CN106566363A - 一种适用于汽车传动轴用水性防腐涂料的圆盘式静电涂装工艺 - Google Patents
一种适用于汽车传动轴用水性防腐涂料的圆盘式静电涂装工艺 Download PDFInfo
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Abstract
本发明公开了一种适用于汽车传动轴用水性防腐涂料的圆盘式静电涂装工艺，采用圆盘式静电喷枪往表面经过铁系磷化处理的钢结构件喷涂水性防腐涂料，而后干燥，其中，所述的水性防腐涂料包括以下重量百分比的组份：氧化干燥型环氧磷酸酯树脂50～70%、颜料及填料5～15%、功能性防锈颜料5～15%、功能性促进剂1～2%、去离子水10～20%。本发明还公开一种水性涂料。本发明解决铁系磷化处理钢结构件水性单组份涂层耐腐蚀性问题、低温固化单组份涂层下线干燥性、抗粘性问题以及单组份水性涂料技术如何满足圆盘式静电涂装流挂与流平的技术问题。
Description
技术领域
本发明涉及一种涂装工艺，尤其是一种适用于汽车传动轴用水性防腐涂料的圆盘式静电涂装工艺。
背景技术
继2015年10月1日《挥发性有机物排污收费试点办法》公布以后，用水代替有机溶剂已成为涂料行业发展的必然趋势。水性防腐涂料以水为溶剂，避免了含有苯类等有机溶剂所带来的易燃易爆等安全问题以及环保、健康问题而越来越受到市场欢迎。汽车传动轴为圆管型钢结构件，壁厚、导热慢，工件常采用铁系磷化液处理，表面呈彩色光滑面，因此导致水性涂层其耐腐蚀更差；工件通常采用圆盘式静电涂装工艺，一次性膜厚可达50-70微米，目前国内汽车传动轴涂装主要以双组份聚氨酯体系及环氧体系涂料为主，存在严重易燃易爆危险，VOC排放高，严重影响喷涂工人的身体健康，因此，汽车传动轴涂装急需向环保化、低碳化方向发展。
CN 104558436A公开了一种丙烯酸改性环氧磷酸酯树脂及其水分散体的制备方法，采用磷酸与环氧反应引入磷酸基团，通过丙烯酸酯类单体进行改性，引入亲水性羧基，其优点在于所用环氧树脂为固体环氧、分子量大，干燥快，树脂中羟基较多，需要添加氨基树脂高温下交联固化；其缺点在于树脂低温固化过程中无交联结构，呈线性大分子量树脂，耐腐蚀差。
CN101851396A公开了一种水性环氧酯树脂组合物及其制备方法以及用其制备的水性涂料，通过预制含羧基乙烯基聚合物和脂肪酸与环氧树脂开环反应，制备乙烯酸改性环氧酯树脂。其优点在于实现了环氧树脂低温或室温交联固化；其缺点在于采用的环氧树脂为高环氧当量树脂，干燥慢、易回粘，树脂自身润湿性差，没有与金属基材键合的功能性基团，耐腐蚀性一般。
CN 101085898A公开了一种环保型常温固化水性环氧树脂涂料及其制备方法，其涉及的水性涂料为双组份环氧涂料，采用直接乳化-固化法制备水性环氧涂料，由此制备的水性涂料具有优异的性能。但是双组份涂料施工活化期短，施工不方便，易造成浪费，且随着时间的增加，油漆的性能下降较快，不利于传动轴静电涂装。由此可见，目前已公布的水性涂料技术涂装工艺或水性树脂技术都没有能够满足汽车传动轴低温固化、流水线生产以及高耐腐蚀性的单组份水性涂料。
发明内容
本发明的目的之一是提供一种适用于汽车传动轴用水性防腐涂料的圆盘式静电涂装工艺，解决铁系磷化处理钢结构件水性单组份涂层耐腐蚀性问题、低温固化单组份涂层下线干燥性、抗粘性问题以及单组份水性涂料技术如何满足圆盘式静电涂装流挂与流平的技术问题。
本发明第一个目的通过以下技术方案来实现：一种适用于汽车传动轴用水性防腐涂料的圆盘式静电涂装工艺：采用圆盘式静电喷枪往表面经过铁系磷化处理的钢结构件喷涂水性防腐涂料，而后干燥，其中，所述的水性防腐涂料包括以下重量百分比的组份：
氧化干燥型环氧磷酸酯树脂 50～70%
颜料及填料 5～15%
功能性防锈颜料 5～15%
功能性促进剂 1～2%
去离子水 10～20%。
本发明的涂装工艺的施工现场环境湿度50-80%，温度0-45度；所述工件为圆管型钢结构件，涂装前工件表面温度达到35-45度；所述的圆盘式静电喷枪的圆盘直径为12厘米，喷涂距离为1.4米，圆盘转速为20000-30000转，静电高压为50-75千伏，要求油漆施工粘度在25℃时，涂2#杯为20-30秒，油漆施工触变值为2.0-2.5之间。所述的干燥方式是指80度30分钟实干，下线后堆叠不回粘。本发明喷涂为一次性厚涂，即干膜厚度大于50微米。
本发明的目的之二是提供一种上述涂装工艺用的水性涂料。具体地，所述水性涂料包括以下重量百分比的组份：
氧化干燥型环氧磷酸酯树脂 50～70%
颜料及填料 5～15%
功能性防锈颜料 5～15%
功能性促进剂 1～2%
去离子水 10～20%。
本发明所述的氧化干燥型环氧磷酸酯树脂是指具有环氧基团、磷酸酯基团以及不饱和共轭双键的丙烯酸磷酸酯改性大分子量环氧酯树脂。作为本发明的一个实施例，该氧化干燥型环氧磷酸酯树脂主要由环氧树脂E03、脂肪酸和丙烯酸酯类单体在引发剂、助溶剂和中和剂存在下制备而成，其中使用的助溶剂为乙二醇单丁醚，中和剂为三乙胺，引发剂为过氧化氢异丙苯。其中，所述环氧树脂是指环氧值为0.025-0.045的E03，其中环氧树脂占固体总重量的25-35%；脂肪酸是指棕榈油酸与亚麻油酸的混合物，混合比为1﹕1，脂肪酸含量占固体总重量的1-5%；丙烯酸酯类单体占固体总重量的50-70%，其中功能性丙烯酸磷酸酯单体占10-20%，树脂的酸值控制在15-20mgKOH/g。所述固化总重量是指除去水、助溶剂之后的固体含量。
本发明所述的氧化干燥型环氧磷酸酯树脂其制备方法包括以下步骤：把助溶剂和环氧树脂E03加入反应釜，升温至溶解，搅拌，同时往反应釜中加入脂肪酸，升温至200-240℃进行脂肪酸-环氧开环反应，至反应物的酸值为4-8 mgKOH/g；然后把反应釜温度冷却至150-180℃，缓慢滴加丙烯酸酯类单体的混合物和引发剂，滴加时间控制在2.5-3.5小时，保温2小时；最后降温至90-100℃，加入中和剂中和至PH值为8.0-10.0，然后将定量的热水在1500转/分钟的转速下缓慢滴加到反应釜，乳化分散，得到含有丙烯酸磷酸酯改性的环氧磷酸酯树脂水分散体，树脂的酸值控制在15-20mgKOH/g，固含为40-45%。
本发明所述的颜料及填料是指铁黑、碳黑N330和硅微粉C499；所述的功能性防锈颜料是指磷酸锌ZP30与有机杂环化合物LD-4的混合物，混合比例为2-4﹕1。
本发明所述的功能性促进剂是指含有双氨基、烷基官能化的水性低聚硅氧烷HYDROSIL2909，其为可控的硅氧烷低聚物，在水中能稳定分散及储存，结构中含有的双氨基能在低温下与环氧磷酯树脂进行交流反应，而结构中另一端的烷基官能团有利于提高助剂与树脂的相容性，增加功能性促进剂在油漆中的储存稳定性。
上述防腐涂料的制备工艺，包括以下步聚：
(1) 把氧化干燥型环氧磷酸酯加入搅拌桶中600-1000r/min低速分散，然后投入颜料、填料及功能性防锈颜料，然后以1500-2000r/min的转速中速搅拌30分钟，然后转移至砂磨机中研磨至细度小于20微米，过程中注意控制温度低于45度。
(2) 在搅拌条件下把助剂加入到步骤1中，1500-2000r/min速度分散20-30分钟，冷却至室温，然后用200目滤网过滤。
本发明与现有技术相比具有如下优点：
水性涂膜低温固化耐腐蚀性差，犹其在经铁系磷化处理的工件表面，其耐腐蚀性更差。同时，与溶剂型双组份环氧涂料、聚氨酯涂料相比，水性单组份涂层其下线干燥性差，表面易粘，影响流水线生产，选择快干型的丙烯酸体系，一方面其耐腐蚀性不足，另一方面，由于油漆表干过快而不利于圆盘式静电涂装的表面效果。而本发明通过氧化干燥型环氧磷酸酯树脂在大分子量环氧树脂主链上引入磷酸酯基团、丙烯酸酯结构、不饱和脂肪酯结构，解决大分子量环氧树脂的水性化问题，解决水性环氧酯树脂干燥性差及耐腐蚀性问题。同时，在涂料中引入功能性促进剂HYDROSIL2909，利用助剂中含有的双氨基结构及烷基结构，增加水性低聚硅氧烷在水性涂料中的稳定性，利用双氨基的高反应活性，有效提升水性树脂的交联密度及干燥速度，解决水性单组份涂层在铁系磷化处理表面的耐腐蚀性问题。
具体实施方式
下面列举一部分具体实施例对本发明进行说明，有必要在此指出的是以下具体实施例只用于对本发明作进一步说明，不代表对本发明保护范围的限制。其他人根据本发明做出的一些非本质的修改和调整仍属于本发明的保护范围。
实施例1~5中的氧化干燥型环氧磷酸酯树脂的制备方法：把助溶剂乙二醇单丁醚和环氧树脂E03加入反应釜，升温至160±5℃溶解，以600转/分钟的速度低速搅拌，然后往反应釜中加入脂肪酸，该脂肪酸由棕榈油酸与亚麻油酸按质量比1:1的组合，升温至200-240℃进行脂肪酸-环氧开环反应，至反应物的酸值为4-8 mgKOH/g；然后把反应釜温度冷却至150-180℃，缓慢滴加丙烯酸酯类单体的混合物和过氧化氢异丙苯引发剂，滴加时间控制在2.5-3.5小时，保温2小时；最后降温至90-100℃，加入中和剂三乙胺中和至PH值为8.0-10.0，然后将定量的热水在1500转/分钟的转速下缓慢滴加到反应釜，乳化分散，得到含有丙烯酸磷酸酯改性的环氧磷酸酯树脂水分散体，树脂的酸值控制在15-20mgKOH/g，固含为40-45%。
将上述实施例1-5的水性防腐涂料用去离子水稀释后，采用圆盘式静电喷枪，喷涂于表面经过除油、除锈及铁系磷化处理的钢型圆管件，固化条件为80度30分钟。施工现场环境湿度50-80%，温度0-45度。钢型圆管件涂装前工件表面温度达到35-45度。圆盘式静电喷枪的圆盘直径为12厘米，喷涂距离为1.4米，圆盘转速为20000-30000转，静电高压为50-75千伏，要求油漆施工粘度在25℃时，涂2#杯为20-30秒，油漆施工触变值为2.0-2.5之间。所述的干燥方式是指80度30分钟实干，下线后堆叠不回粘。喷涂为一次性厚涂，即干膜厚度大于50微米。
完全固化后涂膜性能参见表二：
由表二可见，实施例1-5综合性能好，能够满足汽车传动轴贺盘式静电涂装的生产需求。
Claims (10)
1.一种适用于汽车传动轴用水性防腐涂料的圆盘式静电涂装工艺，其特征是，采用圆盘式静电喷枪往表面经过铁系磷化处理的钢结构件喷涂水性防腐涂料，而后干燥，其中，所述的水性防腐涂料包括以下重量百分比的组份：
氧化干燥型环氧磷酸酯树脂 50～70%
颜料及填料 5～15%
功能性防锈颜料 5～15%
功能性促进剂 1～2%
去离子水 10～20%。
2.根据权利要求1所述的适用于汽车传动轴用水性防腐涂料的圆盘式静电涂装工艺，其特征是，涂装的施工现场环境湿度50-80%，温度0-45度；所述工件为圆管型钢结构件，涂装前工件表面温度达到35-45度；所述的圆盘式静电喷枪的圆盘直径为12厘米，喷涂距离为1.4米，圆盘转速为20000-30000转，静电高压为50-75千伏，要求油漆施工粘度在25℃时，涂2#杯为20-30秒，油漆施工触变值为2.0-2.5之间；所述的干燥方式是指80度30分钟实干；所述喷涂为一次性厚涂，即干膜厚度大于50微米。
3.一种适用于圆盘式静电涂装工艺的水性涂料，其特征是，包括以下重量百分比的组份：
氧化干燥型环氧磷酸酯树脂 50～70%
颜料及填料 5～15%
功能性防锈颜料 5～15%
功能性促进剂 1～2%
去离子水 10～20%。
4.根据权利要求3所述的水性涂料，其特征是，所述的氧化干燥型环氧磷酸酯树脂是指具有环氧基团、磷酸酯基团以及不饱和共轭双键的丙烯酸磷酸酯改性大分子量环氧酯树脂。
5.根据权利要求4所述的水性涂料，其特征是，所述氧化干燥型环氧磷酸酯树脂主要由环氧树脂E03、脂肪酸和丙烯酸酯类单体在引发剂、助溶剂和中和剂存在下制备而成。
6.根据权利要求5所述的水性涂料，其特征是，所述环氧树脂是指环氧值为0.025-0.045的E03，其中环氧树脂占固体总重量的25-35%；所述脂肪酸是指棕榈油酸与亚麻油酸的混合物，混合比为1﹕1，脂肪酸含量占固体总重量的1-5%；所述丙烯酸酯类单体占固体总重量的50-70%，其中功能性丙烯酸磷酸酯单体占10-20%，树脂的酸值控制在15-20mgKOH/g；所述助溶剂为乙二醇单丁醚，中和剂为三乙胺，引发剂为过氧化氢异丙苯。
7.根据权利要求5所述的水性涂料，其特征是，所述的氧化干燥型环氧磷酸酯树脂其制备方法包括以下步骤：把助溶剂和环氧树脂E03加入反应釜，升温至溶解，搅拌，同时往反应釜中加入脂肪酸，升温至200-240℃进行脂肪酸-环氧开环反应，至反应物的酸值为4-8mgKOH/g；然后把反应釜温度冷却至150-180℃，缓慢滴加丙烯酸酯类单体的混合物和引发剂，滴加时间控制在2.5-3.5小时，保温2小时；最后降温至90-100℃，加入中和剂中和至PH值为8.0-10.0，然后将定量的热水在1500转/分钟的转速下缓慢滴加到反应釜，乳化分散，得到含有丙烯酸磷酸酯改性的环氧磷酸酯树脂水分散体，树脂的酸值控制在15-20mgKOH/g，固含为40-45%。
8.根据权利要求5所述的水性涂料，其特征是，所述的颜料及填料为铁黑、碳黑N330和硅微粉C499；所述的功能性防锈颜料为磷酸锌ZP30与有机杂环化合物LD-4的组合，混合比例为2-4﹕1。
9.根据权利要求5所述的水性涂料，其特征是，所述的功能性促进剂为含有双氨基、烷基官能化的水性低聚硅氧烷HYDROSIL2909。
10.权利要求3-9任一项所述的水性涂料的制备工艺，其特征是，包括以下步聚：
(1) 把氧化干燥型环氧磷酸酯加入搅拌桶中600-1000r/min低速分散，然后投入颜料、填料及功能性防锈颜料，然后以1500-2000r/min的转速中速搅拌30分钟，然后转移至砂磨机中研磨至细度小于20微米，控制研磨中温度低于45度；
(2) 在搅拌条件下把助剂加入到步骤(1)中，1500-2000r/min速度分散20-30分钟，冷却至室温，然后过滤。
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| CN110452391A (zh) * | 2019-07-08 | 2019-11-15 | 广州擎天材料科技有限公司 | 一种水性树脂及其制备方法与应用 |
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