CN108998183A - 智能手机边框合成型高光切削液及其制备方法 - Google Patents
智能手机边框合成型高光切削液及其制备方法 Download PDFInfo
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Abstract
本发明公开一种智能手机边框合成型高光切削液,按重量份计包括以下组分:防锈剂A 10‑20份、防锈剂B 3‑8份、表面活性剂25‑35份、分散剂3‑7份、有色金属缓蚀剂0.5‑2份、沉降剂0.1‑0.5份、极压润滑剂0.2‑0.8份、其余成分为水;还提供了其制备方法。本发明提供的切削液为水基完全透明液体保证了加工现场的环境清洁,并可在5S内快速消泡,使用过程中能清晰地观察到工件加工状态,保证了产品加工质量,选用纳米粒子作为极压润滑剂,最大无卡咬负荷值可高达1380N,大大提高了切削液的减摩抗磨性能,硬水适应性高达20000ppm,且具备钙、镁皂分散特性,从而使切削液具有极强的抗硬水能力,保证了切削液的润滑性能和清洗性能的长期稳定,延长了切削液的使用寿命。
Description
技术领域
本发明涉及金属加工切削液领域,具体涉及智能手机边框合成型高光切削液及其制备方法。
背景技术
切削液是由多种超强功能的助剂经科学复合配合而成,用在金属切、削、磨加工过程中,用来冷却和润滑刀具和加工件的工业用液体。
国家***数据显示,我国2015年共生产智能手机18.1亿部,同比增长7.8%,随着消费者对智能手机外壳的美观程度与材料质感的要求越来越高,手机金属外壳的需求逐年递增,已从2012年的10%增长到2015年的38%,由此给手机金属外壳的高光加工带来无限的市场商机,中国是目前世界上制造业产值最高的国家,全球绝大部分智能手机均在中国完成生产,因此中国对手机加工用切削液的需求量也是巨大的。然而,切削液在其使用过程中又往往成为危害职业健康与安全、造成环境污染的源头,目前市面常用的几种高光切削液:油性切削液、溶剂型切削液、乳化切削液,分别存在以下问题:油性切削液容易引起操作者皮炎和呼吸道损害;溶剂型切削液存在易燃、易爆的安全隐患;对于水溶性乳化型切削液等含油切削液,由水、矿物油和乳化剂组成,其特点是润滑性能好,但在冷却性、渗透性、稳定性上较差,使用周期短,排放时存在环保问题,不可生物降解,易产生发霉、发臭等现象,而且若废液不经有效处理而直接排入江、河、海等,将造成严重的大气污染和水质污染,造成生态环境不可逆转的破坏。
而水基合成切削液主要由各种水溶性添加剂(如润滑、抗磨、抗压、防锈、表面活性剂等)和水组成,其特点是不含油,在性能上具有良好的冷却性、清洗性、稳定性,从环保、节约油料资源等方面具有积极的意义,是切削液发展的主流。然而,现有技术中水溶性切削液在使用寿命、防绣性、润滑性、适应不同材质等方面没有非常理想的使用性能和效果,如申请号为201010296416.4的中国专利公开了“一种水溶性切削液及其制备方法”,具有使用寿命长、良好的极压润滑性、防锈性、冷却性和清洗性的优点,但是其消泡性和硬水适应性并不理想,且润滑性欠佳最大无卡咬负荷值不够高。
发明内容
本发明的目的在于提供一种消泡快、抗硬水性好且润滑性能优异的环保型智能手机边框合成型高光切削液以解决现有技术的不足。
本发明的另一目的在于提供上述智能手机边框合成型高光切削液的制备方法。
为达此目的,本发明采用以下技术方案:
一种智能手机边框合成型高光切削液,按重量份计包括以下组分:
所述极压润滑剂为纳米氧化钼、纳米铜粉或纳米硼酸钙。
上述防锈剂A的重量份为10-20份,如11份、11.5份、12份、12.5份、13份、13.5份、14份、14.5份、15份、16份、16.5份、17份、17.5份、18份、18.5份、19份和19.5份;上述防锈剂B的重量份为3-8份,如3.2份、3.5份、3.8份、4.0份、4.5份、4.7份、5.0份、5.5份、5.8份、6.0份、6.2份、6.5份、7.0份、7.2份、7.5份和7.8份;智能手机金属边框经切、削、磨后,原本表面的薄膜被破坏,而且因水基切削液的存在,其表面长期暴露在潮湿的环境中,其表面对环境中的水吸附,形成很薄的湿气层,逐渐累计的水膜达到20-30个分子厚左右,将会形成电化学腐蚀,表面的铁原子不断被氧化,形成Fe(OH)2,而Fe(OH)2在水中不稳定,会继续与水膜中的氧和水形成难溶的Fe(OH)3,Fe(OH)3分散在不断循环的切削液中,是切削液变成红褐色,同样也附着在加工件表面上,防锈剂则是缓解溶液中的氧气和酸性物质与工件表面的接触,并在工件表面定向吸附形成防锈层来达到防锈目的。
上述表面活性剂的重量份为25-35份,如26份、27份、28份、29份、30份、31份、32份、33份、34份和35份;水基切削液会加入一些与水相溶性不太好的物质,表面活性剂可以降低两者之间的表面张力,使其以极微小的状态均匀稳定在水溶液中,并且在金属切削过程中,工件表面常粘有金属粉末、砂粒、油等污垢,表面活性剂可以使切削液具有一定的洗涤能力以除去这些污垢。
上述分散剂的重量份为3-7份,如3.2份、3.5份、3.8份、4.0份、4.2份、4.5份、4.7份、5.0份、5.3份、5.5份、5.8份、6.0份、6.2份、6.5份和6.8份;
上述有色金属缓蚀剂的重量份为0.5-2份,如0.6份、0.7份、0.8份、0.9份、1.0份、1.1份、1.2份、1.3份、1.4份、1.5份、1.6份、1.7份、1.8份和1.9份;
上述沉降剂的重量份为0.1-0.5份,0.12份、0.15份、0.18份、0.2份、0.22份、0.25份、0.28份、0.30份、0.32份、0.34份、0.36份、0.38份、0.40份、0.42份、0.45份和0.48份;
上述极压润滑剂的重量份为0.2-0.8份,如0.22份、0.25份、0.3份、0.32份、0.35份、0.38份、0.40份、0.45份、0.5份、0.56份、0.58份、0.60份、0.65份、0.68份、0.70份、0.75份、0.8份、0.84份和0.88份;极压剂在高速摩擦所形成高温高压的环境下发生分解,与金属表面发生化学反应,生成反应膜,能防止摩擦之间的两个金属卡咬而有效保护金属。纳米粒子作为极压添加剂添加到切削液中和与其相配合的表面活性剂结合,能在水中形成一种稳定的分散悬浮状态,无数的纳米粒子颗粒与金属表面契合形成保护膜,大幅降低金属之间的摩擦强度,对高速摩擦环境中所包含的高温高压重载模式下,效果更为明显:一是纳米粒子是微型的近似球状的粒子,在金属之间摩擦滚动,形成“微滚珠效应”,从而提高摩擦表面的润滑性;二是摩擦过程中,纳米粒子具有填充的作用,可以及时填平摩擦面较大的微凹坑,使摩擦表面始终处于平滑状态,当两种不同粒径的纳米粒子加入到切削液中时,粒径大的粒子作“球轴承”作用,粒径小的粒子作填充修复作用,相互影响使作用最大化;三是加工过程因摩擦化学作用导致出现磨斑,纳米粒子能在其表面沉积,形成一层膜,隔断两个摩擦界面,并具备更高的承载性能,使金属表面不能直接受到剪切应力而变形,即减摩作用;四是少部分纳米粒子在高温高压环境下发生还原,生产金属单质,渗透进入工件基体,并在其表面形成强化膜,从而提高金属抗磨性能,即抗磨作用。选用纳米粒子作为极压润滑剂,大大提高了切削液的减摩抗磨性能,并具有优良的润滑特性,使高速加工完的手机边框达到镜面高光的效果。
进一步地,按重量份计包括以下组分:
进一步地,所述防锈剂A为一乙醇胺、三乙醇胺、2-氨基-2-甲基-1-丙醇或二甘醇胺的任一种或几种。
进一步地,所述防锈剂B为十碳二元酸、十一碳二元酸、十二碳二元酸、多元聚羧酸或多元羧酸酯中的任一种或几种。
由于当前手机边框多采用铝镁合金材质,铝、镁这种两性金属,在偏酸、偏碱的环境中,均易发生腐蚀,而微生物细菌的活跃生长环境为弱酸性,上述技术方案中选用2-氨基-2-甲基-1-丙醇或二甘醇胺等结构的有机胺以及多元聚羧酸或多元羧酸酯等结构的有机酸作为pH缓冲剂,将pH值控制在弱碱范围,能够有效控制微生物细菌的生长,且有利于手机边框铝镁合金在长时间加工的耐腐蚀性,特殊结构的有机胺使体系具备较强的碱储备量,能够维持长时间加工或受到外来细菌污染,而维持pH值长时间不发生变化,使切削液工作液保持长时间的稳定性。
进一步地,所述表面活性剂为反式聚醚RPE-1720、反式聚醚RPE-1740,聚醚多元醇L-61或聚醚多元醇L-62中的任一种或几种。
进一步地,所述分散剂为新葵酸、异辛酸、辛酸或异壬酸中的任一种或几种。由此,可以起到钙镁皂分散作用。
进一步地,所述有机金属缓蚀剂为烷基膦酸酯衍生物。
进一步地,所述沉降剂为阳离子共聚物。
上述技术方案中,由于铝、镁合金质轻,美观、方便携带,当前乃至今后铝镁合金、镁合金手机材质将成为社会主流,而这种材质的金属在加工过程中,由于镁元素不断微量溶解在切削液工作液中,容易积聚造成硬水问题,使切削液变质,缩短使用寿命,本高光切削液所采用的有机酸、有机胺及表面活性剂等均不会与钙镁离子结合而产生沉淀,由于原材料均不会产生硬水问题,大大提高了硬水适应性。
一种上述智能手机边框合成型高光切削液的制备方法,包括以下步骤:
(1)按重量份称取防锈剂A和防锈剂B与适量水搅拌混合后,加热至70-90℃,于300-500rpm下搅拌反应20-30min至完全溶解;
(2)将所述步骤(1)中的溶液降温至50-60℃后,按重量份加入表面活性剂、分散剂和有色金属缓蚀剂搅拌于350-500rpm转速下搅拌20-30min至均匀;
(3)将所述步骤(2)中的溶液降温至40-50℃后,加入沉降剂和极压润滑剂,于350-500rpm转速下搅拌10-15min至溶液呈透明得到高光切削液。
进一步地,所述步骤(1)中加热温度为80℃,搅拌反应反应时间为20min。
本发明提供的智能手机边框合成型高光切削液,具有以下优点:
1、切削液中不含基础油为水基完全透明液体,且将表面活性剂、分散剂及沉降剂等各组分的含量都控制在最佳范围内,切削液消泡快,可以在5S内快速消泡,使用过程中可以很清楚地观察到工件加工状态便于及时掌握工件加工情况并作出调整,提高了产品加工质量,同时由于不含油使加工现场环境清洁干净,降低后期清理的难度,节省了人工成本;
2、选用纳米粒子作为极压润滑剂,利用纳米粒子的“微滚珠效应”和“球轴承”作用,可以提高摩擦表面的润滑性并且及时填平摩擦面较大的微凹坑,同时纳米粒子能在磨斑表面沉积,形成一层膜,隔断两个摩擦界面起减摩作用,且少部分纳米粒子在高温高压环境下发生还原,生产金属单质,渗透进入工件基体并在其表面形成强化膜起抗磨作用,最大无卡咬负荷值可高达1380N,大大提高了切削液的减摩抗磨性能;
3、选用原料均不会与钙镁离子结合产生沉淀,使硬水适应性高达20000ppm,使切削液具有极强的抗硬水能力,保证了切削液的润滑性能和清洗性能的长期稳定,延长了切削液的使用寿命,降低了生产成本,且加工过程中切削粉末易于沉降,避免了刀具堵塞和磨损等而造成加工误差和崩裂等加工问题,有效延长了刀具使用寿命。
具体实施方式
下面通过具体实施方式来进一步说明本发明的技术方案。
如无具体说明,本发明的各种原料均可市售购得,或根据本技术领域的常规方法制备得到。
各实施例及对比例中的组分及加入量如表1所示:
表1原料组分及加入量
实施例1
智能手机边框合成型高光切削液,各组分及重量份见表1,由以下步骤制备得到:
(1)称取三乙醇胺10kg、2-氨基-2-甲基-1-丙醇2kg、十二碳二元酸4kg、三元聚羧酸1kg与42kg水搅拌混合后,加热至80℃,于500rpm下搅拌反应20min至完全溶解;
(2)将上述步骤(1)中的溶液降温至55℃后,按重量份加入35kgRPE-1740、5kg新葵酸和0.5kg烷基膦酸酯衍生物搅拌于400rpm转速下搅拌25min至均匀;
(3)将上述步骤(2)中的溶液降温至40℃后,加入0.1kg阳离子共聚物和0.4kg纳米氧化钼,于300rpm转速下搅拌10min至溶液呈透明得到高光切削液。
实施例2
智能手机边框合成型高光切削液,各组分及重量份见表1,由以下步骤制备得到:
(1)称取三乙醇胺10kg、十二碳二元酸3.5kg、二甘醇胺2kg、三元聚羧酸1.5kg与42kg水搅拌混合后,加热至75℃,于450rpm下搅拌反应25min至完全溶解;
(2)将上述步骤(1)中的溶液降温至50℃后,按重量份加入5kgRPE-1720、30kgRPE-1740、4kg新葵酸、1kg异壬酸和1kg烷基膦酸酯衍生物搅拌于450rpm转速下搅拌30min至均匀;
(3)将上述步骤(2)中的溶液降温至45℃后,加入0.2kg阳离子共聚物沉降剂和0.5kg纳米铜粉,于300rpm转速下搅拌15min至溶液呈透明得到高光切削液。
实施例3
智能手机边框合成型高光切削液,各组分及重量份见表1,由以下步骤制备得到:
(1)称取三乙醇胺8kg、2-氨基-2-甲基-1-丙醇2kg、二甘醇胺1kg、十二碳二元酸3kg、三元聚羧酸2kg与44kg水搅拌混合后,加热至85℃,于450rpm下搅拌反应30min至完全溶解;
(2)将上述步骤(1)中的溶液降温至50℃后,按重量份加入7kgRPE-1720、27kgRPE-1740、3kg新葵酸、2kg异壬酸和1.6kg烷基膦酸酯衍生物搅拌于450rpm转速下搅拌30min至均匀;
(3)将上述步骤(2)中的溶液降温至45℃后,加入0.2kg阳离子共聚物沉降剂和0.2kg纳米铜粉,于300rpm转速下搅拌15min至溶液呈透明得到高光切削液。
实施例4
智能手机边框合成型高光切削液,各组分及重量份见表1,由以下步骤制备得到:
(1)称取三乙醇胺6kg、2-氨基-2-甲基-1-丙醇2.5kg、二甘醇胺2kg、十二碳二元酸2.5kg、三元聚羧酸2.5kg与44kg水搅拌混合后,加热至90℃,于300rpm下搅拌反应20min至完全溶解;
(2)将上述步骤(1)中的溶液降温至50℃后,按重量份加入10kgRPE-1720、25kgRPE-1740、5kg异壬酸和2kg烷基膦酸酯衍生物搅拌于450rpm转速下搅拌30min至均匀;
(3)将上述步骤(2)中的溶液降温至45℃后,加入0.4kg阳离子共聚物沉降剂和0.4kg纳米铜粉,于300rpm转速下搅拌15min至溶液呈透明得到高光切削液。
对比例1
智能手机边框合成型高光切削液,各组分及重量份见表1,由以下步骤制备得到:
称取三乙醇胺5kg、二甘醇胺3kg、十二碳二元酸2.5kg与42.1kg水搅拌混合后,加热至65℃,于300rpm下搅拌反应20min至完全溶解,将溶液降温至50℃后,按重量份加入6kgRPE-1720、32kgRPE-1740、8kg异壬酸和0.7kg烷基膦酸酯衍生物搅拌于450rpm转速下搅拌30min至均匀,将溶液降温至45℃后,加入0.7kg阳离子共聚物沉降剂,于300rpm转速下搅拌15min至溶液呈透明得到高光切削液。
对比例2
智能手机边框合成型高光切削液,各组分及重量份见表1,由以下步骤制备得到:称取2-氨基-2-甲基-1-丙醇5kg、二甘醇胺2kg、十二碳二元酸5kg与33kg水搅拌混合后,加热至70℃,于400rpm下搅拌反应20min至完全溶解,将溶液降温至50℃后,按重量份加入7kgRPE-1720、23kgRPE-1740、4kg新葵酸、2kg异壬酸和0.5kg烷基膦酸酯衍生物搅拌于450rpm转速下搅拌30min至均匀,将溶液降温至45℃后,加入0.5kg阳离子共聚物沉降剂,于300rpm转速下搅拌15min至溶液呈透明得到高光切削液。
将上述实施例1至实施例4,以及对比例1和对比例2制得的切削液按1:20加水进行稀释得到5%的稀释液后进行性能检测,各项技术指标检测结果见表2:
表2性能检测
由表2可以看出,实施例1至实施例4的智能手机边框合成型高光切削液消泡性均小于5S、最大无卡咬负荷PB值高达1380N,硬水适应性可达20000ppm,具有优异的消泡性、减摩抗磨性及硬水适应性,且使用寿命均可以长达3年,放置30天溶液仍然澄清无分层现象,远远高于对比例1和对比例2中的各项性能指标。
以上实施例仅用来说明本发明的详细方法,本发明并不局限于上述详细方法,即不意味着本发明必须依赖上述详细方法才能实施。所属技术领域的技术人员应该明白,对本发明的任何改进,对本发明产品各原料的等效替换及辅助成分的添加、具体方式的选择等,均落在本发明的保护范围和公开范围之内。
Claims (10)
1.一种智能手机边框合成型高光切削液,其特征在于,按重量份计包括以下组分:
所述极压润滑剂为纳米氧化钼、纳米铜粉或纳米硼酸钙。
2.根据权利要求1所述的智能手机边框合成型高光切削液,其特征在于,按重量份计包括以下组分:
3.根据权利要求1所述的智能手机边框合成型高光切削液,其特征在于,所述防锈剂A为一乙醇胺、三乙醇胺、2-氨基-2-甲基-1-丙醇或二甘醇胺的任一种或几种。
4.根据权利要求1所述的智能手机边框合成型高光切削液,其特征在于,所述防锈剂B为十碳二元酸、十一碳二元酸、十二碳二元酸、多元聚羧酸或多元羧酸酯中的任一种或几种。
5.根据权利要求1所述的智能手机边框合成型高光切削液,其特征在于,所述表面活性剂为反式聚醚RPE-1720、反式聚醚RPE-1740,聚醚多元醇L-61或聚醚多元醇L-62中的任一种或几种。
6.根据权利要求1所述的智能手机边框合成型高光切削液,其特征在于,所述分散剂为新葵酸、异辛酸、辛酸或异壬酸中的任一种或几种。
7.根据权利要求1所述的智能手机边框合成型高光切削液,其特征在于,所述有机金属缓蚀剂为烷基膦酸酯衍生物。
8.根据权利要求1所述的智能手机边框合成型高光切削液,其特征在于,所述沉降剂为阳离子共聚物。
9.根据权利要求1~8所述的智能手机边框合成型高光切削液的制备方法,其特征在于,包括以下步骤:
(1)按重量份称取防锈剂A和防锈剂B与适量水搅拌混合后,加热至70-90℃,于300-500rpm下搅拌反应20-30min至完全溶解;
(2)将所述步骤(1)中的溶液降温至50-60℃后,按重量份加入表面活性剂、分散剂和有色金属缓蚀剂搅拌于350-500rpm转速下搅拌20-30min至均匀;
(3)将所述步骤(2)中的溶液降温至40-50℃后,加入沉降剂和极压润滑剂,于350-500rpm转速下搅拌10-15min至溶液呈透明得到高光切削液。
10.根据权利要求9所述的智能手机边框合成型高光切削液,其特征在于,所述步骤(1)中加热温度为80℃,搅拌反应反应时间为20min。
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