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CN106867448B - 一种无石棉密封垫片的制作工艺 - Google Patents

一种无石棉密封垫片的制作工艺 Download PDF

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CN106867448B
CN106867448B CN201611245202.8A CN201611245202A CN106867448B CN 106867448 B CN106867448 B CN 106867448B CN 201611245202 A CN201611245202 A CN 201611245202A CN 106867448 B CN106867448 B CN 106867448B
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凌巧
钱胜利
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TONGLING JINLI ELECTRONICS CO Ltd
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Abstract

本发明公开了一种无石棉密封垫片的制作工艺，采用芳纶1414浆粕为主材，配合纤维素纤维和矿物棉纤维为混杂纤维替代石棉纤维；胶乳选用丁腈胶乳和丁苯胶乳混合；填料选用高岭土、滑石粉和云母粉，并确定其组成的合理配方范围，通过抄取工艺制成无石棉抄取密封纸板，其烧失量≤35%，压缩率=25±5%，回弹率≥45%，拉伸强度≥5Mpa，蠕变松弛率≤30%。

Description

一种无石棉密封垫片的制作工艺
技术领域
本发明涉及一种无石棉密封垫片的制作工艺。
背景技术
非金属垫片主要是由橡胶、树脂、聚四氣己稀、石棉等非金属材料制成。而含有石棉的非金属垫片显示了其优良的拉伸强度、蠕变松弛性能、耐热和耐介质性能等，制成的密封垫片在高温、高压的密封场合性能显得尤为优越。但是，在生产或是使用含石棉的密封垫片过程中，石棉会分裂出极细小的元纤维，该细小的元纤维对人类的健康造成极其严重的危害。
国际上现已公认石棉是一种致癌物质。二十世纪70年代，发达工业国家首先提出无石棉计划。经过二十多年的努力，美国、日本和澳大利亚等国先后成功研制了各种无石棉垫片系列材料替代石棉垫片，其性能巧标达到或是超过了石棉垫片。现如今，世界上许多工业发达的国家已将无石棉材料推广至各应用领域，全面禁止使用任何含石棉的材料；国内研究开发的无石棉密封垫片较多的是传统的密封产品，厂家之间产品质量差异较大，性能指标也有待提高。
早期的无石棉垫片制备主耍是采用橡胶混炼模压工艺，但是随着工业领域对密封产品要求的提高，模压法制备的缺陷越来越明显，其生产效率低、尺寸容易受设备限制、产品力学性能差，长期使用过程中容易发生失效泄漏；经历了工业发展出现了采用压缩成张法，该方法前期对设备的投入较大，对工人素质要求很高，特别是在配方和生产工艺参数的控制尤为严格。因此需要对材料配方和生产中的各个环节有一个透彻深入的了解及长时间的工作经验积累才能确保产品的质量可靠和稳定；现阶段利用胶乳抄取法制备的密封材料使用温度范围更广、产品尺寸也更加灵活。抄取法工艺的关键在于含有纤维和各种辅料的含水分散体系，这也是纤维与基体良好结合的基础。因此，该工艺对无石棉纤维品质的要求较高。
发明内容
本发明的目的是提供一种无石棉密封垫片的制作工艺，综合多种类的纤维、填料、胶乳和化学助剂等的各自优点，用它们组成混杂纤维增强弹性体密封材料，既可改善无石棉纤维的性能，又能降低成本。
本发明采用的技术方案是：一种无石棉密封垫片的制作工艺，包括步骤，
S1，选取原料：采用芳纶1414浆粕为主要材料，选铁木叶纸浆为增强纤维，选用4012矿物棉为配合纤维；胶液采用丁苯胶乳和丁腈胶乳；填料选用1500目高岭土、800目滑石粉和400目云母粉；选用液体硫酸铝为凝聚剂；选用聚二甲基硅氧烷有机硅类消泡剂；选用无机絮凝剂；
S2，纤维悬浮液的制取：
a、无石棉纤维表面预处理，控制芳纶1414浆粕的长径比为100-200，控制铁木叶纸浆长径比为200，控制4012矿物棉长径比为100；
b、将与处理过的无石棉纤维放入打浆机中打浆，其中芳纶1414浆粕打浆时间是30-40min，打浆速度是300r/min； 铁木叶纸浆打浆时间是30-40min，打浆速度是300r/min；4012矿物棉打浆时间是40-60min，打浆速度是450r/min；再将三种浆液混合继续在打浆机中处理，打浆速度是300r/min，直至纤维悬浮液中无白点、结团，则打浆结束；
c、将胶液和填料依次加入纤维悬浮液中，利用碎浆机搅拌20min，再加入凝聚剂和絮凝剂；
d、经过混合、粘结后制成无石棉密封垫片复合材料的悬浮液；
S3、抄取成张：将无石棉密封垫片复合材料的悬浮液中的纤维、胶乳、填料和化学助剂沉淀到网膜上，相互交织形成薄层，当物料组份彼此独立悬浮移动时，借助网膜开始脱水，物料沉积成松散层；当悬浮液中的物料沉淀时，形成絮凝状的纸板；
S4，干燥和硫化：采用烤箱对抄取完毕的纸板进行干燥，干燥后的抄取纸板需进行一定的压延整形；将压延整形后的纸板放入平带平板硫化机中硫化，经辊压硫化后得到无石棉密封垫片。
作为本发明的进一步改进，所述的芳纶1414浆粕、铁木叶纸浆、4012矿物棉、丁苯胶乳、丁腈胶乳、高岭土、滑石粉、云母粉、聚二甲基硅氧烷有机硅类消泡剂和无机絮凝剂的比例是：7-8：9-10：9-11：4-5：9-10：28-30:19-20:2-3：2-7：1-6。
本发明的有益效果是：本发明结合现有抄取技术，采用芳纶1414浆粕为主材，配合纤维素纤维和矿物棉纤维为混杂纤维替代石棉纤维；胶乳选用丁腈胶乳和丁苯胶乳混合；填料选用高岭土、滑石粉和云母粉，并确定其组成的合理配方范围，最终制成无石棉抄取密封纸板，其烧失量≤35%，压缩率=25±5%，回弹率≥45%，拉伸强度≥5Mpa，蠕变松弛率≤30%。
具体实施方式
一种无石棉密封垫片的制作工艺，其特征是：包括步骤，
S1，选取原料：采用芳纶1414浆粕为主要材料，选铁木叶纸浆为增强纤维，选用4012矿物棉为配合纤维；胶液采用丁苯胶乳和丁腈胶乳；填料选用1500目高岭土、800目滑石粉和400目云母粉；选用液体硫酸铝为凝聚剂；选用聚二甲基硅氧烷有机硅类消泡剂；选用无机絮凝剂；选用芳纶1414浆粕为无石棉抄取板材的主要纤维，芳纶1414浆粕具有强度高、尺寸稳定性好、耐高温的特征，被用作垫片复合材料时，能很好的与其它介质相互粘合，造出的垫片具有优良的抗应力松弛性能和密封性能。由于单一的有机纤维不能提高复合材料性能，肉此选用一定比例的矿物棉纤维和纤维素纤维，利用有机纤维与无化纤维的混杂效应进行互补，能显著提高无石棉抄取板材的综合性能；选用高龄土可改善无石棉垫片制品强度，并可减轻油类对制品的膨胀且具有良好的耐热性能。选用滑石粉可改善无石棉密封垫片制品的抗酸碱性、耐热性、抗冲击强度、抗拉强度、抗蠕变能力和电绝缘性能，同时又可改变密封垫片复合材料的加工性能。选用云母可提高其机械强度，增强初性、附着力、抗老化及耐腐蚀性。丁腈胶乳具有良好的耐油性，其非极性溶剂的性能远远优于天然胶乳、氯丁胶乳、丁基胶乳。选用丁苯胶乳可与其它胶乳以任何比例并合，增强制品的机械性能、耐老化性能、优良的粘结性能和对化学物质的稳定性能。选用凝聚剂作为施胶剂，増强复合材料的抗水、防渗性能。选用消泡剂可显著提高无石棉密封垫片复合材料的致密性。选用絮凝剂能增强无石棉密封垫片复合材料的强度、弹性、耐溶剂和耐高温性能。
S2，纤维悬浮液的制取：
a、无石棉纤维表面预处理，控制芳纶1414浆粕的长径比为1:100-200，控制铁木叶纸浆长径比为1:200，控制4012矿物棉长径比为1:100；
b、将与处理过的无石棉纤维放入打浆机中打浆，其中芳纶1414浆粕打浆时间是30-40min，打浆速度是300r/min； 铁木叶纸浆打浆时间是30-40min，打浆速度是300r/min；4012矿物棉打浆时间是40-60min，打浆速度是450r/min；再将三种浆液混合继续在打浆机中处理，打浆速度是300r/min，直至纤维悬浮液中无白点、结团，则打浆结束；
c、将胶液和填料依次加入纤维悬浮液中，利用碎浆机搅拌20min，再加入凝聚剂和絮凝剂；
d、经过混合、粘结后制成无石棉密封垫片复合材料的悬浮液；
悬浮液的稳定是抄取成功的重要前提，而配方组份是影响悬浮液成长的关键。按照工艺顺序流程，严格控制搅拌时间和速度，并依次加入纤维、填料、胶乳和化学助剂，可获取稳定均匀的悬浮液。
S3，抄取成张：将无石棉密封垫片复合材料的悬浮液中的纤维、胶乳、填料和化学助剂沉淀到网膜上，相互交织形成薄层，当物料组份彼此独立悬浮移动时，借助网膜开始脱水，物料沉积成松散层；当悬浮液中的物料沉淀时，形成絮凝状的纸板；抄取无石棉密封纸板的质量取决于悬浮液的配比，悬浮液的配比与原料配比有关，稳定均匀的含水分散体系一般均可抄取出较好质量的无石棉抄取纸；
S4，干燥和硫化：采用烤箱对抄取完毕的纸板进行干燥，干燥后的抄取纸板需进行一定的压延整形；将压延整形后的纸板放入平带平板硫化机中硫化，经辊压硫化后得到无石棉密封垫片。过干燥才能具备一定的强度和初性。无石棉抄取纸经竊圧硫化后，可增强板材的密度、拉伸强度、蠕变松弛性能、压缩回弹性能等其他性能。
芳纶1414浆粕、铁木叶纸浆、4012矿物棉、丁苯胶乳、丁腈胶乳、高岭土、滑石粉、云母粉、聚二甲基硅氧烷有机硅类消泡剂和无机絮凝剂的比例是：7-8：9-10：9-11：4-5：9-10：28-30:19-20:2-3：2-7：1-6；混杂纤维体系中纤维的含量较多时有很好的增强效果，复合材料的密度较大、拉伸效果良好、压缩回弹性能良好、蠕变松弛性能增强，但对烧失量的影响较大，耐高温性能差；而填料含量较高时，材料成本降低、烧失量较好，但会导致拉伸强度、压缩回弹性能、蠕变松弛性能降低。
以上对本发明的实施方式作了说明，但是本发明不限于上述实施方式，在所属技术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做出各种变化。

Claims (2)

1.一种无石棉密封垫片的制作工艺，其特征是：包括步骤，
S1，选取原料：采用芳纶1414浆粕为主要材料，选铁木叶纸浆为增强纤维，选用4012矿物棉为配合纤维；胶液采用丁苯胶乳和丁腈胶乳；填料选用1500目高岭土、800目滑石粉和400目云母粉；选用液体硫酸铝为凝聚剂；选用聚二甲基硅氧烷有机硅类消泡剂；选用无机絮凝剂；
S2，纤维悬浮液的制取：
a、无石棉纤维表面预处理，控制芳纶1414浆粕的长径比为100-200，控制铁木叶纸浆长径比为200，控制4012矿物棉长径比为100；
b、将与处理过的无石棉纤维放入打浆机中打浆，其中芳纶1414浆粕打浆时间是30-40min，打浆速度是300r/min； 铁木叶纸浆打浆时间是30-40min，打浆速度是300r/min；4012矿物棉打浆时间是40-60min，打浆速度是450r/min；再将三种浆液混合继续在打浆机中处理，打浆速度是300r/min，直至纤维悬浮液中无白点、结团，则打浆结束；
c、将胶液和填料依次加入纤维悬浮液中，利用碎浆机搅拌20min，再加入凝聚剂和絮凝剂；
d、经过混合、粘结后制成无石棉密封垫片复合材料的悬浮液；
S3、抄取成张：将无石棉密封垫片复合材料的悬浮液中的纤维、胶乳、填料和化学助剂沉淀到网膜上，相互交织形成薄层，当物料组份彼此独立悬浮移动时，借助网膜开始脱水，物料沉积成松散层；当悬浮液中的物料沉淀时，形成絮凝状的纸板；
S4，干燥和硫化：采用烤箱对抄取完毕的纸板进行干燥，干燥后的抄取纸板需进行一定的压延整形；将压延整形后的纸板放入平带平板硫化机中硫化，经辊压硫化后得到无石棉密封垫片。
2.根据权利要求1所述的一种无石棉密封垫片的制作工艺，其特征是：所述的芳纶1414浆粕、铁木叶纸浆、4012矿物棉、丁苯胶乳、丁腈胶乳、高岭土、滑石粉、云母粉、聚二甲基硅氧烷有机硅类消泡剂和无机絮凝剂的比例是：7-8：9-10：9-11：4-5：9-10：28-30:19-20:2-3：2-7：1-6。
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