CN112725864A - 一种长寿命铝阴极板的制备方法 - Google Patents
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- JRBRVDCKNXZZGH-UHFFFAOYSA-N alumane;copper Chemical compound [AlH3].[Cu] JRBRVDCKNXZZGH-UHFFFAOYSA-N 0.000 claims abstract description 12
- 238000001746 injection moulding Methods 0.000 claims abstract description 12
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- 229910052801 chlorine Inorganic materials 0.000 abstract description 4
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- 229910052751 metal Inorganic materials 0.000 abstract description 3
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Abstract
本发明涉及一种长寿命铝阴极板的制备方法,属于有色金属湿法冶金技术领域。本发明将铜铝复合导电头焊接在铝梁的端头,将铝板焊接在铝梁的底端;铝梁外表面、铝板的液位线以上区域和铝板两侧边缘首先进行粗化处理,然后进行阳极氧化处理分别得到Al2O3陶瓷膜I、Al2O3陶瓷膜II和Al2O3陶瓷膜III;在铝梁外表面的Al2O3陶瓷膜I上涂覆耐酸耐磨树脂漆形成铝基/Al2O3/涂料多功能防腐层;铝板液位线以上区域的Al2O3陶瓷膜II和铝板两侧边缘的Al2O3陶瓷膜III表面涂覆耐酸环氧树脂涂层,最后在环氧树脂涂层上注塑PP塑料形成铝基/Al2O3/涂料/PP塑料多功能防腐层。本发明的Al2O3/涂料/PP塑料多功能防腐层有效防止了电解液中氟氯离子对铝阴极的腐蚀,铝阴极板的使用寿命可提高30%‑60%。
Description
技术领域
本发明涉及一种长寿命铝阴极板的制备方法,属于有色金属湿法冶金技术领域。
背景技术
目前,大约90%的锌都是采用湿法冶金技术提取,阳极板(铅基合金材料)和阴极板(铝板)是锌电积过程不可缺少的电极板。金属铝的导电性仅次于铜,而且其标准电极电位低于锌,因此,一般都采用纯铝板作为阴极板面,铝合金型材作为导电梁,铜铝复合材料作为导电头,采用搅拌摩擦焊技术将铝板、铝导电梁和铜铝复合导电头焊接在一起形成铝阴极板。在锌电积实际生产中,铝阴极受到酸雾、电解液中氟氯离子等腐蚀影响,铝阴极板易出现在液位线部位腐蚀断裂、侧边腐蚀变薄的现象,最终无法使用。铝阴极板的更新替换增加了冶金企业的生产成本。
发明内容
本发明针对现有技术中铝阴极板易出现在液位线部位腐蚀断裂、侧边腐蚀变薄等问题,提供一种长寿命铝阴极板的制备方法,本发明通过在铝梁外面、铝板液位线以上区域及铝板两侧边缘原位生长Al2O3陶瓷膜,可有效防止电解液中氟氯离子对铝阴极的腐蚀,显著提高其使用寿命。
一种长寿命铝阴极板,包括铝梁1、铜铝复合导电头2和铝板3,铜铝复合导电头2固定设置在铝梁1的端头,铝板3的顶端固定设置在铝梁1底端,铝梁1外层原位生长Al2O3陶瓷膜I,Al2O3陶瓷膜I的外层涂覆有防腐涂料层,铝板3顶部液位线以上区域原位生长Al2O3陶瓷膜II,Al2O3陶瓷膜II的外层涂覆有环氧树脂层I,环氧树脂层I外层固定设置有PP塑料层I,铝板3两侧端边缘原位生长Al2O3陶瓷膜III,Al2O3陶瓷膜III的外层涂覆设置有环氧树脂层II,环氧树脂层II外层固定设置有PP塑料层II。
一种长寿命铝阴极板的制备方法,具体步骤包括:
(1)将铜铝复合导电头焊接在铝梁的端头;
(2)将铝板焊接在铝梁的底端;
(3)铝梁外表面、铝板的液位线以上区域和铝板两侧边缘首先进行粗化处理,然后进行阳极氧化处理分别原位生长得到Al2O3陶瓷膜I、Al2O3陶瓷膜II和Al2O3陶瓷膜III;
(4)在铝梁外表面的Al2O3陶瓷膜I上涂覆耐酸耐磨树脂漆形成铝基/Al2O3/涂料多功能防腐层;铝板液位线以上区域的Al2O3陶瓷膜II和铝板两侧边缘的Al2O3陶瓷膜III表面涂覆耐酸环氧树脂涂层,最后在环氧树脂涂层上注塑PP塑料形成铝基/Al2O3/涂料/PP塑料多功能防腐层;
所述Al2O3陶瓷膜I的厚度为20-30μm,Al2O3陶瓷膜II的厚度为20-40μm,Al2O3陶瓷膜III的厚度为20-50μm,Al2O3陶瓷膜II的高度为80-140mm,Al2O3陶瓷膜III的宽度为13-16mm;Al2O3陶瓷膜I、Al2O3陶瓷膜II和Al2O3陶瓷膜III的硬度为400-800Hv;
所述步骤(3)粗化处理的粗糙度Ra为50-100;
所述步骤(3)阳极氧化的温度为0-15℃,阳极氧化的电流密度为300-600A|m2,氧化时间为1-5h;
所述步骤(3)阳极氧化溶液中含有硫酸180-200g/L,草酸30-40g/L,甘油20-30g/L;
所述步骤(4)注塑温度为240-280℃,注塑时间为20-50s;
优选的,防腐涂料层包括防腐底漆和耐酸树脂面漆,防腐底漆为三方底漆或者四防底漆,耐酸树脂面漆为环氧类树脂,防腐涂料层的厚度为20--30μm;
优选的,环氧树脂层I的厚度为10--20μm,环氧树脂层II的厚度为20--30μm,PP塑料层I的厚度为2--3mm,PP塑料层II的厚度为15--22mm。
优选的,阳极氧化处理原位生长得到Al2O3陶瓷膜I、Al2O3陶瓷膜II和Al2O3陶瓷膜III后24h内涂覆防腐涂料层或环氧树脂涂层。
本发明的有益效果是:
本发明通过在铝梁外面、铝板液位线以上区域及铝板两侧边缘原位生长Al2O3陶瓷膜,可有效防止电解液中氟氯离子对铝阴极的腐蚀,显著提高其使用寿命。
附图说明
图1为长寿命铝阴极板结构示意图;
图2为A处剖视图;
图3为B处剖视图;
图4为C处剖视图;
图中,1-铝梁、2-铜铝复合导电头、3-铝板。
具体实施方式
下面结合具体实施方式对本发明作进一步详细说明,但本发明的保护范围并不限于所述内容。
实施例1:一种长寿命铝阴极板(见图1-4),包括铝梁1、铜铝复合导电头2和铝板3,铜铝复合导电头2固定设置在铝梁1的端头,铝板3的顶端固定设置在铝梁1底端,铝梁1外层原位生长Al2O3陶瓷膜I,Al2O3陶瓷膜I的外层涂覆有防腐涂料层;铝板3顶部液位线以上区域原位生长Al2O3陶瓷膜II,Al2O3陶瓷膜II的外层涂覆有环氧树脂层I,环氧树脂层I外层固定设置有PP塑料层I,铝板3两侧端边缘原位生长Al2O3陶瓷膜III,Al2O3陶瓷膜III的外层涂覆设置有环氧树脂层II,环氧树脂层II外层固定设置有PP塑料层II;
一种长寿命铝阴极板的制备方法,具体步骤包括:
(1)将铜铝复合导电头焊接在铝梁的端头;
(2)将铝板焊接在铝梁的底端;
(3)铝梁外表面、铝板的液位线以上区域和铝板两侧边缘首先进行粗化处理至粗糙度Ra为60,然后进行阳极氧化处理分别原位生长得到Al2O3陶瓷膜I、Al2O3陶瓷膜II和Al2O3陶瓷膜III;其中阳极氧化的温度为0℃,阳极氧化的电流密度为300A|m2,氧化时间为2h,阳极氧化溶液中含有硫酸180g/L,草酸20g/L,甘油30g/L;
本实施例中Al2O3陶瓷膜I的平均厚度为20μm,Al2O3陶瓷膜II的平均厚度为20μm,Al2O3陶瓷膜III的平均厚度为30μm,Al2O3陶瓷膜II的宽度为120mm,Al2O3陶瓷膜III的宽度为16mm;Al2O3陶瓷膜I、Al2O3陶瓷膜II和Al2O3陶瓷膜III的硬度为680Hv;
(4)在铝梁外表面的Al2O3陶瓷膜I上涂覆耐酸树脂漆形成铝基/Al2O3/涂料多功能防腐层,铝板的液位线以上区域的Al2O3陶瓷膜II和铝板两侧边缘的Al2O3陶瓷膜III表面涂覆环氧树脂涂层,然后在环氧树脂涂层上注塑PP塑料形成铝基/Al2O3/涂料/PP塑料多功能防腐层。
具体实施方法是:将粗化好的铝板与铝导电梁焊接,然后放入特制的电解槽里进行阳极氧化,氧化时间结束后取出极板,进行热水封闭处理,接着喷四防底漆,待其干燥后喷耐酸环氧树脂漆,待环氧树脂固化后进行注塑处理;
其中防腐涂料层包括防腐底漆和耐酸环氧树脂面漆,防腐底漆为四防底漆,耐酸树脂面漆为环氧类树脂漆;防腐涂料层的厚度为22-30μm,环氧树脂层I的厚度为20μm,环氧树脂层II的厚度为25μm,PP塑料层I的厚度为3mm,PP塑料层II的厚度为16mm;注塑温度为250℃,注塑时间为30s;
本实施例铝阴极板相比市售铝阴极版的使用寿命提高40%。
实施例2:一种长寿命铝阴极板的制备方法,具体步骤包括:
(1)将铜铝复合导电头焊接设置在铝梁的端头;
(2)将铝板焊接在铝梁的底端;
(3)铝梁外表面、铝板的液位线以上区域和铝板两侧边缘进行粗化处理至粗糙度Ra为80,然后进行阳极氧化处理分别原位生长得到Al2O3陶瓷膜I、Al2O3陶瓷膜II和Al2O3陶瓷膜III;其中阳极氧化的温度为8℃,阳极氧化的电流密度为400A|m2,氧化时间为3h,阳极氧化溶液中含有硫酸200g/L,草酸30g/L,甘油20g/L;
本实施例中Al2O3陶瓷膜I的平均厚度为30μm,Al2O3陶瓷膜II的平均厚度为30μm,Al2O3陶瓷膜III的平均厚度为30μm,Al2O3陶瓷膜II的宽度为160mm,Al2O3陶瓷膜III的宽度为17mm;Al2O3陶瓷膜I、Al2O3陶瓷膜II和Al2O3陶瓷膜III的硬度为550Hv;
(4)在铝梁外表面的Al2O3陶瓷膜I上涂覆耐酸树脂漆形成铝基/Al2O3/涂料多功能防腐层,铝板的液位线以上区域的Al2O3陶瓷膜II和铝板两侧边缘的Al2O3陶瓷膜III表面涂覆环氧树脂涂层,然后在环氧树脂涂层上注塑PP塑料形成铝基/Al2O3/涂料/PP塑料多功能防腐层。
具体实施方法是:将粗化好的铝板与铝导电梁焊接,然后放入特制的电解槽里进行阳极氧化,氧化时间结束后取出极板,进行热水封闭处理,接着喷三方底漆,待其干燥后喷耐酸环氧树脂漆,待环氧树脂固化后进行注塑处理。
其中防腐涂料层包括防腐底漆和耐酸环氧树脂面漆,防腐底漆为三方底漆,耐酸树脂面漆为环氧类树脂漆;防腐涂料层的厚度为20-25μm,环氧树脂层I的厚度为18μm,环氧树脂层II的厚度为23μm,PP塑料层I的厚度为3.5mm,PP塑料层II的厚度为18mm;注塑温度为270℃,注塑时间为40s;
本实施例铝阴极板相比市售铝阴极版的使用寿命提高50%。
实施例3:一种长寿命铝阴极板的制备方法,具体步骤包括:
(1)将铜铝复合导电头焊接设置在铝梁的端头;
(2)将铝板焊接在铝梁的底端;
(3)铝梁外表面、铝板的液位线以上区域和铝板两侧边缘进行粗化处理至粗糙度Ra为60,然后进行阳极氧化处理分别原位生长得到Al2O3陶瓷膜I、Al2O3陶瓷膜II和Al2O3陶瓷膜III;其中阳极氧化的温度为15℃,阳极氧化的电流密度为500A|m2,氧化时间为1h,阳极氧化溶液中含有硫酸190g/L,草酸35g/L,甘油25g/L;
本实施例中Al2O3陶瓷膜I的平均厚度为40μm,Al2O3陶瓷膜II的平均厚度为40μm,Al2O3陶瓷膜III的平均厚度为40μm,Al2O3陶瓷膜II的宽度为180mm,Al2O3陶瓷膜III的宽度为16mm;Al2O3陶瓷膜I、Al2O3陶瓷膜II和Al2O3陶瓷膜III的硬度为400Hv;
(4)在铝梁外表面的Al2O3陶瓷膜I上涂覆耐酸树脂漆形成铝基/Al2O3/涂料多功能防腐层,铝板的液位线以上区域的Al2O3陶瓷膜II和铝板两侧边缘的Al2O3陶瓷膜III表面涂覆环氧树脂涂层,然后在环氧树脂涂层上注塑PP塑料形成铝基/Al2O3/涂料/PP塑料多功能防腐层;
具体实施方法是:将粗化好的铝板与铝导电梁焊接,然后放入特制的电解槽里进行阳极氧化,氧化时间结束后取出极板,进行热水封闭处理,接着喷三方底漆,待其干燥后喷耐酸环氧树脂漆,待环氧树脂固化后进行注塑处理;
其中防腐涂料层包括防腐底漆和耐酸环氧树脂面漆,防腐底漆为三方底漆,耐酸树脂面漆为环氧类树脂漆,防腐涂料层的厚度为22-26μm,环氧树脂层I的厚度为22μm,环氧树脂层II的厚度为24μm,PP塑料层I的厚度为4mm,PP塑料层II的厚度为22mm;注塑温度为240℃,注塑时间为45s;
本实施例铝阴极板相比市售铝阴极版的使用寿命提高35%。
以上结合附图对本发明的具体实施例作了详细说明,但是本发明并不限于上述实施例,在本领域普通技术人员所具备的知识范围内,还可以在不脱离本发明宗旨的前提下作出各种变化。
Claims (6)
1.一种长寿命铝阴极板的制备方法,其特征在于,具体步骤如下:
(1)将铜铝复合导电头焊接在铝梁的端头;
(2)将铝板焊接在铝梁的底端;
(3)铝梁外表面、铝板的液位线以上区域和铝板两侧边缘首先进行粗化处理,然后进行阳极氧化处理分别得到Al2O3陶瓷膜I、Al2O3陶瓷膜II和Al2O3陶瓷膜III;
(4)在铝梁外表面的Al2O3陶瓷膜I上涂覆耐酸耐磨树脂漆形成铝基/Al2O3/涂料防腐层;铝板液位线以上区域的Al2O3陶瓷膜II和铝板两侧边缘的Al2O3陶瓷膜III表面涂覆耐酸环氧树脂涂层,最后在环氧树脂涂层上注塑PP塑料形成铝基/Al2O3/涂料/PP塑料防腐层。
2.根据权利要求1所述长寿命铝阴极板的制备方法,其特征在于:Al2O3陶瓷膜I的厚度为20-30μm,Al2O3陶瓷膜II的厚度为20-40μm,Al2O3陶瓷膜III的厚度为20-50μm,Al2O3陶瓷膜II的高度为80-140mm,Al2O3陶瓷膜III的宽度为13-16mm。
3.根据权利要求1所述长寿命铝阴极板的制备方法,其特征在于:步骤(3)粗化处理的粗糙度Ra为50-100。
4.根据权利要求1所述长寿命铝阴极板的制备方法,其特征在于:步骤(3)阳极氧化的温度为0-15℃,阳极氧化的电流密度为300-600A|m2,氧化时间为1-5h。
5.根据权利要求1所述长寿命铝阴极板的制备方法,其特征在于:步骤(3)阳极氧化溶液中含有硫酸180-200g/L,草酸30-40g/L,甘油20-30g/L。
6.根据权利要求1所述长寿命铝阴极板的制备方法,其特征在于:步骤(4)注塑温度为240-280℃,注塑时间为20-40s。
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