WO2018133704A1 - 一种纳米陶瓷涂层绝缘钢轨 - Google Patents

一种纳米陶瓷涂层绝缘钢轨 Download PDF

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Publication number
WO2018133704A1
WO2018133704A1 PCT/CN2018/071904 CN2018071904W WO2018133704A1 WO 2018133704 A1 WO2018133704 A1 WO 2018133704A1 CN 2018071904 W CN2018071904 W CN 2018071904W WO 2018133704 A1 WO2018133704 A1 WO 2018133704A1
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Prior art keywords
rail
coating
nano ceramic
coated
nano
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PCT/CN2018/071904
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English (en)
French (fr)
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王安斌
钟峻青
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上海工程技术大学
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Publication of WO2018133704A1 publication Critical patent/WO2018133704A1/zh

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    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B5/00—Rails; Guard rails; Distance-keeping means for them
    • E01B5/02—Rails
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B2204/00—Characteristics of the track and its foundations

Definitions

  • the invention belongs to the technical field of rail transit, and particularly relates to an insulated rail of an ultra-high insulation performance rail system.
  • Rail transit such as subways, light rails, trams, and new rail transit systems
  • DC electric traction systems and use the travel rails as return lines.
  • Most of this current can flow back to the negative pole of the power supply through the running rail, but a small part leaks from the track and ground insulation to the track bed and the surrounding soil to form stray current.
  • the presence of stray currents causes electrochemical corrosion of the rail itself and the public facilities piping and buildings around the track, reducing the service life of rails, buried pipelines and buildings.
  • the track of the tram compared with the subway and the light rail, the track is completely buried underground, and the stray current is more harmful.
  • the fastener system for fixed rail rails usually adopts insulation design and provides insulation blocks and sheaths on the outer side of the rails of the embedded rails to increase the insulation resistance between the rails and the surrounding structures; this method can effectively increase the track Insulation resistance, but the gap between the insulation block and the sheath and the fastener, the insulation block and the sheath will be formed during the installation and use.
  • the gap is not only in the direction of the rail, but also because of the joints and fasteners of the insulating parts. Due to the complicated working conditions caused by the discontinuous structure, and the rail section will be deformed under the load of the vehicle in the cross section of the rail, regardless of the vertical direction, the horizontal direction and the torsional deformation of the rail and the insulating guard and the sheath. Dynamic gaps, etc., can not maintain the insulation performance of the track system under the actual operating environment conditions and humid environment, and can not fundamentally solve the stray current problem of the track system.
  • insulating materials have become a research topic.
  • new F and H grade insulating material systems began to appear, and heat resistant polyester imides, polyamideimides, polyimides, polymaleimides, polydiphenyl ethers, etc. were successively developed. Insulating varnishes, adhesives and films, as well as a range of new products such as modified epoxy, unsaturated polyester, aramid fiber paper and composites.
  • Most of the heat resistance grades of electrical products have been upgraded to Class B.
  • New F and H grade insulating materials have been adopted in special motors such as metallurgy, cranes and locomotive motors.
  • F and H grade insulating materials to improve their performance, such as modified diphenyl ether, modified bismaleimide, modified polyester imide wire enamel, polyamide.
  • Solvent-free impregnating resins and quick-drying impregnating varnishes have been rapidly developed, and less rubber powder mica tapes and VPI (vacuum pressure impregnation) impregnating resins have begun to be applied.
  • a new generation of high temperature resistant and wear resistant ceramic insulating coatings can form a layer with a higher volume resistivity on the surface of the object to be coated.
  • the dielectric strength (breakdown strength) is greater than 10 4 kV/m at room temperature greater than 10 12 ⁇ m and high.
  • a ceramic coating that can withstand a strong electric field without being broken down.
  • the coating has high mechanical strength and good chemical stability, and is resistant to aging, water, chemical, and long-term refractory barbecue. With the resistance to mechanical shock and thermal shock, the latest application of nano materials has greatly improved the engineering insulation performance.
  • the object of the present invention is to overcome the defects of the prior art described above and to provide a nano-ceramic coated insulated steel rail which can fundamentally solve the stray current problem of the track system and has low cost and good performance.
  • the object of the invention can be achieved by a technical solution of a nanoceramic coated insulating rail, the surface of which comprises a rail top surface (3) and other rail outer surfaces (4), said rail top surface (3) refers to the rolling contact surface of the wheel and the upper surface portion adjacent thereto, and the other outer surface (4) of the rail is included in the longitudinal direction of the rail, including the upper and lower sides of the rail foot, the sides of the rail waist, and the upper and lower surfaces of the rail head. And a side surface, characterized in that the nano-ceramic insulating coating (2) is uniformly coated on the outer surface (4) of the other rail, and the material of the nano-ceramic insulating coating (2) comprises a bonding material and a reinforcing material. And active hardener.
  • the nano-ceramic insulating coating is a permanent combination of a nano-ceramic insulating coating and a rail surface.
  • the nano ceramic insulating coating (2) has a thickness (5) of between 100 and 1000 ⁇ m.
  • the nano ceramic insulating coating (2) is a high insulation resistance material having a resistivity of not less than 10 megaohms.
  • the nano ceramic insulating coating (2) is a commercially available nano ceramic insulating material and has good mechanical properties, and specifically includes: a material having an adhesion of not less than 3 MPa, an abrasion loss of not more than 10 mg, and an impact resistance of not less than 30 cm.
  • the nano ceramic insulating coating (2) comprises a bonding material, a reinforcing material, an active hardening agent and the like;
  • the bonding material is acetal, polyester, modified polyester, polyurethane, polyimide One or more of the reinforcing materials; one or more of alumina, silicon carbide, silicon nitride, silicon dioxide, magnesium oxide, mica;
  • the active hardener is dodecyl One or more of sodium sulfonate, cetyltrimethylammonium bromide, polyethylene glycol, and Tween.
  • the material of the nano ceramic insulating coating adopts the two-component alcohol system nano ceramic coating model XS-725A/B (Guangzhou Yinna New Material Technology Co., Ltd.), and its main component is nano glass dispersion, silicon nano-dispersion base liquid. , carbon composite material, composite alcohol auxiliary; two-component XS-725A and XS-725B are mixed in a ratio of 7:5 and uniformly stirred.
  • the nano ceramic insulating coating (2) is composed of an adhesive layer (21) and an insulating layer (22); the adhesive layer (21) is coated on the surface of the rail by a coating process, the insulating layer (22) At least one layer is provided, and a coating process is applied on the surface of the adhesion layer (21).
  • the adhesive layer (21) is coated on the surface of the rail after hardening, coated with an insulating layer (22) on the surface, and after hardening, is coated with an insulating layer (22);
  • the thickness of the adhesive layer (21) is not more than 200 ⁇ m, and the thickness of each insulating layer (22) is not more than 200 ⁇ m.
  • the above coating process includes:
  • the first step the surface cleaning process of the rail
  • the second step the "coating-hardening" process of the adhesion layer
  • the third step the "coating-hardening" process of the insulation layer.
  • the fourth step repeating the multi-layer coating treatment of the "coating-hardening" process of the insulating layer;
  • the material of the adhesive layer (21) is at least a nano ceramic insulating material having an adhesive adhesion of not less than 3 MPa; the adhesive layer can be firmly bonded to the steel rail, and can also be firmly bonded to the insulating layer to insulate the nano ceramic.
  • the coating and the rail surface are permanently bonded.
  • the insulating layer (22) material is a nano ceramic insulating material comprising at least a reinforcing material having an abrasion resistance of not more than 10 mg, an impact resistance of not less than 30 cm, and a resistivity of not less than 10 megaohms, and a reactive hardener, which has high insulation. Resistance and good mechanical properties.
  • the adhesion layer (21) and the insulating layer (22) may also be coated with a nano ceramic insulating material that simultaneously satisfies the functions of the adhesion layer (21) and the insulating layer (22).
  • the nano ceramic insulating coating (2) is coated on the surface of the rail by a mechanical or manual coating method and a coating process; the coating method is spraying or brushing or roller coating or atomizing or liquefying Soaking; the coating process is directly processed after the last step of the rail manufacturing, or processed at the track laying site.
  • the top surface (3) of the rail is supported or suspended by the tooling (16), and the nano-ceramic insulating coating (2) is uniformly coated by the relative movement of the automatic coating machine or the artificial coating along the rail (1).
  • the tooling (16) is a mechanical clamp or a magnetic rail.
  • the final surface finish of the nano ceramic insulating coating (2) is above the national standard GB/T3505, and the difference in thickness of the nano ceramic insulating coating (2) on the surface of the rail is not more than 100 ⁇ m.
  • a nano ceramic coated insulated steel rail proposed by the present invention applies a high resistivity material having a resistivity of not less than 10 megaohms as an insulating coating on the surface of the rail rail, and the nano ceramic coating
  • the layered insulating rail has the functions of anti-corrosion, water resistance, aging resistance, friction resistance, moist heat resistance, atmospheric aging resistance and strong adhesion. It fundamentally eliminates the track system. The generation of stray current avoids the damage caused by unfavorable factors such as electrochemical corrosion to the public facilities pipelines and buildings around the track and the track, and the application of the nano-ceramic coated insulated rail can no longer use the rail insulation block and protection.
  • the orbital insulation resistance of the nano-ceramic coated insulated rail of the present invention is more than 5 times higher than that of the conventional rail insulation block and sheathing scheme under the actual application environment conditions, and the nano ceramic coating is not required.
  • the use of insulated rails greatly simplifies the track laying process and reduces the cost of track insulation, improves the efficiency of track laying, and simplifies and reduces operations. Repair work, to ensure that the rail insulation performance and operational efficiency and safety.
  • Figure 1a is a schematic view showing the structure of a general rail of the present invention.
  • Figure 1b is a schematic view showing the structure of a grooved rail of the present invention.
  • Figure 2a is a schematic view of the thickness of the coating of the present invention.
  • Figure 2b is a cross-sectional view taken along line A-A of Figure 2a of the present invention (three layers);
  • Figure 2c is a cross-sectional view taken along line A-A of Figure 2a of the coating of the present invention (two layers);
  • Figure 3 is a process flow of the coating process of the present invention.
  • Figure 4a is a schematic view of a general rail suspension tooling of the present invention.
  • Figure 4b is a side view of Figure 4a
  • Figure 4c is a schematic view of the trough type rail suspension tooling of the present invention.
  • Figure 4d is a side view of Figure 4c
  • Figure 5a is a schematic view of a general rail support tool of the present invention.
  • Figure 5b is a side view of Figure 5a
  • Figure 5c is a schematic view of the groove type rail supporting tool of the present invention.
  • Figure 5d is a side view of Figure 5c
  • Figure 6a is a schematic view showing the structure of a general rail of Embodiment 4 of the present invention.
  • Figure 6b is a schematic view showing the structure of a groove type rail of Embodiment 4 of the present invention.
  • a nano ceramic insulated steel rail is coated with a nano ceramic insulating coating 2 on the surface of a general rail rail 1; the nano ceramic insulating coating 2 is uniformly covered on the surface of the rail 1; the surface of the rail 1 includes Rail top surface 3 and other rail outer surface 4, rail outer surface 4 is in the longitudinal direction of the rail including the bottom and bottom of the rail bottom, the sides of the rail and the upper and lower sides of the rail head and the side; the rail top surface 3 is the rolling contact surface of the wheel and the phase
  • the adjacent upper surface portion is 50 mm wide, the rail top surface 3 is not used as a non-coating area, that is, the non-coating area, and the rail 1 non-coating area is used to mount the tooling in the coating to support or suspend the rail; nano ceramic
  • the material of the insulating coating 2 is a two-component alcohol system nano ceramic coating model XS-725A/B (Guangzhou Yina New Material Technology Co., Ltd.), and the nano ceramic coating comprises a bond
  • the main components are nano glass dispersion, silicon nano-dispersion base liquid, carbon composite material and composite alcohol auxiliary; the two-component XS-725A and XS-725B are mixed and evenly stirred in a ratio of 7:5, and the mixer speed is 500 rpm. Minutes, in Coated ambient temperature 10-40 degrees C, after mixing the nano ceramic coating must be used within 8 hours.
  • the nano ceramic insulating coating 2 has high insulation resistance exceeding 10 megaohms or more to meet the insulation performance requirements of the track eliminating stray current, and has high mechanical performance index: adhesion is not less than 3 MPa; wear amount is not more than 10 mg; impact resistance Not less than 30cm.
  • the nano ceramic insulating coating 2 is permanently bonded to the surface of the rail 1.
  • the nano-ceramic insulating coating 1 of the nano ceramic insulating rail 1 has a total thickness of 5 between 400 and 500 ⁇ m, and is coated on the surface of the rail by a mechanical or manual coating method and a coating process;
  • the method is spray coating; the coating process is carried out in a special nano-ceramic insulated rail coating plant.
  • the rail 1 is suction-suspended by the tooling 16.
  • the position of the suction suspension is where the top surface of the rail 3 does not need to be coated with the nano-ceramic insulating coating 2, and does not hinder the coating of the nano-ceramic insulating coating.
  • This suspension is positioned by the magnetic rail through the top surface of the non-coated rail.
  • the coating is carried out by a mechanical or manual coating method and a coating process.
  • the nano-ceramic insulating coating 2 is composed of an adhesion layer 21 and two insulating layers 22.
  • the material of the adhesion layer 21 and the material of the insulating layer 22 are the same, and both are the above-mentioned two-component alcohol system.
  • the nano ceramic coating model XS-725A/B which simultaneously satisfies the functions of the adhesive layer 21 and the insulating layer 22. Through the three-pass coating process, the process is shown in Figure 3:
  • the first step the rail surface cleaning process 12;
  • the second step the adhesion layer "coating - hardening" process 13, the adhesion layer thickness of 100 ⁇ m;
  • the third step intermediate coating "coating - hardening" process 14, the thickness of the intermediate insulating layer is 150 ⁇ m;
  • the fourth step the surface insulation layer "coating - hardening" process 14, the surface insulation layer thickness of 200 ⁇ m;
  • the coating in the coating process of the nano-ceramic insulating coating can be applied by a relatively uniform moving movement along the rail by an automatic coating machine, which is applied to all the coated surfaces once in the direction of the rail, after each layer is coated.
  • the next step of coating is carried out after baking for 30-60 minutes in a dryer at a temperature of 100-180 degrees Celsius or 12 hours at a normal temperature.
  • the final surface finish of the nano-ceramic insulating coating is required to be four grades (GB/T3505), and the difference in coating thickness on the rail surface is not more than 50 ⁇ m.
  • a trough-type nano-ceramic insulated steel rail is coated with a nano-ceramic insulating coating 2 on the surface of the trough-shaped rail rail 1;
  • the surface of the rail 1 includes a rail top surface 3 and other rail outer surfaces 4, nano ceramics
  • the insulating coating 2 is uniformly covered on the outer surface 4 of the rail;
  • the outer surface 4 of the rail is included in the longitudinal direction of the rail, including the upper and lower sides of the rail bottom, the sides of the rail, and the upper and lower sides of the rail head and the side; but the top surface of the rail 3 is the wheel
  • the rolling contact surface and the adjacent upper surface portion 50 mm wide area are not used as the non-coating area, that is, the non-coating area, and the rail 1 non-coating area is used to mount the tooling in the coating to support or suspend the rail;
  • the material of the insulating coating comprises a bonding material, a reinforcing material, an active hardening agent and the like; the
  • the nano-ceramic insulating rail 2 has a total thickness of the nano-ceramic insulating coating of between 200 and 400 ⁇ m, coated on the surface of the rail by a mechanical or manual coating method and a coating process; the coating method is brush coating; The process is processed at the track laying site.
  • the nano-ceramic insulating coating 2 is composed of an adhesive layer 21 and an insulating layer 22, and is coated by a two-pass coating process.
  • the process includes: 1) cleaning the surface of the rail; 2) The adhesive layer was "coated-hardened", the thickness of the adhesive layer was 100 ⁇ m; 3) the insulating layer was "coated-hardened", and the thickness of the insulating layer was 200 ⁇ m.
  • the material of the adhesive layer 21 and the material of the insulating layer 22 are different commercially available materials, each satisfying the following properties:
  • the material of the adhesive layer 21 is a commercially available nano ceramic insulating material containing at least a bonding adhesion of not less than 3 MPa;
  • the layer 22 material is a commercially available nano ceramic insulating material comprising at least a reinforcing material having an abrasion resistance of not more than 10 mg, an impact resistance of not less than 30 cm, and a resistivity of not less than 10 megaohms, and a reactive hardener.
  • the coating process of the nano ceramic insulating coating as shown in FIG. 4c to FIG. 4d, the steel rail 1 is suction-suspended by the tooling 16, and the position of the adsorption suspension is where the rail top surface 3 does not need to be coated with the nano ceramic insulating coating 2.
  • the coating of the nano-ceramic insulating coating is not hindered, and the suspension is positioned by the magnetic rail through the top surface of the non-coated surface rail. After being positioned by the tooling 16, the coating is carried out by a mechanical or manual coating method and a coating process.
  • the coating in the coating process of the nano-ceramic insulating coating can be applied by a relatively uniform movement of the artificial squeegee along the rail, which can be done by multiple stacking of all the coated sections.
  • the final surface finish of the nano-ceramic insulating coating is required to be four grades (GB/T3505), and the difference in coating thickness on the rail surface is not more than 50 ⁇ m.
  • the coating process of the nano ceramic insulating coating uses a special tooling support for the rail, and the contact surface of the special tooling 16 and the rail 1 does not hinder the coating of the nanoceramic insulating coating.
  • the rest are the same as in the first embodiment.
  • the main structure of this embodiment is the same as that of Embodiment 1.
  • the nano-ceramic insulating coating 2 can be applied to the entire outer surface of the entire rail 1, including the rolling contact between the top surface of the rail and the wheel. surface.

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Abstract

一种纳米陶瓷涂层绝缘钢轨，钢轨(1)的表面包括钢轨顶面(3)和其他钢轨外表面(4)，钢轨顶面(3)是指和车轮的滚动接触面及相邻近的上表面部分，其他钢轨外表面(4)是沿轨道纵向的包含轨脚上下及侧面、轨腰两面及轨头上下面和侧面，在其他钢轨外表面(4)均匀涂覆纳米陶瓷绝缘涂层(2)，纳米陶瓷绝缘涂层(2)的材料包含粘接材料、增强材料和活性硬化剂。该纳米陶瓷涂层绝缘钢轨除具备高的绝缘电阻、防腐蚀、耐水、耐老化、耐摩擦、耐湿热性、耐大气老化性及强附着力等功能；从根本上消除轨道系统杂散电流的产生，避免了电化学腐蚀、成本低。

Description

一种纳米陶瓷涂层绝缘钢轨 技术领域
本发明属于轨道交通技术领域，具体涉及一种超高绝缘性能轨道系统绝缘钢轨。
背景技术
轨道交通例如地铁、轻轨、有轨电车、新型轨道交通系统等，多采用直流电力牵引系统并把走行轨作为回流线路。该电流绝大部分能够经过走行轨流回到电源负极，但还有一小部分从轨道与地面绝缘不良的位置泄露到道床及周围的土壤中，形成杂散电流。杂散电流的存在会对钢轨本身及轨道周围的公共设施管路及建筑物等发生电化学腐蚀，降低轨道、埋地管线及建筑物等的使用寿命。特别对于有轨电车的轨道相对于地铁、轻轨而言，轨道完全埋入地下，其杂散电流的危害性更为严重。
对固定轨道钢轨的扣件系统通常采用绝缘设计及对埋入式轨道的钢轨外侧设置绝缘护块及护套，增大钢轨与周边构筑物之间的绝缘电阻；此方法虽可以有效地增加轨道的绝缘电阻，但绝缘护块及护套与扣件、绝缘护块及护套之间在安装及使用过程中会形成缝隙，这种缝隙不仅在沿钢轨行车方向因绝缘零部件接头及扣件等的不连续结构造成的复杂工况造成，而且在轨道截面上由于钢轨在车辆载荷作用下会产生变形，无论在垂直方向、水平方向及钢轨的扭转变形会和绝缘护块及护套之间产生动态间隙等，在实际运行环境条件下及潮湿的环境下依然无法保持轨道系统的绝缘性能，无法从根本上解决轨道系统的杂散电流问题。
人类利用电以后，绝缘材料就成为研究课题。20世纪80年代，开始出现新的F、H级绝缘材料体系，相继开发了聚酯亚胺、聚酰胺酰亚胺、聚酰亚胺、聚马来酰亚胺、聚二苯醚等耐热性绝缘漆、粘合剂和薄膜，以及改性环氧、不饱和聚酯、聚芳酰胺纤维纸及其复合材料等系列新产品。电工产品耐热等级大多提升为B级，在冶金、吊车、机车电机等特殊电机中开始采用新的F、H级绝缘材料。90年代，相关机构大规模的自主开发F、H级绝缘材料，使其性能 得到提高，如改性二苯醚、改性双马来酰亚胺、改性聚酯亚胺漆包线漆、聚酰胺酰亚胺漆包线漆、聚酰亚胺漆包线漆、F、H级玻璃纤维制品、高性能聚酰亚胺薄膜、F级环氧粉云母带等。无溶剂浸渍树脂和快干浸渍漆得到迅速发展，少胶粉云母带、VPI(真空压力浸渍)浸渍树脂开始应用。新一代耐高温耐磨陶瓷绝缘涂料，可在被涂物体表面形成一层具有较高体积电阻率，室温下大于10 12Ωm和高的介电强度(击穿强度)大于10 4kV/m。涂层能承受较强电场而不被击穿的陶瓷涂层，该涂层具有较高的机械强度和良好的化学稳定性，能耐老化，耐水，耐化学腐蚀，长时间耐火烧烤性，同时还具有耐机械冲击和热冲击性能，纳米材料的最新应用，大大提高了工程绝缘性能。
发明内容
本发明的目的就是为了克服上述现有技术存在的缺陷而提供一种可从根本上解决轨道系统杂散电流问题、成本低、性能好的纳米陶瓷涂层绝缘钢轨。
本发明的目的可以通过以下技术方案来实现：一种纳米陶瓷涂层绝缘钢轨，该钢轨(1)的表面包括钢轨顶面(3)和其他钢轨外表面(4)，所述的钢轨顶面(3)是指和车轮的滚动接触面及相邻近的上表面部分，所述的其他钢轨外表面(4)是沿轨道纵向的包含轨脚上下及侧面、轨腰两面及轨头上下面和侧面，其特征在于，在所述的其他钢轨外表面(4)均匀涂覆纳米陶瓷绝缘涂层(2)，所述的纳米陶瓷绝缘涂层(2)的材料包含粘接材料、增强材料和活性硬化剂。纳米陶瓷绝缘涂层是纳米陶瓷绝缘涂层和钢轨表面永久性结合。
所述的纳米陶瓷绝缘涂层(2)的厚度(5)在100-1000μm之间。
所述的纳米陶瓷绝缘涂层(2)为电阻率不小于10兆欧姆的高绝缘电阻材料。
所述的纳米陶瓷绝缘涂层(2)为市售纳米陶瓷绝缘材料，具有良好的机械性能，具体包括：附着力不小于3MPa、磨耗量不大于10mg、耐冲击性不小于30cm的材料。
所述的纳米陶瓷绝缘涂层(2)包含粘接材料、增强材料、活性硬化剂等组成；所述的粘接材料为缩醛、聚酯、改性聚酯、聚氨酯、聚酰亚胺中的一种或多种；所述的增强材料为氧化铝、碳化硅、氮化硅、二氧化硅、氧化镁、云母 中的一种或多种；所述的活性硬化剂为十二烷基磺酸钠、十六烷基三甲基溴化铵、聚乙二醇、吐温中的一种或多种。
进一步，纳米陶瓷绝缘涂层的材料采用双组份醇体系纳米陶瓷涂料型号XS-725A/B(广州亦纳新材料科技有限公司)，其主要成份为纳米玻璃分散液、硅纳米级分散基础液、碳复合材料、复合醇助剂；双组份XS-725A和XS-725B按比例7:5混合均匀搅拌后使用。
所述的纳米陶瓷绝缘涂层(2)由粘附层(21)和绝缘层(22)组成；所述的粘附层(21)采用涂覆工艺涂覆在钢轨表面，所述的绝缘层(22)至少设有一层，涂覆工艺涂覆在粘附层(21)表面。
所述的粘附层(21)涂覆在钢轨表面硬化后，在其表面涂覆绝缘层(22)，硬化后涂覆下一层绝缘层(22)；
所述的粘附层(21)的厚度不大于200μm，每一层绝缘层(22)的厚度不大于200μm。
上述涂覆工艺过程包含：
第一步：钢轨表面清理工序；
第二步：粘附层“涂覆-硬化”工序；
第三步：绝缘层“涂覆-硬化”工序；或
第四步：重复绝缘层“涂覆-硬化”工序的多层涂覆处理；
上述各工序均为常规施工工序。
上述粘附层(21)材料为至少含有粘接附着力不小于3MPa的纳米陶瓷绝缘材料；该粘附层可以牢固地与钢轨粘结，同时也能与绝缘层牢固粘结，使纳米陶瓷绝缘涂层和钢轨表面永久性结合。
上述绝缘层(22)材料为至少含有磨耗量不大于10mg、耐冲击性不小于30cm及电阻率不小于10兆欧姆的增强材料和活性硬化剂等组成的纳米陶瓷绝缘材料，该材料具有高绝缘电阻以及良好的机械性能。
实际应用中也可以采用同时满足粘附层(21)和绝缘层(22)功能的纳米陶瓷绝缘材料来涂覆实现粘附层(21)和绝缘层(22)。
所述的纳米陶瓷绝缘涂层(2)采用机械化或人工的涂覆方法及涂覆工序涂覆在钢轨表面上；所述的涂覆方法是喷涂或刷涂或辊涂或雾化浸透或液化浸透； 所述涂覆的工序是在钢轨制造的最后一道工序后直接处理，或在轨道铺设现场处理。
涂覆时，通过工装(16)支承或悬挂钢轨顶面(3)定位，采用自动涂覆机或人工涂刷具沿钢轨(1)相对移动，将纳米陶瓷绝缘涂层(2)均匀涂覆在所述的其他钢轨外表面(4)；所有需涂覆表面一次沿钢轨方向涂覆，或分段多次叠加完成；所述工装(16)为机械夹具或磁力轨。
所述的纳米陶瓷绝缘涂层(2)的最后表面光洁度在国标GB/T3505三级以上，纳米陶瓷绝缘涂层(2)在钢轨表面的厚度差不大于100μm。
与现有技术相比，本发明提出的一种纳米陶瓷涂层绝缘钢轨，在轨道钢轨的表面涂覆电阻率不小于10兆欧姆的高电阻率材料作为绝缘涂层，所述的纳米陶瓷涂层绝缘钢轨除具备高的绝缘电阻外，同时其纳米陶瓷涂层具备防腐蚀、耐水、耐老化、耐摩擦、耐湿热性、耐大气老化性及强附着力等功能；从根本上消除轨道系统杂散电流的产生，避免了电化学腐蚀等不利因素对轨道及轨道周围的公共设施管路及建筑物等造成的危害，且纳米陶瓷涂层绝缘钢轨的应用可不再使用钢轨绝缘护块及护套等设备或不再要求其高绝缘性能，本发明的纳米陶瓷涂层绝缘钢轨的轨道绝缘电阻比传统的钢轨绝缘护块及护套方案实际应用环境条件下提高5倍以上，纳米陶瓷涂层绝缘钢轨的使用可大大简化轨道铺设工艺及降低轨道绝缘成本，提高轨道铺设效率，也简化和降低运营维修工作量等，确保轨道绝缘性能及运营效率和安全。
附图说明
图1a是本发明的一般钢轨结构示意图；
图1b是本发明的槽型钢轨结构示意图；
图2a是本发明的涂层厚度示意图；
图2b是图2a的A-A剖视图为本发明的涂层的组成(三层)；
图2c是图2a的A-A剖视图为本发明的涂层的组成(二层)；
图3是本发明的本发明涂覆工艺流程工序；
图4a是本发明的一般钢轨悬挂工装示意图；
图4b是图4a的侧视图；
图4c是本发明的槽型钢轨悬挂工装示意图；
图4d是图4c的侧视图；
图5a是本发明的一般钢轨支承工装示意图；
图5b是图5a的侧视图；
图5c是本发明的槽型钢轨支承工装示意图；
图5d是图5c的侧视图；
图6a是本发明的实施例4一般钢轨结构示意图；
图6b是本发明的实施例4槽型钢轨结构示意图；
图中：
1、钢轨；2、纳米陶瓷绝缘涂层；3、钢轨顶面；4、钢轨外表面；5、厚度；12、钢轨表面清理工序；13、粘附层“涂覆-硬化”工序；14、绝缘层“涂覆-硬化”工序；15a、粘结层厚度；15b、绝缘层厚度；16、工装；21、粘附层；22、绝缘层。
具体实施方式
下面结合附图和具体实施例对本发明进行详细说明。
实施例1：
如图1a所示，一种纳米陶瓷绝缘钢轨，在一般轨道钢轨1的表面涂覆纳米陶瓷绝缘涂层2；纳米陶瓷绝缘涂层2是均匀地覆盖在钢轨1表面上；钢轨1的表面包括钢轨顶面3和其他钢轨外表面4，钢轨外表面4是沿轨道纵向的包含轨底上下及侧面、轨腰两面及轨头上下面和侧面；钢轨顶面3即车轮的滚动接触面及相邻近的上表面部分50mm宽的区域，钢轨顶面3不做为必涂覆区域即非涂覆区，钢轨1非涂覆区用来在涂覆中安装工装以便支承或悬挂钢轨；纳米陶瓷绝缘涂层2的材料采用双组份醇体系纳米陶瓷涂料型号XS-725A/B(广州亦纳新材料科技有限公司)，其纳米陶瓷涂料包含粘接材料、增强材料、活性硬化剂等，其主要成份为纳米玻璃分散液、硅纳米级分散基础液、碳复合材料、复合醇助剂；双组份XS-725A和XS-725B按比例7:5混合均匀搅拌后使用，搅拌机速度500转/分钟，在环境温度10-40摄氏度涂覆，混合后的纳米陶瓷涂料必须在8小时内使用。该纳米陶瓷绝缘涂层2具有高绝缘电阻超过10兆欧以上 满足轨道消除杂散电流的绝缘性能要求，同时具有高的机械性能指标：附着力不小于3MPa；磨耗量不大于10mg；耐冲击性不小于30cm。纳米陶瓷绝缘涂层2与钢轨1表面永久性结合。
如图2a所示，纳米陶瓷绝缘钢轨1的纳米陶瓷绝缘涂层2的总厚度5在400-500μm之间，采用机械化或人工的涂覆方法及涂覆工序涂覆在钢轨表面上；涂覆方法是喷涂；涂覆的工序是在专门的纳米陶瓷绝缘钢轨涂覆车间进行。如图4a-4b所示，将钢轨1通过工装16吸附悬挂，吸附悬挂的位置为钢轨顶面3不需要涂覆纳米陶瓷绝缘涂层2的地方，不妨碍纳米陶瓷绝缘涂层的涂覆，这种悬挂通过磁力轨通过非涂覆面钢轨顶面定位。通过工装16定位后采用机械化或人工的涂覆方法及涂覆工序进行涂覆。
如图2b所示，纳米陶瓷绝缘涂层2由粘附层21和两层绝缘层22组成，该实施例中粘附层21材料和绝缘层22材料相同，均为上述采用双组份醇体系纳米陶瓷涂料型号XS-725A/B，该材料同时满足粘附层21和绝缘层22功能。通过三遍涂覆工艺，其工艺过程如图3所示包含：
第一步：钢轨表面清理工序12；
第二步：粘附层“涂覆-硬化”工序13，粘附层厚度100μm；
第三步：中间绝缘层“涂覆-硬化”工序14，中间绝缘层厚度150μm；
第四步：表面绝缘层“涂覆-硬化”工序14，表面绝缘层厚度200μm；
上述各工序均为本领域常用工序。
纳米陶瓷绝缘涂层的涂覆工艺中的涂覆可采用自动涂覆机沿钢轨相对均匀移动涂覆，所述的涂覆是所有需涂覆表面一次沿钢轨方向涂覆，每层涂覆后用温度100-180摄氏度的烘干器烘烤30-60分钟后或常温12小时后再进行下步涂覆。
纳米陶瓷绝缘涂层最后的表面光洁度要求为四级(国标GB/T3505)，在钢轨表面涂层厚度差不大于50μm。
实施例2：
如图1b所示，一种槽型纳米陶瓷绝缘钢轨，在槽型轨道钢轨1的表面涂覆纳米陶瓷绝缘涂层2；钢轨1的表面包括钢轨顶面3和其他钢轨外表面4，纳米陶瓷绝缘涂层2是均匀地覆盖在钢轨外表面4上；钢轨外表面4是沿轨道纵向 的包含轨底上下及侧面、轨腰两面及轨头上下面和侧面；但钢轨顶面3即车轮的滚动接触面及相邻近的上表面部分50mm宽的区域不做为必涂覆区域即非涂覆区，钢轨1非涂覆区用来在涂覆中安装工装以便支承或悬挂钢轨；纳米陶瓷绝缘涂层的材料包含粘接材料、增强材料、活性硬化剂等组成；纳米陶瓷绝缘涂层2具有高绝缘电阻超过10兆欧以上满足轨道消除杂散电流的绝缘性能要求，同时具有高的机械性能指标：附着力不小于3MPa；磨耗量不大于10mg；耐冲击性不小于30cm，纳米陶瓷绝缘涂层与钢轨表面永久性结合。
纳米陶瓷绝缘钢轨2的纳米陶瓷绝缘涂层的总厚度在200-400μm之间，采用机械化或人工的涂覆方法及涂覆工序涂覆在钢轨表面上；涂覆方法是刷涂；涂覆的工序是在轨道铺设现场处理。
如图2c所示，纳米陶瓷绝缘涂层2由一层粘附层21和一层绝缘层22组成，通过两遍涂覆工艺涂覆完成，其工艺过程包含：1)钢轨表面清理；2)粘附层“涂覆-硬化”，粘附层厚度100μm；3)绝缘层“涂覆-硬化”，绝缘层厚度200μm。
该实施例中粘附层21材料和绝缘层22材料为不同的市售材料，各自满足如下性能：粘附层21材料为至少含有粘接附着力不小于3MPa的市售纳米陶瓷绝缘材料；绝缘层22材料为至少含有磨耗量不大于10mg、耐冲击性不小于30cm及电阻率不小于10兆欧姆的增强材料和活性硬化剂等组成的市售纳米陶瓷绝缘材料。
纳米陶瓷绝缘涂层的涂覆工艺，如图4c-图4d所示，将钢轨1通过工装16吸附悬挂，吸附悬挂的位置为钢轨顶面3不需要涂覆纳米陶瓷绝缘涂层2的地方，不妨碍纳米陶瓷绝缘涂层的涂覆，这种悬挂通过磁力轨通过非涂覆面钢轨顶面定位。通过工装16定位后采用机械化或人工的涂覆方法及涂覆工序进行涂覆。
纳米陶瓷绝缘涂层的涂覆工艺中的涂覆可采用人工涂刷具沿钢轨相对均匀移动涂覆，所述的涂覆可以是所有需涂覆断面分带多次叠加完成。
每层涂覆后在常温24小时后再进行下步涂覆。
纳米陶瓷绝缘涂层最后的表面光洁度要求为四级(国标GB/T3505)，在钢轨表面涂层厚度差不大于50μm。
实施例3：
纳米陶瓷绝缘涂层的涂覆工艺，如图5a-图5d所示对钢轨使用专用工装支承，专用工装16和钢轨1的接触面不妨碍纳米陶瓷绝缘涂层的涂覆。其余同实施例1。
实施例4：
如图6a-6b所示，该实施例的主体结构同实施例1，该实施例中，纳米陶瓷绝缘涂层2可以涂满整个钢轨1的全部外表面，包括钢轨顶面和车轮的滚动接触面。
以上所述的仅是本发明的优选实施方式。应当指出，对于本领域的普通技术人员来说，在不脱离本发明原理的前提下，无需经过创造性劳动就能够联想到的技术特征，还可以做出若干变型和改进，这些变化显然都应视为等同特征，仍属于本发明的保护范围之内。

Claims (9)

  1. 一种纳米陶瓷涂层绝缘钢轨，该钢轨(1)的表面包括钢轨顶面(3)和其他钢轨外表面(4)，所述的钢轨顶面(3)是指和车轮的滚动接触面及相邻近的上表面部分，所述的其他钢轨外表面(4)是沿轨道纵向的包含轨脚上下及侧面、轨腰两面及轨头上下面和侧面，其特征在于，在所述的其他钢轨外表面(4)均匀涂覆纳米陶瓷绝缘涂层(2)，所述的纳米陶瓷绝缘涂层(2)的材料包含粘接材料、增强材料和活性硬化剂；
    所述的纳米陶瓷绝缘涂层(2)中所述的粘接材料为缩醛、聚酯、改性聚酯、聚氨酯、聚酰亚胺中的一种或多种；所述的增强材料为氧化铝、碳化硅、氮化硅、二氧化硅、氧化镁、云母中的一种或多种；所述的活性硬化剂为十二烷基磺酸钠、十六烷基三甲基溴化铵、聚乙二醇、吐温中的一种或多种。
  2. 根据权利要求1所述的一种纳米陶瓷涂层绝缘钢轨，其特征在于，所述的纳米陶瓷绝缘涂层(2)的厚度(5)在100-1000μm之间。
  3. 根据权利要求1所述的一种纳米陶瓷涂层绝缘钢轨，其特征在于，所述的纳米陶瓷绝缘涂层(2)为电阻率不小于10兆欧姆的高绝缘电阻材料。
  4. 根据权利要求1所述的一种纳米陶瓷涂层绝缘钢轨，其特征在于，所述的纳米陶瓷绝缘涂层(2)为附着力不小于3MPa、磨耗量不大于10mg、耐冲击性不小于30cm的材料。
  5. 根据权利要求1所述的一种纳米陶瓷涂层绝缘钢轨，其特征在于，所述的纳米陶瓷绝缘涂层(2)由粘附层(21)和绝缘层(22)组成；所述的粘附层(21)涂覆在钢轨表面，所述的绝缘层(22)至少设有一层，涂覆在粘附层(21)表面。
  6. 根据权利要求5所述的一种纳米陶瓷涂层绝缘钢轨，其特征在于，所述的粘附层(21)涂覆在钢轨表面硬化后，在其表面涂覆绝缘层(22)，硬化后涂覆下一层绝缘层(22)；
    所述的粘附层(21)的厚度不大于200μm，每一层绝缘层(22)的厚度不大于200μm。
  7. 根据权利要求1所述的一种纳米陶瓷涂层绝缘钢轨，其特征在于，所述的纳米陶瓷绝缘涂层(2)采用机械化或人工的涂覆方法及涂覆工序涂覆在钢轨表面上；所述的涂覆方法是喷涂或刷涂或辊涂或雾化浸透或液化浸透；所述涂覆的工序是在钢轨制造的最后一道工序后直接处理，或在轨道铺设现场处理。
  8. 根据权利要求7所述的一种纳米陶瓷涂层绝缘钢轨，其特征在于，涂覆时，通过工装(16)支承或悬挂钢轨顶面(3)定位，采用自动涂覆机或人工涂刷具沿钢轨(1)相对移动，将纳米陶瓷绝缘涂层(2)均匀涂覆在所述的其他钢轨外表面(4)；所有需涂覆表面一次沿钢轨方向涂覆，或分段多次叠加完成；所述工装(16)为机械夹具或磁力轨。
  9. 根据权利要求1所述的一种纳米陶瓷涂层绝缘钢轨，其特征在于，所述的纳米陶瓷绝缘涂层(2)的最后表面光洁度在国标GB/T3505三级以上，纳米陶瓷绝缘涂层(2)在钢轨表面的厚度差不大于100μm。
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