenden Schritte auf: A method according to the invention has the following steps for coating the insulation component:
Zumindest abschnittsweises Behandeln der Oberfläche des Isolationsbauteils mit wenigstens einer kalten Plasmaflamme und At least partially treating the surface of the insulating member with at least one cold plasma flame and
Aufbringen von wenigstens einer Schutzschicht auf die behandelnde Oberfläche des Isolationsbauteils. Die voranstehende Verfahrensweise kann mit anderen Worten auch als das „Aktivieren" der Oberfläche des Isolationsbauteils im chemischen Sinn und dem anschließenden Be- schichten beschrieben werden. Applying at least one protective layer to the treating surface of the insulating component. In other words, the above procedure can also be described as the "activation" of the surface of the insulation component in the chemical sense and the subsequent coating.
Problematisch bei dem Material PEEK ist es, dass dieses Material aufgrund seiner hohen Resistenz gegen aggressive Umgebungen zugleich eine hohe Widerstandsfähigkeit hin- sichtlich der Reaktionsfähigkeit mit sich bringt. Es kann also als „reaktionsträge" beschrieben werden. Dies verhindert, dass in konventioneller Weise über Klebeverfahren oder ähnliches ein Kraftschluss zwischen einer Beschich- tung mit einer Schutzschicht und dem Material des Isolati- onsbauteils erfolgen kann. Erst durch den Einsatz eines erfindungsgemäßen Verfahrens kann die Oberfläche des Isolationsbauteils aktiviert werden, so dass diese Oberfläche in chemischer Weise in der Lage ist, die dem Material eigene Reaktionsträgheit zu überwinden und einen entspre- chenden Kraftschluss mit der Schutzschicht einzugehen. Dabei ist zu bemerken, dass durch die Plasmaflamme, welche zum Beispiel mit einem Gasverhältnis von Stickstoff zu Sauerstoff von 1:1 betrieben wird, eine besonders gute Aktivierung erfolgt. Auf diese Weise wird das Material PEEK oberflächenaktiv und kann eine tragfähige Verbindung oder eine Reaktion mit anderen Chemikalien in einer wirtschaftlich vertretbaren Zeit eingehen. The problem with the PEEK material is that it also has high resistance to reactivity due to its high resistance to aggressive environments. Thus, it can be described as "inert", which prevents the adhesion from being able to occur in a conventional manner via a bonding process with a protective layer and the material of the insulating component Be activated surface of the insulating component, so that this surface is chemically capable of overcoming the material's own inertia and to enter into a corresponding frictional connection with the protective layer, It should be noted that by the plasma flame, which, for example, with A particularly good activation takes place in this way, the material PEEK becomes surface-active and can enter into a viable connection or a reaction with other chemicals in an economically justifiable time.
Das Aktivierungsverfahren mittels einer kalten Plasmaflam- me ist darüber hinaus relativ kostengünstig durchführbar. Mit anderen Worten: wird durch die Plasmaflamme eine temporäre Veränderung der chemischen Eigenschaften des Isolationsbauteils an dessen Oberfläche durchgeführt, so dass anschließend die Schutzschicht haften bleiben kann. Das Haften der Schutzschicht ist wichtig, da während des Einbringens eines entsprechenden elektrisch leitfähigen Heizkabels mit einer solchen Isolierung in Förderbereiche für Ölsand eine notwendige Dehnungsfähigkeit von bis zu 1% und mehr für die Schutzschicht notwendig ist. Würde ein Kraft- schluss zwischen der Schutzschicht und dem Isolationsbauteil aus PEEK nicht bestehen, so würde dies dazu führen, dass Risse in der Schutzschicht entstehen könnten und auf diese Weise die aggressive Umweltumgebung ein vorzeitiges Korrodieren des PEEK-Materials und dementsprechend ein vorzeitiges Versagen des Heizkabels mit sich bringen würde. Moreover, the activation process by means of a cold plasma process is relatively inexpensive to carry out. In other words, a temporary change in the chemical properties of the insulating component is carried out on its surface by the plasma flame, so that subsequently the protective layer can adhere. The adhesion of the protective layer is important because during the introduction of a corresponding electrically conductive heating cable with such insulation in areas for oil sands a necessary elongation of up to 1% and more is necessary for the protective layer. Failure to provide a bond between the PEEK insulating layer and the PEEK insulation component would result in cracks in the protective layer and, thus, the aggressive environmental environment could cause premature corrosion of the PEEK material and premature failure of the heating cable would bring with it.
Ein weiterer Vorteil eines erfindungsgemäßen Verfahrens ist es, dass durch die Plasmaaktivierung der Oberfläche des Isolationsbauteils diese Aktivierung zeitlich relativ lange anhält . Insbesondere verbleibt diese Aktivierung über mehrere Tage aktiv, so dass der Schritt des Behandeins der Oberfläche mit der Plasmaflamme von dem Schritt des Aufbringens von wenigstens einer Schutzschicht zeitlich und örtlich separat ausgestaltet sein kann. Insbesondere ist es möglich, dass die Schutzschicht erst nach der Montage des jeweiligen Isolationsbauteils auf dem elektrisch leitfähigen Heizkabel durchgeführt wird. Dies bringt den Vorteil mit sich, dass die Schutzschicht auch an den Stoßbereichen einzelner Isolationsbauteile in Längsrichtung des elektrisch leitfähigen Heizkabels eine geschlossene Schutzschicht bilden kann. Auf diese Weise kann eine noch weiter verbesserte Abschirmung gegen die aggressiven Umweltbedingungen erzielt werden. A further advantage of a method according to the invention is that, due to the plasma activation of the surface of the insulation component, this activation lasts for a relatively long time. In particular, this activation remains active for several days, so that the step of treating the surface with the plasma flame can be configured temporally and spatially separately from the step of applying at least one protective layer. In particular, it is possible for the protective layer to be carried out only after the assembly of the respective insulation component on the electrically conductive heating cable. This has the advantage that the protective layer can form a closed protective layer even at the abutting areas of individual insulation components in the longitudinal direction of the electrically conductive heating cable. In this way, even further improved shielding against the harsh environmental conditions can be achieved.
Im Rahmen der vorliegenden Erfindung ist unter dem abschnittsweise Behandeln der Oberfläche des Isolationsbau- teils mit wenigstens einer kalten Plasmaflamme zu verstehen, dass zumindest die Abschnitte der Oberfläche des Isolationsbauteils entsprechend behandelt und beschichtet werden, welche nach dem Anbringen des Isolationsbauteils um das elektrisch leitfähige Heizkabel herum zu dessen Isolierung nach außen zeigen und dementsprechend in Kontakt mit den aggressiven Umweltbedingungen gelangen würden. Das elektrische leitfähige Heizkabel ist im Rahmen der vorliegenden Erfindung vorzugsweise ein Kupferkabel mit ca. 100 bis 160 mm Durchmesser. In the context of the present invention, treating the surface of the insulating component with at least one cold plasma flame in sections means that at least the portions of the surface of the insulating component are appropriately treated and coated after the insulating component has been attached to the electrically conductive heating cable to show its isolation to the outside and would accordingly come in contact with the aggressive environmental conditions. The electric conductive heating cable is in the frame The present invention preferably a copper cable with about 100 to 160 mm in diameter.
Ein erfindungsgemäßes Verfahren kann zum Beispiel mithilfe eines Ringes durchgeführt werden, in welchem eine oder mehrere kalte Plasmaflammen auf den Mittelpunkt dieses Ringes zeigen. Auf diese Weise, insbesondere durch eine Rotation um den Mittelpunkt dieses Ringes, kann eine kontinuierliche Behandlung der Oberfläche des Isolationsbau- teils stattfinden. Hierzu wird vorzugsweise eine Wechselspannung an dem Ring angelegt und über Gasanschlüsse Sauerstoff, Stickstoff und C3H8 dem Ring und damit der Plasmaflamme zu deren Erzeugung zugeführt. Wie hier zu erkennen ist, ist ein weiterer Vorteil die besonders umwelt- freundliche Aktivierung dadurch, dass beim Plasmaverfahren keine unnötigen Abgase entstehen, welche als Umweltbelastung wahrgenommen werden könnten. A method according to the invention can be carried out, for example, by means of a ring in which one or more cold plasma flames point to the center of this ring. In this way, in particular by a rotation about the center of this ring, continuous treatment of the surface of the insulating component can take place. For this purpose, an alternating voltage is preferably applied to the ring and fed via gas connections oxygen, nitrogen and C 3 H 8 the ring and thus the plasma flame for their production. As can be seen here, a further advantage is the particularly environmentally friendly activation in that during the plasma process no unnecessary exhaust gases are produced, which could be perceived as environmental pollution.
Bei der Schutzschicht kann es sich um unterschiedliche Ausbildungen handeln. Insbesondere ist darauf hinzuweisen, dass nicht nur eine Schutzschicht, sondern auch mehrere Schutzschichten übereinander mit gleicher oder unterschiedlicher chemischer und/oder physikalischer Ausgestaltung zum Einsatz kommen können. Entscheidend ist jedoch, dass nicht nur zwischen der Schutzschicht und dem Material des Isolationsbauteils, sondern auch zwischen den einzelnen Schutzschichten eine entsprechende kraftschlüssige beziehungsweise materialschlüssige Verbindung besteht, um die wie weiter oben beschriebenen Anforderungen an die Dehnungsgrenze in erfindungsgemäßer Weise zu erzielen. The protective layer can be different formations. In particular, it should be pointed out that not only one protective layer but also several protective layers can be used one above the other with the same or different chemical and / or physical design. It is crucial, however, that not only between the protective layer and the material of the insulating component, but also between the individual protective layers, a corresponding frictional or material-locking connection exists to achieve the requirements described above, the strain limit in the inventive manner.
Es kann von Vorteil sein, wenn bei einem erfindungsgemäßen Verfahren wenigstens eine Schutzschicht als Sol-Gel- Schicht durch ein Sol -Gel -Verfahren aufgebracht wird. Da- bei ist die Hauptkomponente einer dafür verwendeten Sol- Gel-Lösung nach Schichtaufbringung und Aushärtung bzw. It may be advantageous if, in a method according to the invention, at least one protective layer is applied as a sol-gel layer by a sol-gel method. In this case, the main component of a sol-gel solution used after layer application and curing or
Trocknung der Sol -Gel -Lösung insbesondere Si02 oder Ti02. Beim Aufbringen der Sol-Gel-Schicht weist diese einen 99%- tigen bzw. annähernd 99%-tigen Alkohol -Antei 1 auf. Dieser Alkohol -Anteil verdampft, so dass nach dem Aushärtung bzw. der Trocknung der Sol -Gel -Lösung Si02 oder Ti02 übrig bleibt. Mit anderen Worten kann eine Glas- oder Keramik- Sol-Gel-Lösung verwendet werden, wobei Keramiklösungen eine noch höhere Abschottung gegen die aggressiven Umweltbedingungen mit sich bringen. Drying of the sol-gel solution, in particular Si0 2 or Ti0 2 . When applying the sol-gel layer this has a 99% or approximately 99% alcohol -Antei 1 on. This alcohol content vaporizes, so that after curing or drying of the sol-gel solution Si0 2 or Ti0 2 remains. In other words, a glass or ceramic sol-gel solution can be used, with ceramic solutions providing even greater foreclosure against the harsh environmental conditions.
Das Sol -Gel -Verfahren wird eingesetzt, indem die aktivier- te Oberfläche zum Beispiel mit einer Sol-Gel-Lösung eingesprüht wird. Diese Lösung weist ein Lösungsmittel, zum Beispiel einen Alkohol auf. Dieser verdampft sehr schnell beziehungsweise sofort und hinterlässt durch das Verdampfen einen dünnen Film mit oxidischen und voroxidischen Na- nopartikeln. Durch das Aufbringen und Verdampfen des Lösungsmittels kann darüber hinaus sichergestellt werden, dass ein im Wesentlichen oder vollständig abgeschlossener Film das Material des Isolationsbauteils umgibt. Auf diese Weise entsteht sozusagen eine dichte, glasartige Oxid- Schicht. Diese Oxidschicht bringt einerseits den Vorteil mit sich, dass sie das Material des Isolationsbauteils, insbesondere das PEEK, in gewünschter Weise vor den aggressiven Umweltbedingungen schützt. Darüber hinaus ist die Oxidschicht beim Aushärten in der Lage, eine gute Haf- tung mit der Oberfläche des Materials des Isolationsbauteils einzugehen. Damit wird ermöglicht, dass eine Materialdehnung von über 1% der Schutzschicht ausgehalten werden kann. Dies rührt daher, dass ein Werkstoff, je dünner er wird, umso mehr Längenverformung ertragen kann, ohne eine Anrissbildung zu zeigen. Auf diese Weise wird sichergestellt, dass die gewünschte Abschirmung gegen die aggressiven Umweltbedingungen nicht nur nach dem Durchführen des erfindungsgemäßen Verfahrens besteht, sondern auch noch beim Einbringen in die gewünschte Position im Erdinneren zur Erwärmung von Ölsand. The sol-gel process is used by spraying the activated surface with, for example, a sol-gel solution. This solution has a solvent, for example an alcohol. It vaporizes very quickly or instantly and leaves a thin film with oxidic and pre-oxidic nanoparticles through evaporation. In addition, the application and evaporation of the solvent can ensure that a substantially or completely sealed film surrounds the material of the insulating component. In this way, so to speak, creates a dense, glassy oxide layer. On the one hand, this oxide layer has the advantage that it protects the material of the insulating component, in particular the PEEK, from the aggressive environmental conditions in the desired manner. In addition, during curing, the oxide layer is able to form a good adhesion with the surface of the material of the insulating component. This makes it possible that a material expansion of more than 1% of the protective layer can be sustained. This is due to the fact that a material, the thinner it is, the more length deformation can endure without showing a cracking. In this way it is ensured that the desired shielding against the aggressive environmental conditions not only after carrying out the method according to the invention, but also when introducing into the desired position in the earth's interior for heating oil sands.
Ebenfalls von Vorteil kann es sein, wenn bei einem erfindungsgemäßen Verfahren die Schutzschicht derart aufgetra- gen wird, dass eine Schichtdicke von mindestens 2 μπι erzielt wird. Bevorzugt ist eine Schichtdicke von zwischen 2 und 5 μπι . Dabei ist darauf hinzuweisen, dass die Schutzschicht auch aus einzelnen Schutzschichtfilmen bestehen kann, die übereinander gelagert eine entsprechend größere Schutzschichtdicke von insbesondere bis zu 30 μπι erzielen können. Unter 2 μπι ist dabei eine Mindestschichtdicke zu verstehen, um offene Stellen und durchgängige Risse in der Schutzschicht vermeiden. Ein solcher durchgängiger Riss ist dabei auf die radiale Ausrichtung des Isolationsbauteils zu beziehen. Dieser würde dazu führen, dass eine Leckage besteht, durch welche das Material des Isolationsbauteils, also insbesondere das PEEK, direkt den aggressiven Umweltbedingungen ausgesetzt wäre. An dieser Stelle würde demnach eine Korrosionsleckage bestehen, die zu einem Versagen der Isolierung und dementsprechend zu einem Kurzschluss des elektrisch leitfähigen Heizkabels während dessen Einsatz führen könnte. Durch das Durchführen eines erfindungsgemäßen Verfahrens mit der Mindestschichtdicke von 2 μπι wird somit die Funktionssicherheit durch ein erfindungsgemäßes Verfahren für den Einsatz eines isolierten elektrisch leitfähigen Heizkabels deutlich erhöht. It may likewise be advantageous if in a method according to the invention the protective layer is applied in such a way. conditions that a layer thickness of at least 2 μπι is achieved. Preferably, a layer thickness of between 2 and 5 μπι. It should be noted that the protective layer can also consist of individual protective layer films, which can store one another achieve a correspondingly greater protective layer thickness of in particular up to 30 μπι. Under 2 μπι is a minimum layer thickness to understand to avoid open spots and continuous cracks in the protective layer. Such a continuous crack is to refer to the radial orientation of the insulating component. This would lead to a leakage through which the material of the insulating component, ie in particular the PEEK, would be exposed directly to the aggressive environmental conditions. At this point, therefore, there would be a corrosion leak, which could lead to a failure of the insulation and, accordingly, to a short circuit of the electrically conductive heating cable during its use. By carrying out a method according to the invention with the minimum layer thickness of 2 μπι thus the reliability is significantly increased by an inventive method for the use of an insulated electrically conductive heating cable.
Ebenfalls vorteilhaft kann es sein, wenn bei einem erfin- dungsgemäßen Verfahren der Schritt des Aufbringens der Schutzschicht zumindest zweimal durchgeführt wird. Auf diese Weise wird die Schichtdicke der Schutzschicht vergrößert. Insbesondere erfolgt ein Vergrößern der Schichtdicke auf ca. 30 μπι, so dass ein noch besserer Schutz ge- gen Korrosionsleckage erzielt werden kann. Dabei werden die einzelnen Schritte des Aufbringens der Schutzschicht derart durchgeführt, dass zwischen den einzelnen Aufbringschritten nur zum Teil oder überhaupt nicht eine Trocknung beziehungsweise Aushärtung der vorher aufgebrachten It may also be advantageous if, in a method according to the invention, the step of applying the protective layer is carried out at least twice. In this way, the layer thickness of the protective layer is increased. In particular, the layer thickness is increased to about 30 μm, so that even better protection against corrosion leakage can be achieved. The individual steps of applying the protective layer are carried out such that between the individual application steps only partially or not at all a drying or curing of the previously applied
Schutzschicht stattfinden konnte. Dies bringt den Vorteil mit sich, dass zum Zeitpunkt des Aufbringens der nächsten Schutzschicht die darunter liegende Schutzschicht noch in der Lage ist, eine kraftschlüssige Verbindung, zum Bei- spiel durch Material schluss , einzugehen. Beim Aufbringen mehrerer Schutzschichten übereinander kann sowohl jeweils eine gleiche Schutzschicht, als auch unterschiedliche Schutzschichten eingesetzt werden. Insbesondere können verschiedene Schutzschichten übereinander gelagert werden, um deren Schutzqualität mit unterschiedlichen Schwerpunkten zu einer gemeinsamen und dementsprechend höherwertigen Schutzschicht zu kombinieren. Auch vorteilhaft kann es sein, wenn einem erfindungsgemäßen Verfahren nach dem Aufbringen der Schutzschicht zumindest ein Trocknungsschritt für die Schutzschicht folgt. Dieser Trocknungsschritt wird bei einer Temperatur oberhalb der Raumtemperatur, insbesondere zwischen 100 °C und 200 °C durchgeführt. Bevorzugt ist ein Temperaturbereich zwischen 120 °C und 180 °C. Auf diese Weise kann die Geschwindigkeit der Durchführung des Verfahrens beschleunigt werden. Der Trocknungsschritt dient dazu, das Aushärten der aufgebrachten Schutzschicht zu beschleunigen. Dabei ist darauf hinzuweisen, dass beim Einsatz von mehreren Schutzschichtfilmen, die aufeinander aufgebracht werden, der Trocknungsschritt abschließend, also nach dem letzten Aufbringen eines Schutzschichtfilms, durchgeführt werden soll . Auf diese Weise können die einzelnen Schutzschichten relativ zügig hintereinander übereinander aufgebracht werden und abschließend über den Trocknungsschritt eine zügige Fertigstellung des Isolationsbauteils durch ein erfindungsgemäßes Verfahren gewährleistet bleiben. Der Trocknungsschritt kann zum Beispiel durch das Aufheizen der Isolationsbauteile gemeinsam in einem Ofen vor der Montage an dem Heizkabel stattfinden. Selbstverständlich ist es auch möglich, dass ein erfindungsgemäßes Verfahren in einer einzigen Produktionslinie durchgeführt wird, so dass im Wesentlichen kontinuierlich ein Aktivieren desProtective layer could take place. This has the advantage that, at the time of application of the next protective layer, the underlying protective layer is still able to form a non-positive connection, for example play by material reason to enter. When applying several protective layers on top of each other, both a same protective layer, as well as different protective layers can be used. In particular, different protective layers can be stored one above the other in order to combine their quality of protection with different focal points to form a common and accordingly higher-grade protective layer. It can also be advantageous if, after the application of the protective layer, a method according to the invention is followed by at least one drying step for the protective layer. This drying step is carried out at a temperature above room temperature, in particular between 100 ° C and 200 ° C. A temperature range between 120 ° C and 180 ° C is preferred. In this way, the speed of implementation of the method can be accelerated. The drying step serves to accelerate the curing of the applied protective layer. It should be noted that when using several protective layer films which are applied to one another, the drying step is to be carried out finally, ie after the last application of a protective layer film. In this way, the individual protective layers can be applied one after the other in a relatively rapid manner one after another, and finally a rapid completion of the insulating component by a method according to the invention can be ensured via the drying step. The drying step may take place, for example, by heating the insulation components together in an oven prior to mounting on the heating cable. Of course, it is also possible that a method according to the invention is carried out in a single production line, so that substantially continuously activating the
Isolationsbauteils, ein Beschichten des Isolationsbauteils und anschließend insbesondere ein Trocknen des Isolationsbauteils im kontinuierlichen Verfahren stattfinden kann. Ein weiterer Vorteil kann es sein, wenn bei einem erfindungsgemäßen Verfahren zumindest eine Schutzschicht als Kleber, insbesondere direkt auf der Oberfläche des Isolationsbauteils, aufgebracht wird. Bei der Ausführungsform gemäß diesem Unteranspruch wird der Vorteil erzielt, dass der Kraftschluss zwischen einem Kleber und dem Material des Isolationsbauteils, also insbesondere dem PEEK, besonders stark ausgebildet werden kann. Dabei kann der Kleber bereits selbst die abschließende Schutzschicht darstellen oder aber nur einen Teil dieser Schutzschicht, der wiederum mit einer zusätzlichen darauf angebrachten Schutzschicht versehen wird. Der Kleber ist dabei insbesondere als Haftvermittler zum Beispiel für ein Sol -Gel -Verfahren bei dieser Ausführungsform zu verstehen. Als Kleber kann zum Beispiel ein Phenol-Novolac-Cyanat-Ester eingesetzt werden . Isolation component, a coating of the insulating component and then, in particular, a drying of the insulating component can take place in a continuous process. It may be a further advantage if, in a method according to the invention, at least one protective layer is applied as an adhesive, in particular directly on the surface of the insulating component. In the embodiment according to this subclaim, the advantage is achieved that the frictional connection between an adhesive and the material of the insulating component, ie in particular the PEEK, can be made particularly strong. In this case, the adhesive itself may already represent the final protective layer or only a part of this protective layer, which in turn is provided with an additional protective layer attached thereto. The adhesive is to be understood in particular as a primer, for example, for a sol-gel method in this embodiment. As an adhesive, for example, a phenol novolac cyanate ester can be used.
Um den Kleber anzubringen, ist vorzugsweise ein Ringpinsel zu verwenden, der derart angeordnet ist, dass durch diesen Ringpinsel beim Auftragen das Isolationsbauteil in einer Weise geführt wird, dass nach dem Aufbringen das aufgebrachte Klebermaterial in noch flüssiger Weise am Isolationsbauteil entlang wieder Richtung Ringpinsel durch die Schwerkraft bewegt nach unten läuft. Auf diese Weise kann eine im Wesentlichen konstante und vor allem abgeschlossene Schutzschicht ausgebildet werden. Darüber hinaus wird vermieden, dass Dickensprünge hinsichtlich der Schichtdicke der Schutzschicht entstehen. To attach the adhesive, preferably a ring brush is used, which is arranged such that the insulation component is guided by this ring brush during application in such a way that after application, the applied adhesive material in still liquid on the insulation component along direction ring brush through the Gravity moves down. In this way, a substantially constant and above all closed protective layer can be formed. In addition, it is avoided that thickness jumps arise with regard to the layer thickness of the protective layer.
Es wird darauf hingewiesen, dass im Rahmen der vorliegenden Erfindung nicht nur eine einzelne Schutzschicht, sondern auch eine Vielzahl von Schutzschichten übereinander angebracht werden kann. Insbesondere ist eine Einzel - Schutzschicht bzw. Schutzschichtfilm als Kleber oder als Sol-Gel-Schicht , also als glasartige Oxidschicht ausgebildet. Auch mehrere Schichten aus Kleber oder Sol-Gel- Schicht sind im Rahmen der vorliegenden Erfindung denk- bar. Insbesondere ist auch eine Kombination eines Klebers und einer Sol -Gel -Schicht denkbar, wobei insbesondere der Kleber direkt auf der Oberfläche des Isolationsbauteils aufgebracht worden ist. It should be noted that within the scope of the present invention, not only a single protective layer but also a plurality of protective layers can be stacked on top of each other. In particular, a single protective layer or protective layer film is formed as an adhesive or as a sol-gel layer, that is to say as a vitreous oxide layer. Several layers of adhesive or sol-gel layer are also conceivable within the scope of the present invention. bar. In particular, a combination of an adhesive and a sol-gel layer is conceivable, wherein in particular the adhesive has been applied directly to the surface of the insulating component.
Ein erfindungsgemäßes Verfahren kann dahingehend weitergebildet werden, dass nach dem Aufbringen der Schutzschicht in Form des Klebers ein Aushärtungsschritt derart durchgeführt wird, dass der Kleber formstabil wird ohne bereits vollständig auszuhärten. Dies führt dazu, dass auch weitere Schutzschichten aufgebracht werden können. Das weitere Aufbringen kann zum Beispiel in einem nächsten Prozessschritt durch das Einsprühen der Oberfläche mit einem alkoholischen Sol-Gel-Gemisch erfolgen. Aus Feuerschutzgrün- den erfolgt der Aushärtungsschritt vorzugsweise mit einem größeren Abstand im Betrieb mit Flammen oder mit Wärmestrahlern. Der Kleber zeigt vorzugsweise nach seiner Aushärtung einen thermischen Zersetzungspunkt von 400 bis 420 °Celsius. Dementsprechend kann auch der Kleber selbst be- reits eine Schutzwirkung entfalten, und als Schutzschicht im Rahmen des vorliegenden Verfahrens verstanden werden. Das bedeutet, dass auch der Kleber selbst eine Abschirmung gegen die aggressiven Umweltbedingungen mit sich bringt. Ebenfalls vorteilhaft ist es, wenn bei einem erfindungsgemäß Verfahren dieses für die Beschichtung eines Isolationsbauteils mit einer hohlzylindrischen Form ausgebildet ist, die insbesondere eine Länge aufweist, die kleiner als die Länge des elektrischen Heizkabels ist. Damit kann eine kom- pakte Einheit des Isolationsbauteils mit einer Länge von zum Beispiel weniger als circa 10m in hoher Stückzahl erfindungsgemäß behandelt und beschichtet werden. Die Anwendung kann durch Kombination einer Vielzahl von Isolationsbauteilen auch bei deutlich längeren elektrischen Heizkabeln erfolgen, indem die einzelnen Isolationsbauteile aneinander angrenzend verwendet werden. Dies reduziert neben den Fertigungskosten auch den Aufwand für die Lagerung und den Transport der Isolationsbauteile . Ein weiterer Vorteil wird dann erzielt, wenn bei einem erfindungsgemäßen Verfahren nach dem Behandeln der Oberfläche des Isolationsbauteils mit wenigstens einer kalten Plasma- Flame und vor dem Aufbringen der wenigstens einen Schutz - schicht auf die behandelte Oberfläche des Isolationsbauteils eine Montage auf dem elektrischen Heizkabel durchgeführt wird. Damit kann eine besonders effektive Schutzwirkung durch die Beschichtung erzielt werden. Dies beruht insbesondere auf der Tatsache, dass bei einer nach der Montage durchgeführten Beschichtung mit der Schutzschicht auch die Stöße zwischen einzelnen aneinandergrenzenden Isolationsbauteilen in erfindungsgemäßer Weise behandelt und beschichtet werden. Damit entsteht unabhängig von der Anzahl der verwendeten und aneinandergrenzenden Isolationsbauteile eine durchgehende oder im Wesentlichen durchgehende Schutzschicht über den Verlauf des gesamten elektrischen Heizkabels. A method according to the invention can be further developed such that after the application of the protective layer in the form of the adhesive, a curing step is carried out in such a way that the adhesive becomes dimensionally stable without already completely curing. This leads to the fact that also further protective layers can be applied. The further application can take place, for example, in a next process step by spraying the surface with an alcoholic sol-gel mixture. For reasons of fire protection, the curing step preferably takes place with a greater distance when operating with flames or with heat radiators. The adhesive preferably exhibits a thermal decomposition point of 400 to 420 ° Celsius after its curing. Accordingly, the adhesive itself can already have a protective effect, and be understood as a protective layer in the context of the present method. This means that even the adhesive itself provides a shield against the harsh environmental conditions. It is also advantageous if, in a method according to the invention, this is designed for coating an insulating component with a hollow-cylindrical shape, which in particular has a length which is smaller than the length of the electric heating cable. In this way, a compact unit of the insulation component having a length of, for example, less than approximately 10 m in large quantities can be treated and coated in accordance with the invention. The application can be done by combining a variety of insulation components even with much longer electrical heating cables by the individual insulation components are used adjacent to each other. This reduces not only the production costs but also the expense of storing and transporting the insulation components. A further advantage is achieved if, in a method according to the invention, after the surface of the insulating component has been treated with at least one cold plasma flame and before the at least one protective layer is applied to the treated surface of the insulating component, an assembly is carried out on the electrical heating cable , Thus, a particularly effective protective effect can be achieved by the coating. This is based, in particular, on the fact that in the case of a coating carried out after assembly with the protective layer, the joints between individual adjoining insulating components are treated and coated in accordance with the invention. This results in a continuous or substantially continuous protective layer over the course of the entire electrical heating cable, regardless of the number of used and adjoining insulation components.
Vorteilhaft ist es auch, wenn bei einem erfindungsgemäßen Verfahren um das Isolationsbauteil herum das Behandeln der Oberfläche und das Aufbringen der wenigstens einen Schutzschicht durchgeführt wird. Insbesondere bei rotationssymmetrischen elektrischen Heizkabeln, zum Beispiel mit einem runden Querschnitt, erfolgt auf diese Weise eine vollständig umgebende Schutzschicht, so dass von allen Seiten der Schutz gegen Korrosion gegeben ist. It is also advantageous if, in a method according to the invention, the treatment of the surface around the insulating component and the application of the at least one protective layer are carried out. In particular, in the case of rotationally symmetrical electrical heating cables, for example with a round cross-section, in this way a completely surrounding protective layer takes place, so that the protection against corrosion is given from all sides.
Auch ist es im Rahmen der vorliegenden Erfindung möglich, dass die Behandlung der Oberfläche des Isolationsbauteils mit wenigstens einer kalten Plasma-Flamme mit einem das Iso- lationsbauteil umgebenden Ring durchgeführt wird. Ein solcher Ring ist insbesondere bei der Erzeugung einer umlaufenden Schutzschicht vorteilhaft, wie sie im voranstehenden Absatz beschrieben worden ist. Damit kann eine kostengünstige Fertigung, insbesondere in kontinuierlicher oder semikontinuierli - eher Weise, durchgeführt werden. It is also possible within the scope of the present invention for the treatment of the surface of the insulating component to be carried out with at least one cold plasma flame with a ring surrounding the insulating component. Such a ring is particularly advantageous in the production of a circumferential protective layer, as has been described in the preceding paragraph. This can be a cost-effective production, in particular in a continuous or semikontinuierli - tend manner to be performed.
Darüber hinaus ist es von Vorteil, wenn bei einem erfindungsgemäßen Verfahren wenigstens zwei Schutzschichten, ins- besondere alle Schutzschichten aus demselben oder im Wesentlichen demselben Material bestehen. Große Schichtdicken können damit schichtweise aufgetragen werden, ohne dass Materialunterschiede, wie unterschiedliche Wärmeausdehnungen oder ähnliches, zu mechanischen oder elektrischen oder thermischen Problemen führen könnten. Moreover, it is advantageous if in a process according to the invention at least two protective layers, in particular particular all protective layers consist of the same or substantially the same material. Large layer thicknesses can thus be applied in layers without material differences, such as different thermal expansions or the like, that could lead to mechanical or electrical or thermal problems.
Ein weiterer Gegenstand der vorliegenden Erfindung ist ein Isolationsbauteil, aufweisend PEEK, für die Isolierung ei- nes elektrisch leitfähigen Heizkabels. Dieses Isolationsbauteil zeichnet sich dadurch aus, dass die Oberfläche des Isolationsbauteils zumindest abschnittsweise mit einer Schutzschicht versehen ist. Vorzugsweise ist ein erfindungsgemäßes Isolationsbauteil derart ausgebildet, dass es durch ein erfindungsgemäßes Verfahren erzeugt werden kann. Dementsprechend weist ein erfindungsgemäßes Isolationsbauteil die gleichen Vorteile auf, wie sie ausführlich mit Bezug auf ein erfindungsgemäßes Verfahren erläutert worden sind . Another object of the present invention is an insulation component, comprising PEEK, for the isolation of an electrically conductive heating cable. This insulating component is characterized in that the surface of the insulating component is at least partially provided with a protective layer. Preferably, an insulation component according to the invention is designed such that it can be produced by a method according to the invention. Accordingly, an insulation component according to the invention has the same advantages as have been explained in detail with reference to a method according to the invention.
Ein weiterer Gegenstand der vorliegenden Erfindung ist ein elektrisch leitfähiges Heizkabel, welches durch zumindest ein erfindungsgemäßes Isolationsbauteil isoliert worden ist, das die Merkmale der vorliegenden Erfindung aufweist. Ein entsprechend elektrisch leitfähiges Heizkabel weist dementsprechend die gleichen Vorteile auf, wie sie hinsichtlich eines erfindungsgemäßen Isolationsbauteils beziehungsweise hinsichtlich eines erfindungsgemäßen Verfahrens ausführlich erläutert worden sind. Another object of the present invention is an electrically conductive heating cable, which has been isolated by at least one insulation component according to the invention, having the features of the present invention. Accordingly, a correspondingly electrically conductive heating cable has the same advantages as have been explained in detail with regard to an insulation component according to the invention or with regard to a method according to the invention.
Die vorliegende Erfindung wird näher erläutert anhand der beigefügten Zeichnungsfiguren. Die dabei verwendeten Begrifflichkeiten „links", „rechts", „oben" und „unten" beziehen sich auf eine Ausrichtung der Zeichnungsfiguren mit normal lesbaren Bezugszeichen. Es zeigen: The present invention will be explained in more detail with reference to the accompanying drawing figures. The terms "left", "right", "top" and "bottom" used herein refer to an alignment of the drawing figures with normally readable reference numerals. Show it:
Figur 1 in schematischer Ansicht eine Möglichkeit der Figure 1 is a schematic view of a way the
Durchführung des erfindungsgemäßen Verfahrens, Figur 2 eine in erfindungsgemäßer Weise hergestellte Ausführungsform eines Isolationsbauteils, Figur 3 ein weiteres Ausführungsbeispiel eines erfindungsgemäß hergestellten Isolationsbauteils, Carrying out the method according to the invention, FIG. 2 shows an embodiment of an insulating component produced in accordance with the invention, FIG. 3 shows a further exemplary embodiment of an insulating component produced according to the invention,
Figur 4 ein weiteres Ausführungsbeispiel eines erfindungsgemäß hergestellten Isolationsbauteils, FIG. 4 shows a further exemplary embodiment of an insulation component produced according to the invention,
Figur 5 ein weiteres Ausführungsbeispiel eines erfindungsgemäß hergestellten Isolationsbauteils, FIG. 5 shows a further exemplary embodiment of an insulation component produced according to the invention,
Figur 6 ein weiteres Ausführungsbeispiel eines erfin- dungsgemäß hergestellten Isolationsbauteils, und FIG. 6 shows a further exemplary embodiment of an insulation component produced according to the invention, and
Figur 7 ein weiteres Ausführungsbeispiel eines erfindungsgemäßen Isolationsbauteils. Figure 7 shows another embodiment of an insulation component according to the invention.
Anhand von Figur 1 soll die Durchführung eines erfindungsgemäßen Verfahrens erläutert werden. Für das Durchführen des Verfahrens ist ein Plasmaflammenring vorgesehen, der schematisch in Figur 1 dargestellt ist und mit C3H8 beschickt werden kann. Darüber hinaus ist am unteren Bereich des Ringes ein Anschluss für eine Wechselspannung vorgesehen um das Plasma in gewünschter Weise zu erzeugen. Zur Behandlung der Oberfläche des Isolationsbauteils 10 wird der Ring, insbesondere in rotierender Weise, entlang der Achse des Isolationsbauteils 10 bewegt. Dabei wird die Oberfläche des Isolationsbauteils 10 aktiviert. Diese Aktivierung überwindet die Reaktionsträgheit und ermöglicht auf diese Weise eine kraftschlüssige Verbindung mit dem Isolationsbauteil, Ein solcher nächster Produktionsschritt ist das Aufbringen einer Schutzschicht 20. Das Ergebnis eines solchen Produktionsschrittes ist in Figur 2 dargestellt . Figur 2 zeigt beispielhaft in schematischem Querschnitt eine Ausführungsform eines Isolationsbauteils 10. Dieses ist mit einer Schutzschicht 20 versehen. Die Schutzschicht 20 ist dabei bei dieser Ausführungsform eine Sol-Gel- Schicht 22, mit einer Dicke D, die größer oder gleich 2 μπι ist . The implementation of a method according to the invention will be explained with reference to FIG. For carrying out the method, a plasma flame ring is provided, which is shown schematically in FIG. 1 and can be charged with C 3 H 8 . In addition, a connection for an AC voltage is provided at the bottom of the ring to produce the plasma in the desired manner. To treat the surface of the insulation component 10, the ring, in particular in a rotating manner, is moved along the axis of the insulation component 10. In this case, the surface of the insulation component 10 is activated. This activation overcomes the inertness of the reaction and thus enables a frictional connection with the insulating component. Such a next production step is the application of a protective layer 20. The result of such a production step is shown in FIG. FIG. 2 shows, by way of example, a schematic cross section of an embodiment of an insulation component 10. This is provided with a protective layer 20. The protective layer 20 is in this embodiment, a sol-gel layer 22, with a thickness D, which is greater than or equal to 2 μπι.
Das Sol -Gel -Verfahren ist dabei vorzugsweise in einer Wei- se durchgeführt worden, dass über eine Verdampfung eines Lösungsmittels der gewünschte Film mit einer gewünschten Schichtdicke erzeugt worden ist. Anschließend wurde ein Aushärtungsprozess durchgeführt, der eine glasartige Oxidschicht aus Nanopartikeln hinterlassen hat. The sol-gel process has preferably been carried out in such a way that the desired film having a desired layer thickness has been produced by evaporation of a solvent. Subsequently, a curing process was performed which left a glassy oxide layer of nanoparticles.
Figur 3 zeigt die Isolationssituation mit einem erfindungsgemäßen Isolationsbauteil 10 gemäß Figur 2. Dort befindet sich das Isolationsbauteil 10 in isolierter Weise ummantelnd um das elektrisch leitfähige Heizkabel 100. In dieser Anordnung kann das Heizkabel in der aggressiven Um- weltbedingung zum Beispiel bei der Förderung von Ölsand zur Beheizung desselben eingesetzt werden. FIG. 3 shows the insulation situation with an insulation component 10 according to the invention according to FIG. 2. In this arrangement, the insulation component 10 can be wrapped around the electrically conductive heating cable 100 in an insulated manner. In this arrangement, the heating cable can be used in the aggressive environmental condition, for example in the extraction of oil sands used for heating the same.
In den Figuren 4, 5,6 und 7 sind alternative Ausführungsformen eines erfindungsgemäßen Isolationsbauteils 10 durch ein erfindungsgemäßes Verfahren dargestellt. Diese unterscheiden sich durch unterschiedliche Schichtdickenarten und unterschiedlicher Anzahl von Schichtdicken. In Figur 4 ist eine Ausführungsform gezeigt, bei welcher fünf Schutzschichten eine gemeinsame Schutzschicht 20 ergeben. Dabei wurden fünf Filme einer Sol -Gel -Lösung übereinander als jeweilige Sol -Gel -Schicht 22 erzeugt. Auf diese Weise konnte die Schichtdicke D vergrößert, insbe- sondere auf einen Bereich von 30 μπι erhöht werden. FIGS. 4, 5, 6 and 7 show alternative embodiments of an insulation component 10 according to the invention by a method according to the invention. These differ by different Schichtdickenarten and different number of layer thicknesses. FIG. 4 shows an embodiment in which five protective layers result in a common protective layer 20. In this case, five films of a sol-gel solution were produced one above the other as respective sol-gel layer 22. In this way, the layer thickness D could be increased, in particular be increased to a range of 30 μπι.
Figur 5 zeigt die Möglichkeit der Kombination von verschiedenen Materialien für die Schutzschicht 20. Das Iso- lationsbauteil 10 dieser Ausführungsform ist zuerst mit einem Kleber 24 beschichtet worden. Dieser Kleber 24 wurde in einem Aushärteprozess nur zum Teil zum Aushärten gebracht, so dass er formstabil aber noch viskos verblieb. Anschließend wurde in einem Sol -Gel -Verfahren eine Sol- Gel-Schicht 22 auf den Kleber 24 aufgebracht. Auf diese Weise konnte eine kraftschlüssige Verbindung zwischen dem Isolationsbauteil 10 und dem Kleber 24 sowie zwischen dem Kleber 24 und der Sol -Gel -Schicht 22 erzielt werden. Somit konnten die chemischen Bestandseigenschaften und damit die Schutzmechanismen der Kleberschicht 24 und der Sol-Gel- Schicht 22 miteinander kombiniert werden, um den aggressiven Umweltbedingungen hinsichtlich des Schutzes des Isolationsbauteils 10 bei dessen Einsatz noch besser zu trot- zen. FIG. 5 shows the possibility of combining different materials for the protective layer 20. The lation component 10 of this embodiment has first been coated with an adhesive 24. This adhesive 24 was only partially cured in a curing process, so that it remained dimensionally stable but still viscous. Subsequently, a sol-gel layer 22 was applied to the adhesive 24 in a sol-gel process. In this way, a frictional connection between the insulating member 10 and the adhesive 24 and between the adhesive 24 and the sol-gel layer 22 could be achieved. Thus, the chemical composition properties and thus the protective mechanisms of the adhesive layer 24 and the sol-gel layer 22 could be combined with one another in order to even better resist the aggressive environmental conditions with regard to the protection of the insulating component 10 during its use.
In Figur 6 ist eine alternative Ausführungsform des Isolationsbauteils 10 dargestellt. Die Schutzschicht 20 bei dieser Ausführungsform besteht aus einem Kleber 24. Dieser ist ebenfalls in einer Weise aufgebracht, wie dies ein erfindungsgemäßes Verfahren vorschreibt, also nach dem Plasmaaktivieren der Oberfläche des Isolationsbauteils 10. FIG. 6 shows an alternative embodiment of the insulation component 10. The protective layer 20 in this embodiment consists of an adhesive 24. This is likewise applied in a manner prescribed by a method according to the invention, that is to say after the plasma activation of the surface of the insulating component 10.
In Figur 7 ist dargestellt, dass auch der Kleber als Kle- berschicht 24 doppelt oder sogar mehrfach ausgeführt sein kann. Auf diese Weise wird ebenfalls die Schichtdicke D vergrößert, so dass die Abschirmungswirkung gegen die aggressiven Umweltbedingungen vergrößert wird. Ein weiterer Vorteil vergrößerter Schichtdicken D ist es, dass auf die- se Weise die mechanische Stabilität der Schutzschicht 20 verstärkt werden kann. Während des Einsatzes können auf diese Weise Risse noch weiter minimiert werden, so dass die Dauerstabilität des entsprechend isolierten elektrisch leitenden Heizkabels 100 noch weiter erhöht worden ist. FIG. 7 shows that the adhesive as adhesive layer 24 can also be double or even multiple. In this way, the layer thickness D is also increased, so that the shielding effect is increased against the aggressive environmental conditions. A further advantage of increased layer thicknesses D is that in this way the mechanical stability of the protective layer 20 can be enhanced. During use, cracks can be further minimized in this way, so that the long-term stability of the correspondingly insulated electrically conductive heating cable 100 has been increased even further.
Die voranstehenden Ausführungsformen beschreiben die vorliegende Erfindung nur im Rahmen von Beispielen. Dementsprechend können einzelne Merkmale zu diesen Ausführungs- beispielen, sofern ^hnisch sinnvoll, frei miteinander kombiniert werden, ae den Rahmen der vorliegenden Erfin- dung zu verlassen. The above embodiments describe the present invention by way of example only. Accordingly, individual features may be related to these embodiments. Examples, insofar as they are sensibly, freely combined with one another, leave the scope of the present invention.

Claims

Patentansprüche claims
1. Verfahren für die Beschichtung eines Isolationsbauteils (10) , aufweisend PEEK, zur Isolierung eines elektrisch leitfähigen Heizkabels (100) mit den folgenden Schritten: A method of coating an insulating member (10) comprising PEEK to insulate an electrically conductive heating cable (100), comprising the steps of:
Zumindest abschnittsweises Behandeln der Oberfläche des Isolationsbauteils (10) mit wenigstens einer kalten Plasma-Flamme und  At least partially treating the surface of the insulating member (10) with at least one cold plasma flame and
Aufbringen von wenigstens einer Schutzschicht (20) auf die behandelte Oberfläche des Isolationsbauteils (10) .  Applying at least one protective layer (20) to the treated surface of the insulating component (10).
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass wenigstens eine Schutzschicht (10) als Sol -Gel -Schicht (22) durch ein Sol -Gel -Verfahren aufgebracht wird, wobei die 2. The method according to claim 1, characterized in that at least one protective layer (10) as a sol-gel layer (22) by a sol-gel method is applied, wherein the
Hauptkomponente der Sol -Gel -Lösung nach Ihrer Trocknung insbesondere Si02 oder Ti02 ist. Main component of the sol-gel solution after drying, in particular Si0 2 or Ti0 2 is.
3. Verfahren nach mindestens einem der vorhergehenden 3. Method according to at least one of the preceding
Ansprüche 1 oder 2, dadurch gekennzeichnet, dass die Claims 1 or 2, characterized in that the
Schutzschicht (20) derart aufgetragen wird, dass eine Protective layer (20) is applied such that a
Schichtdicke (D) von mindestens 2 μπι erzielt wird. Layer thickness (D) of at least 2 μπι is achieved.
4. Verfahren nach mindestens einem der vorhergehenden 4. The method according to at least one of the preceding
Ansprüche, dadurch gekennzeichnet, dass der Schritt des Aufbringens der Schutzschicht (20) zumindest zweimal, insbesondere mit dem gleichen Material, durchgeführt wird, so dass sich die Schichtdicke (D) der Schutzschicht (20) vergrößert . Claims, characterized in that the step of applying the protective layer (20) is performed at least twice, in particular with the same material, so that the layer thickness (D) of the protective layer (20) increases.
5. Verfahren nach mindestens einem der vorhergehenden 5. The method according to at least one of the preceding
Ansprüche, dadurch gekennzeichnet, dass nach dem Aufbringen der Schutzschicht (20) zumindest ein Trockungsschritt für die Schutzschicht (20) folgt, der bei einer Temperatur oberhalb der Raumtemperatur, insbesondere zwischen 100°C und 200°C, durchgeführt wird.  Claims, characterized in that after the application of the protective layer (20) at least one drying step for the protective layer (20) follows, which is carried out at a temperature above room temperature, in particular between 100 ° C and 200 ° C.
6. Verfahren nach mindestens einem der vorhergehenden 6. Method according to at least one of the preceding
Ansprüche, dadurch gekennzeichnet, dass zumindest eine Schutzschicht (20) als Kleber (24) , insbesondere direkt auf der Oberfläche des Isolationsbauteils (10) , aufgebracht wird. Claims, characterized in that at least one Protective layer (20) as an adhesive (24), in particular directly on the surface of the insulating member (10) is applied.
7. Verfahren nach Anspruch 6, dadurch gekennzeichnet, dass nach dem Aufbringen der Schutzschicht (20) in Form des 7. The method according to claim 6, characterized in that after the application of the protective layer (20) in the form of
Klebers (24) ein Aushärtungsschritt derart durchgeführt wird, dass der Kleber (24) formstabil wird ohne bereits vollständig auszuhärten .  Adhesive (24) a curing step is performed such that the adhesive (24) is dimensionally stable without already fully curing.
8. Verfahren nach einem der vorangegangenen Ansprüche, dadurch gekennzeichnet, dass dieses für die Beschichtung eines Isolationsbauteils (10) mit einer hohlzylindrischen Form ausgebildet ist, die insbesondere eine Länge aufweist, die kleiner als die Länge des elektrischen Heizkabels ist. 8. The method according to any one of the preceding claims, characterized in that it is designed for the coating of an insulating component (10) having a hollow cylindrical shape, which in particular has a length which is smaller than the length of the electric heating cable.
9. Verfahren nach einem der vorangegangenen Ansprüche, dadurch gekennzeichnet, dass nach dem Behandeln der 9. The method according to any one of the preceding claims, characterized in that after treating the
Oberfläche des Isolationsbauteils (10) mit wenigstens einer kalten Plasma-Flame und vor dem Aufbringen der wenigstens einen Schutzschicht (20) auf die behandelte Oberfläche des Isolationsbauteils (10) eine Montage auf dem elektrischen Heizkabel (100) durchgeführt wird. Surface of the insulating member (10) with at least one cold plasma flame and before the application of the at least one protective layer (20) on the treated surface of the insulating member (10) an assembly on the electric heating cable (100) is performed.
10. Verfahren nach einem der vorangegangenen Ansprüche, dadurch gekennzeichnet, dass um das Isolationsbauteil (10) herum das Behandeln der Oberfläche und das Aufbringen der wenigstens einen Schutzschicht (20) durchgeführt wird. 10. The method according to any one of the preceding claims, characterized in that around the insulating member (10) around the treatment of the surface and the application of the at least one protective layer (20) is performed.
11. Verfahren nach einem der vorangegangenen Ansprüche, dadurch gekennzeichnet, dass die Behandlung der Oberfläche des Isolationsbauteils (10) mit wenigstens einer kalten 11. The method according to any one of the preceding claims, characterized in that the treatment of the surface of the insulating component (10) with at least one cold
Plasma-Flamme mit einem das Isolationsbauteil (10) umgebenden Ring durchgeführt wird. Plasma flame is performed with a surrounding the insulating member (10) ring.
12. Verfahren nach einem der vorangegangenen Ansprüche, dadurch gekennzeichnet, dass wenigstens zwei Schutzschichten (20) , insbesondere alle Schutzschichten (20) aus demselben oder im Wesentlichen demselben Material bestehen. 12. The method according to any one of the preceding claims, characterized in that at least two protective layers (20), in particular all protective layers (20) consist of the same or substantially the same material.
13. Isolationsbauteil (10), aufweisend PEEK, für die 13. insulation component (10), comprising PEEK, for the
Isolierung eines elektrisch leitfähigen Heizkabels (100) dadurch gekennzeichnet, dass die Oberfläche des Insulation of an electrically conductive heating cable (100), characterized in that the surface of the
Isolationsbauteils (10) zumindest abschnittsweise mit einer Schutzschicht (20) versehen ist. Insulating component (10) is at least partially provided with a protective layer (20).
14. Isolationsbauteil (10) nach Anspruch 8, dadurch 14. insulation component (10) according to claim 8, characterized
gekennzeichnet, dass die Schutzschicht (20) durch ein characterized in that the protective layer (20) by a
Verfahren mit den Merkmalen eines der Ansprüche 1 bis 12 erzeugt werden kann. Method with the features of one of claims 1 to 12 can be produced.
15. Elektrisch leitfähiges Heizkabel (100), isoliert mit zumindest einem Isolationsbauteil (10) mit den Merkmalen eines der Ansprüche 13 oder 14. 15. Electrically conductive heating cable (100), insulated with at least one insulation component (10) having the features of one of claims 13 or 14.
EP12742833.2A 2011-08-08 2012-07-19 Method for coating an insulation component and insulation component Withdrawn EP2671232A1 (en)

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