CN114752095A - 含聚脲涂层改性尼龙的托辊结构及其制造方法 - Google Patents
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Abstract
本发明涉及一种含聚脲涂层改性尼龙的托辊结构,所述的托辊包括辊筒,芯轴,轴承,轴承座及相应密封组件;辊筒筒体采用含聚脲涂层的改性尼龙材料,聚脲平整喷涂在改性尼龙材料的外表面;芯轴贯穿筒体且内部设有支撑环。采用了该发明的含聚脲涂层改性尼龙的托辊结构,由于结合了高性能改性尼龙材料和聚脲材料,通过结构上的合理设计,使得托辊具有耐磨,耐侯,抗静电,阻燃等特点,且其他物性指标均满足煤矿井下或井上物料运输的要求,相比传统尼龙托辊具有更长使用寿命的优势。
Description
技术领域
本发明涉及输送机领域,特别涉及煤矿井下输送带用托辊,具体是指一种可应用于煤矿的含聚脲涂层改性尼龙的托辊结构及其制造方法。
背景技术
托辊是带式输送机的重要组成部分,在整个输送体系中起到支撑作用。在长程的输送过程中需要的托辊数量大,成本高,因而托辊的稳定性和使用寿命都至关重要。目前胶带输送机托辊主要包括钢制托辊、陶瓷托辊、塑料托辊等几种类型。在过去的实践过程中,钢制和陶瓷托辊暴露出许多问题。钢制托辊不耐腐蚀,特别是煤矿井下和洗煤厂环境下,含硫矿物导致钢材严重腐蚀,使用寿命大大缩短,短的更换周期也导致了维护的困难和成本的增加,另外钢制托辊长时间磨损下产生的毛刺也容易划伤传送带。陶瓷托辊则存在抗冲击性能差、质量重、成本较高等问题。与钢制、陶瓷托辊相比,塑料托辊具有成本低、易制造、重量轻、耐腐蚀、抗冲击等优点,在实际使用过程中质轻易维护和更换,噪音小,能有效提升输送机的整体稳定性和降低成本。
然而纯塑料托辊存在热稳定性差,抗静电和阻燃性能差,耐磨性能不理想等问题,难以广泛应用于恶劣工况环境例如煤矿井下作业。因此输送机托辊领域亟待开发出一种成本低、重量轻、阻燃抗静电、使用寿命长的新型托辊。材料学研究表明,通过合理的聚合物基材选择和改性填料添加,所制备的聚合物基复合材料能有效提升托辊材料的强度、热稳定性、耐磨性、阻燃抗静电性,用以代替传统的钢制、陶瓷、塑料托辊,必然成为输送机领域的重点研究方向。尼龙托辊是目前有广泛市场和前景的托辊类型,相关改性成果包括:《一种大型连续纤维增强尼龙托辊》申请号,公开号CN212075451U,使用连续长纤维对尼龙材料实现了增强增韧;《一种抗阻燃抗静电托辊》公开号CN213058945U,通过内外辊筒体的尼龙材料设置制备了一种阻燃抗静电的尼龙托辊;《托辊用高性能聚合物基复合材料及其制造方法》公开号CN101423665A,使用聚己内酰胺、玻璃纤维、陶瓷粉体、润滑剂、阻燃剂、抗静电剂、抗老化剂、表面改性剂为原料制备托辊用高性能聚合物基复合材料,具有改善的强度和韧性。
然而尼龙基材固有的强度和摩擦磨损等性能限制了尼龙托辊的尺寸和使用寿命,而聚氨酯、聚脲等材料则具有更突出的耐磨防腐蚀能力。通过合理的结构设计结合不同聚合物材料的性能优势,无须在PA中添加大量可能引起性能劣化的无机粉体与固体润滑剂,能够实现较低成本高性能复合结构托辊的制造,具有极大的应用价值。
发明内容
本发明的目的是为了克服上述现有技术中的缺点,提供一种新型低成本,易制造,长寿命的煤矿井下输送带用的含聚脲涂层改性尼龙的托辊结构及其制造方法。
为了实现上述目的,本发明含聚脲涂层改性尼龙的托辊结构及其制造方法如下:
该含聚脲涂层改性尼龙的托辊结构,所述的托辊包括辊筒,芯轴,轴承,轴承座及相应密封组件;
所述的辊筒的筒体采用含聚脲涂层的改性尼龙材料,所述的改性尼龙材料经表面处理剂处理后,将所述的聚脲喷涂在所述的改性尼龙材料外表面;
所述的芯轴贯穿所述的辊筒的筒体且内部设有支撑环;
所述的聚脲涂层是由半预聚体、端氨基聚醚、胺扩链剂及耐磨填料等原料现场喷涂成型的聚脲弹性体;
聚脲成分视实际情况而定,聚脲中添加耐磨填料(SiC,PTFE粉等,2~15%),助剂(抗静电剂等),含A、R两组分。A组分为半预聚物,为多异氰酸酯和聚醚多元醇低聚物;R组分包括端氨基聚醚和扩链剂,并按需求添加相应填料和化学助剂。
较佳地,所述的改性尼龙材料为纤维、固体润滑剂协同改性的聚己内酰胺(PA6)基复合材料。
较佳地,所述的聚己内酰胺(PA6)基复合材料包括以下按重量计的成分:聚己内酰胺50~80份、纤维10~30份、固体润滑剂0~5份、抗老化剂0.05~1份、抗静电剂0.05~2份、阻燃剂5~15份、偶联剂0.02~1.5份。
较佳地,所述的抗静电剂为非离子型抗静电剂和/或乙氧基化烷基胺。
较佳地,所述的阻燃剂为环保型氰尿酸三聚氰胺、氢氧化镁、氢氧化铝,并采取氢氧化镁或氢氧化铝与氰尿酸三聚氰胺混合使用的方式。
较佳地,所述的偶联剂为硅烷偶联剂、钛酸酯偶联剂、铝酸酯偶联剂中的一种或多种,所述的硅烷偶联剂为硅烷偶联剂KH-550、KH-560、KH-570中的一种或多种。
较佳地,所述的纤维为玻纤、碳纤维中的一种或多种,所述的碳纤维为T300、T400、T700、T800中的一种或多种。
较佳地,所述的聚脲涂层厚度为1~5mm。
较佳地,所述的表面处理剂为羟基丙烯酸酯类涂料,聚氨酯底涂剂,尼龙表面处理剂中的一种或多种。
本发明还提供了所述的含聚脲涂层改性尼龙的托辊结构的制造方法,所述的制造方法包括以下步骤:
(1)取填料质量分数为1%~5%的偶联剂溶于一定比例的水-乙醇溶液以配置改性液,加入待处理填料与改性液在50℃~80℃下混合,处理时间为0.5h~2h;随后转移至120℃干燥箱烘干;
(2)除纤维外,将其他原料按照比例加入到高速混合机中混合1~5min,然后向混合后的原料中加入玻纤并放入双螺杆挤出机中挤出造粒,然后在80℃~120℃下干燥后,注塑成型;
(3)对PA6基复合材料表面进行清洁、打磨预处理,后使用表面改性剂进行涂覆,在80℃烘干或自然放置至固化;
(4)通过喷涂聚脲的方法在PA6基复合材料表面喷涂1~5mm厚聚脲涂层,固化成型后装配其余组件完成托辊制备。
较佳地,步骤(1)中所述的填料为纤维、陶瓷粉体;所述的水-乙醇溶液比例为1:6~1:10。
采用了本发明的含聚脲涂层改性尼龙的托辊结构及其制造方法,其中辊筒主体采用纤维、固体润滑剂和其他化学助剂协同改性的尼龙材料,为辊筒主体提供高强度,抗静电,阻燃等基本性能;采用喷涂聚脲技术,通过合理的结构设计结合改性尼龙和聚脲材料的性能优势,实现更低磨耗和耐候、耐腐蚀等优异性能。
具体实施方式
为了能够更清楚地理解本发明的技术内容,下面对本发明的具体实施方法作进一步说明。
传统尼龙材料的强度和摩擦磨损等性能限制了尼龙托辊的尺寸和使用寿命,难以满足高轻度,阻燃抗静电的实际使用要求,因此有必要对尼龙基材进行改性以满足煤矿井下等恶劣工况的使用要求。本发明配方中使用纤维材料和陶瓷粉体能有效提升尼龙的强度韧性,热稳定性,摩擦磨损性能,所述固体润滑剂优选为二硫化钼和聚四氟乙烯,且该尼龙本体固体润滑剂是非必要的成分,在一般情况下少加或不加均有利于减少不必要的其它性能劣化。同时,为了改善托辊用复合材料的阻燃和抗静电性能,配方中添加了一定量的抗静电剂和阻燃剂。阻燃剂优选为氰尿酸三聚氰胺和氢氧化镁或氢氧化铝混合使用,抗静电剂优选为乙氧基化烷基胺。
本发明中通过聚脲涂层的设置能有效提升耐磨性和耐腐蚀性,延长产品使用寿命。聚脲材料本身具有极佳的摩擦磨损性能,进一步在聚脲配方中添加耐磨填料与化学助剂以进一步提高耐磨能力和阻燃抗静电能力,阿克隆磨耗降低至2.5mg。典型的聚脲指标如下表所示:
但聚脲涂层与改性尼龙材料的结合力较差,因此使用表面改性剂对改性尼龙材料表面进行改性处理,经表面处理后实现了尼龙辊筒辊体与聚脲涂层的牢固结合。根据中华人民共和国国家标准GB/T 2510-2006检测结果,聚脲涂层附着力改性前小于1MPa,经改性后大于2.5MPa(具体由试验工艺而定)。
采用本发明的含聚脲涂层改性尼龙托辊的结构设计有利方面包括:其基体改性尼龙材料可通过调节纤维和其他助剂的含量实现综合性能的灵活调控;采用喷涂聚脲的技术,外部聚脲涂层能够有效保护辊筒筒体,实现更低磨耗和耐候、耐腐蚀等优异性能;制备过程简易,成本较低,性能可灵活调控,且通过配方设计物性指标可符合煤矿井下使用要求。
下面结合具体实施例来进行进一步的描述。
实施例1:
将质量百分比为77%的聚己内酰胺、20%改性后碳纤维、2.6%阻燃剂、0.2%抗静电剂、0.2%抗老化剂混合均匀,将混合好的原料利用双螺杆挤出机进行挤出造粒,注塑成型后得到改性尼龙辊筒。对改性尼龙材料进行表面处理,此后通过喷涂聚脲技术在辊筒表面均匀喷涂2mm厚聚脲涂层(聚脲A、R组分配方视实际情况而定,预计较佳的,R组分中耐磨填料10~15%,阻燃填料2~4%)。完全固化后得到含聚脲涂层改性尼龙材料托辊结构。
适用于非煤矿井下的一般工矿条件下的较长寿命输送机托辊筒体。
实施例2:
将质量百分比为59.6%的混合聚己内酰胺、30%改性后碳纤维、10%阻燃剂、0.25%抗静电剂、0.15%抗老化剂混合均匀,将混合好的原料利用双螺杆挤出机进行挤出造粒,得到高强度、抗静电、阻燃型托辊用复合材料。注塑成型后对改性尼龙材料进行表面处理,通过喷涂聚脲技术在辊筒表面均匀喷涂3mm厚聚脲涂层(聚脲A、R组分配方视实际情况而定,预计较佳的,R组分中耐磨填料8~10%,阻燃填料8~10%)。完全固化后得到含聚脲涂层改性尼龙材料托辊结构。
适用于煤矿井下耐磨、抗静电、阻燃要求下的输送机用托辊。
采用了本发明的含聚脲涂层改性尼龙的托辊结构及其制造方法,其中辊筒主体采用纤维、固体润滑剂和其他化学助剂协同改性的尼龙材料,为辊筒主体提供高强度,抗静电,阻燃等基本性能;采用喷涂聚脲技术,通过合理的结构设计结合改性尼龙和聚脲材料的性能优势,实现更低磨耗和耐候、耐腐蚀等优异性能。
在此说明书中,本发明已参照其特定的实施例作了描述。但是,很显然仍可以做出各种修改和变换而不背离本发明的精神和范围。因此,说明书应被认为是说明性的而非限制性的。
Claims (11)
1.一种含聚脲涂层改性尼龙的托辊结构,其特征在于,所述的托辊包括辊筒,芯轴,轴承,轴承座及相应密封组件;
所述的辊筒的筒体采用含聚脲涂层的改性尼龙材料,所述的改性尼龙材料经表面处理剂处理后,将所述的聚脲喷涂在所述的改性尼龙材料外表面;
所述的芯轴贯穿所述的辊筒的筒体且内部设有支撑环;
所述的聚脲涂层是由半预聚体、端氨基聚醚、胺扩链剂及耐磨填料等原料现场喷涂成型的聚脲弹性体。
2.根据权利要求1所述的含聚脲涂层改性尼龙的托辊结构,其特征在于,所述的改性尼龙材料为纤维、固体润滑剂协同改性的聚己内酰胺(PA6)基复合材料。
3.根据权利要求2所述的含聚脲涂层改性尼龙的托辊结构,其特征在于,所述的聚己内酰胺(PA6)基复合材料包括以下按重量计的成分:聚己内酰胺50~80份、纤维10~30份、固体润滑剂0~5份、抗老化剂0.05~1份、抗静电剂0.05~2份、阻燃剂5~15份、偶联剂0.02~1.5份。
4.根据权利要求3所述的含聚脲涂层改性尼龙的托辊结构,其特征在于,所述的抗静电剂为非离子型抗静电剂和/或乙氧基化烷基胺。
5.根据权利要求3所述的含聚脲涂层改性尼龙的托辊结构,其特征在于,所述的阻燃剂为环保型氰尿酸三聚氰胺、氢氧化镁、氢氧化铝,并采取氢氧化镁或氢氧化铝与氰尿酸三聚氰胺混合使用的方式。
6.根据权利要求3所述的含聚脲涂层改性尼龙的托辊结构,其特征在于,所述的偶联剂为硅烷偶联剂、钛酸酯偶联剂、铝酸酯偶联剂中的一种或多种,所述的硅烷偶联剂为硅烷偶联剂KH-550、KH-560、KH-570中的一种或多种。
7.根据权利要求3所述的含聚脲涂层改性尼龙的托辊结构,其特征在于,所述的纤维为玻纤、碳纤维中的一种或多种,所述的碳纤维为T300、T400、T700、T800中的一种或多种。
8.根据权利要求1所述的含聚脲涂层改性尼龙的托辊结构,其特征在于,所述的聚脲涂层厚度为1~5mm。
9.根据权利要求1所述的含聚脲涂层改性尼龙的托辊结构,其特征在于,所述的表面处理剂为羟基丙烯酸酯类涂料,聚氨酯底涂剂,尼龙表面处理剂中的一种或多种。
10.一种权利要求1至9中任一项所述的含聚脲涂层改性尼龙的托辊结构的制造方法,其特征在于,所述的制造方法包括以下步骤:
(1)取填料质量分数为1%~5%的偶联剂溶于一定比例的水-乙醇溶液以配置改性液,加入待处理填料与改性液在50℃~80℃下混合,处理时间为0.5h~2h;随后转移至120℃干燥箱烘干;
(2)除纤维外,将其他原料按照比例加入到高速混合机中混合1~5min,然后向混合后的原料中加入玻纤并放入双螺杆挤出机中挤出造粒,然后在80℃~120℃下干燥后,注塑成型;
(3)对PA6基复合材料表面进行清洁、打磨预处理,后使用表面改性剂进行涂覆,在80℃烘干或自然放置至固化;
(4)通过喷涂聚脲的方法在PA6基复合材料表面喷涂1~5mm厚聚脲涂层,固化成型后装配其余组件完成托辊制备。
11.根据权利要求10所述的含聚脲涂层改性尼龙的托辊结构的制造方法,其特征在于,步骤(1)中所述的填料为纤维、陶瓷粉体;所述的水-乙醇溶液比例为1:6~1:10。
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