Acid, alkali and salt resistant enamel coating, its preparation method and application in cable bridge

Abstract

The application discloses an acid, alkali and salt resistant enamel coating and a preparation method and application thereof in cable bridge, and belongs to the technical field of anticorrosive materials. The acid, alkali and salt resistant enamel coating is prepared from the following raw materials in parts by weight: 100 parts of silica ore, 20-35 parts of borax, 5-15 parts of magnesium carbonate, 8-20 parts of sodium aluminate, 10-15 parts of Al2O3, 3-8 parts of ZrO2, 1-4 parts of TiO2, 5-10 parts of Li2O, 4-8 parts of Na2O, 1-1.5 parts of CoO, 2-4 parts of NiO and 3-5 parts of MnO. The enamel composite cable bridge is obtained by electrostatically spraying glaze on a steel framework and sintering, the adhesion between the outer enamel and the inner steel plate is good, the enamel coating is thin, and the surface is smooth, so that the bridge has excellent acid, alkali and salt corrosion resistance under the premise of meeting the large-span requirement, and the problem that the bridge is prone to corrosion at the present stage is solved.

Description

Technical Field

[0001] This invention belongs to the field of anti-corrosion materials technology, specifically relating to an acid, alkali and salt resistant enamel coating, its preparation method and its application in cable trays. Background Technology

[0002] The information disclosed in this background section is intended only to enhance understanding of the overall background of the invention and is not necessarily to be construed as an admission or in any way implying that such information constitutes prior art known to those skilled in the art.

[0003] Cable trays are a common type of electrical equipment. Currently, in the field of cable trays, there are generally three treatment methods to achieve corrosion protection: first, galvanizing the surface of the steel cable tray; second, covering the internal steel frame with fiberglass or plastic; and third, directly producing polymer cable trays from plastic. However, the drawbacks of these three types of cable trays are also obvious. The galvanized layer of galvanized cable trays is not firmly adhered and is prone to peeling off, and it is not resistant to acid and alkali corrosion; the fiberglass or plastic-coated steel cable trays generally have a coating layer of more than 0.5cm, making the cable trays bulky and unsightly; and polymer cable trays, due to material limitations, cannot meet the mechanical properties of steel cable trays, making them unsuitable for applications requiring large spans.

[0004] Enamel is a coating produced through high-temperature sintering. Its manufacturing process involves mixing various substances such as glass, quartz, potassium feldspar, boric acid, and kaolin, applying the mixture to a base metal or ceramic surface, and then sintering it at high temperatures. Enamel coatings are characterized by their smooth surface, high hardness, strong adhesion, rich colors, ease of cleaning, and good high-temperature and chemical resistance. However, enamel coatings are susceptible to stress, which can damage the coating and affect its lifespan. Compared to other anti-corrosion materials, enamel has relatively poor corrosion resistance and is easily affected by moisture, acidic gases, and oxidants. Furthermore, as it is mostly composed of ceramic materials, its adhesion strength to the metal substrate is often insufficient, leading to coating peeling over prolonged use.

[0005] Therefore, further research is needed to improve the adhesion strength between the enamel coating and the metal substrate, and to improve the corrosion resistance of the enamel coating, so as to apply the enamel coating to the corrosion protection of cable trays. Summary of the Invention

[0006] To address the shortcomings of existing technologies, the present invention aims to provide an acid, alkali, and salt resistant enamel coating, its preparation method, and its application in cable trays. The enamel coating provided by the present invention has excellent corrosion resistance and can solve the current problem of easy corrosion of cable trays.

[0007] To achieve the above objectives, the technical solution of the present invention is as follows:

[0008] A first aspect of the present invention provides an acid, alkali, and salt resistant enamel coating, said acid, alkali, and salt resistant enamel coating being composed of the following raw materials in parts by weight:

[0009] 100 parts silica ore, 20-35 parts borax, 5-15 parts magnesium carbonate, 8-20 parts sodium aluminate, 10-15 parts Al2O3, 3-8 parts ZrO2, 1-4 parts TiO2, 5-10 parts Li2O, 4-8 parts Na2O, 1-1.5 parts CoO, 2-4 parts NiO, and 3-5 parts MnO.

[0010] This invention introduces borax into the acid, alkali, and salt resistant enamel coating, which enhances the gloss of the enamel surface, making it smoother and more refined. This effectively prevents the steel frame from contacting the external environment, making it less susceptible to corrosion. Magnesium carbonate enhances the adhesion of the enamel, resulting in a stronger bond between the enamel layer and the steel frame, preventing detachment and extending the service life of the cable tray. Sodium aluminate, containing aluminum ions, reacts with metal oxides on the surface of the steel frame, improving the corrosion resistance of the enamel layer. Furthermore, sodium aluminate promotes the melting and flowability of the enamel material, lowering the processing temperature and thus reducing production costs. Through the synergistic effect of these materials, the adhesion strength between the enamel coating and the metal substrate is improved, as is the corrosion resistance of the enamel coating. This allows the acid, alkali, and salt resistant enamel coating of this invention to be applied to cable tray corrosion protection.

[0011] In some embodiments of the present invention, the acid, alkali, and salt resistant enamel coating is composed of the following raw materials in parts by weight:

[0012] 100 parts silica ore, 25-30 parts borax, 5-10 parts magnesium carbonate, 8-15 parts sodium aluminate, 12-15 parts Al2O3, 4-5 parts ZrO2, 2 parts TiO2, 5-6 parts Li2O, 4 parts Na2O, 1 part CoO, 2 parts NiO, and 3-4 parts MnO.

[0013] In some embodiments of the present invention, the acid, alkali, and salt resistant enamel coating is composed of the following raw materials in parts by weight:

[0014] 100 parts silica ore, 25 parts borax, 12 parts magnesium carbonate, 8 parts sodium aluminate, 12 parts Al2O3, 5 parts ZrO2, 2 parts TiO2, 6 parts Li2O, 4 parts Na2O, 1 part CoO, 2 parts NiO, and 3 parts MnO.

[0015] In some embodiments of the present invention, the acid, alkali, and salt resistant enamel coating is composed of the following raw materials in parts by weight:

[0016] 100 parts silica ore, 30 parts borax, 10 parts magnesium carbonate, 15 parts sodium aluminate, 15 parts Al2O3, 4 parts ZrO2, 2 parts TiO2, 5 parts Li2O, 4 parts Na2O, 1 part CoO, 2 parts NiO, and 4 parts MnO.

[0017] In some embodiments of the present invention, the silica ore has a silica content of more than 90 wt.% and a particle size distribution D75 of less than 10 micrometers.

[0018] A second aspect of the present invention provides a method for preparing the above-mentioned acid, alkali, and salt resistant enamel coating, comprising the following steps:

[0019] (1) Preparation of glaze: Weigh the raw materials of acid, alkali and salt enamel coating in proportion and stir to mix them to obtain glaze;

[0020] (2) The glaze is uniformly adhered to the substrate surface by electrostatic spraying;

[0021] (3) Sinter the glazed substrate so that the glaze melts and adheres evenly to the substrate surface. The sintering temperature is 800-900℃ and the sintering time is 1-5 minutes. Cool to obtain the product.

[0022] In some embodiments of the present invention, the stirring speed is 30-50 rpm and the stirring time is 20-50 min.

[0023] In some embodiments of the present invention, the electrostatic spraying is dry electrostatic spraying with a voltage of 70-100kV.

[0024] In some embodiments of the present invention, when electrostatically spraying glaze, the spraying thickness is 0.1 to 0.5 mm.

[0025] A third aspect of the present invention provides the application of the above-described acid, alkali, and salt resistant enamel coating or the acid, alkali, and salt resistant enamel coating prepared by the above-described preparation method in improving the acid, alkali, and salt corrosion resistance of cable trays.

[0026] In a fourth aspect, the present invention provides an enamel composite cable tray, comprising a steel frame, the surface of which is covered with the aforementioned acid, alkali and salt resistant enamel coating.

[0027] The enamel-lined composite cable tray is prepared by the following method:

[0028] (1) Preparation of glaze: Weigh the raw materials of acid, alkali and salt enamel coating in proportion and stir to mix them to obtain glaze;

[0029] (2) Making the steel frame: Fold the steel coil into the shape of a bridge frame and cut it to the required length;

[0030] (3) The glaze is uniformly adhered to the surface of the steel frame by electrostatic spraying, with a spraying thickness of 0.1 to 0.5 mm;

[0031] (4) Sinter the glazed substrate so that the glaze melts and adheres evenly to the surface of the steel frame. The sintering temperature is 800-900℃ and the sintering time is 1-5 minutes. Cool to obtain the final product.

[0032] In some embodiments of the present invention, the thickness of the enamel layer on the enamel composite cable tray obtained after cooling is 0.15 to 0.28 mm.

[0033] The beneficial effects of this invention are as follows:

[0034] This invention provides an acid, alkali, and salt resistant enamel coating, which has excellent resistance to acid, alkali, and salt corrosion, good adhesion to the metal substrate, and is not easy to fall off; the enamel coating is relatively thin, has a smooth surface, and is aesthetically pleasing.

[0035] This invention also provides an enamel-coated composite cable tray, which is obtained by electrostatically spraying enamel onto a steel frame and sintering it. The inner layer is a steel frame, and the outer layer is an acid, alkali, and salt corrosion resistant enamel coating. The enamel coating is relatively thin and has a smooth surface, which makes the enamel-coated composite cable tray both aesthetically pleasing and provides excellent resistance to acid, alkali, and salt corrosion while meeting the requirements for large spans, thus solving the current problem of easy corrosion of cable trays. The adhesion between the outer enamel layer and the inner steel plate is good, making it difficult to fall off and resulting in a long service life. Detailed Implementation

[0036] To enable those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention will be described in detail below with reference to specific embodiments.

[0037] Example 1

[0038] A method for preparing an enamel-lined composite cable tray, wherein the raw material composition of the enamel layer is shown in Table 1.

[0039] The specific preparation method of enamel composite cable trays is as follows:

[0040] (1) Preparation of glaze: Weigh the raw materials of each enamel layer according to the formula in Table 1, stir evenly with a stirrer at a speed of 35 rpm for 45 min.

[0041] (2) Making steel frame: Use a bending machine to bend the steel coil into the shape of a bridge frame and cut it into steel frames with a length of 6 meters.

[0042] (3) Use electrostatic spraying to evenly adhere the glaze to the surface of the steel frame, with a spraying thickness of 0.2mm.

[0043] (4) Place the steel frame with glaze into the sintering furnace for drying and sintering, so that the glaze melts and adheres evenly to the surface of the steel frame. The sintering temperature is 850℃ and the sintering time is 3min.

[0044] (5) Remove the enamel bridge from the sintering furnace and let it cool.

[0045] The enamel-lined cable trays made using the above method have an enamel layer thickness of approximately 0.15-0.18 mm and exhibit excellent corrosion resistance.

[0046] Example 2

[0047] A method for preparing an enamel-lined composite cable tray, wherein the raw material composition of the enamel layer is shown in Table 1.

[0048] The specific preparation method of enamel composite cable trays is as follows:

[0049] (1) Preparation of glaze: Weigh the raw materials of each enamel layer according to the formula, stir evenly with a stirrer at a speed of 40 rpm for 40 min.

[0050] (2) Making steel frame: Use a bending machine to bend the steel coil into the shape of a bridge frame and cut it into steel frames with a length of 6 meters.

[0051] (3) Use electrostatic spraying to evenly adhere the glaze to the surface of the steel frame, with a spraying thickness of 0.25mm.

[0052] (4) Place the steel frame with glaze into the sintering furnace for drying and sintering, so that the glaze melts and adheres evenly to the surface of the steel frame. The sintering temperature is 800℃ and the sintering time is 3min.

[0053] (5) Remove the enamel bridge from the sintering furnace and let it cool.

[0054] The enamel-lined cable trays made using the above method have an enamel layer thickness of approximately 0.19-0.22 mm and exhibit excellent corrosion resistance.

[0055] Comparative Examples 1-3

[0056] Using the scheme of Example 1, an enamel composite cable tray was prepared according to the raw material composition given in Table 1.

[0057] Table 1. Raw material composition of the enamel layer in the examples and comparative examples.

[0058]

[0059]

[0060] Acid, alkali and salt corrosion resistance test

[0061] The enamel composite cable tray samples obtained in the examples and comparative examples were subjected to a 96-hour neutral salt spray test (salt resistance test), a 72-hour immersion test in 5% nitric acid (acid resistance test), and a 72-hour immersion test in 10% sodium hydroxide solution (alkali resistance test), respectively. After the tests, their appearance and whether the enamel layer had peeled off were observed. The test results are shown in Table 2.

[0062] Table 2. Results of acid, alkali, and salt resistance tests on samples obtained from the examples and comparative examples.

[0063]

[0064] Adhesion test

[0065] The enamel composite cable tray samples obtained in the examples and comparative examples were subjected to coating adhesion tests (GB / T9286). The test results are shown in Table 3.

[0066] Adhesion grading 0 0 1 2 2

[0067] Note: The grading of adhesion test results in GB / T 9286 is as follows:

[0068] Level 0: The cut edges are completely smooth, and there is no peeling within the mesh;

[0069] Level 1: A small amount of coating has peeled off at the intersection of the cuts, but the affected cross-cut area is no more than 5%;

[0070] Level 2: Coating peeling at the intersection of cuts and / or along the edges of cuts, with the affected cross-cut area being greater than 5% but not more than 15%;

[0071] Level 3: The coating is partially or completely peeled off in large fragments along the cut edge, and / or partially or completely peeled off at different locations on the grid, with the affected cross-cut area being greater than 15% but not more than 35%.

[0072] Level 4: Large fragments of coating peel off along the cut edge, and / or some squares are partially or completely peeled off, with the affected cross-cut area being greater than 35% but not greater than 65%.

[0073] Level 5: The degree of detachment exceeds that of Level 4.

[0074] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An acid, alkali, and salt resistant enamel coating, characterized in that, The acid, alkali, and salt resistant enamel coating is composed of the following raw materials in parts by weight: 100 parts silica ore, 25-30 parts borax, 5-10 parts magnesium carbonate, 8-15 parts sodium aluminate, 12-15 parts Al2O3, 4-5 parts ZrO2, 1-4 parts TiO2, 5-6 parts Li2O, 4-8 parts Na2O, 1-1.5 parts CoO, 2-4 parts NiO, and 3-4 parts MnO; The method for preparing the acid, alkali, and salt resistant enamel coating includes the following steps: (1) Preparation of glaze: Weigh the raw materials of acid, alkali and salt resistant enamel coating according to the proportion and stir to mix them to obtain glaze; (2) The glaze is uniformly adhered to the substrate surface by electrostatic spraying; (3) Sinter the glazed substrate so that the glaze melts and adheres evenly to the substrate surface. The sintering temperature is 800~900℃ and the sintering time is 1~5 min. Cool to obtain the product.

2. The acid, alkali, and salt resistant enamel coating as described in claim 1, characterized in that, The acid, alkali, and salt resistant enamel coating is composed of the following raw materials in parts by weight: 100 parts silica ore, 30 parts borax, 10 parts magnesium carbonate, 15 parts sodium aluminate, 15 parts Al2O3, 4 parts ZrO2, 2 parts TiO2, 5 parts Li2O, 4 parts Na2O, 1 part CoO, 2 parts NiO, and 4 parts MnO.

3. The acid, alkali, and salt resistant enamel coating as described in any one of claims 1-2, characterized in that, The silica ore has a silica content of over 90 wt.% and a particle size distribution D75 of less than 10 micrometers.

4. The acid, alkali, and salt resistant enamel coating as described in claim 1, characterized in that, The stirring is performed at a speed of 30-50 rpm for a duration of 40-50 min.

5. The acid, alkali, and salt resistant enamel coating as described in claim 1, characterized in that, The electrostatic spraying is a dry electrostatic spraying method with a voltage of 70~100 kV.

6. The acid, alkali, and salt resistant enamel coating as described in claim 1, characterized in that, When electrostatically spraying glaze, the coating thickness is 0.1~0.5 mm.

7. The application of the acid, alkali and salt resistant enamel coating according to any one of claims 1-6 in improving the acid, alkali and salt corrosion resistance of cable trays.

8. A porcelain-enamel composite cable tray, characterized in that, It includes a steel frame, the surface of which is covered with an acid, alkali and salt resistant enamel coating as described in any one of claims 1-6; The enamel-lined composite cable tray is prepared by the following method: (1) Preparation of glaze: Weigh the raw materials of acid, alkali and salt enamel coating in proportion and stir to mix them to obtain glaze; (2) Making the steel frame: Fold the steel coil into the shape of a bridge frame and cut it to the required length; (3) The glaze is uniformly adhered to the surface of the steel frame by electrostatic spraying, with a spraying thickness of 0.1~0.5 mm; (4) Sinter the glazed substrate so that the glaze melts and adheres evenly to the surface of the steel frame. The sintering temperature is 800~900℃ and the sintering time is 1~5 min. Cool to obtain the product.

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