Reciprocating piston compressor wear-resistant reinforced coating and preparation method and application thereof

Abstract

The invention discloses a wear-resistant enhanced coating for a reciprocating piston compressor as well as a preparation method and application of the wear-resistant enhanced coating, and solves the technical problems that the maintenance cost is increased and the production efficiency is influenced due to the adoption of a wear part replacement mode in the prior art. The coating comprises 30-70% of an intelligent polymer, 5-30% of nano-scale metal particles, 10-40% of a solvent and 1-10% of an additive. The sum of the weight percentages of the components is 100%. The intelligent polymer is polyvinyl alcohol, polyurethane, polyacrylate or epoxy resin. According to the invention, the worn part can be automatically repaired in the running process of the compressor. And nano-scale metal particles in the coating can be released and filled into an abrasion area under the action of friction force and heat to form new combination with the surrounding metal surface, so that the service life of the compressor is effectively prolonged.

Description

Technical Field

[0001] The invention relates to the technical field of wear-resistant enhanced coatings, and in particular to a reciprocating piston compressor wear-resistant enhanced coating and a preparation method and application thereof. Background Art

[0002] Reciprocating piston compressors are widely used in the industrial field, mainly for compressing gas or steam. However, due to the continuous friction between the piston and the cylinder wall, and the long-term wear of moving parts such as the connecting rod and crankshaft, the compressor often suffers from performance degradation or even failure after running for a period of time. The traditional solution is usually to regularly check and replace worn parts, but this method not only increases the company's maintenance costs, but may also reduce production efficiency due to downtime for maintenance.

[0003] In the prior art, although there are some solutions to the problem of compressor wear, such as the use of wear-resistant materials and optimized structural design, these methods are often difficult to fundamentally solve the wear problem and are costly. In addition, with the continuous development of industrial technology, the performance requirements for compressors are getting higher and higher, and traditional solutions can no longer meet the needs of modern industry.

[0004] In view of the above technical problems, the present invention proposes a wear-resistant enhanced coating for a reciprocating piston compressor and a preparation method and application thereof, aiming to achieve automatic repair of key wear parts of the compressor through the wear-resistant enhanced coating, thereby extending the service life of the compressor, reducing maintenance costs, and improving production efficiency. Summary of the invention

[0005] The purpose of the present invention is to provide a reciprocating piston compressor wear-resistant enhanced coating and its preparation method and application, so as to solve the technical problem that the method of replacing worn parts in the prior art not only increases maintenance costs but also affects production efficiency.

[0006] To achieve the above object, the present invention provides the following technical solutions: In a first aspect, the present invention provides a wear-resistant enhanced coating for a reciprocating piston compressor, wherein the wear-resistant enhanced coating is composed of the following components in weight percentage: 30-70% of a smart polymer, 5-30% of nano-scale metal particles, 10-40% of a solvent, and 1-10% of an additive; the sum of the weight percentages of the components is 100%; the smart polymer is polyvinyl alcohol, polyurethane, polyacrylate or epoxy resin.

[0007] Furthermore, the nano-scale metal particles are nano-silver particles, nano-copper particles, nano-zinc particles, nano-titanium particles or nano-aluminum particles. The nano-scale metal particles are made of metals with good wear resistance, corrosion resistance and lubricity. These particles will be used to fill the worn parts and form new metal surfaces. Suitable metal particles are selected according to the required performance. If high conductivity and antibacterial properties are required, nano-silver particles can be selected; if high wear resistance is required, nano-copper or nano-titanium particles can be selected.

[0008] Furthermore, the degree of polymerization of the polyvinyl alcohol is 500-2000, the degree of polymerization of the polyurethane is 1000-5000, the degree of polymerization of the polyacrylate is 800-3000, and the degree of polymerization of the epoxy resin is 300-1500.

[0009] Furthermore, the solvent includes water or an organic solvent, and the organic solvent is ethanol, acetone or xylene.

[0010] Furthermore, the additives include crosslinking agents, repair groups or microcapsules, dispersants, antioxidants, light stabilizers, defoamers, thickeners, and initiators.

[0011] Furthermore, the cross-linking agent is isocyanate or epoxy resin, the repair group is a Diels-Alder reaction group, the dispersant is polyvinyl alcohol, polyacrylate or sodium hexametaphosphate, the antioxidant is a hindered phenol antioxidant, the light stabilizer is a hindered amine light stabilizer, the defoaming agent is silicone oil or polyether, the thickener is carboxymethyl cellulose, and the initiator is azobisisobutyronitrile.

[0012] In a second aspect, the present invention provides a method for preparing a wear-resistant enhanced coating for a reciprocating piston compressor, comprising the following steps: A1. Mixing the smart polymer, nano-scale metal particles, solvent and additives in proportion; A2. Mixing in a high-speed stirrer or ultrasonic disperser to ensure that the metal particles are evenly distributed in the polymer matrix to form a coating mixture; A3. The prepared coating mixture causes the polymer to undergo a cross-linking reaction under specific conditions to form a coating material with a three-dimensional network structure.

[0013] Furthermore, in step A3, the specific conditions are that the temperature is between 135° C. and 140° C., the pressure is at normal pressure or low pressure, and ultraviolet light is used for illumination.

[0014] In a third aspect, the present invention provides an application of a wear-resistant enhanced coating for a reciprocating piston compressor, comprising the following steps: B1. Pretreatment: Pretreatment of the key wear parts of the compressor, including cleaning, rust removal and degreasing, to ensure that the coating can firmly adhere to the metal surface; B2. Coating construction: Use spraying, brushing or dipping to evenly coat the prepared wear-resistant enhanced coating on the key wear parts of the compressor, with a coating thickness of 30-100μm; B3. Curing: Place the coated compressor parts in an oven or heating device and perform curing at 135°C to 140°C; B4. Repair: When the reciprocating piston compressor is working, metal particles are released under the action of friction and heat, filling into the worn parts to form a new metal surface and achieve repair.

[0015] Furthermore, in step B1, the key wear includes the compressor piston, cylinder wall, connecting rod and crankshaft.

[0016] Based on the above technical solution, the embodiments of the present invention can at least produce the following technical effects: (1) The wear-resistant enhanced coating for a reciprocating piston compressor provided by the present invention can automatically repair worn parts during the operation of the compressor. The nano-scale metal particles in the coating can be released and filled into the worn area under the action of friction and heat, forming a new bond with the surrounding metal surface, thereby effectively extending the service life of the compressor. This repair mechanism reduces the performance degradation and failure risk caused by wear.

[0017] (2) The application of the wear-resistant enhanced coating for reciprocating piston compressors provided by the present invention solves the problem that the traditional compressor maintenance method usually requires regular inspection and replacement of worn parts. The traditional maintenance method not only increases the maintenance cost of the enterprise, but also may reduce production efficiency due to downtime for maintenance. The wear-resistant enhanced coating of the present invention can reduce the number of parts replacement and downtime for maintenance caused by wear, thereby effectively reducing maintenance costs. In addition, since the coating reduces friction resistance, it further reduces energy consumption, saving operating costs for the enterprise. DETAILED DESCRIPTION

[0018] The technical solutions in the embodiments of the present invention will be described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention. In addition, the technical solutions between the various embodiments can be combined with each other, but they must be based on the ability of ordinary technicians in this field to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0019] 1. Preparation Example Embodiment 1: Preparation of wear-resistant enhanced coating for reciprocating piston compressor 1.1 Components: 60% smart polymer, 15% nano-scale metal particles, 20% solvent, and 5% additives; the smart polymer is polyvinyl alcohol, the nano-scale metal particles are made of metallic silver, the solvent is ethanol, and the additives include toluene diisocyanate (TDI), Diels-Alder reaction groups, sodium hexametaphosphate, hindered phenol antioxidants, hindered amine light stabilizers, silicone oil, carboxymethyl cellulose, and azobisisobutyronitrile.

[0020] 1.2 Preparation method The following steps are involved: A1. Mixing the smart polymer, nano-scale metal particles, solvent and additives in proportion; A2. Mix and disperse in a high-speed stirrer or ultrasonic disperser to ensure that the metal particles are evenly distributed in the polymer matrix to form a coating mixture; A3. The prepared coating mixture causes the polymer to undergo a cross-linking reaction under specific conditions to form a coating material with a three-dimensional network structure.

[0021] 1.3 Application B1. Pretreatment: Pretreatment of the key wear parts of the compressor, including cleaning, rust removal and degreasing, to ensure that the coating can firmly adhere to the metal surface; B2. Coating construction: Use spraying to evenly coat the prepared wear-resistant enhanced coating on the key wear parts of the compressor. During construction, attention should be paid to controlling the coating thickness and uniformity; B3. Curing: Place the coated compressor parts in an oven or heating device and perform curing at a specific temperature.

[0022] Example 2 Preparation of wear-resistant enhanced coating for reciprocating piston compressor 2.1 Components: 70% smart polymer, 19% nano-scale metal particles, 10% solvent, and 1% additives; the smart polymer is polyurethane, the nano-scale metal particles are made of metallic copper, the solvent is acetone, and the additives include epoxy resin, Diels-Alder reactive groups, isocyanate, hindered phenol antioxidants, hindered amine light stabilizers, silicone oil, carboxymethyl cellulose, and azobisisobutyronitrile.

[0023] 2.2 Preparation method The following steps are involved: A1. Mixing the smart polymer, nano-scale metal particles, solvent and additives in proportion; A2. Mix and disperse in a high-speed stirrer or ultrasonic disperser to ensure that the metal particles are evenly distributed in the polymer matrix to form a coating mixture; A3. The prepared coating mixture causes the polymer to undergo a cross-linking reaction under specific conditions to form a coating material with a three-dimensional network structure.

[0024] 2.3 Application B1. Pretreatment: Pretreatment of the key wear parts of the compressor, including cleaning, rust removal and degreasing, to ensure that the coating can firmly adhere to the metal surface; B2. Coating construction: Use brushing to evenly apply the prepared wear-resistant enhanced coating on the key wear parts of the compressor. During construction, attention should be paid to controlling the coating thickness and uniformity; B3. Curing: Place the coated compressor parts in an oven or heating device and perform curing at a specific temperature.

[0025] Embodiment 3: Preparation of wear-resistant enhanced coating for reciprocating piston compressor 3.1 Components: 50% smart polymer, 10% nano-scale metal particles, 30% solvent, and 10% additives; the smart polymer is polyacrylate, the nano-scale metal particles are made of metallic silver, the solvent is xylene, and the additives include sodium hexametaphosphate, Diels-Alder reactive groups, epoxy resin, hindered phenol antioxidants, hindered amine light stabilizers, silicone oil, carboxymethyl cellulose, and azobisisobutyronitrile.

[0026] 3.2 Preparation method The following steps are involved: A1. Mixing the smart polymer, nano-scale metal particles, solvent and additives in proportion; A2. Mix and disperse in a high-speed stirrer or ultrasonic disperser to ensure that the metal particles are evenly distributed in the polymer matrix to form a coating mixture; A3. The prepared coating mixture causes the polymer to undergo a cross-linking reaction under specific conditions to form a coating material with a three-dimensional network structure.

[0027] 3.3 Application B1. Pretreatment: Pretreatment of the key wear parts of the compressor, including cleaning, rust removal and degreasing, to ensure that the coating can firmly adhere to the metal surface; B2. Coating construction: Use the dipping method to evenly coat the prepared wear-resistant enhanced coating on the key wear parts of the compressor. During construction, attention should be paid to controlling the coating thickness and uniformity; B3. Curing: Place the coated compressor parts in an oven or heating device and perform curing at a specific temperature.

[0028] Embodiment 4: Preparation of wear-resistant enhanced coating for reciprocating piston compressor 4.1 Components: 40% smart polymer, 10% nano-scale metal particles, 40% solvent, and 10% additives; the smart polymer is epoxy resin, the nano-scale metal particles are made of titanium, the solvent is ethyl water, and the additives include sodium hexametaphosphate, repair microcapsules, polyvinyl alcohol, hindered phenol antioxidants, hindered amine light stabilizers, silicone oil, carboxymethyl cellulose, and azobisisobutyronitrile.

[0029] 4.2 Preparation method Same as Example 1.

[0030] 4.3 Application Same as Example 1.

[0031] Embodiment 5: Preparation of wear-resistant enhanced coating for reciprocating piston compressor 5.1 Components: 70% smart polymer, 19% nano-scale metal particles, 10% solvent, and 1% additives; the smart polymer is polyurethane, the nano-scale metal particles are made of metal aluminum, the solvent is acetone, and the additives include cross-linking agent, repair microcapsule, dispersant, stabilizer, defoamer, chain extender, and catalyst.

[0032] 5.2 Preparation method Same as Example 1.

[0033] 5.3 Application Same as Example 1.

[0034] 2. Performance Test The wear-resistant enhanced coatings of the reciprocating piston compressors prepared in Examples 1-5 were tested: 1. Wear resistance test: Use a wear tester to test the wear resistance of the coating to evaluate its wear resistance during use.

[0035] 2. Repair performance test: simulate the friction and wear conditions during the operation of the compressor, observe and record the repair effect of the coating. Optimize the repair performance of the coating by adjusting the composition and preparation process of the coating material.

[0036] 3. Other performance tests: other performance tests such as high temperature resistance and lubricity are conducted to ensure that the coating meets the design requirements. The coated parts are placed in a high temperature environment, and their changes, including color, hardness, and strength, are observed and recorded. The degree of high temperature resistance is obtained from the recorded conditions. After testing, the wear-resistant enhanced coatings of the reciprocating piston compressors prepared in Examples 1-5 are all resistant to high temperatures; the lubricity of the coating is tested using a friction coefficient tester according to the standard test method ASTM D4172, and the friction coefficient and wear of the coating during the friction process are recorded.

[0037] The test results are shown in Table 1 below: Table 1 Performance test results The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, and these changes and improvements fall within the scope of the present invention to be protected. The scope of the present invention to be protected is defined by the attached claims and their equivalents.

Claims

1. Wear-resistant enhanced coating for reciprocating piston compressor, characterized in that: The wear-resistant enhanced coating is composed of the following components in weight percentage: 30-70% of smart polymer, 5-30% of nano-scale metal particles, 10-40% of solvent, and 1-10% of additives; the sum of the weight percentages of the components is 100%; The smart polymer is polyvinyl alcohol, polyurethane, polyacrylate or epoxy resin.

2. The wear-resistant enhanced coating for a reciprocating piston compressor according to claim 1, characterized in that: The nano-scale metal particles are nano-silver particles, nano-copper particles, nano-zinc particles, nano-titanium particles or nano-aluminum particles.

3. The wear-resistant enhanced coating for a reciprocating piston compressor according to claim 1, characterized in that: The polymerization degree of the polyvinyl alcohol is 500-2000, the polymerization degree of the polyurethane is 1000-5000, the polymerization degree of the polyacrylate is 800-3000, and the polymerization degree of the epoxy resin is 300-1500.

4. The wear-resistant enhanced coating for a reciprocating piston compressor according to claim 1, characterized in that: The solvent includes water or an organic solvent, and the organic solvent is ethanol, acetone or xylene.

5. The wear-resistant enhanced coating for a reciprocating piston compressor according to claim 1, characterized in that: The additives include crosslinking agents, repair groups or microcapsules, dispersants, antioxidants, light stabilizers, defoamers, thickeners, and initiators.

6. The wear-resistant enhanced coating for a reciprocating piston compressor according to claim 5, characterized in that: The crosslinking agent is isocyanate or epoxy resin, the repair group is a Diels-Alder reaction group, the dispersant is polyvinyl alcohol, polyacrylate or sodium hexametaphosphate, the antioxidant is a hindered phenol antioxidant, the light stabilizer is a hindered amine light stabilizer, the defoamer is silicone oil or polyether, the thickener is carboxymethyl cellulose, and the initiator is azobisisobutyronitrile.

7. The method for preparing the wear-resistant enhanced coating of a reciprocating piston compressor according to any one of claims 1 to 6, characterized in that: The following steps are involved: A1. Mixing the smart polymer, nano-scale metal particles, solvent and additives in proportion; A2. Mixing in a high-speed stirrer or ultrasonic disperser to ensure that the metal particles are evenly distributed in the polymer matrix to form a coating mixture; A3. The prepared coating mixture causes the polymer to undergo a cross-linking reaction under specific conditions to form a coating material with a three-dimensional network structure.

8. The method for preparing the wear-resistant enhanced coating of a reciprocating piston compressor according to claim 7, characterized in that: In step A3, the specific conditions are that the temperature is between 135° C. and 140° C., the pressure is at normal pressure or low pressure, and ultraviolet light is used for illumination.

9. Application of wear-resistant enhanced coating for reciprocating piston compressor, characterized in that: The following steps are involved: B1. Pretreatment: Pretreatment of key wear parts of the compressor, including cleaning, rust removal and degreasing, to ensure that the coating can firmly adhere to the metal surface; B2. Coating construction: Use spraying, brushing or dipping to evenly coat the prepared wear-resistant enhanced coating on the key wear parts of the compressor, with a coating thickness of 30-100μm; B3. Curing: Place the coated compressor parts in an oven or heating device and perform curing at 135°C to 140°C; B4. Repair: When the reciprocating piston compressor is working, metal particles are released under the action of friction and heat, filling into the worn parts to form a new metal surface and achieve repair.

10. The use of the wear-resistant enhanced coating for a reciprocating piston compressor according to claim 9, characterized in that: In step B1, the key wear includes the compressor piston, cylinder wall, connecting rod and crankshaft.

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