Railway rod insulator and manufacturing method thereof

Abstract

The present invention relates to a railway rod-type insulator and a manufacturing method thereof, belonging to the technical field of rod-type insulator preparation. The railway rod-type insulator comprises an insulator body and an antifouling layer coated on its surface; the antifouling layer comprises the following raw materials: methylphenyl silicone rubber, an adhesion promoter, ethyl acetate, ethyl orthosilicate, and dibutyltin dilaurate; the adhesion promoter is a hyperbranched epoxy resin having the characteristics of a hyperbranched structure and low viscosity, and its molecular chain is not easily entangled, so that it still has good compatibility with methylphenyl silicone rubber without the introduction of a silane coupling agent. The adhesion promoter utilizes a large number of epoxy groups contained in the adhesion promoter to generate a large number of hydroxyl groups upon curing and ring opening, thereby enhancing the adsorption of metals on the insulator surface and thus improving the adhesion of the antifouling coating. The adhesion promoter contains pyridinic nitrogen to form a complex with the metal on the insulator surface, and the ππ stacking effect of the pyridine ring further improves the adhesion performance of the antifouling coating.

Description

Technical Field

[0001] The present invention belongs to the technical field of rod-type insulator preparation, and in particular relates to a railway rod-type insulator and a method for preparing the same. Background Art

[0002] Railway rod insulators provide electrical insulation and mechanical support in power systems. However, they are constantly exposed to the air, and their operating environment is severely impacted by bird strikes, thunderstorms, and other factors. When air humidity is low, the contamination layer covering the insulator surface is non-conductive, allowing the insulator to operate reliably and safely. However, when air humidity is high, the soluble salts contained in the contamination dissolve in water, forming conductive ions. Under the operating voltage, leakage current flows through the insulator surface. The thermal effect of this current causes multiple dry areas to form on the insulator surface. The resistance of these dry areas is much greater than that of the wet areas. The higher voltages applied to these dry areas cause localized electric field distortion, generating arcs, which can even develop into flashovers across the poles under certain conditions. Therefore, improving the anti-pollution capabilities of railway rod insulators is one way to prevent and reduce pollution flashover accidents involving these insulators.

[0003] For example, Chinese patent CN201610339859.4 discloses a self-cleaning high-strength rod-shaped porcelain insulator, which includes an insulator body, and a layer or several layers of nano-molecular structure layers are provided on the glaze layer on the surface of the body. The principle is: the functional substance long-chain alkylsilane is reacted with the glaze layer on the surface of the insulator, so that the functional substance is chemically bonded to the surface of the insulator to form a nano-scale multi-layer molecular structure. Among them, the long-chain alkylsilane includes one or more mixtures of dodecyltrimethoxysilane, vinyltriacetylsilane, and butadienyltriethoxysilane. It can be seen that in the above patent, an anti-fouling layer is formed on the surface of the insulator body by silicone, which is a silicone coating. It has poor adhesion and is prone to peeling and falling off of the anti-fouling coating, which ultimately leads to the failure of the anti-fouling layer and fails to achieve the purpose of preventing and reducing the occurrence of iron flashover accidents.

[0004] Therefore, the present invention provides a railway rod insulator and a manufacturing method thereof, wherein an anti-fouling layer that is not easy to peel or fall off is formed on the surface of the railway rod insulator body by modified organic silicon. Summary of the Invention

[0005] The object of the present invention is to provide a railway rod insulator and a manufacturing method thereof, so as to solve the problems mentioned in the background technology.

[0006] The purpose of the present invention can be achieved through the following technical solutions:

[0007] A railway rod-type insulator comprises an insulator body and an anti-fouling layer coated on the surface of the insulator body.

[0008] Furthermore, the antifouling layer comprises the following raw materials: methylphenyl silicone rubber, an adhesion promoter, ethyl acetate, ethyl orthosilicate and dibutyltin dilaurate.

[0009] Furthermore, the added mass of the adhesion promoter is 15-20% of the mass of the methyl phenyl silicone rubber.

[0010] Furthermore, the mass of the added ethyl acetate is 2-2.5 times the mass of the methyl phenyl silicone rubber.

[0011] Furthermore, the added mass of the tetraethyl orthosilicate is 2-3% of the mass of the methylphenyl silicone rubber.

[0012] Furthermore, the added mass of the dibutyltin dilaurate is 2-4% of the mass of the methylphenyl silicone rubber.

[0013] Furthermore, the adhesion promoter comprises the following steps:

[0014] Step A: After uniformly mixing 5-hydroxy-2-pyridinecarboxylic acid and toluene, heating to 80-85° C., adding dropwise toluene containing 2,2-dihydroxymethylpropionic acid, p-toluenesulfonic acid and methylhydroquinone, continuing stirring and reacting for 2-3 hours after complete addition, reducing the temperature to 60° C. and performing vacuum rotary evaporation to obtain a branched monomer, wherein the molar ratio of 5-hydroxy-2-pyridinecarboxylic acid and 2,2-dihydroxymethylpropionic acid is 1:1, the mass of the added p-toluenesulfonic acid is 2-3% of the mass of the 5-hydroxy-2-pyridinecarboxylic acid and 2,2-dihydroxymethylpropionic acid, and the mass of the added methylhydroquinone is 4-5% of the mass of the 5-hydroxy-2-pyridinecarboxylic acid and 2,2-dihydroxymethylpropionic acid;

[0015] In the above reaction, 5-hydroxy-2-pyridinecarboxylic acid is an AB-type monomer, and 2,2-dihydroxymethylpropionic acid is an AB2-type monomer. Under the action of p-toluenesulfonic acid catalyst and methylhydroquinone inhibitor, the hydroxyl and carboxyl groups of the two react to obtain a branched monomer. It can be seen that the branched monomer is an AB2-type branched monomer, and its molecular formula contains pyridinic nitrogen.

[0016] Step B: After uniformly mixing the branched monomer, p-toluenesulfonic acid and toluene, heat to 90-100° C., stir and react for 3-4 hours, heat to 100-110° C., continue stirring and reacting for 1-2 hours, then add toluene containing a capping agent and dibutyltin dilaurate, continue stirring and reacting for 6-8 hours, cool to 60° C. and perform vacuum rotary evaporation to obtain an adhesion promoter, wherein the mass ratio of the branched monomer to the capping agent is 26:45-50, the mass of the added p-toluenesulfonic acid is 2-3% of the mass of the branched monomer, and the mass of the added dibutyltin dilaurate is 2-3% of the mass of the capping agent.

[0017] In the above reaction, a hyperbranched polymer is obtained by utilizing the self-condensation polymerization reaction of the branched monomer, and the terminal groups of the hyperbranched polymer are carboxyl groups or hydroxyl groups. When a capping agent is added, the capped carboxyl groups or hydroxyl groups can react with the isocyanate in the capping agent, so that epoxy groups are introduced into the hyperbranched product.

[0018] Furthermore, the capping agent is prepared by the following steps:

[0019] After isophorone diisocyanate, dibutyltin dilaurate and acetone are evenly mixed and heated to 45-50°C, glycidol is slowly added dropwise with stirring. After the addition is complete, stirring and reacting are continued for 3-4 hours, and then the temperature is reduced to 30°C and vacuum rotary evaporation is performed to obtain a capping agent, wherein the molar ratio of isophorone diisocyanate to glycidol is 1:1, and the added mass of dibutyltin dilaurate is 1-3% of the total mass of isophorone diisocyanate and glycidol.

[0020] In the above reaction, isophorone diisocyanate and glycidol are reacted in a molar ratio of 1:1 to obtain a blocking agent. It can be seen that one mole of the blocking agent contains one mole of isocyanate groups and one mole of epoxy groups.

[0021] The manufacturing method of the railway rod insulator comprises the following steps:

[0022] Step 1: After uniformly mixing methylphenyl silicone rubber and ethyl acetate, an adhesion promoter is added and stirred evenly. Finally, ethyl orthosilicate and dibutyltin dilaurate are added and stirred until uniformly mixed to obtain a mixture;

[0023] Step 2: Grind and clean the surface of the railway rod insulator body, then apply the mixture on the surface of the railway rod insulator body, and solidify it after application.

[0024] Beneficial effects of the present invention:

[0025] To solve the problems in the background technology, the present invention uses methylphenyl silicone rubber as the film-forming resin of the anti-fouling layer, taking advantage of the low cost and excellent waterproof and anti-fouling properties of methylphenyl silicone rubber. At the same time, a homemade adhesion promoter is introduced to improve the adhesion between the anti-fouling layer and the insulator surface. The principle is explained as follows:

[0026] The adhesion promoter is a hyperbranched epoxy resin. First, it has the characteristics of a hyperbranched structure and low viscosity. Its molecular chains are not easily entangled, so it still has good compatibility with methyl phenyl silicone rubber without the introduction of a silane coupling agent. Second, the adhesion promoter utilizes a large number of epoxy groups contained in the adhesion promoter to generate a large number of hydroxyl groups through curing and ring opening, thereby enhancing the adsorption of the metal on the surface of the insulator, thereby improving the adhesion of the anti-fouling coating. Finally, the adhesion promoter contains pyridinic nitrogen to form a complex with the metal on the surface of the insulator, and the ππ stacking effect of the pyridinic ring further improves the adhesion performance of the anti-fouling coating.

[0027] In summary, the railway rod insulator provided by the present invention has excellent anti-fouling performance, and the anti-fouling coating has a strong adhesion effect. DETAILED DESCRIPTION

[0028] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0029] Example 1

[0030] Preparation of capping agent:

[0031] Mix 0.1 mol of isophorone diisocyanate, 0.3 g of dibutyltin dilaurate and 40 mL of acetone, heat to 45°C, slowly add 0.1 mol of glycidol dropwise while stirring, continue stirring and react for 4 hours, cool to 30°C and evaporate under reduced pressure to obtain the capping agent.

[0032] Example 2

[0033] Preparation of capping agent:

[0034] After 0.1 mol of isophorone diisocyanate, 0.9 g of dibutyltin dilaurate and 40 mL of acetone are mixed evenly and heated to 50°C, 0.1 mol of glycidol is slowly added dropwise while stirring. After the addition is complete, the reaction is continued with stirring for 3 hours, and the temperature is lowered to 30°C and vacuum rotary evaporation is performed to obtain a capping agent.

[0035] Example 3

[0036] Preparation of adhesion promoter:

[0037] Step A: 0.1 mol of 5-hydroxy-2-pyridinecarboxylic acid and 100 mL of toluene were mixed uniformly, heated to 80° C., and toluene containing 0.1 mol of 2,2-dihydroxymethylpropionic acid, 0.54 g of p-toluenesulfonic acid, and 1.1 g of methylhydroquinone was added dropwise. After the addition was complete, stirring was continued for 3 hours, and the temperature was reduced to 60° C. and vacuum rotary evaporation was performed to obtain a branched monomer;

[0038] Step B: 260 g of the branched monomer, 0.52 g of p-toluenesulfonic acid and 300 mL of toluene were mixed uniformly, heated to 90 ° C, stirred and reacted for 4 h, heated to 100 ° C, continued to stir and react for 2 h, and then 500 mL of toluene containing 450 g of the end-capping agent prepared in Example 1 and 0.9 g of dibutyltin dilaurate was added, and the reaction was continued with stirring for 6 h. The mixture was cooled to 60 ° C and evaporated under reduced pressure to obtain an adhesion promoter.

[0039] Example 4

[0040] Preparation of adhesion promoter:

[0041] Step A: 0.1 mol of 5-hydroxy-2-pyridinecarboxylic acid and 100 mL of toluene were mixed uniformly, heated to 85° C., and toluene containing 0.1 mol of 2,2-dihydroxymethylpropionic acid, 0.71 g of p-toluenesulfonic acid, and 1.8 g of methylhydroquinone was added dropwise. After the addition was complete, stirring was continued for 2 hours, and the temperature was reduced to 60° C. and vacuum rotary evaporation was performed to obtain a branched monomer;

[0042] Step B: 260 g of the branched monomer, 0.78 g of p-toluenesulfonic acid and 300 mL of toluene were mixed uniformly, heated to 100 ° C, stirred and reacted for 3 h, heated to 110 ° C, continued to stir and react for 1 h, and then 500 mL of toluene containing 500 g of the end-capping agent prepared in Example 2 and 1.5 g of dibutyltin dilaurate was added, and the reaction was continued with stirring for 8 h. The mixture was cooled to 60 ° C and evaporated under reduced pressure to obtain an adhesion promoter.

[0043] Example 5

[0044] Preparation of a railway rod insulator:

[0045] Step 1: After uniformly mixing the methylphenyl silicone rubber and ethyl acetate, add the adhesion promoter prepared in Example 3 and stir evenly. Finally, add ethyl orthosilicate and dibutyltin dilaurate, and continue stirring until uniformly mixed to obtain a mixture; the added mass of the adhesion promoter is 15% of the mass of the methylphenyl silicone rubber; the added mass of the ethyl acetate is 2 times the mass of the methylphenyl silicone rubber; the added mass of the ethyl orthosilicate is 2% of the mass of the methylphenyl silicone rubber; and the added mass of the dibutyltin dilaurate is 2% of the mass of the methylphenyl silicone rubber;

[0046] Step 2: Grind and clean the surface of the railway rod insulator body, then apply the mixture on the surface of the railway rod insulator body, and solidify it after application.

[0047] Example 6

[0048] Preparation of a railway rod insulator:

[0049] Step 1: After uniformly mixing the methylphenyl silicone rubber and ethyl acetate, add the adhesion promoter prepared in Example 4 and stir evenly. Finally, add ethyl orthosilicate and dibutyltin dilaurate, and continue stirring until uniformly mixed to obtain a mixture; the added mass of the adhesion promoter is 20% of the mass of the methylphenyl silicone rubber; the added mass of the ethyl acetate is 2.5 times the mass of the methylphenyl silicone rubber; the added mass of the ethyl orthosilicate is 3% of the mass of the methylphenyl silicone rubber; and the added mass of the dibutyltin dilaurate is 4% of the mass of the methylphenyl silicone rubber;

[0050] Step 2: Grind and clean the surface of the railway rod insulator body, then apply the mixture on the surface of the railway rod insulator body, and solidify it after application.

[0051] Example 7

[0052] Preparation of a railway rod insulator:

[0053] Step 1: After uniformly mixing the methylphenyl silicone rubber and ethyl acetate, add the adhesion promoter prepared in Example 3 and stir evenly. Finally, add ethyl orthosilicate and dibutyltin dilaurate, and continue stirring until uniformly mixed to obtain a mixture; the added mass of the adhesion promoter is 20% of the mass of the methylphenyl silicone rubber; the added mass of the ethyl acetate is 2.5 times the mass of the methylphenyl silicone rubber; the added mass of the ethyl orthosilicate is 3% of the mass of the methylphenyl silicone rubber; and the added mass of the dibutyltin dilaurate is 4% of the mass of the methylphenyl silicone rubber;

[0054] Step 2: Grind and clean the surface of the railway rod insulator body, then apply the mixture on the surface of the railway rod insulator body, and solidify it after application.

[0055] Comparative Example 1

[0056] Preparation of a railway rod insulator: Compared with Example 5, the adhesion promoter is replaced with an adhesion promoter prepared in the following steps, and the rest is the same:

[0057] After uniformly mixing 260 g of 2,2-dihydroxymethylpropionic acid, 0.52 g of p-toluenesulfonic acid and 300 mL of toluene, heat to 90 ° C, stir and react for 4 h, raise the temperature to 100 ° C, continue stirring and react for 2 h, then add 500 mL of toluene containing 450 g of end-capping agent and 0.9 g of dibutyltin dilaurate, continue stirring and react for 6 h, cool to 60 ° C and evaporate under reduced pressure to obtain an adhesion promoter.

[0058] Comparative Example 2

[0059] Preparation of a railway rod insulator: Compared with Example 6, an equal amount of the adhesion promoter is replaced with methylphenyl silicone rubber, and the rest is the same.

[0060] Example 8

[0061] The anti-fouling coatings of the insulators obtained in Examples 5-7 and Comparative Examples 1-2 were subjected to the following performance tests:

[0062] Contact angle: At room temperature and 45% relative humidity, a 2 μL drop of water was placed on the antifouling coating using a micropipette. A digital camera was used to observe the water drop image and measure the contact angle. Each sample was tested three times and the average value was taken.

[0063] Adhesion: Tested in accordance with GB / T 9286. Adhesion is divided into six levels from 0 to 5, with 0 being the best and 5 being the worst.

[0064] The above tests are shown in Table 1.

[0065]

[0066] It can be seen from the data in Table 1 that the adhesion properties of the anti-fouling coatings of the insulators obtained in Examples 5-7 are better than those of the anti-fouling coatings of the insulators obtained in Comparative Examples 1-2.

[0067] Throughout the specification, references to terms such as "one embodiment," "example," or "specific example" indicate that the specific features, structures, materials, or characteristics described in conjunction with that embodiment or example are included in at least one embodiment or example of the present invention. In this specification, schematic representations of these terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0068] The above contents are merely examples and explanations of the present invention. Those skilled in the art may make various modifications or additions to the described specific embodiments or replace them in similar ways. As long as they do not deviate from the invention or exceed the scope defined by the claims, they should all fall within the scope of protection of the present invention.

Claims

1. A railway rod insulator, characterized in that: The invention comprises an insulator body and an anti-fouling layer coated on the surface of the insulator body; the anti-fouling layer comprises the following raw materials: methyl phenyl silicone rubber, adhesion promoter, ethyl acetate, ethyl orthosilicate and dibutyltin dilaurate; The adhesion promoter comprises the following steps: Step A: After uniformly mixing 5-hydroxy-2-pyridinecarboxylic acid and toluene, heat to 80-85° C., dropwise add toluene containing 2,2-dihydroxymethylpropionic acid, p-toluenesulfonic acid and methylhydroquinone, continue stirring and reacting for 2-3 hours after complete addition, and vacuum rotary evaporate to obtain a branched monomer; Step B: After the branched monomer, p-toluenesulfonic acid and toluene are uniformly mixed, the mixture is heated to 90-100° C., stirred and reacted for 3-4 hours, and then the mixture is heated to 100-110° C., stirred and reacted for 1-2 hours, and then toluene containing a capping agent and dibutyltin dilaurate is added, stirred and reacted for 6-8 hours, and vacuum rotary evaporation is performed to obtain an adhesion promoter; The added mass of the adhesion promoter is 15-20% of the mass of the methyl phenyl silicone rubber; The added mass of the ethyl acetate is 2-2.5 times the mass of the methyl phenyl silicone rubber; In step A, the molar ratio of 5-hydroxy-2-pyridinecarboxylic acid to 2,2-dihydroxymethylpropionic acid is 1:1; In step B, the mass ratio of the branching monomer to the end-capping agent is 26:45-50; The end-capping agent comprises the following steps: After isophorone diisocyanate, dibutyltin dilaurate and acetone are evenly mixed and heated to 45-50°C, glycidol is slowly added dropwise while stirring. After the addition is complete, the mixture is stirred and reacted for 3-4 hours, and then vacuum rotary evaporation is performed to obtain a capping agent; The molar ratio of isophorone diisocyanate and glycidol is 1:1, and the added mass of dibutyltin dilaurate is 1-3% of the total mass of isophorone diisocyanate and glycidol.

2. The method for manufacturing a railway rod insulator according to claim 1, characterized in that: The following steps are involved: Step 1: After uniformly mixing methylphenyl silicone rubber and ethyl acetate, an adhesion promoter is added and stirred evenly. Finally, ethyl orthosilicate and dibutyltin dilaurate are added and stirred until uniformly mixed to obtain a mixture; Step 2: Grind and clean the surface of the railway rod insulator body, then apply the mixture on the surface of the railway rod insulator body, and solidify it after application.

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