CN106009157A - 一种高性能聚乙烯基复合材料及其制备方法和应用 - Google Patents
一种高性能聚乙烯基复合材料及其制备方法和应用 Download PDFInfo
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Abstract
本发明涉及聚乙烯基复合材料,具体是一种高性能聚乙烯基复合材料,本发明以高密度聚乙烯(HDPE)为基础材料,通过添加氯化聚乙烯(CPE)等高聚物对其进行共混改性,然后在以多相共混的加工方式添加活性陶瓷晶须、陶瓷微球等材料,制备出具有高强度、高耐磨、隔热保温等功能的高防腐石油化工管道专用材料,制备方法主要包括制备活性陶瓷晶须/陶瓷微球复合材料‑A料、制备HDPE/PP/CPE高填充母料‑B料和制备高性能聚乙烯基复合材料步骤。该高性能聚乙烯基复合材料具有高强度、高耐磨和隔热保温功能,可用于石油化工管道防腐,比纯HDPE防腐材料性能更加优异。
Description
技术领域
本发明涉及一种聚乙烯基复合材料及其制备方法和应用,具体涉及一种高性能聚乙烯基复合材料及其制备方法和应用。
背景技术
目前,我国在陆地和海洋石油天然气开采及输送过程中主要采用金属钢管,对金属钢管特别是钢管内外壁防腐措施主要采用环氧树脂、酚醛树脂等喷涂,或采用合金钢管或渗氮钢管。环氧树脂材料主要的缺陷是耐高温性能很差,耐磨、刺穿和碰撞赔损性能较差;酚醛树脂耐温性能相对提高,但耐磨性能差,绝热保温功能相对较低,使得油井注入的高压水蒸气的热散失率几乎与纯钢管相当。如果开采使用合金钢管或渗氮钢管,虽然解决了腐蚀问题,但价格昂贵,且仍解决不了偏磨和绝热保温问题。
本发明旨在解决以上普遍采用防腐材料的缺陷,开发以聚乙烯基树脂合金为基础材料,共混具有高强度、高耐温、高耐磨及绝热保温特性的微米级活性陶瓷晶须和陶瓷微球,制备出功能性防腐新材料。该新材料的主要技术特点是秉承了传统高聚物树脂的高防腐性能,同时较大幅度提高其耐高温性能、耐磨性能和绝热保温性能等。该材料可广泛应用于石油天然气开采管道、输送管道等金属管道内外壁防腐、防磨和绝热保温。
发明内容
本发明旨在解决上述问题,提供了一种聚乙烯基复合材料及其制备方 法和应用,制备出的聚乙烯基复合材料拉伸强度、断裂伸长率、微卡软化点均有一定提升,同时导热系数较低,磨损质量降低50%左右,其采用的技术方案如下:
一种高性能聚乙烯基复合材料,其特征在于,包含以下重量份数的组分:
HDPE 90份~110份
B料 30份~40份
所述B料为HDPE/PP/CPE高填充母料,所述B料包含以下重量份数的组分:
所述A料为陶瓷晶须/陶瓷微球复合材料,所述A料包含以下重量份数的组分:
所述硅烷偶联剂溶液为无水乙醇稀释硅烷偶联剂形成的溶液,所述无水乙醇和硅烷偶联剂的体积分数比为8∶1~10∶1。
优选地,所述陶瓷晶须为镁盐类晶须,单晶纤维直径≤1μm,长度为 10μm~80μm;所述陶瓷微球为中空密闭型微球,所述陶瓷微球粒径为1000目~2500目。
优选地,所述A料中陶瓷晶须为100份,陶瓷微球为80份。
高性能聚乙烯基复合材料中陶瓷晶须和陶瓷微球组分可较大幅度地提高材料的耐热性、耐磨性和力学性能,使之更适合用于石油开采管道的防腐,同时降低体系的熔融流动性和熔融指数。因陶瓷晶须和陶瓷微球被活化处理后亲合性较好,其球形粒径、大小分布及“滚珠效应”均对熔体流动性做出了贡献;陶瓷晶须和陶瓷微球还赋予了高性能聚乙烯基复合材料突出的绝热保温和阻燃性能,因为体系中所添加的陶瓷晶须和陶瓷微球材料本身的热传导率很低低,红外线透过率很小,是很好的隔热材料;另外专门为达到复合材料体系绝热保温性能而添加的陶瓷微球为中空密闭型微球,微球内部为及稀薄的气体,两种不同材料存在密度及导热系数差,所以具有独特的绝热保温特性。
优选地,所述B料中HDPE为50份,PP为100份,用于保证高性能聚乙烯基复合材料的高防腐性能。
一种上述高性能聚乙烯基复合材料的制备方法,其特征在于,包括以下步骤:
(1)制备A料,将陶瓷晶须、陶瓷微球和硅烷偶联剂进行高速剪切捏合,捏合温度≤50℃,捏合时间为10min~12min,接着再加入分散剂或润滑剂继续高速捏合3min~5min,制成A料;
(2)制备B料,将HDPE、PP、CPE和A料放入塑料开炼机进行混炼,所述开炼机前棍温度为160℃~170℃,后棍温度为150℃~160℃,混炼时间为10min~12min,混炼后切片卸料停放12h~24h,然后破碎成小片粒状, 制成B料;
(3)制备高性能聚乙烯基复合材料,将HDPE和B料放入双螺杆挤出机进行共混造粒,所述双螺杆挤出机各段温度分别设定为130℃、150℃、170℃、180℃、190℃和180℃,螺杆转速为60r/min~100r/min,采用水冷切粒方式进行拉条切粒,冷却水温20℃~40℃,切粒后制得高性能聚乙烯基复合材料。
通过对陶瓷晶须、陶瓷微球和硅烷偶联剂进行高速剪切捏合,以及制备B料时的混炼,使陶瓷晶须和陶瓷微球在高性能聚乙烯基复合材料中充分分散,大幅减少“聚团”颗粒,使复合材料的综合性能大幅提高。
一种利用上述高性能聚乙烯基复合材料的制备方法制备的高性能聚乙烯基复合材料。
将上述高性能聚乙烯基复合材料用于管道防腐,例如将高性能聚乙烯基复合材料敷设在管道内、外壁,或者是将高性能聚乙烯基复合材料制备成内、外高防腐复合衬管。
具体实施方式
下面结合实例对本发明作进一步说明:
下面详细描述本发明的实施例,仅用于解释本发明,而不能理解为对本发明的限制。
在本发明的描述中,需要理解的是,术语“HDPE”为高密度聚乙烯,术语“PP”为聚丙烯,术语“CPE”为氯化聚乙烯。
一种高性能聚乙烯基复合材料,其特征在于,包含以下重量份数的组分:
HDPE 90份~110份
B料 30份~40份
B料为HDPE/PP/CPE高填充母料,B料包含以下重量份数的组分:
A料为陶瓷晶须/陶瓷微球复合材料,A料包含以下重量份数的组分:
硅烷偶联剂溶液为无水乙醇稀释硅烷偶联剂形成的溶液,无水乙醇和硅烷偶联剂的体积分数比为8∶1~10∶1;
润滑剂优选为聚乙烯蜡;
以上各组分来源:
HDPE(高密度聚乙烯),牌号DGDB2480OH,齐鲁石化公司;
PP(聚丙烯粉料),牌号PPR4220,燕山石化公司;
CPE(氯化聚乙烯),氯含量35%,牌号为H135,山东临淄颐祥化工有限公司;
陶瓷晶须,镁盐类晶须,化学式MgSO4·5MgO·8H2O,上海格润亚纳米材料有限公司产;
陶瓷微球,主要成分SiO2和Al2O3,真实密度2.3g/cm3,上海格润亚纳米材料有限公司;
硅烷偶联剂,牌号:KH550,南京轩浩新材料科技有限公司;
润滑剂,牌号:聚乙烯蜡A-C6A,上海凯茵化工有限公司;
分散剂,牌号:LUBDE360B,上海凯茵化工有限公司。
在试验中发现,所述A料中陶瓷晶须为100份,陶瓷微球为80份时,高性能聚乙烯基复合材料强度、耐磨性和隔热保温性最佳。
为了进一步提升高性能聚乙烯基复合材料的强度、耐磨性和隔热保温性,所述陶瓷晶须为镁盐类晶须,单晶纤维直径≤1μm,长度为10μm~80μm;所述陶瓷微球为中空密闭型微球,所述陶瓷微球粒径为1000目~2500目。
为了保证高性能聚乙烯基复合材料的高防腐性能,所述B料中HDPE为50份,PP为100份。
上述高性能聚乙烯基复合材料的制备方法,其特征在于,包括以下步骤:
(1)制备A料,将陶瓷晶须和陶瓷微球放入电烘箱中,在100℃左右温度下干燥3~5小时,使其水分≤1%,干燥后将陶瓷晶须、陶瓷微球和硅烷偶联剂放入CNF-A1型50立升超声波高速剪切捏合机(青岛科技大学高分子工程材料研究所研制)中,同时加入硅烷偶联剂溶液,进行高速剪切捏合,例如捏合机搅拌叶片转速为800~1200转/分,捏合温度≤50℃,捏合时间为10min~12min,接着再加入分散剂或润滑剂继续高速捏合3min~5min,制成A料;
(2)制备B料,将HDPE、PP、CPE和A料放入XK-300开放式塑料开炼机进行混炼,该XK-300开放式塑料开炼机前棍温度为160℃~170℃,后棍温度为150℃~160℃,混炼时间为10min~12min,混炼过程充分翻炼,使各组分分散均匀,混炼后切片卸料停放12h~24h,然后将切片后的材料放入SPW700HB塑料粉碎机(台州磐石机械有限公司产)破碎成小片粒状,制成B料;
(3)制备高性能聚乙烯基复合材料,将HDPE和B料放入TSE-65D双螺杆挤出造粒机进行共混造粒,所述TSE-65D双螺杆挤出造粒机各段温度分别设定为130℃、150℃、170℃、180℃、190℃和180℃,螺杆转速为60r/min~100r/min,采用水冷切粒方式进行拉条切粒,冷却水温20℃~40℃,切粒后制得高性能聚乙烯基复合材料。
上述高性能聚乙烯基复合材料的应用,将所述高性能聚乙烯基复合材料用于管道防腐,例如将高性能聚乙烯基复合材料敷设在管道内、外壁,或者是将高性能聚乙烯基复合材料制备成内、外高防腐复合衬管,同时可广泛应用于其它防腐工程领域。
实施例1:
制备A料,称取陶瓷晶须(单晶纤维直径≤1μm,长度10μm~80μm)10kg,陶瓷微球(1250目)8kg,硅烷偶联剂溶液300g,聚乙烯蜡200g,投入到CNF-A1型50立升超声波高速剪切捏合机,在捏合机搅拌叶片转速1000转/分,捏合温度≤50℃的条件下捏合11min,接着再加入分散剂继续高速捏合4min然后放料冷却至室温,制成A料;
制备B料,称取HDPE 5kg,PP 10kg,CPE 1.5kg,A料12kg,放入XK-300开放式塑料开炼机进行混炼,开炼机前棍温度160℃~170℃,后棍 温度150℃~160℃,混炼过程充分翻炼,混炼时间11min,然后切片卸料停放12h,将停放消除内应力的共混料切片料放入塑料SWP700HB塑料粉碎机进行破碎成小片粒状,制成B料。
制备高性能聚乙烯基复合材料,称取HDPE 20kg,B料2kg,放入CNF-A1型50立升超声波高速剪切捏合机中,在捏合机搅拌叶片转速1000转/分,在捏合温度≥80℃条件下共混捏合3min后卸料,然后通过自动上料辅机将共混料放入TSE-65D双螺杆挤出造粒机中进行共混造粒,双螺杆挤出机各段温度分别设定为130℃、150℃、170℃、180℃、190℃和180℃,采用水冷切粒方式进行拉条切粒,冷却水温20℃~40℃,切粒后制得高性能聚乙烯基复合材料。
实施例2
A料和B料的制备方法同上述实施例1。
制备高性能聚乙烯基复合材料,称取HDPE 20kg,B料4kg,放入CNF-A1型50立升超声波高速剪切捏合机中,在捏合机搅拌叶片转速1000转/分,在捏合温度≥80℃条件下共混捏合3min后卸料,然后通过自动上料辅机将共混料投放到TSE-65D双螺杆挤出造粒机中进行共混造粒,双螺杆挤出机各段温度分部设定为:130℃、150℃、170℃、180℃、190℃、180℃,采用水冷切粒方式进行拉条切粒,冷却水温20℃~40℃,切粒后制得高性能聚乙烯基复合材料。
实施例3
A料和B料的制备方法同上述实施例1。
制备高性能聚乙烯基复合材料,称取HDPE 20kg,B料6kg,放入CNF-A1型50立升超声波高速剪切捏合机中,在捏合机搅拌叶片转速1000 转/分,在捏合温度≥80℃条件下共混捏合3min后卸料,然后通过自动上料辅机将共混料投放到TSE-65D双螺杆挤出造粒机中进行共混造粒,挤出机各段温度分部设定为:130℃、150℃、170℃、180℃、190℃、180℃,采用水冷切粒方式进行拉条切粒,冷却水温20℃~40℃,切粒后制得高性能聚乙烯基复合材料。
实施例4
对实施例1~3制备的高性能聚乙烯基复合材料进行性能测试。
耐磨性用体积磨损表征,按照GB/T 3960-1983塑料滑动摩擦磨损试验方法进行测试;低温冲击强度,依据GB/T17748-2008标准进行测试;耐热性用维卡软化点表征,依照GB/T 8802-2001热塑性塑料管材、管件维卡软化温度的测定;抗拉强度按照GB/T 1040-1992塑料拉伸性能试验方法进行测试;拉伸断裂伸长率按照GB/T 1040.1-2006标准进行测试;附着性测试,根据GB/T 11211-2009进行测定;耐热性测试,根据CNS 10757(1995)标准进行测定;酸浸渍试验,根据CNS 10757(1995)标准测定;耐油性试验,根据CNS 10757(1995)标准测定。
绝热性能用红外线透过率表征,根据标准GB10294-1988进行测试,采用LS102/LS103A光学透过率测量仪,测试原理是采用紫外光源,红外光源和可见光源照射被测透明物质,感应器分别探测三种光源的入射光强和透过被测透明物质后的光强,透过光强与入射光强的比值即为透过率,用百分数表示。
采用以上测试方法分别对纯HDPE和实施例1~3制备的高性能聚乙烯基复合材料进行性能测试,结果如下:
高性能聚乙烯基复合材料性能测试结果
由试验数据可以看出,高性能聚乙烯基复合材料拉伸强度比纯HDPE最高提升10%~28%,断裂伸长率提升13%~15%,微卡软化点提高11%~14%,磨损质量降低56%。
上面以举例方式对本发明进行了说明,但本发明不限于上述具体实施例,凡基于本发明所做的任何改动或变型均属于本发明要求保护的范围。
Claims (7)
1.一种高性能聚乙烯基复合材料,其特征在于,包含以下重量份数的组分:
HDPE 90份~110份
B料 30份~40份
所述B料为HDPE/PP/CPE高填充母料,所述B料包含以下重量份数的组分:
所述A料为陶瓷晶须/陶瓷微球复合材料,所述A料包含以下重量份数的组分:
所述硅烷偶联剂溶液为无水乙醇稀释硅烷偶联剂形成的溶液,所述无水乙醇和硅烷偶联剂的体积分数比为8∶1~10∶1。
2.根据权利要求1所述的高性能聚乙烯基复合材料,其特征在于,所述A料中陶瓷晶须为100份,陶瓷微球为80份。
3.根据权利要求1所述的高性能聚乙烯基复合材料,所述陶瓷晶须为镁盐类晶须,单晶纤维直径≤1μm,长度为10μm~80μm;所述陶瓷微球为中空密闭型微球,所述陶瓷微球粒径为1000目~2500目。
4.根据权利要求3所述的高性能聚乙烯基复合材料,其特征在于,所述B料中HDPE为50份,PP为100份。
5.一种根据权利要求1~4中的任一项所述的高性能聚乙烯基复合材料的制备方法,其特征在于,包括以下步骤:
(1)制备A料,将陶瓷晶须、陶瓷微球和硅烷偶联剂进行高速剪切捏合,捏合温度≤50℃,捏合时间为10min~12min,接着再加入分散剂或润滑剂继续高速捏合3min~5min,制成A料;
(2)制备B料,将HDPE、PP、CPE和A料放入塑料开炼机进行混炼,所述开炼机前棍温度为160℃~170℃,后棍温度为150℃~160℃,混炼时间为10min~12min,混炼后切片卸料停放12h~24h,然后破碎成小片粒状,制成B料;
(3)制备高性能聚乙烯基复合材料,将HDPE和B料放入双螺杆挤出机进行共混造粒,所述双螺杆挤出机各段温度分别设定为130℃、150℃、170℃、180℃、190℃和180℃,螺杆转速为60r/min~100r/min,采用水冷切粒方式进行拉条切粒,切粒后制得高性能聚乙烯基复合材料。
6.一种根据权利要求5所述的高性能聚乙烯基复合材料的制备方法制备的高性能聚乙烯基复合材料。
7.根据权利要求6所述的高性能聚乙烯基复合材料的应用,其特征在于,将所述高性能聚乙烯基复合材料用于管道防腐。
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