A wear-resistant and deformation-resistant modified polyethylene composite material for carrier rollers and a preparation method thereof

Abstract

The application belongs to the technical field of composite materials, and particularly relates to a wear-resistant and deformation-resistant modified polyethylene composite material for a carrier roller and a preparation method thereof; the wear-resistant and deformation-resistant modified polyethylene composite material for the carrier roller comprises the following raw materials in parts by weight: 50-60 parts of HDPE, 20-30 parts of UHMWPE, 12-20 parts of a reinforcing filler, and 3-5 parts of PE-g-MAH; SCPP and MoS2 in the reinforcing filler form a core-shell structure through electrostatic adsorption, SCPP provides deformation resistance support for the composite material by virtue of its inorganic rigid skeleton, and the problem that the polyethylene matrix is easy to bend is solved; MoS2 is tightly coated on the surface of SCPP, the friction coefficient is reduced, and the agglomeration of MoS2 when added alone is avoided; PE-g-MAH forms chemical bonding with the hydroxyl groups on the surface of SCPP and the oxygen-containing groups on the edge of MoS2, the interfacial bonding force between the core-shell filler and the non-polar polyethylene matrix is significantly improved, and the interfacial defects are reduced.

Description

Technical Field

[0001] This invention belongs to the field of composite material technology, specifically relating to a wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers and its preparation method. Background Technology

[0002] In material handling systems in mining, ports, and logistics, idlers serve as the core component supporting the conveyor belt and materials, and their performance directly determines conveying efficiency and equipment maintenance costs. Currently, idlers on the market mainly use metals (such as carbon steel and stainless steel), ordinary polyethylene, and traditional modified PE as base materials. However, as conveying systems develop towards higher load capacity, longer lifespan, and lower energy consumption, existing materials are gradually revealing significant technical shortcomings: while metal idlers possess high rigidity and resistance to deformation, their high density leads to increased drive load and energy consumption in the conveying system; simultaneously, metal surfaces are prone to corrosion, and the high coefficient of friction of metal idlers can cause conveyor belt aging due to frictional heat during long-term operation, resulting in high maintenance and replacement costs.

[0003] To improve the performance of ordinary polyethylene, existing technologies mostly employ single-filler modification. However, single-filler modification easily leads to an increased coefficient of friction, exacerbating conveyor belt wear; the poor interfacial compatibility between the filler and the PE matrix also results in uneven filler dispersion, making it difficult to adapt to long-term stable industrial scenarios. Therefore, developing a composite material for idlers that combines excellent wear resistance, deformation resistance, low coefficient of friction, and controllable thermal stability has become an urgent technical problem to be solved in the field of conveyor equipment. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention proposes a wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers and its preparation method. This invention utilizes electrostatic adsorption to construct reinforcing fillers, resolving the issues of uneven mixing and dispersion and functional conflicts inherent in traditional fillers. Through processes such as matrix resin pretreatment, segmented temperature-controlled extrusion granulation, and gradient cooling molding, the stability of the core-shell structure and the absence of internal stress in the finished product are ensured. Simultaneously, the interfacial bonding is strengthened by PE-g-MAH compatibilizers, the processability and toughness are balanced by blending HDPE and UHMWPE, and stability is improved by compounding additives, forming a multi-component synergistic system. The resulting composite material exhibits comprehensive superiority over traditional systems in terms of deformation resistance, wear resistance, surface hardness, and aging resistance. It solves the problems of filler agglomeration in traditional single-filler modified polyethylene, as well as insufficient deformation resistance and wear resistance, effectively compensating for the shortcomings of traditional materials in rigidity, stability, and practicality.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0006] This invention provides a wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers, comprising the following raw materials in parts by weight: 50-60 parts HDPE (high-density polyethylene), 20-30 parts UHMWPE (ultra-high molecular weight polyethylene), 12-20 parts reinforcing filler, 3-5 parts PE-g-MAH (polyethylene grafted maleic anhydride), 0.1-0.3 parts antioxidant 1010, 0.2-0.5 parts antioxidant 168, and 0.5-1 parts calcium stearate;

[0007] The reinforcing filler comprises raw materials in the following mass ratio: SCPP (strontium calcium polyphosphate) micro powder:MoS2 = 8-12:5-8;

[0008] The method for preparing the reinforcing filler includes the following steps:

[0009] (1) Disperse SCPP micro powder in deionized water to prepare a suspension with a solid content of 10%, and sonicate it for 30 min to ensure full dispersion. Add MoS2 to the suspension and mechanically stir at a constant temperature of 60 °C to obtain a mixture.

[0010] (2) Slowly add dilute hydrochloric acid to the mixture to adjust the pH value of the solution to 3.0-4.0. After stirring the reaction for 2 hours, filter the solution, wash it with deionized water until neutral, dry it in a vacuum drying oven at 80 °C for 12 hours, grind it slightly, and pass it through a 400-mesh sieve to obtain the reinforcing filler.

[0011] The SCPP micro powder comprises raw materials in the following mass ratio: Sr(NO3)2:Ca(NO3)2·4H2O: diammonium hydrogen phosphate = 1:0.8-1.2:1;

[0012] The method for preparing the SCPP micro powder includes the following steps:

[0013] (a) Weigh Sr(NO3)2 and Ca(NO3)2·4H2O, dissolve them in deionized water, and prepare a mixed salt solution with a total Sr-calcium metal ion concentration of 0.5-1.0 mol / L. Weigh diammonium hydrogen phosphate, dissolve it in deionized water, and prepare a precipitant solution with a phosphate ion concentration of 0.5-1.0 mol / L.

[0014] (b) Under constant temperature of 60-80 ℃ and continuous mechanical stirring, the mixed salt solution and the precipitant solution are slowly added dropwise in parallel to the reactor containing deionized water as the bottom liquid through a constant flow pump. The volume of deionized water accounts for 10-30% of the sum of the volumes of the mixed salt solution and the precipitant solution. At the same time, ammonia solution is added dropwise to maintain the pH value of the reaction system at 9.0-10.5 to obtain a mixed solution.

[0015] (c) Continue to stir and age the mixture at 60-80 °C for 2-4 hours, then filter and wash to obtain a filter cake. Place the filter cake in a forced-air drying oven and dry for 6-12 hours to obtain the SCPP precursor. Calcinate the SCPP precursor by raising the temperature from room temperature to 300 °C at a rate of 2-5 °C / min and holding for 30 min. Then raise the temperature to 800-1000 °C at the same rate and calcine at this temperature for 2-4 hours. Cool to room temperature with the furnace, grind lightly, and then pass through a 400-mesh sieve to obtain SCPP micro powder.

[0016] This invention also provides a method for preparing a wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers, specifically including the following steps:

[0017] S1. Place HDPE and UHMWPE in a forced-air drying oven and dry at 80 ℃ for 2 hours. Cool to obtain dried HDPE and UHMWPE. Add the dried HDPE to a high-speed mixer and stir at a speed of 400-600 rpm. Then heat to 80 ℃, add reinforcing filler, and continue stirring for 5 minutes to form a mixture.

[0018] S2, reduce the speed to 200-300 rpm, slowly add dry UHMWPE to the mixture, shear mix for 5-10 min, then add PE-g-MAH, antioxidant 1010, antioxidant 168 and calcium stearate, increase the speed to 400-600 rpm, mix for 8-15 minutes until the material is uniform, and obtain the premix.

[0019] S3. The premixed material is fed into a co-rotating twin-screw extruder for melt extrusion granulation. The extruder settings are as follows: feeding section: 160-170 ℃, melting section: 180-200 ℃, homogenization section: 195-210 ℃, die head temperature: 190-200 ℃, screw speed: 80-120 rpm. Vacuum exhaust is turned on at the rear of the melting section. The extruded strip is cooled in a water tank, air-dried, and then granulated to obtain composite granular material.

[0020] S4. After drying the composite granular material for 3 hours, it is molded to obtain a wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers.

[0021] Compared with the prior art, the beneficial effects achieved by the present invention are as follows:

[0022] This invention uses HDPE, UHMWPE, and reinforcing fillers as raw materials to prepare a high-performance wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers. In the reinforcing filler, SCPP and MoS2 form a composite reinforcing filler with SCPP as the core and MoS2 as the shell through electrostatic adsorption, achieving a strong interfacial bond between the two fillers. SCPP, as a rigid core, provides deformation-resistant support to the composite material with its inorganic rigid skeleton, solving the problem of easy bending of the polyethylene matrix. MoS2, as a lubricating shell, tightly coats the SCPP surface and can directionally migrate to the material surface during friction to form a lubricating film, reducing the friction coefficient. It also avoids the agglomeration problem when MoS2 is added alone, thus simultaneously improving deformation resistance and wear resistance. The maleic anhydride groups in PE-g-MAH can form chemical bonds with the hydroxyl groups on the SCPP surface and the oxygen-containing groups at the edges of MoS2, significantly improving the core-shell filling... The interfacial bonding strength between the core-shell material and the non-polar polyethylene matrix is ​​enhanced, reducing interfacial defects. HDPE provides excellent processing fluidity, solving the problems of difficult melting and molding of UHMWPE, ensuring stable and controllable subsequent extrusion and injection molding processes. UHMWPE, with its ultra-long molecular chain structure, endows the material with excellent wear resistance and impact resistance, compensating for the insufficient wear resistance of HDPE under extreme working conditions. The unique process of first mixing HDPE with reinforcing fillers and then adding UHMWPE at a low speed effectively solves the technical bottleneck of UHMWPE powder's easy dust generation and difficulty in dispersion, ensuring uniform distribution of the core-shell filler in the matrix and avoiding performance fluctuations caused by uneven mixing. Calcium stearate, as a lubricant, can reduce the internal friction of the material during melting, improve processing fluidity, and reduce the adhesion between the material and equipment, ensuring a smooth product surface, while avoiding interfacial weakening caused by excessive lubrication. In summary, this invention achieves synergistic function of fillers through core-shell structure design, and the final wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers has excellent wear resistance, deformation resistance, and processing stability. Attached Figure Description

[0023] Figure 1 The image shows the wear resistance properties of the wear-resistant and deformation-resistant modified polyethylene composite material for idlers prepared according to this invention.

[0024] Figure 2 The diagram shows the aging resistance of the wear-resistant and deformation-resistant modified polyethylene composite material for idlers prepared according to the present invention. Detailed Implementation

[0025] To make the objectives, technical solutions and advantages of the present invention clearer, the present invention will be further described in detail below with reference to specific embodiments, but the present invention is not limited to the following embodiments.

[0026] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those familiar to those skilled in the art. Furthermore, any methods and materials similar to or equivalent to those described herein may be applied to this invention. The preferred embodiments and materials described herein are for illustrative purposes only and do not limit the scope of this application.

[0027] Unless otherwise specified, all methods described in the following examples are conventional. Unless otherwise specified, all materials used in the following examples are new materials purchased from the market. Specifically, HDPE, model: JHMGC100S, melt flow rate: 0.20-0.26 g / cm³. 3 (5kg), density: 0.94-0.950g / cm³ 3 Purchased from Jilin Petrochemical Company; UHMWPE, weight-average molecular weight (Mn): 2.0-3.0×10 6 g / mol, purchased from the No. 2 Additives Plant of Beijing Dongfang Petrochemical Co., Ltd.; PE-g-MAH, E528, melt flow rate 6.7 g / 10 min, purchased from DuPont, USA.

[0028] Example 1: This example provides a wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers. The wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers comprises the following raw materials in parts by weight: 50 parts HDPE, 20 parts UHMWPE, 12 parts reinforcing filler, 3 parts PE-g-MAH, 0.1 parts antioxidant 1010, 0.2 parts antioxidant 168, and 0.5 parts calcium stearate;

[0029] The reinforcing filler comprises raw materials in the following mass ratio: SCPP micro powder:MoS2 = 8:5;

[0030] The method for preparing the reinforcing filler includes the following steps:

[0031] (1) Disperse SCPP in deionized water to prepare a suspension with a solid content of 10%, and sonicate it for 30 min to ensure full dispersion. Add MoS2 to the suspension and mechanically stir at 500 rpm at a constant temperature of 60 ℃ to obtain a mixture.

[0032] (2) Slowly add dilute hydrochloric acid to the mixture to adjust the pH of the solution to 3.0. After stirring the reaction for 2 hours, filter the solution, wash it with deionized water until neutral, dry it in a vacuum drying oven at 80 °C for 12 hours, grind it, and pass it through a 400-mesh sieve to obtain the reinforcing filler.

[0033] The SCPP micro powder comprises raw materials in the following mass ratio: Sr(NO3)2:Ca(NO3)2·4H2O: diammonium hydrogen phosphate = 1:0.8:1;

[0034] The method for preparing the SCPP micro powder includes the following steps:

[0035] (a) Weigh Sr(NO3)2 and Ca(NO3)2·4H2O, dissolve them in deionized water, and prepare a mixed salt solution with a total Sr-calcium metal ion concentration of 0.5 mol / L. Weigh diammonium hydrogen phosphate, dissolve it in deionized water, and prepare a precipitant solution with a phosphate ion concentration of 0.5 mol / L.

[0036] (b) Under continuous mechanical stirring at 300 rpm in a constant temperature machine at 60 ℃, the mixed salt solution and the precipitant solution are slowly added dropwise in parallel to the reactor containing deionized water as the bottom liquid through a constant flow pump. The volume of deionized water accounts for 10% of the sum of the volumes of the mixed salt solution and the precipitant solution. At the same time, ammonia solution is added dropwise to maintain the pH value of the reaction system at 9.0, and a mixed solution is obtained.

[0037] (c) The mixture was kept at 60 °C and stirred for 2 hours. Then it was filtered and the precipitate was washed repeatedly with hot deionized water at 60 °C until the filtrate was neutral. Then it was washed twice with anhydrous ethanol to obtain a filter cake. The filter cake was placed in a forced-air drying oven and dried at 100 °C for 6 hours to obtain the SCPP precursor. The SCPP precursor was calcined. The SCPP precursor was placed in an alumina crucible and heated in a muffle furnace from room temperature to 300 °C at a heating rate of 2 °C / min and held for 30 min. Then it was heated to 800 °C at the same rate and calcined at this temperature for 4 hours. The furnace was cooled to room temperature, lightly ground, and then passed through a 400-mesh sieve to obtain SCPP micro powder.

[0038] This embodiment also provides a method for preparing a wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers, specifically including the following steps:

[0039] S1. Place HDPE and UHMWPE in a forced-air drying oven and dry at 80 ℃ for 2 hours. Cool to obtain dried HDPE and UHMWPE. Add the dried HDPE to a high-speed mixer and stir at 400 rpm. Then heat to 80 ℃, add reinforcing filler, and continue stirring for 5 minutes to form a mixture.

[0040] S2, reduce the speed to 200 rpm, slowly add dry UHMWPE to the mixture, shear mix for 10 min, then add PE-g-MAH, antioxidant 1010, antioxidant 168 and calcium stearate, increase the speed to 400 rpm, mix for 15 min until the material is uniform, and obtain the premix.

[0041] S3. The premixed material is fed into a co-rotating twin-screw extruder for melt extrusion granulation. The extruder is set with the following parameters: feeding section: 160℃, melting section: 180℃, homogenization section: 195℃, die head temperature: 190℃, screw speed: 80 rpm. Vacuum exhaust is turned on at the rear of the melting section, and the vacuum degree is set to -0.08 MPa. The extruded strip is cooled in a water tank, air-dried, and then granulated to obtain composite granular material.

[0042] S4. After drying the composite granular material at 80°C for 3 hours, it is molded to obtain a wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers.

[0043] Example 2: This example provides a wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers. The wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers comprises the following raw materials in parts by weight: 55 parts HDPE, 25 parts UHMWPE, 15 parts reinforcing filler, 4 parts PE-g-MAH, 0.2 parts antioxidant 1010, 0.3 parts antioxidant 168, and 0.8 parts calcium stearate;

[0044] The reinforcing filler comprises raw materials in the following mass ratio: SCPP micro powder:MoS2 = 10:6;

[0045] The method for preparing the reinforcing filler includes the following steps:

[0046] (1) Disperse SCPP in deionized water to prepare a suspension with a solid content of 10%, and sonicate it for 30 min to ensure full dispersion. Add MoS2 to the suspension and mechanically stir at 500 rpm at a constant temperature of 60 ℃ to obtain a mixture.

[0047] (2) Slowly add dilute hydrochloric acid to the mixture to adjust the pH of the solution to 3.5. After stirring the reaction for 2 hours, filter the solution, wash it with deionized water until neutral, dry it in a vacuum drying oven at 80 °C for 12 hours, grind it slightly, and pass it through a 400-mesh sieve to obtain the reinforcing filler.

[0048] The SCPP micro powder comprises raw materials in the following mass ratio: Sr(NO3)2:Ca(NO3)2·4H2O: diammonium hydrogen phosphate = 1:1:1;

[0049] The method for preparing the SCPP micro powder includes the following steps:

[0050] (a) Weigh Sr(NO3)2 and Ca(NO3)2·4H2O, dissolve them in deionized water, and prepare a mixed salt solution with a total Sr-calcium metal ion concentration of 0.8 mol / L. Weigh diammonium hydrogen phosphate, dissolve it in deionized water, and prepare a precipitant solution with a phosphate ion concentration of 0.8 mol / L.

[0051] (b) Under continuous mechanical stirring at 400 rpm in a constant temperature machine at 70 ℃, the mixed salt solution and the precipitant solution are slowly added dropwise in parallel to the reactor containing deionized water as the bottom liquid through a constant flow pump. The volume of deionized water accounts for 20% of the sum of the volumes of the mixed salt solution and the precipitant solution. At the same time, ammonia solution is added dropwise to maintain the pH value of the reaction system at 10, and a mixed solution is obtained.

[0052] (c) The mixture was kept at 70 °C and stirred for 3 hours. Then it was filtered and the precipitate was washed repeatedly with hot deionized water at 70 °C until the filtrate was neutral. Then it was washed twice with anhydrous ethanol to obtain a filter cake. The filter cake was placed in a forced-air drying oven and dried at 120 °C for 8 hours to obtain the SCPP precursor. The SCPP precursor was calcined. The SCPP precursor was placed in an alumina crucible and heated in a muffle furnace at a heating rate of 3 °C / min from room temperature to 300 °C and held for 30 min. Then it was heated to 900 °C at the same rate and calcined at this temperature for 3 hours. The furnace was cooled to room temperature, lightly ground, and then passed through a 400-mesh sieve to obtain SCPP micro powder.

[0053] This embodiment also provides a method for preparing a wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers, specifically including the following steps:

[0054] S1. Place HDPE and UHMWPE in a forced-air drying oven and dry at 80 ℃ for 2 hours. Cool to obtain dried HDPE and UHMWPE. Add the dried HDPE to a high-speed mixer and stir at 500 rpm. Then heat to 80 ℃, add reinforcing filler, and continue stirring for 5 min to form a mixture.

[0055] S2, reduce the speed to 300 rpm, slowly add dry UHMWPE to the mixture, shear mix for 8 min, then add PE-g-MAH, antioxidant 1010, antioxidant 168 and calcium stearate, increase the speed to 500 rpm, mix for 10 min until the material is uniform, and obtain the premix.

[0056] S3. The premixed material is fed into a co-rotating twin-screw extruder for melt extrusion granulation. The extruder is set with the following parameters: feeding section: 165℃, melting section: 190℃, homogenization section: 200℃, die head temperature: 195℃, screw speed: 100 rpm. Vacuum exhaust is turned on at the rear of the melting section, and the vacuum degree is set to -0.05 MPa. The extruded strip is cooled in a water tank, air-dried, and then granulated to obtain composite granular material.

[0057] S4. After drying the composite granular material at 80 °C for 3 hours, it is molded to obtain a wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers.

[0058] Example 3: This example provides a wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers. The wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers comprises the following raw materials in parts by weight: 60 parts HDPE, 30 parts UHMWPE, 20 parts reinforcing filler, 5 parts PE-g-MAH, 0.3 parts antioxidant 1010, 0.5 parts antioxidant 168, and 1 part calcium stearate.

[0059] The reinforcing filler comprises raw materials in the following mass ratio: SCPP micro powder:MoS2 = 12:8;

[0060] The method for preparing the reinforcing filler includes the following steps:

[0061] (1) Disperse SCPP in deionized water to prepare a suspension with a solid content of 10%, and sonicate it for 30 min to ensure full dispersion. Add MoS2 to the suspension and mechanically stir at 500 rpm at a constant temperature of 60 ℃ to obtain a mixture.

[0062] (2) Slowly add dilute hydrochloric acid to the mixture to adjust the pH of the solution to 4.0. After stirring the reaction for 2 hours, filter the solution, wash it with deionized water until neutral, dry it in a vacuum drying oven at 80 °C for 12 hours, grind it slightly, and pass it through a 400-mesh sieve to obtain the reinforcing filler.

[0063] The SCPP micro powder comprises raw materials in the following mass ratio: Sr(NO3)2:Ca(NO3)2·4H2O: diammonium hydrogen phosphate = 1:1.2:1;

[0064] The method for preparing the SCPP micro powder includes the following steps:

[0065] (a) Weigh Sr(NO3)2 and Ca(NO3)2·4H2O, dissolve them in deionized water, and prepare a mixed salt solution with a total Sr-calcium metal ion concentration of 1.0 mol / L. Weigh diammonium hydrogen phosphate, dissolve it in deionized water, and prepare a precipitant solution with a phosphate ion concentration of 1.0 mol / L.

[0066] (b) Under continuous mechanical stirring at 500 rpm in a constant temperature machine at 80 ℃, the mixed salt solution and the precipitant solution are slowly added dropwise in parallel to the reactor containing deionized water as the bottom liquid through a constant flow pump. The volume of deionized water accounts for 30% of the sum of the volumes of the mixed salt solution and the precipitant solution. At the same time, ammonia solution is added dropwise to maintain the pH value of the reaction system at 10.5, and a mixed solution is obtained.

[0067] (c) The mixture was kept at 80 °C and stirred for 4 hours. Then it was filtered and the precipitate was washed repeatedly with hot deionized water at 80 °C until the filtrate was neutral. Then it was washed twice with anhydrous ethanol to obtain a filter cake. The filter cake was placed in a forced-air drying oven and dried at 120 °C for 6 hours to obtain the SCPP precursor. The SCPP precursor was calcined. The SCPP precursor was placed in an alumina crucible and heated in a muffle furnace at a heating rate of 5 °C / min from room temperature to 300 °C and held for 30 min. Then it was calcined at the same rate to 1000 °C for 2 hours. It was cooled to room temperature with the furnace, lightly ground, and then passed through a 400-mesh sieve to obtain SCPP micro powder.

[0068] This embodiment also provides a method for preparing a wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers, specifically including the following steps:

[0069] S1. Place HDPE and UHMWPE in a forced-air drying oven and dry at 80 ℃ for 2 hours. Cool to obtain dried HDPE and UHMWPE. Add the dried HDPE to a high-speed mixer and stir at 600 rpm. Then heat to 80 ℃, add reinforcing filler, and continue stirring for 5 minutes to form a mixture.

[0070] S2, reduce the speed to 300 rpm, slowly add dry UHMWPE to the mixture, shear mix for 10 min, then add PE-g-MAH, antioxidant 1010, antioxidant 168 and calcium stearate, increase the speed to 600 rpm, mix for 8 minutes until the material is uniform, and obtain the premix.

[0071] S3. The premixed material is fed into a co-rotating twin-screw extruder for melt extrusion granulation. The extruder is set with the following parameters: feeding section: 170℃, melting section: 200℃, homogenization section: 210℃, die head temperature: 200℃, screw speed: 120 rpm. Vacuum exhaust is turned on at the rear of the melting section, and the vacuum degree is set to -0.05 MPa. The extruded strip is cooled in a water tank, air-dried, and then granulated to obtain composite granular material.

[0072] S4. After drying the composite granular material at 80 °C for 3 hours, it is molded to obtain a wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers.

[0073] The difference between Comparative Example 1 and Example 2 is that no reinforcing filler is added; the rest is exactly the same as Example 2.

[0074] The difference between Comparative Example 2 and Example 2 is that SCPP is not added; otherwise, they are exactly the same as Example 2.

[0075] Experimental example:

[0076] 1. Test specimens were prepared using the wear-resistant and deformation-resistant modified polyethylene composite materials for idler rollers prepared in Examples 1-3 and Comparative Examples 1-2 of this invention. The tensile stress and strain behavior of the specimens were tested on a CMT6103 electronic universal testing machine, strictly in accordance with the GB / T 1040-2006 series standards, at room temperature. The specimen thickness was 3 mm, and the tensile test rate was 2 mm / min. The compression specimen size was 10 mm × 6 mm × 5 mm. Each group of samples was measured in parallel 5 times, and the average value was taken. The elastic modulus, tensile strength, and elongation at break are recorded in Table 1.

[0077] 2. Test samples were prepared using the wear-resistant and deformation-resistant modified polyethylene composite materials for idlers prepared in Examples 1-3 and Comparative Examples 1-2 of the present invention. The thermal conductivity of the samples was tested using an FM3615 thermal conductivity meter. The sample thickness was 6 mm and the diameter was 130 mm. The test was conducted at room temperature.

[0078] 3. Test specimens were prepared using the wear-resistant and deformation-resistant modified polyethylene composite materials for idlers prepared in Examples 1-3 and Comparative Examples 1-2 of this invention. The Rockwell hardness of the specimens was tested using an electric Rockwell hardness tester. The testing process was carried out according to GB9342-88 standard, using an R-type scale as the hardness scale. The sample thickness was 6 mm and the sample width was 20 mm. The test was conducted at room temperature. Each group of samples was measured in parallel five times, and the average value was taken.

[0079] 4. Test specimens were prepared using the wear-resistant and deformation-resistant modified polyethylene composite materials for idler rollers prepared in Examples 1-3 and Comparative Examples 1-2 of this invention. The test method was as follows: The tribological properties of the materials were studied using a ball-disc friction and wear testing machine. GCr15 stainless steel balls and the prepared specimens were used as the friction pair. The diameter of the steel balls was 6.35 mm, and the roughness was Ra = 0.02 μm. The specimen surfaces were sequentially polished with 400#, 800#, 1000#, 1200#, 1500#, and 2000# sandpaper, and then polished one by one on an MP-2B metallographic polishing machine. After cleaning with anhydrous ethanol using a 030S ultrasonic cleaner, the specimens were tested. The fixed parameters for the friction test were: rotation radius of 4 mm; test time of 30 min; and sample sizes of Φ40 mm × 6 mm and Φ30 mm × 6 mm. Friction tests were conducted under different external conditions (ambient temperature, humidity, load, and speed). The depth and width of the wear tracks were measured, and the wear cross-sectional area of ​​the material was calculated to determine its volumetric wear rate. Calculation formula: ω = V / 2πrnF; where ω is the wear rate, which is the wear volume per unit load and unit sliding distance, in mm. 3 / N·m; V is the wear volume, V=2πr×A, mm 3 ; r is the wear radius, mm; A is the wear cross-sectional area, mm²; n is the total number of revolutions; F is the load, N. The results are as follows: Figure 1 As shown.

[0080] Table 1: Performance Test Results

[0081]

[0082] Table 1 shows that the elastic modulus and tensile strength of Examples 1-3 are much higher than those of Comparative Example 1, indicating that the added reinforcing filler greatly improves the material's resistance to deformation. Comparative Example 1 exhibits high elongation at break, but its elastic modulus and hardness are low. Compared with Examples 1-3, this shows that the addition of reinforcing filler improves tensile strength and hardness while maintaining high toughness, indicating that the wear-resistant and deformation-resistant modified polyethylene composite material for idlers prepared by this invention has excellent mechanical properties. The thermal conductivity of Examples 1-3 reaches 0.28-0.31, which can reduce the heat transfer generated by friction during idler operation and reduce energy consumption. The Rockwell hardness of Examples 1-3 is significantly higher than that of Comparative Examples 1-2, indicating that the surface of the wear-resistant and deformation-resistant modified polyethylene composite material for idlers prepared by this invention is better scratch-resistant and dent-resistant.

[0083] Figure 1 The wear rate of the wear-resistant and deformation-resistant modified polyethylene composite materials for idlers prepared in Examples 1-3 and Comparative Examples 1-2 of the present invention is shown. The wear rate of Examples 1-3 is significantly lower than that of the comparative examples, indicating that the present invention has a significant effect on improving the wear resistance of materials, and can effectively reduce the wear of idlers during use and extend their service life. Figure 2 To test the thermo-oxidative stability of Example 2 and Comparative Example 1, the tensile strength retention rate was used as the performance retention rate. As shown in the figure, the performance retention rate of Example 2 changed relatively slowly over time and remained at a high level even after a long period of time, indicating that the performance decayed slowly during long-term use and that it had excellent stability properties such as aging resistance. In contrast, the performance retention rate of Comparative Examples 1-2 decreased significantly over time, indicating that their performance stability was poor and their performance decayed quickly during use. This further demonstrates the advantages of the present invention in improving the stability of material performance, enabling components such as idler rollers to maintain good performance during long-term use.

[0084] In summary, this invention achieves precise coating of SCPP and MoS2 through electrostatic adsorption, solving the problems of uneven dispersion and functional conflicts in traditional fillers. Subsequent processes such as gradient mixing, segmented temperature-controlled extrusion, and gradient cooling molding ensure the stability of the core-shell structure and eliminate internal stress in the product. Furthermore, matrix blending and additive compounding balance the material's processability and mechanical properties. In terms of results, the rigidity-lubrication synergy of the core-shell filler and the interfacial strengthening of the compatibilizer enable the material to comprehensively surpass traditional systems in terms of deformation resistance, wear resistance, and surface hardness. It also possesses aging resistance, thermal conductivity, and electrostatic control capabilities, preventing wear, deformation, and safety hazards during long-term operation of idlers. This breakthrough overcomes traditional technical bottlenecks and adapts to the conveying needs of various scenarios such as mines and ports, providing a reliable solution for long-life, low-maintenance idlers.

[0085] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A wear resistant and deformation resistant modified polyethylene composite material for a carrier roller, characterized in that, The raw materials include the following weight parts: 50-60 parts of HDPE, 20-30 parts of UHMWPE, 12-20 parts of reinforcing filler, 3-5 parts of PE-g-MAH, 0.1-0.3 parts of antioxidant 1010, 0.2-0.5 parts of antioxidant 168, and 0.5-1 parts of calcium stearate; The reinforcing filler includes the following mass ratio of raw materials: SCPP micro powder: MoS2 = 8-12:5-8; The preparation method of the reinforcing filler includes the following steps: (1) Take the SCPP micro powder and disperse it in deionized water to prepare a suspension, ultrasonic treatment, add MoS2 into the suspension, constant temperature stirring, to obtain a mixture; (2) Slowly add dilute hydrochloric acid to the mixture, adjust the pH, continue stirring, suction filtration, washing, drying, grinding, sieving, to obtain the reinforcing filler; The SCPP micro powder includes the following mass ratio of raw materials: Sr(NO3)2: Ca(NO3)2·4H2O: diammonium hydrogen phosphate = 1:0.8-1.2:1; The preparation method of the SCPP micro powder includes the following steps: (a) Weigh Sr(NO3)2 and Ca(NO3)2·4H2O, dissolve in deionized water to prepare a mixed salt solution, weigh diammonium hydrogen phosphate, dissolve in deionized water to prepare a precipitant solution; (b) Under constant temperature stirring, slowly add the mixed salt solution and the precipitant solution, and add an ammonia solution, maintain the pH, to obtain a mixed solution; (c) Constant temperature stirring and aging of the mixed solution, then suction filtration, washing, to obtain a filter cake, drying, to obtain the SCPP precursor, calcination of the SCPP precursor, furnace cooling, grinding, sieving, to obtain the SCPP micro powder.

2. The wear resistant and deformation resistant modified polyethylene composite material for carrier roller according to claim 1, characterized in that, In step (a), the total strontium and calcium metal ion concentration of the mixed salt solution is 0.5-1.0 mol / L; the phosphate ion concentration of the precipitant solution is 0.5-1.0 mol / L; In step (b), the pH is maintained at 9.0-10.

5.

3. A process for the preparation of the wear resistant and deformation resistant modified polyethylene composite material for the carrier roller according to any one of claims 1-2, characterized by, Specifically includes the following steps: S1, dry and cool the HDPE and UHMWPE to obtain dry HDPE and UHMWPE, add the dry HDPE to a high-speed mixer, stir, then heat, add the reinforcing filler, continue stirring, to form a mixture; S2, slowly add the dry UHMWPE to the mixture, shear mix, then add PE-g-MAH, antioxidant 1010, antioxidant 168 and calcium stearate, stir and mix until the material is uniform, to obtain a premix; S3, melt extrusion granulation of the premix, vacuum exhaust, cooling, cutting, to obtain a composite granular material; S4, dry the composite granular material, shape, to obtain a modified polyethylene composite material for the roller.

4. The method for preparing a wear-resistant and deformation-resistant modified polyethylene composite material for idler rollers according to claim 3, characterized in that, In step S3, the parameters of the extrusion granulation are set as follows: feeding section: 160-170 ℃, melting section: 180-200 ℃, homogenization section: 195-210 ℃, die temperature: 190-200 ℃, screw rotation speed: 80-120 rpm.

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