技术领域technical field
本发明涉及一种瓷质绝缘子的制备方法，特别涉及一种非圆形的、用于电力机车车顶的瓷质绝缘子的制备方法，属于电瓷绝缘子制造领域。The invention relates to a preparation method of a porcelain insulator, in particular to a preparation method of a non-circular porcelain insulator used for the roof of an electric locomotive, and belongs to the field of electric porcelain insulator manufacture.
背景技术Background technique
在电力系统中，用于支撑和固定母线与带电导体的绝缘材料称为绝缘子，电力机车车顶绝缘子是指支撑受电弓从电动车辆从接触网导线上受取电流的一种绝缘子。电力机车车顶绝缘子是电力机车、电动车辆绝缘性能的主要保障，经数据统计，电力机车因绝缘降低等造成的机车故障率占各类故障的25％以上，从而给铁路运输安全带来很大的危害。In the power system, the insulating material used to support and fix the busbar and the live conductor is called an insulator. The roof insulator of an electric locomotive refers to an insulator that supports the pantograph to receive current from the catenary wire from the electric vehicle. Electric locomotive roof insulators are the main guarantee for the insulation performance of electric locomotives and electric vehicles. According to statistics, the locomotive failure rate of electric locomotives due to insulation degradation accounts for more than 25% of all types of failures, which brings great benefits to the safety of railway transportation. hazards.
目前圆形的瓷质绝缘子是电力机车车顶绝缘子中使用最为广泛的一种绝缘子，其具有良好的机械性能和电气性能，而且产品种类齐全，使用范围广。但是由于圆形绝缘子在运行的过程中，容易造成污染物在其背风面沉积，导致污闪的出现，绝缘性能急剧下降。然而非圆形的车顶瓷质绝缘子可以有效的避免圆形绝缘子背风一面容易产生污秽的问题。非圆形绝缘子采用多层伞和大小伞有序相隔的形状，多层伞裙和杆径的横截面均为非圆形的流线型结构，在机车运行过程中，非圆长轴方向随机车行进方向安装，以流线形态随机车行走，并通过流线形消除绝缘子背风面的涡流负压区，使灰尘污秽和含水气流与绝缘子表面迅速分离脱落，也减少了污染物在绝缘子背风面区域沉积污秽物的现象，改善了电力机车车顶绝缘子出现污闪络、冰闪络等现象。同时，经过数据分析，在材料成本没有增加的情况下，该种非圆形电力机车车顶绝缘子的弯曲破坏强度提高10％-12％，而且弯曲荷载下的偏移量也会降低22％-24％。比如中国专利文献(申请号：201410759575.1)就公开一种电力机车车顶的母线支柱和受电弓支柱瓷质绝缘子，属于一种比较典型的非圆形绝缘子。At present, circular porcelain insulators are the most widely used insulators for electric locomotive roof insulators. They have good mechanical and electrical properties, and have a complete range of products and a wide range of applications. However, during the operation of circular insulators, pollutants are likely to be deposited on its leeward side, resulting in pollution flashover and a sharp drop in insulation performance. However, non-circular roof porcelain insulators can effectively avoid the problem of pollution on the leeward side of circular insulators. The non-circular insulator adopts the shape of multi-layer umbrellas and large and small umbrellas separated in an orderly manner. The cross-sections of the multi-layer sheds and rod diameters are all non-circular streamlined structures. During the operation of the locomotive, the direction of the non-circular long axis moves along with the locomotive. It is installed in the same direction and walks with the car in a streamlined shape, and the eddy current negative pressure area on the leeward side of the insulator is eliminated through the streamlined shape, so that the dust, pollution and water-containing air flow are quickly separated from the surface of the insulator, and the deposition of pollutants on the leeward side of the insulator is also reduced. The phenomenon of dirt and dirt has improved the phenomenon of pollution flashover and ice flashover of electric locomotive roof insulators. At the same time, after data analysis, in the case of no increase in material costs, the bending failure strength of this type of non-circular electric locomotive roof insulator is increased by 10%-12%, and the offset under bending load will also be reduced by 22%- twenty four%. For example, the Chinese patent document (Application No.: 201410759575.1) discloses a porcelain insulator for a busbar support and a pantograph support on the roof of an electric locomotive, which belongs to a relatively typical non-circular insulator.
当前，非圆形电力机车车顶绝缘子一直都采用靠模法成型，即数控机车底座上的四角卡盘单向固定泥坯的下端，上端不固定，靠模固定在导轨上不能移动，当刀架自动进刀时，刀体则随靠模的轮廓形状自动横向进刀，形成车刀纵横走刀的复合运动，从而车出所需要的外形，该种方法机械化程度高，还可以实现自动控制，成型装备结构简单，容易操作，适用于批量生产。但是在实际生产中发现靠模法成型的合格率仅仅为25％-45％。对其成型过程研究，主要存在如下三个问题：At present, the roof insulators of non-circular electric locomotives have always been formed by the profiling method, that is, the four-corner chuck on the base of the CNC locomotive fixes the lower end of the mud blank in one direction, and the upper end is not fixed. The profiling is fixed on the guide rail and cannot be moved. When the frame automatically feeds the tool, the tool body automatically feeds the tool horizontally according to the contour shape of the template, forming a compound movement of the turning tool moving vertically and horizontally, so as to turn out the required shape. This method has a high degree of mechanization and can also realize automatic control. The molding equipment is simple in structure, easy to operate, and suitable for mass production. However, in actual production, it is found that the qualified rate of profiling is only 25%-45%. There are mainly three problems in the study of its forming process:
1、泥坯的干坯强度偏低、韧性偏少；1. The dry billet of the mud billet has low strength and low toughness;
2、泥坯的塑性较差，成型过程中修坯刀具与泥坯接触时会产生碰撞，出现了一些微小裂纹，成型过程中这些裂纹没能够进一步修复，干燥过程中，毛坯的收缩又加剧了这些裂纹的扩展，从而使成型好的产品因为出现微裂纹而沦为了废品；2. The plasticity of the mud blank is poor. During the forming process, the trimming tool will collide with the mud blank, and some tiny cracks will appear. These cracks cannot be further repaired during the forming process. During the drying process, the shrinkage of the blank is intensified. The expansion of these cracks makes the formed product a waste product due to the appearance of micro cracks;
3、一端单向固定，因旋转与偏心，导致上端的偏心载荷加大，更易出现杆径开裂等缺陷，从而也影响了成品率。3. One end is fixed in one direction. Due to rotation and eccentricity, the eccentric load on the upper end is increased, and defects such as rod diameter cracking are more likely to occur, which also affects the yield.
鉴于此，如何更好的从绝缘子泥坯本身的特质出发，通过恰当的方式来提高泥坯的干坯强度和塑性性能，使之在靠模法成型时既能提高产品的加工效率，以便使其能够满足工业大批量成型的要求，这是至关重要的，更能使所成型的制品不再出现裂纹，以提高其成型的合格率。In view of this, how to better proceed from the characteristics of the insulator mud itself, and improve the dry strength and plasticity of the mud in an appropriate way, so that it can not only improve the processing efficiency of the product during profiling, so that the It is very important that it can meet the requirements of industrial mass molding, and it can make the formed products no longer have cracks, so as to improve the qualified rate of their molding.
发明内容Contents of the invention
本发明解决的技术问题是，从绝缘子泥坯的材料组成考虑，提高绝缘子的干坯强度和塑性性能的方法，以保证绝缘子的合格率。The technical problem solved by the invention is, considering the material composition of the insulator mud blank, a method for improving the dry blank strength and plasticity of the insulator, so as to ensure the qualified rate of the insulator.
本发明的技术方案是，提供一种瓷质绝缘子的制备方法，包括配料、球磨、过筛、除铁、榨泥、粗炼、陈腐、精炼、干燥、修坯、烧结工序；在除铁工序后，将短切纤维与部分泥浆混合，然后用搅拌机以500-800r/min的转速搅拌30分钟以上，再加入到泥浆池中，与泥浆池中的泥浆继续搅拌40分钟以上，使短切纤维均匀分散于泥浆中，然后进行榨泥工序；所述短切纤维为玻璃纤维和/或合成纤维，以泥浆干基的质量计，短切纤维的加入量为泥浆总质量的0.2％-0.6％，优选0.4％-0.6％。The technical solution of the present invention is to provide a preparation method of porcelain insulators, including batching, ball milling, sieving, iron removal, mud pressing, rough refining, aging, refining, drying, billet trimming, and sintering; in the iron removal process Finally, mix the chopped fiber with part of the mud, then use a mixer to stir at a speed of 500-800r/min for more than 30 minutes, then add it to the mud pool, and continue to stir with the mud in the mud pool for more than 40 minutes to make the chopped fiber Uniformly disperse in the mud, and then perform the mud squeezing process; the chopped fibers are glass fibers and/or synthetic fibers, and the amount of chopped fibers added is 0.2%-0.6% of the total mass of the mud based on the mass of the dry basis of the mud , preferably 0.4%-0.6%.
优选地，在除铁工序后，将短切纤维与部分泥浆混合；其中短切纤维与部分泥浆(干基)的质量比为1：(5-20)。Preferably, after the iron removal process, the chopped fibers are mixed with part of the slurry; wherein the mass ratio of the chopped fibers to part of the slurry (dry basis) is 1: (5-20).
优选地，先将短切纤维浸泡于苯酚的四氯乙烷溶液中进行分散，再加入泥料中；所述苯酚的四氯乙烷溶液的浓度为0.5-2g/mL。用苯酚的四氯乙烷溶液中进行分散时，对于合成纤维的分散效果提高非常明显。Preferably, the chopped fibers are firstly soaked in a phenol tetrachloroethane solution for dispersion, and then added to the mud; the concentration of the phenol tetrachloroethane solution is 0.5-2 g/mL. When dispersed in tetrachloroethane solution of phenol, the dispersion effect on synthetic fibers is significantly improved.
优选地，所述短切纤维的分散时间为10-60分钟。Preferably, the dispersion time of the chopped fibers is 10-60 minutes.
优选地，利用超声或搅拌对短切纤维进行分散。Preferably, the chopped fibers are dispersed using ultrasound or agitation.
优选地，所述短切纤维的直径为2-3μm、长度为0.8-4cm。Preferably, the chopped fibers have a diameter of 2-3 μm and a length of 0.8-4 cm.
优选地，配料步骤中的原料组成为：Preferably, the raw material composition in the batching step is:
其中，所述α-氧化铝粉的粒径为325-2000目，纯度≥99％；所述高岭土的可塑性指数≥20。Wherein, the particle size of the α-alumina powder is 325-2000 mesh, and the purity is ≥99%; the plasticity index of the kaolin is ≥20.
优选地，将修坯得到的回坯泥置于化浆池中进行化浆处理制得回坯泥浆，将回坯泥浆过筛除去残余的短切纤维，然后将除去短切纤维的回坯泥浆重新回收使用。Preferably, the returned mud obtained by trimming is placed in the slurry tank for chemical treatment to obtain the returned mud, and the returned mud is sieved to remove residual chopped fibers, and then the returned mud from which the chopped fibers has been removed Recycle.
优选地，将除去短切纤维的回坯泥浆与球磨后的原浆按照质量比为1：(2-3)混合均匀后使用。Preferably, the recycled slurry from which chopped fibers have been removed and the raw slurry after ball milling are uniformly mixed at a mass ratio of 1: (2-3) before use.
优选地，所述短切纤维的弹性模量为5GPa以上。Preferably, the modulus of elasticity of the chopped fibers is above 5 GPa.
优选地，所述瓷质绝缘子为非圆形绝缘子。Preferably, the porcelain insulator is a non-circular insulator.
优选地，非圆形绝缘子为椭圆形绝缘子。Preferably, the non-circular insulators are oval insulators.
虽然在复合材料中引入纤维来增强是一种应用较多的技术，但是对于陶瓷材料特别是电瓷材料中，并没有发现类似的应用。在企业的合作生产中，部分生产厂家考虑到添加纤维后的泥料、坯料难以回收利用，废泥料过多等的问题。再陶瓷的制备工艺中如何引入何种纤维，如何选择纤维的尺寸，以及如何在陶瓷物料中才能有效地将纤维分散，最后实现干坯的性能提高都是现有技术中不曾遇到或解决过的技术问题。Although introducing fibers into composite materials for reinforcement is a widely used technology, no similar application has been found for ceramic materials, especially electroceramic materials. In the cooperative production of enterprises, some manufacturers consider that the mud and blanks after adding fibers are difficult to recycle, and there are too many waste muds. How to introduce what kind of fiber in the ceramic preparation process, how to choose the size of the fiber, and how to effectively disperse the fiber in the ceramic material, and finally to improve the performance of the dry body have never been encountered or solved in the prior art. technical issues.
本发明可供使用的短切纤维可为玻璃纤维或者合成纤维。本发明将高强度、高模量的短切纤维引入绝缘子泥坯中，使其与泥坯有效结合。当泥坯在修坯过程中，承受刀具传来的外荷载时，短切纤维与泥坯共同分担荷载，当外荷载大于泥坯的断裂强度，并产生裂纹时，短切纤维也能独立承受载荷，在泥坯中起桥接作用阻碍了裂纹的开展，从而提高了泥坯的断裂强度。本发明的方法主要是针对电瓷绝缘子、特别是非圆形的瓷质绝缘子设计的。The chopped fibers that can be used in the present invention can be glass fibers or synthetic fibers. The invention introduces high-strength, high-modulus chopped fibers into the insulator mud to effectively combine with the mud. When the mud billet bears the external load from the cutter during the trimming process, the chopped fiber and the mud billet share the load together. When the external load is greater than the breaking strength of the mud billet and cracks occur, the chopped fiber can also bear it independently The load plays a bridging role in the mud billet and hinders the development of cracks, thereby improving the fracture strength of the mud billet. The method of the invention is mainly designed for electric porcelain insulators, especially non-circular porcelain insulators.
本发明的技术方案是通过以下途径实现的，将Φ＝2-3μm、L＝0.8-4cm的短切纤维放置于放入预先升温至80-100℃的烘箱中烘干至恒重，然后从烘箱中取出随后立即放入密闭干燥器中冷却至常温。再用精密天平称取占电瓷的干泥料(干坯料)总质量的0.2％-0.6％的纤维，并取适量的苯酚-四氯乙烷溶液，将纤维置于该溶液中浸泡15-20min进行分散处理，然后再倒入到经过过筛、除铁等工艺处理后的泥坯浆料中，通过高速搅拌机以500-800r/min的转速充分搅拌30-50min，并经过榨泥、炼泥、烘干等工序后制得纤维增韧干坯泥段。The technical solution of the present invention is achieved by the following approach, the chopped fibers of Φ=2-3μm, L=0.8-4cm are placed in an oven heated to 80-100°C in advance and dried to constant weight, and then from Take it out of the oven and immediately put it in a closed desiccator to cool to room temperature. Then use a precision balance to weigh 0.2%-0.6% of the fiber that accounts for the total mass of the dry mud (dry blank) of the electric porcelain, and take an appropriate amount of phenol-tetrachloroethane solution, and soak the fiber in the solution for 15-20min Carry out dispersion treatment, and then pour it into the mud slurry after sieving, iron removal and other processes, and fully stir it with a high-speed mixer at a speed of 500-800r/min for 30-50min, and go through mud squeezing and mud refining After processes such as drying and drying, the fiber-toughened dry mud section is obtained.
本发明利用苯酚-四氯乙烷溶液作为短切纤维的分散剂，与未分散的短切纤维相比，其分散的效果有较大的提高。分散效果以百分数计，未添加此种分散剂时，合成纤维有效的分散程度可达到60％左右，而加入此种分散剂分散程度可达到90％左右。可见此种分散剂特别适合分散陶瓷泥料中的短切纤维。The invention utilizes the phenol-tetrachloroethane solution as the dispersant of the chopped fibers, and compared with the undispersed chopped fibers, the dispersing effect is greatly improved. The dispersing effect is expressed as a percentage. When the dispersant is not added, the effective dispersing degree of the synthetic fiber can reach about 60%, and the dispersing degree can reach about 90% when the dispersing agent is added. It can be seen that this kind of dispersant is especially suitable for dispersing chopped fibers in ceramic mud.
本发明的主要工艺流程如下：配料—球磨粉碎—过筛、除铁—引入短切纤维(先分散处理)—榨泥—粗炼、陈腐、精炼—干燥—成型、修坯—回坯泥的处理。The main technological process of the present invention is as follows: batching-ball milling-sieving, iron removal-introducing chopped fibers (firstly dispersed treatment)-squeezing mud-rough refining, stale, refining-drying-molding, trimming-returning of mud deal with.
在配料工艺中，提前对所需的原材料进行化学成分分析，验证合格后方可使用，然后用配料车进行配料工作。In the batching process, the chemical composition of the required raw materials is analyzed in advance, and they can be used only after they pass the verification, and then the batching work is carried out with a batching truck.
在球磨粉碎工艺中，将称量好的原材料全部投入球磨机中，按照1:1(原材料与水的质量比)的配比加水，然后球磨4-6h。In the ball milling process, put all the weighed raw materials into the ball mill, add water according to the ratio of 1:1 (mass ratio of raw materials to water), and then ball mill for 4-6 hours.
在过筛、除铁工艺中，将球磨后的泥浆放浆过160目的振动筛除去其中的硬泥块、木屑等有害杂质，然后通过除铁机除去泥浆中的铁杂质，取少量浆料过先后经过80目和250目标准筛，检测其筛余量达到0.1-0.3％。In the sieving and iron removal process, the ball-milled mud is put through a 160-mesh vibrating screen to remove harmful impurities such as hard mud and sawdust, and then the iron impurities in the mud are removed by an iron remover, and a small amount of slurry is passed through After successively passing through 80-mesh and 250-mesh standard sieves, it is detected that the sieve residue reaches 0.1-0.3%.
在引入短切纤维工艺中，将Φ＝2-3μm、L＝0.8-4cm的短切纤维放置于放入预先升温至80-100℃的烘箱中烘干至恒重，然后从烘箱中取出随后立即放入密闭干燥器中冷却至常温。再用精密天平称取电瓷干泥料总质量的0.2％-0.6％的纤维，并取适量的苯酚-四氯乙烷溶液，将纤维置于该溶液中浸泡15-20min进行分散处理，然后再倒入到经过过筛、除铁等工艺处理后的泥坯浆料中，通过高速搅拌机以500-800r/min的转速充分搅拌30-50min。In the process of introducing chopped fibers, the chopped fibers with Φ=2-3μm and L=0.8-4cm are placed in an oven heated to 80-100°C in advance and dried to constant weight, then taken out from the oven and then Immediately cool to room temperature in a closed desiccator. Then use a precision balance to weigh 0.2%-0.6% of the total mass of the electric porcelain dry mud fiber, and take an appropriate amount of phenol-tetrachloroethane solution, soak the fiber in the solution for 15-20min for dispersion treatment, and then Pour it into the mud slurry after sieving, iron removal and other processes, and fully stir for 30-50min with a high-speed mixer at a speed of 500-800r/min.
在榨泥工艺中，通过加压设备将泥浆压送至板框式榨泥机中，并将榨泥压力逐步加大，最终不超过2.0MPa，并持续1.5-2.0h。取适量泥块，进行烘干测试，要求其含水率达到20-22％。In the mud squeezing process, the mud is sent to the plate and frame mud squeezing machine by pressure equipment, and the mud squeezing pressure is gradually increased, and finally does not exceed 2.0MPa, and lasts for 1.5-2.0h. Take an appropriate amount of mud and conduct a drying test, requiring its moisture content to reach 20-22%.
在粗炼、陈腐、精炼工艺中，使用粗炼机对榨好的泥饼进行粗炼，并将粗炼后的泥段按批次排放在陈腐室中，陈腐时间不得少于24h。然后再使用真空炼泥机对泥段进行精炼，并且适量泥块烘干测试其含水率，要求达到19-20％。In the process of rough refining, aging and refining, the crushed mud cake is roughly refined by using a rough refiner, and the mud cakes after rough refining are discharged in batches in the aging room, and the aging time shall not be less than 24 hours. Then use a vacuum mud refiner to refine the mud section, and dry an appropriate amount of mud to test its moisture content, which is required to reach 19-20%.
在干燥过程中，将精炼后的泥段先阴干至发麻白色再进入高温烘房中烘干，直到泥段的水分不超过2％时才能出烘房。During the drying process, the refined mud section is first dried in the shade until it turns numb and white, and then it is dried in a high-temperature drying room until the moisture content of the mud section does not exceed 2%.
在修坯工艺中，按照产品的图纸要求，使用非圆形绝缘子加工装置对烘干后的泥段进行修坯操作，加工出所需要的产品。上述步骤完成后，坯料已经成型。在回坯泥的处理工艺中，将回坯泥置于化浆池中进行化浆处理制得回坯泥浆，将回坯泥浆过160目振动筛除去残余的短切纤维，然后将此时的回坯泥浆与原浆按照1：2.4(质量比)混合搅拌均匀以后再重新使用。In the trimming process, according to the drawing requirements of the product, the non-circular insulator processing device is used to trim the dried mud section to process the required products. After the above steps are completed, the blank has been formed. In the treatment process of the returned body mud, the returned body mud is placed in the slurry tank for chemical slurry treatment to obtain the returned body mud, and the returned body mud is passed through a 160-mesh vibrating screen to remove the remaining chopped fibers, and then the The return mud and the original pulp are mixed according to 1:2.4 (mass ratio) and then reused.
经过试验比较，玻璃纤维的分散性优于合成纤维，干坯的强度较高。玻璃纤维这种无机非金属材料经过烧结可以很好地融入陶瓷基体中，不会对电瓷性能产生明显不利影响。After testing and comparison, the dispersibility of glass fiber is better than that of synthetic fiber, and the strength of dry blank is higher. Glass fiber, an inorganic non-metallic material, can be well integrated into the ceramic matrix after sintering, and will not have a significant adverse effect on the performance of the electric porcelain.
本发明的有益效果是，采用高强度、高模量的短切纤维增韧技术来提高非圆形电力机车车顶绝缘子的干坯强度和塑性性能，该方法不仅能够很好的解决了短切纤维在坯料泥浆中的分散性问题，而且更好地弥补了非圆形车顶绝缘子干法靠模成型中存在的伞间微裂纹、杆径开裂等不足，提高了非圆形绝缘子产品的合格率和生产效率，节约了生产成本。The beneficial effect of the present invention is that the toughening technology of chopped fiber with high strength and high modulus is used to improve the dry strength and plasticity of non-circular electric locomotive roof insulators. The dispersion of fibers in the raw material slurry can better make up for the deficiencies of micro-cracks between umbrellas and rod diameter cracks in the dry profiling of non-circular roof insulators, and improve the qualification of non-circular insulator products. rate and production efficiency, saving production costs.
具体实施方式detailed description
下面结合实施例对本发明作进一步说明。The present invention will be further described below in conjunction with embodiment.
实施例1Example 1
步骤一：按照以下非圆形电力机车车顶绝缘子的配方进行配料：Step 1: Make ingredients according to the following formula for non-circular electric locomotive roof insulators:
其中，煅烧α氧化铝粉采用325-2000目、纯度≥99％的纯工业氧化铝作为主要原料，所使用的高岭土要求其可塑性指标大于等于2.0，可塑性指数≥20，干燥强度≥3MPa，Al2O3≥24％，并加入少量的矿化剂来降低绝缘子的烧成温度，同时使得材料成分中Al2O3的含量达到61-65％，提高其机械和电气性能。Among them, calcined α-alumina powder uses pure industrial alumina of 325-2000 mesh and purity ≥ 99% as the main raw material. The kaolin used requires its plasticity index to be greater than or equal to 2.0, plasticity index ≥ 20, dry strength ≥ 3MPa, Al2 O3 ≥ 24%, and a small amount of mineralizer is added to reduce the firing temperature of the insulator, and at the same time make the content of Al2 O3 in the material composition reach 61-65%, and improve its mechanical and electrical properties.
步骤二：将称量好的原材料全部投入球磨机中，按照1:1(原材料与水的质量比)的配比加水，然后球磨4-6h。Step 2: Put all the weighed raw materials into the ball mill, add water according to the ratio of 1:1 (mass ratio of raw materials to water), and then ball mill for 4-6 hours.
步骤三：将球磨后的泥浆放浆过160目的振动筛除去其中的硬泥块、木屑等有害杂质，然后通过除铁机除去泥浆中的铁杂质，取少量浆料过先后经过80目和250目标准筛，检测其筛余量达到0.1-0.3％。Step 3: Put the ball-milled slurry through a 160-mesh vibrating screen to remove harmful impurities such as hard mud and sawdust, and then remove iron impurities in the slurry through an iron remover. Take a small amount of slurry and pass it through 80-mesh and 250-mesh The target standard sieve is used to detect that the sieve residue reaches 0.1-0.3%.
步骤四：将Φ＝2-3μm、L＝0.8-4cm的短切玻璃纤维放置于放入预先升温至80-100℃的烘箱中烘干至恒重，然后从烘箱中取出随后立即放入密闭干燥器中冷却至常温，再用精密天平称取坯料干料总质量的0.4％的纤维。取适量的苯酚-四氯乙烷溶液，将纤维置于该溶液中浸泡15-20min，然后再倒入到经过过筛、除铁等工艺处理后的泥坯浆料中，通过高速搅拌机以500-800r/min的转速充分搅拌均匀。Step 4: Place the chopped glass fiber with Φ=2-3μm and L=0.8-4cm in an oven heated to 80-100°C in advance and dry to constant weight, then take it out of the oven and put it in a sealed container immediately Cool to normal temperature in a desiccator, and then weigh 0.4% of the fiber of the total mass of the blank dry material with a precision balance. Take an appropriate amount of phenol-tetrachloroethane solution, soak the fiber in the solution for 15-20 minutes, and then pour it into the mud slurry that has been processed by sieving, iron removal, etc., and use a high-speed mixer at 500 The speed of -800r/min is fully stirred evenly.
其中短切玻璃纤维的性能如下:Wherein the performance of chopped glass fiber is as follows:
步骤五：通过加压设备将泥浆压送至板框式榨泥机中，并将榨泥压力逐步加大，最终不超过2.0MPa，并持续1.5-2.0h。取适量泥块，进行烘干测试，要求其含水率达到20-22％。Step 5: Send the mud to the plate-and-frame mud press through the pressurization equipment, and gradually increase the mud pressing pressure, and finally not exceed 2.0MPa, and last for 1.5-2.0h. Take an appropriate amount of mud and conduct a drying test, requiring its moisture content to reach 20-22%.
步骤六：使用粗炼机对榨好的泥饼进行粗炼，并将粗炼后的泥段按批次排放在陈腐室中，陈腐时间不得少于24h。然后再使用大型真空炼泥机对泥段进行精炼，并且适量泥块烘干测试其含水率，要求达到19-20％。再取适量粗炼后的泥块使用小型真空炼泥机炼制D＝20mm、L＝140mm的试棒。Step 6: Roughly refine the squeezed mud cakes with a roughing machine, and discharge the coarsely refined mud segments in batches in the aging room, and the aging time shall not be less than 24 hours. Then use a large vacuum mud refiner to refine the mud section, and dry an appropriate amount of mud to test its moisture content, which is required to reach 19-20%. Then take an appropriate amount of rough smelted mud and use a small vacuum mud refiner to refine a test bar with D=20mm and L=140mm.
步骤七：将精炼后的泥段和试棒先阴干至发麻白色再进入高温烘房中烘干，直到泥段的水分不超过2％时才能出烘房。Step 7: Dry the refined mud section and test rod in the shade until they turn numb and white, and then enter the high-temperature drying room for drying. The clay section cannot leave the drying room until the moisture content of the mud section does not exceed 2%.
步骤八：按照产品的图纸要求，使用非圆形绝缘子加工装置对烘干后的泥段进行修坯操作，加工出所需要的产品。其中，在修坯过程中也发现干坯出现原有伞裂、伞崩的现象明显减少，使得产品的成品率由原来的40-45％提高到85-90％，生产效率明显提高。Step 8: According to the drawing requirements of the product, use a non-circular insulator processing device to trim the dried mud section to process the required product. Among them, in the trimming process, it is also found that the phenomenon of the original umbrella cracking and umbrella collapse in the dry blank is significantly reduced, so that the yield of the product is increased from the original 40-45% to 85-90%, and the production efficiency is significantly improved.
步骤九：将回坯泥置于化浆池中进行化浆处理制得回坯泥浆，将回坯泥浆过160目振动筛除去残余的短切纤维，然后将此时的回坯泥浆与原浆按照1：2.4(质量比)混合搅拌均匀以后再重新使用。Step 9: Put the returned mud in the slurry tank for chemical treatment to obtain the returned mud, pass the returned mud through a 160-mesh vibrating sieve to remove the remaining chopped fibers, and then mix the returned mud with the original pulp According to 1:2.4 (mass ratio), mix and stir evenly before reuse.
步骤十：取若干烘干后的试棒，用抗折试验机测试其干坯抗折强度。Step 10: Take a number of dried test bars and test their dry billet flexural strength with a flexural testing machine.
其中抗折试验机的测试跨距L＝100mm，从表中数据对比可以看出，对于该配方而言，其中不掺加玻璃纤维的干坯试棒抗折强度平均值为4.64MPa，掺加0.4％的玻璃纤维后，其抗折强度平均值为7.03MPa，较之前提高51.51％。Wherein the test span L=100mm of the flexural testing machine, as can be seen from the comparison of the data in the table, for this formula, the average value of the flexural strength of the dry blank test bar without glass fiber is 4.64MPa, and the After adding 0.4% glass fiber, the average flexural strength is 7.03MPa, which is 51.51% higher than before.
实施例2Example 2
实施例2的基本步骤和实施例1是一样的，只是在所使用短切纤维的种类上作出调整，将使用的玻璃纤维改为合成聚酯纤维，掺量仍为干泥料总质量的0.4％。The basic steps of embodiment 2 are the same as that of embodiment 1, except that adjustments are made on the type of chopped fibers used, and the glass fibers used are changed into synthetic polyester fibers, and the dosage is still 0.4% of the total mass of dry mud. %.
其中短切合成聚酯纤维的性能如下:Wherein the performance of chopped synthetic polyester fiber is as follows:
按照产品的图纸要求，使用非圆形绝缘子加工装置对烘干后的泥段进行修坯操作，加工出所需要的产品。其中，在修坯过程中也发现干坯出现原有伞裂、伞崩的现象明显减少，产品的成品率也可由原来的40-45％提高到65-75％，生产效率得到明显提高。According to the drawing requirements of the product, the non-circular insulator processing device is used to trim the dried mud section to process the required product. Among them, in the blank trimming process, it is also found that the phenomenon of the original umbrella cracking and umbrella collapse of the dry blank is significantly reduced, and the yield of the product can also be increased from the original 40-45% to 65-75%, and the production efficiency has been significantly improved.
取若干烘干后的试棒，用抗折试验机测试其干坯抗折强度。Take a number of dried test bars, and use a flexural testing machine to test their dry billet flexural strength.
其中抗折试验机的测试跨距L＝100mm，从表中数据对比可以看出，对于该配方而言，其中不掺加纤维的干坯试棒抗折强度平均值为4.64MPa，掺加0.4％的聚酯纤维后，其抗折强度平均值为6.11MPa，较之前提高31.68％。Among them, the test span of the flexural testing machine is L=100mm. From the comparison of the data in the table, it can be seen that for this formula, the average value of the flexural strength of the dry billet test bar without fiber is 4.64MPa, and the average value of the flexural strength of the dry billet test bar with 0.4 After adding % polyester fiber, the average flexural strength is 6.11MPa, which is 31.68% higher than before.
综上所述，本发明所提供的方法不仅能够很好的解决了短切纤维在坯料泥浆中的分散性问题，而且玻璃纤维和/或合成纤维都能提高坯料的塑性性能，更好地弥补了非圆形绝缘子干法靠模成型中存在的伞间微裂纹、杆径开裂不足，提高了非圆形绝缘子产品的合格率和生产效率，节约了生产成本。In summary, the method provided by the present invention can not only solve the problem of the dispersion of chopped fibers in the blank slurry, but also the glass fiber and/or synthetic fiber can improve the plastic properties of the blank and better compensate for the It eliminates the micro-cracks between umbrellas and insufficient rod diameter cracks in the dry profiling of non-circular insulators, improves the qualification rate and production efficiency of non-circular insulator products, and saves production costs.
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| CN201710316401.1ACN107010981A (en) | 2017-05-08 | 2017-05-08 | A kind of preparation method of porcelain insulator |
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| CN201710316401.1ACN107010981A (en) | 2017-05-08 | 2017-05-08 | A kind of preparation method of porcelain insulator |
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| CN108053956A (en)* | 2017-12-13 | 2018-05-18 | 刘敏 | A kind of preparation process of compound porcelain insulator |
| CN116924820A (en)* | 2023-06-27 | 2023-10-24 | 萍乡欧姆绝缘子有限公司 | Formula of high-performance column porcelain insulator and porcelain insulator thereof |
| CN119661199A (en)* | 2024-12-16 | 2025-03-21 | 江西新龙电瓷电器制造有限公司 | Preparation method of high-strength high-toughness coating rod insulator for high-speed rail contact net |
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| RU2209724C1 (en)* | 2002-03-07 | 2003-08-10 | Итяксов Николай Николаевич | Method for making fibrous molded articles |
| CN104402409A (en)* | 2014-10-25 | 2015-03-11 | 青岛智谷创新技术有限公司 | High insulating electric ceramic |
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| CN108053956B (en)* | 2017-12-13 | 2019-06-14 | 刘敏 | A kind of preparation process of compound porcelain insulator |
| CN116924820A (en)* | 2023-06-27 | 2023-10-24 | 萍乡欧姆绝缘子有限公司 | Formula of high-performance column porcelain insulator and porcelain insulator thereof |
| CN119661199A (en)* | 2024-12-16 | 2025-03-21 | 江西新龙电瓷电器制造有限公司 | Preparation method of high-strength high-toughness coating rod insulator for high-speed rail contact net |
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