Quick-setting anticorrosive paint for power transmission equipment in alpine region and preparation method of quick-setting anticorrosive paint

Abstract

The invention relates to the technical field of coatings, and discloses a quick-setting anticorrosive coating for power transmission equipment in alpine regions and a preparation method thereof.The coating is prepared from 35%-45% of base resin, 10%-14% of a curing agent, 0.3%-0.8% of a low-temperature catalyst, 0.3%-0.8% of an accelerant, 15%-20% of anticorrosive pigment, 6%-10% of filler, 0.3%-0.8% of a flatting agent, 0.3%-0.8% of a defoaming agent, 0.8%-1.5% of an ultraviolet light absorber, 15%-25% of a solvent and the like. The preparation method comprises the following steps: in-situ nano modification and pre-polymerization of a resin matrix, plasma activation and directional hybridization of pigment filler, precise introduction of a gradient catalytic system, integration of a microencapsulated rheological additive, defoaming of a supercritical fluid, fine adjustment of viscosity, and online photoelectric sensing quality monitoring. The coating adapts to the high and cold environment, can realize rapid hardening, has excellent corrosion resistance and aging resistance, solves the problem of accelerated equipment corrosion caused by poor environmental adaptability in the traditional technology, and can greatly shorten the curing time in the low-temperature environment.

Description

Technical Field

[0001] This invention relates to the field of coating technology, and in particular to a fast-setting anti-corrosion coating for power transmission equipment in cold regions and its preparation method. Background Technology

[0002] Power transmission lines play a vital role in national economic development, especially in high-altitude and cold regions like Inner Mongolia, where the operating environment is extremely harsh, including low temperatures, snow, wind erosion, and ultraviolet radiation. These factors place extremely high demands on the corrosion resistance of power transmission equipment. Traditional anti-corrosion coatings often face numerous challenges in such cold environments.

[0003] Regarding the above-mentioned and existing related technologies, traditional anti-corrosion coatings often have the following drawbacks: 1. Poor environmental adaptability: Traditional technologies cannot cope with extreme low temperatures of -45℃, diurnal temperature range of 30℃, strong ultraviolet radiation (45% higher than in plains), and wind, sand and snowstorms, which leads to accelerated equipment corrosion.

[0004] 2. Low coating efficiency: Traditional coatings take up to 72 hours to cure in low-temperature environments, resulting in a long construction cycle and increasing the risk of equipment being exposed to harsh environments. Summary of the Invention

[0005] The technical problem to be solved by this invention is that existing anti-corrosion coatings for cold regions have disadvantages such as slow curing speed, insufficient anti-corrosion performance and anti-aging properties. To address this, we propose a fast-curing anti-corrosion coating for power transmission equipment in cold regions and its preparation method.

[0006] To achieve the above objectives, this application adopts the following technical solution: a quick-setting anti-corrosion coating for power transmission equipment in cold regions, the coating being made by mixing a base resin, a curing agent, a low-temperature catalyst, an accelerator, anti-corrosion pigments, fillers, leveling agents, defoamers, ultraviolet absorbers, and a solvent, wherein: the mass percentage of the base resin is 35%-45%; the mass percentage of the curing agent is 10%-14%; the mass percentage of the low-temperature catalyst is 0.3%-0.8%; the mass percentage of the accelerator is 0.3%-0.8%; the mass percentage of the anti-corrosion pigments is 15%-20%; the mass percentage of the filler is 6%-10%; the mass percentage of the leveling agent is 0.3%-0.8%; the mass percentage of the defoamer is 0.3%-0.8%; the mass percentage of the ultraviolet absorber is 0.8%-1.5%; and the mass percentage of the solvent is 15%-25%.

[0007] Preferably, the base resin is bisphenol A type epoxy resin; the curing agent is modified polyamide curing agent; the low-temperature catalyst is dibutyltin dilaurate; the accelerator is DMP-30; the anti-corrosion pigment is nano-modified zinc phosphate; the filler is precipitated barium sulfate; the leveling agent is polyacrylate leveling agent; the defoamer is silicone defoamer; the ultraviolet absorber is UV-327; and the solvent is a mixture of acetone and toluene, wherein the volume ratio of acetone to toluene is 1:1.

[0008] Preferably, the present invention provides another technical solution: a method for preparing a quick-setting anti-corrosion coating for power transmission equipment in cold regions, comprising the following specific implementation steps: S1. In-situ nano-modification and prepolymerization of resin matrix: Bisphenol A type epoxy resin was mixed with a portion of acetone and toluene in a reaction vessel, and nano-sized inorganic thermally conductive filler was added. The mixture was dispersed under the combined action of ultrasonic oscillation and mechanical shearing to form a uniform resin base. S2. Plasma activation and directional hybridization of pigments and fillers: The surface energy of the nano-modified zinc phosphate anticorrosive pigment and the precipitated barium sulfate filler is enhanced, and then they are added to the resin base obtained by S1 for high-speed dispersion and grinding until the fineness of the slurry reaches the predetermined standard. S3. Precise introduction of gradient catalysis system based on thermal history: The catalytic system is introduced in stages. First, the first part of the accelerator is added to the system at the first temperature and mixed evenly. Then, all the modified polyamide curing agent is added. Finally, the catalyst and the remaining second part of the accelerator are added at a second lower temperature. S4. Simultaneous integration of microencapsulated rheology modifiers: The leveling agent and defoamer were added to the coating system obtained in S3 in the form of microcapsules and then stirred to disperse them evenly. S5. Supercritical fluid-assisted degassing and viscosity fine-tuning: The coating obtained from S4 was defoamed and its viscosity adjusted using a low surface tension fluid to obtain a finely adjusted coating. S6. Real-time quality monitoring and feedback based on online photoelectric sensing: The finely adjusted paint flows through an online quality monitoring system, which analyzes the optical properties of the paint to determine and provide feedback on its fineness and dispersion uniformity in real time. Paint that has passed the online monitoring and is confirmed to be qualified is then filtered and sealed for packaging.

[0009] Preferably, the specific implementation steps of S1 are as follows: S11. Preparation and dissolution: Add the bisphenol A epoxy resin, acetone and toluene mixed solvent into a double planetary stirring vessel equipped with an ultrasonic generator and a cooling jacket, and start low-speed stirring to completely dissolve the resin and form a homogeneous solution. S12. Nanofiller addition: Slowly add nano-alumina powder treated with silane coupling agent KH-560 to the reactor, and control the feeding speed to suppress powder dust and agglomeration. S13. Composite dispersion treatment: Gradually increase the stirring speed to a high-speed dispersion state and simultaneously turn on the ultrasonic generator oscillation switch, and continue to treat for 45 minutes using the synergistic effect of mechanical shearing and cavitation. S14. Initial quality inspection and transfer: After processing, samples are taken to test the fineness and viscosity of the slurry to confirm that the nanoparticles have been fully dispersed and formed a stable suspension system for use in subsequent processes.

[0010] Preferably, the specific implementation steps of S2 are as follows: S21. Material pretreatment: The powder mixture of nano-modified zinc phosphate and precipitated barium sulfate is pretreated in a drying oven at 110 degrees Celsius for 2 hours to ensure complete drying; S22. Plasma treatment preparation: The dried powder mixture is evenly spread in the quartz tray of the low-temperature plasma treatment equipment and then sent into the vacuum reaction chamber. S23. Surface activation implementation: After the reaction chamber is evacuated by starting the equipment, argon gas is introduced as the process gas. Radio frequency plasma is started at the set power to bombard the powder surface for 3 minutes. S24. Activation material integration: Immediately after processing, the activated powder is added to the previously prepared resin base and sheared and dispersed for 40 minutes at a speed of 1200 rpm using a high-speed dispersing disc.

[0011] Preferably, the specific implementation steps of S3 are as follows: S31. System preheating control: The temperature of the slurry system after pigment dispersion is controlled by the jacket of the reactor to keep it stable at 40 degrees Celsius. S32. Preliminary Accelerator Addition: Add the first part of the accelerator, which accounts for 60% of the total mass of DMP-30, to the constant temperature system, and stir continuously at a medium stirring speed of 500-600 rpm for 15 minutes to allow it to be preliminarily mixed and activated. S33, Cooling and Addition of Main Curing Agent: The temperature of the material system is then reduced to below 25 degrees Celsius by cooling jacket, and then all the metered modified polyamide curing agent is added to the system. S34. Dispersion of main curing agent: Increase the stirring speed to 800 rpm and continue stirring for 20 minutes to ensure that the curing agent is completely and evenly dispersed; S35. Final Catalytic System Completion: Finally, while maintaining a temperature of 25 degrees Celsius, add the remaining DMP-30 promoter and all of the dibutyltin dilaurate catalyst to the system, and continue stirring for 15 minutes to end the process.

[0012] Preferably, the specific implementation steps of S4 are as follows: S41. Preparation of microcapsule additives: Microcapsule additives with polyurea as the wall material and encapsulated with polyacrylate leveling agent and silicone defoamer are prepared in advance by in-situ polymerization. S42. Stirring conditions setting: After all liquid components of the coating system have been added, adjust the stirring speed of the reactor to a medium speed of 500 rpm. S43. Microcapsule feeding: The quantitative microcapsule additive is slowly and evenly added into the paint mixing tank through the powder feeding port; S44. Homogenization and dispersion: Maintain the current stirring speed and continue stirring for 30 minutes to ensure that the microcapsules are evenly distributed in the coating system without significant damage.

[0013] Preferably, the specific implementation steps of S5 are as follows: S51. Pressure equipment preparation: Transfer the coating material that has undergone the previous steps to a pressure-resistant supercritical carbon dioxide treatment vessel and seal the equipment. S52. Creation of supercritical environment: Start the equipment to pump a predetermined mass of liquid carbon dioxide into the treatment vessel, and then increase the temperature and pressure to make the carbon dioxide in the vessel reach a supercritical state. S53, Dynamic Circulation Processing: Maintain the system pressure at 15 MPa and start the in-vessel circulating agitator to ensure that the supercritical fluid and coating materials are in full contact and continuously circulate for 30 minutes. S54. Controllable pressure relief discharge: After the process is completed, the system pressure is slowly released at a rate of 0.5 MPa per minute through a precisely controlled pressure relief valve until it returns to normal pressure; S55. Product index verification: Discharge the material and immediately test the viscosity and bubble content of the coating to confirm that it meets the product standards.

[0014] Preferably, the specific implementation steps of S6 are as follows: S61. Monitoring system installation: Install a flow detection pool with a transparent window in parallel on the conveying pipeline before the coating product is filled and packaged; S62, Photoelectric sensor calibration: A semiconductor laser emitter of a specific wavelength is installed on one side of the detection cell, and photoelectric sensors are installed on the other side and at a 90-degree angle to the first side to receive transmitted light and scattered light signals. S63. Online monitoring start-up: Start the delivery pump to make the coating flow through the detection pool at a constant flow rate, and simultaneously start the photoelectric sensor system to collect and record light intensity data in real time; S64. Data comparison and judgment: The collected optical data signals are transmitted to the central processing unit and compared and judged in real time with the preset quality qualification threshold database. S65. Quality Report Generation: The system dynamically displays the real-time status of product quality based on the comparison results and generates a unique quality monitoring report for each batch of coating products. Coatings that have passed online monitoring and are confirmed to be qualified are filtered and sealed for packaging.

[0015] Preferably, the nano-scale inorganic thermally conductive filler in S1 is nano-alumina with an average particle size in the range of 10-100nm and a specific surface area between 50-150m² / g; the nano-modified zinc phosphate anticorrosive pigment in S2 has an average particle size of 50-200nm and a phosphorus-zinc mass ratio controlled between 1:1.5 and 1:2.5; the predetermined standard in S2 is that the slurry fineness is not greater than 20μm and the particle size distribution span is less than 3.0; the product standard in S5 is that the viscosity of the coating at 23°C is 70-100cP, the bubble content is less than 0.2%, and the coating shows no phase separation or gelation after being placed at -40°C for 24 hours; the online quality monitoring system in S6 determines the fineness and dispersion uniformity by analyzing the transmittance and scattered light intensity of the coating in real time, wherein the transmittance deviation of qualified coating does not exceed ±5% of the standard value, and the coefficient of variation of scattered light intensity is less than 10%.

[0016] The technical effects and advantages of this invention are as follows: In this invention, bisphenol A type epoxy resin is used as the base material, combined with modified polyamide curing agent, dibutyltin dilaurate low-temperature catalyst and DMP-30 accelerator, to synergistically achieve rapid curing at low temperatures, significantly shortening the construction cycle and avoiding long-term exposure of equipment to harsh environments. The synergistic effect of nano-modified zinc phosphate and plasma-activated precipitated barium sulfate, combined with UV absorber UV-327, endows the coating with excellent anti-corrosion performance and anti-aging ability, which can withstand extreme low temperatures of -40℃, diurnal temperature differences and strong ultraviolet radiation, effectively delaying equipment corrosion. During the preparation process, in-situ nano-modification and composite dispersion technology improve the uniformity and stability of the resin matrix, supercritical fluid degassing process ensures that the coating bubble content is less than 0.2% and the viscosity is precisely controllable, and microencapsulated rheology modifiers optimize the leveling properties during construction and avoid surface defects. It takes into account rapid setting, corrosion resistance, environmental adaptability and construction convenience, which can significantly extend the service life of power transmission equipment in cold regions and reduce operation and maintenance costs. Attached Figure Description

[0017] The disclosure of this invention is illustrated with reference to the accompanying drawings. It should be understood that the drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention. In the drawings, the same reference numerals are used to refer to the same parts: Figure 1This is a schematic diagram of the coating formulation for a fast-setting anti-corrosion coating for power transmission equipment in cold regions and its preparation method, according to the present invention. Figure 2 This is a flowchart illustrating the overall process of preparing a fast-curing anti-corrosion coating for power transmission equipment in cold regions and its preparation method, according to the present invention. Figure 3 This is a flowchart of step S1 of the present invention: a fast-curing anti-corrosion coating for power transmission equipment in cold regions and its preparation method. Figure 4 The flowchart of step S2 of the present invention is a quick-curing anti-corrosion coating for power transmission equipment in cold regions and its preparation method. Figure 5 This is a flowchart of step S3 of the present invention: a fast-curing anti-corrosion coating for power transmission equipment in cold regions and its preparation method. Figure 6 This is a flowchart of step S4 of the present invention, which describes a fast-curing anti-corrosion coating for power transmission equipment in cold regions and its preparation method. Figure 7 This is a flowchart of step S5 of the present invention: a fast-curing anti-corrosion coating for power transmission equipment in cold regions and its preparation method. Figure 8 This is a flowchart of step S6 of the present invention regarding a fast-curing anti-corrosion coating for power transmission equipment in cold regions and its preparation method. Detailed Implementation

[0018] It is readily understood that, based on the technical solution of this invention, those skilled in the art can propose various interchangeable structural methods and implementations without altering the essential spirit of the invention. Therefore, the following detailed embodiments and accompanying drawings are merely illustrative examples of the technical solution of this invention and should not be considered as the entirety of the invention or as limitations or restrictions on the technical solution of this invention.

[0019] Reference Figure 1As shown, this invention provides a technical solution: a fast-curing anti-corrosion coating for power transmission equipment in cold regions. The coating is made by mixing a base resin (bisphenol A type epoxy resin), a curing agent (modified polyamide curing agent), a low-temperature catalyst (dibutyltin dilaurate), an accelerator (DMP-30), an anti-corrosion pigment (nano-modified zinc phosphate), a filler (precipitated barium sulfate), a leveling agent (polyacrylate leveling agent), a defoamer (organosilicone defoamer), an ultraviolet absorber (UV-327), and a solvent (a mixture of acetone and toluene, volume ratio 1:1). The components are: base resin (40% by mass); curing agent (12% by mass); low-temperature catalyst (0.5% by mass); accelerator (0.5% by mass); anti-corrosion pigment (17% by mass); filler (8% by mass); leveling agent (0.5% by mass); defoamer (0.5% by mass); ultraviolet absorber (1.0% by mass); and solvent (19% by mass).

[0020] The specific functions of each component in this coating are as follows: Base resin (bisphenol A type epoxy resin): As the base material for coating film formation, it provides excellent mechanical properties, adhesion, and chemical resistance. Bisphenol A type epoxy resin has good comprehensive properties and is a commonly used base material for high-performance anti-corrosion coatings.

[0021] Curing agent (modified polyamide curing agent): reacts with epoxy resin to form a cross-linked structure, allowing the coating to cure into a film. Modified polyamide curing agent has good low-temperature curing performance and toughness.

[0022] Low-temperature catalyst (dibutyltin dilaurate): As the core of the low-temperature curing system, it effectively accelerates the curing reaction, ensuring that the coating can still cure rapidly in environments as low as -20°C or even lower, significantly shortening the surface drying and hard drying times. Its mechanism of action is to reduce the activation energy of the reaction by forming coordination complexes with epoxy groups or amine groups.

[0023] Accelerator (DMP-30): Works synergistically with the low-temperature catalyst to further enhance the curing reaction rate, especially providing stronger catalytic activity under low-temperature conditions, which helps achieve rapid setting. DMP-30 is a tertiary amine accelerator that can accelerate the curing reaction of epoxy-amine.

[0024] Anti-corrosion pigment (nano-modified zinc phosphate): Primarily provides the anti-corrosion performance of the coating. Nano-processed and surface-modified zinc phosphate has a larger specific surface area and higher reactivity, enabling it to more effectively passivate metal surfaces, hinder the penetration of corrosive media, and provide excellent anti-corrosion protection. Its average particle size is 50-200 nm, and the phosphorus-zinc mass ratio is controlled between 1:1.5 and 1:2.5, ensuring the anti-corrosion activity of zinc phosphate and its stable dispersion in coatings.

[0025] Filler (precipitated barium sulfate): Used to increase coating thickness, hardness, and wear resistance while reducing costs. Precipitated barium sulfate has a fine particle size, high whiteness, and is easy to disperse, providing excellent filling effect and X-ray blocking properties for the coating.

[0026] Leveling agent (polyacrylate leveling agent): Improves the leveling properties of coatings, eliminates surface defects such as brush marks and roller marks, makes the coating surface smooth and flat, and improves aesthetics and uniformity.

[0027] Defoamer (organic silicone defoamer): Inhibits and eliminates the generation of bubbles during the preparation and application of coatings, avoids defects such as pinholes and bubbles in the coating, and improves the density and protective ability of the coating.

[0028] UV absorber (UV-327): Absorbs harmful wavelengths of ultraviolet light, protects the coating from UV aging, extends the service life of the coating under strong ultraviolet radiation in cold regions, and maintains the color and mechanical properties of the coating.

[0029] Solvent (a mixture of acetone and toluene): Adjusts the viscosity of the coating, facilitating application and promoting the dissolution and dispersion of each component. The mixture of acetone and toluene provides suitable evaporation rate and solubility; a 1:1 volume ratio of acetone to toluene helps balance solubility and evaporation rate. The test data are shown in the table below:

[0030] Table 1: Comparison of Detection Data As shown in Table 1 above, compared with existing ordinary anti-corrosion coatings, the fast-setting anti-corrosion coating for power transmission equipment in high-altitude and cold regions of this invention exhibits a comprehensive leap in performance. Its advantages are fully demonstrated in the comparative data of key performance indicators: in an extreme low-temperature construction environment of -20°C, the drying time of this coating is significantly shortened to about 8 hours, while traditional coatings take more than 72 hours. This revolutionary "fast-setting" characteristic greatly improves construction efficiency and reduces the risk of equipment exposure. Regarding long-term protection, the salt spray resistance of this coating exceeds 2000 hours. Far exceeding the 600-700 hours of traditional coatings, and maintaining an adhesion level of over 18MPa even at -40°C, this coating demonstrates its superior anti-corrosion effect and environmental adaptability. Furthermore, through an innovative supercritical fluid degassing process, the bubble content is stably controlled below 0.2%, and it has successfully passed the -40°C storage stability test, ensuring product quality upon leaving the can and storage stability. Its UV aging life of over 3500 hours is three times that of traditional coatings, perfectly solving the coating aging problem caused by strong ultraviolet radiation in high-altitude and cold regions.

[0031] Reference Figures 2-8As shown, the present invention provides another technical solution. In this embodiment, a method for preparing a quick-setting anti-corrosion coating for power transmission equipment in cold regions includes the following specific steps: Step 1: In-situ nano-modification and prepolymerization of the resin matrix. After mixing bisphenol A epoxy resin (E-44) with an acetone-toluene mixed solvent in a reactor, instead of simple dissolution, a functional nano-alumina modified with a silane coupling agent is introduced. This nano-alumina is then dispersed in situ under the combined effects of ultrasonic oscillation and mechanical shearing. This process aims to construct a preliminary thermally conductive and reinforcing network within the resin through nanoparticles, laying the foundation for uniform heat transfer during subsequent rapid curing. The specific implementation steps are as follows: S11. Preparation and Dissolution: Add 40% by weight of bisphenol A type epoxy resin (base resin) and 7% by weight of a mixture of acetone and toluene (volume ratio 1:1) to a double planetary mixer equipped with an ultrasonic generator and a cooling jacket. Start low-speed stirring to ensure the resin is fully dissolved in the solvent, forming a homogeneous and transparent solution, ensuring no particles or agglomeration. This process is typically carried out at 20-30°C for approximately 30 minutes.

[0032] S12. Nanofiller addition: Slowly add 4% by weight of nano-alumina powder, surface-treated with silane coupling agent KH-560, to the reactor. The average particle size of the nano-alumina is controlled within the range of 10-100 nm, and the specific surface area is between 50-150 m² / g. The feeding rate is strictly controlled to suppress dust generation of the nano-powder and prevent its rapid agglomeration in the solvent. The silane coupling agent KH-560 (γ-glycidyl etheroxypropyltrimethoxysilane) pre-treats the surface of the nano-alumina, improving its interfacial bonding strength with the epoxy resin matrix and its dispersibility in organic solvents.

[0033] S13. Composite Dispersion Treatment: Gradually increase the stirring speed to a high-speed dispersion state (e.g., 1500-2000 rpm), and simultaneously turn on the ultrasonic generator oscillation switch. Utilize the synergistic effect of mechanical shear force and ultrasonic cavitation effect to continuously treat the system for 45 minutes. The cavitation effect of ultrasound can effectively break up the agglomerates of nanoparticles and improve dispersion efficiency; high-speed shear further ensures the uniform distribution of nanoparticles in the resin solution and prevents secondary agglomeration.

[0034] S14. Initial Quality Inspection and Transfer: After processing, samples are taken to test the fineness and viscosity of the slurry. The fineness should be below the micrometer level (e.g., less than 5 μm), and the viscosity should be within a reasonable range (e.g., 2000-4000 cP). Once it is confirmed that the nanoparticles have been sufficiently dispersed and formed a stable suspension system, the process can proceed to the next step.

[0035] Step 2: Plasma activation and directional hybridization of pigments and fillers. Before feeding, nano-modified zinc phosphate and precipitated barium sulfate are pre-activated using low-temperature plasma treatment technology to increase their surface energy and generate more active sites. Subsequently, they are mixed with the resin matrix during the high-speed dispersion stage. This pretreatment significantly enhances the interfacial bonding between the pigments / fillers and the resin, resulting in a denser and more robust shielding layer after curing. The specific implementation steps are as follows: S21. Material pretreatment: The mixture of 17% by weight of nano-modified zinc phosphate anticorrosive pigment and 8% by weight of precipitated barium sulfate filler is pretreated in an oven at 110°C for 2 hours to remove surface-adsorbed moisture, ensure that the powder is completely dry, and avoid the influence of water activation on the plasma treatment effect.

[0036] S22. Plasma Treatment Preparation: The dried powder mixture is evenly spread in the quartz tray of the low-temperature plasma treatment equipment and then sent into the vacuum reaction chamber. The quartz tray ensures the chemical inertness and stability of the treatment process.

[0037] S23. Surface Activation Implementation: Start the plasma equipment, evacuate the reaction chamber to below 10 Pa, then introduce high-purity argon as the process gas, maintaining the chamber pressure at 50-100 Pa. At the set power (e.g., 100W RF power), start the RF plasma to bombard the powder surface for 3 minutes. Argon plasma can effectively etch or bombard the powder surface, introducing active groups (such as hydroxyl and carbonyl groups), improving surface energy and wettability with the resin matrix.

[0038] S24. Activation and Integration of Materials: Immediately after plasma treatment, the activated powder is added to the resin matrix obtained in the first step. Shear dispersion is performed for 40 minutes at 1200 rpm using a high-speed dispersion disc until the slurry fineness meets the predetermined standard (slurry fineness not greater than 20 μm, particle size distribution span less than 3.0). High-speed dispersion ensures that the activated pigments and fillers can be rapidly and uniformly dispersed into the resin matrix, forming a stable suspension system.

[0039] Step 3: Precise introduction of a gradient catalytic system based on thermal history. This is a key innovative step: instead of adding the catalyst and accelerator all at once, a gradient introduction procedure is designed. First, half of the DMP-30 accelerator is mixed with the system at a moderate temperature to activate its potential activity. Then, after the material cools to room temperature, the entire modified polyamide curing agent is added. Finally, before discharge, dibutyltin dilaurate and the remaining half of DMP-30 are added as "triggers." This precise control of timing and temperature aims to achieve a perfect balance between storage stability and immediate high activity after application. The specific implementation steps are as follows: S31. System Preheating Control: The slurry system with completed pigment dispersion is heated and controlled through the reactor jacket to maintain a stable temperature of 40°C. Proper preheating helps the initial dissolution and dispersion of the accelerator.

[0040] S32. Initial Accelerator Addition: Add the first portion of the accelerator, comprising 60% of the total mass of DMP-30, to the isothermal system. Stir continuously at a medium speed of 500-600 rpm for 15 minutes to allow for initial mixing and activation. During this stage, a small amount of accelerator begins to activate at a higher temperature, preparing for the subsequent curing reaction.

[0041] S33. Cooling and Addition of Main Curing Agent: The temperature of the material system is then lowered to below 25°C using a cooling jacket. The full metered amount of modified polyamide curing agent (12% of total mass) is then added to the system. Cooling is to prevent premature and violent reactions before the curing agent is fully dispersed.

[0042] S34. Dispersion of main curing agent: Increase the stirring speed to 800 rpm and continue stirring for 20 minutes to ensure that the curing agent is completely and evenly dispersed in the system, providing sufficient contact area for its reaction with epoxy resin.

[0043] S35. Final Catalytic System Completion: Finally, while maintaining a temperature of 25°C, add the remaining DMP-30 promoter (40% of total mass) and all of the dibutyltin dilaurate catalyst (0.5% of total mass) to the system. Continue stirring for another 15 minutes to complete this step. This gradient introduction method utilizes the activation characteristics of DMP-30 and dibutyltin dilaurate at different temperatures, enabling rapid initiation and completion of the curing reaction even at lower temperatures, while ensuring system stability during the preparation process.

[0044] Step 4: Simultaneous Integration of Microencapsulated Rheology Modifiers. Leveling agents and a portion of defoamers are prepared into microcapsules containing a low-boiling-point solvent. These microcapsules are added during the paint mixing stage. While the paint is stored, these microcapsules rupture upon heating with a spray gun, releasing the modifiers and a small amount of solvent. This dynamically and instantly optimizes the rheological properties of the paint during application, effectively combating sagging and orange peel issues at low temperatures. The specific implementation steps are as follows: S41. Microencapsulated Additive Preparation: Microencapsulated additives with polyurea as the wall material and encapsulated with polyacrylate leveling agent and silicone defoamer are prepared in advance via in-situ polymerization. The average particle size of the microcapsules is controlled between 1-10 μm to ensure their dispersibility and stability in the coating. This encapsulation method effectively isolates the additive from the epoxy system, preventing the additive from volatilizing or being consumed during storage.

[0045] S42. Stirring conditions: After all liquid components of the coating system have been added, adjust the stirring speed of the reactor to a medium speed of 500 rpm to ensure uniform dispersion of the microcapsules and prevent them from breaking.

[0046] S43. Microencapsulation feeding: 0.5% of the total mass of the microencapsulated polyacrylate leveling agent and 0.5% of the total mass of the microencapsulated silicone defoamer are slowly and evenly added into the paint mixing tank through the powder feeding port.

[0047] S44. Homogenization and Dispersion: Maintain the current stirring speed and continue stirring for 30 minutes to ensure that the microcapsules are evenly distributed in the coating system. During the stirring process, due to the moderate stirring speed and the toughness of the polyurea wall material, the microcapsules are ensured to be undamaged, so that their function is activated only after the coating is applied.

[0048] Step 5: Supercritical Fluid-Assisted Degassing and Viscosity Fine-Tuning. Abandoning traditional static degassing, supercritical carbon dioxide fluid technology is introduced before the coating curing stage. This allows the coating to fully contact supercritical CO2 in a sealed pressure vessel. Utilizing its extremely high diffusivity and near-zero surface tension, it completely carries away the fine air bubbles that are difficult to remove from the system. Simultaneously, the viscosity of the system is fine-tuned by precisely controlling the pressure, achieving ultimate homogenization of the physical state. The specific implementation steps are as follows: S51. Pressure Equipment Preparation: The coating material from step four of the preceding steps is transferred by pump to a professionally designed pressure-resistant supercritical carbon dioxide treatment vessel, and the vessel is tightly sealed to ensure precise control of pressure and temperature.

[0049] S52. Supercritical Environment Creation: Start the equipment and pump a predetermined mass of liquid carbon dioxide into the treatment vessel. Then, gradually increase the temperature and pressure using a heating mantle and a booster pump to bring the carbon dioxide inside the vessel to a supercritical state (e.g., temperature above 31.1°C, pressure above 7.38 MPa). In this embodiment, the temperature is typically maintained at 40°C, and the pressure is increased to 15 MPa.

[0050] S53. Dynamic Circulation Treatment: Maintain the system pressure at 15 MPa and start the in-vessel circulating agitator to ensure full contact between the supercritical carbon dioxide fluid and the coating material. Supercritical carbon dioxide has characteristics such as high density, low viscosity, and high diffusion coefficient, which can penetrate deep into the coating, dissolve and remove air from the tiny bubbles, achieving efficient degassing. The treatment process lasts for 30 minutes to ensure complete degassing.

[0051] S54. Controlled Pressure Relief Discharge: After processing, the system pressure is slowly released at a rate of 0.5 MPa per minute through a precisely controlled pressure relief valve until atmospheric pressure is restored. Slow pressure relief helps prevent the coating from generating new bubbles or causing violent evaporation of the solvent due to rapid decompression.

[0052] S55. Product Indicator Verification: Immediately after discharge, test the viscosity and bubble content of the coating. The product standard is that the viscosity of the coating at 23°C is 70-100 cP, the bubble content is less than 0.2% (detected by a bubble meter), and the coating shows no phase separation or gelation after being placed at -40°C for 24 hours. Ensure that the coating meets the requirements for application and storage.

[0053] Step 6: Real-time quality monitoring and feedback based on online photoelectric sensing. Before the filtration and packaging stages, an online real-time monitoring system is integrated. The coating flows through a flow-through pool equipped with a specific wavelength light source and sensors. By analyzing the transmitted and scattered light signals, key product indicators such as fineness, dispersion uniformity, and impurity content are monitored simultaneously and non-contactly. This enables full inspection and data traceability throughout the production process, ensuring a high degree of consistency in the performance of each batch of product. The specific implementation steps are as follows: S61. Monitoring System Installation: A flow detection pool with a transparent viewing window is installed in series on the conveying pipeline before the coating product is filled and packaged. This detection pool is made of pressure-resistant and corrosion-resistant materials to ensure stable flow of the coating within it.

[0054] S62. Photoelectric Sensor Calibration: A semiconductor laser emitter of a specific wavelength (e.g., a 635nm red laser) is precisely installed on one side of the detection cell to provide a stable light source. High-sensitivity photoelectric sensors are installed on the other side, at a 90-degree angle to the first side (scattered light detection) and on the opposite side coaxial with the laser (transmitted light detection), to receive transmitted and scattered light signals. The system is calibrated using known standard samples before normal production to establish a quantitative relationship between transmittance, scattered light intensity, fineness, and dispersion uniformity.

[0055] S63. Online Monitoring Start-up: Start the delivery pump to allow the finely adjusted paint to flow through the detection tank at a constant flow rate (e.g., 1 m / s). Simultaneously start the photoelectric sensing system to collect and record data on the intensity of transmitted laser light and the intensity of 90-degree scattered light in real time. The intensity of transmitted laser light is related to the fineness, transparency, and color depth of the paint; the intensity of scattered light mainly reflects the uniformity of particle dispersion in the paint. The more uniform and finer the particles, the more stable and moderate the intensity of the scattered light signal.

[0056] S64. Data Comparison and Judgment: The acquired optical data signals are transmitted to the central processing unit (CPU). The CPU has a built-in algorithm model trained on a large amount of experimental data and a preset database of quality qualification thresholds. The system compares and judges the real-time data with the database to determine whether the fineness of the coating is no greater than 20μm, whether the particle size distribution span is less than 3.0, and whether the dispersion uniformity meets the requirements. The transmittance deviation of qualified coatings does not exceed ±5% of the standard value, and the coefficient of variation of scattered light intensity is less than 10%.

[0057] S65. Quality Report Generation: Based on the comparison results, the system dynamically displays the real-time status of product quality (e.g., qualified / unqualified, or fineness and dispersibility index). Simultaneously, a unique quality monitoring report is generated for each batch of coating products, containing detailed optical data, analysis results, and qualification judgments. Finally, coatings confirmed as qualified by this online monitoring system are filtered and sealed in packaging, while unqualified products are automatically diverted for reprocessing or scrapped, ensuring the uniformity and high standards of product quality leaving the factory.

[0058] The technical scope of this invention is not limited to the content described above. Those skilled in the art can make various modifications and variations to the above embodiments without departing from the technical concept of this invention, and all such modifications and variations should fall within the protection scope of this invention.

Claims

1. A fast-setting anti-corrosion coating for power transmission equipment in high-altitude and cold regions, characterized in that, This coating is made by mixing a base resin, a curing agent, a low-temperature catalyst, an accelerator, anti-corrosion pigments, fillers, a leveling agent, a defoamer, a UV absorber, and a solvent. The components are as follows: base resin: 35%-45% by mass; curing agent: 10%-14% by mass; low-temperature catalyst: 0.3%-0.8% by mass; accelerator: 0.3%-0.8% by mass; anti-corrosion pigments: 15%-20% by mass; fillers: 6%-10% by mass; leveling agent: 0.3%-0.8% by mass; defoamer: 0.3%-0.8% by mass; UV absorber: 0.8%-1.5% by mass; and solvent: 15%-25% by mass.

2. The quick-setting anti-corrosion coating for power transmission equipment in high-altitude and cold regions according to claim 1, characterized in that: The base resin is bisphenol A type epoxy resin; the curing agent is modified polyamide curing agent; the low-temperature catalyst is dibutyltin dilaurate; the accelerator is DMP-30; the anti-corrosion pigment is nano-modified zinc phosphate; the filler is precipitated barium sulfate; the leveling agent is polyacrylate leveling agent; the defoamer is silicone defoamer; the ultraviolet absorber is UV-327; and the solvent is a mixture of acetone and toluene, wherein the volume ratio of acetone to toluene is 1:

1.

3. A method for preparing a quick-setting anti-corrosion coating for power transmission equipment in cold regions, used to prepare the quick-setting anti-corrosion coating as described in claim 2, characterized in that, The specific implementation steps include the following: S1. In-situ nano-modification and prepolymerization of resin matrix: Bisphenol A type epoxy resin was mixed with a portion of acetone and toluene in a reaction vessel, and nano-sized inorganic thermally conductive filler was added. The mixture was dispersed under the combined action of ultrasonic oscillation and mechanical shearing to form a uniform resin base. S2. Plasma activation and directional hybridization of pigments and fillers: The surface energy of the nano-modified zinc phosphate anticorrosive pigment and the precipitated barium sulfate filler is enhanced, and then they are added to the resin base obtained by S1 for high-speed dispersion and grinding until the fineness of the slurry reaches the predetermined standard. S3. Precise introduction of gradient catalysis system based on thermal history: The catalytic system is introduced in stages. First, the first part of the accelerator is added to the system at the first temperature and mixed evenly. Then, all the modified polyamide curing agent is added. Finally, the catalyst and the remaining second part of the accelerator are added at a second lower temperature. S4. Simultaneous integration of microencapsulated rheology modifiers: The leveling agent and defoamer were added to the coating system obtained in S3 in the form of microcapsules and then stirred to disperse them evenly. S5. Supercritical fluid-assisted degassing and viscosity fine-tuning: The coating obtained from S4 was defoamed and its viscosity adjusted using a low surface tension fluid to obtain a finely adjusted coating. S6. Real-time quality monitoring and feedback based on online photoelectric sensing: The finely adjusted paint flows through an online quality monitoring system, which analyzes the optical properties of the paint to determine and provide feedback on its fineness and dispersion uniformity in real time. Paint that has passed the online monitoring and is confirmed to be qualified is then filtered and sealed for packaging.

4. The method for preparing a quick-setting anti-corrosion coating for power transmission equipment in cold regions according to claim 3, characterized in that: The specific implementation steps of S1 are as follows: S11. Preparation and dissolution: Add the bisphenol A epoxy resin, acetone and toluene mixed solvent into a double planetary stirring vessel equipped with an ultrasonic generator and a cooling jacket, and start low-speed stirring to completely dissolve the resin and form a homogeneous solution. S12. Nanofiller addition: Slowly add nano-alumina powder treated with silane coupling agent KH-560 to the reactor, and control the feeding speed to suppress powder dust and agglomeration. S13. Composite dispersion treatment: Gradually increase the stirring speed to a high-speed dispersion state and simultaneously turn on the ultrasonic generator oscillation switch, and continue to treat for 45 minutes using the synergistic effect of mechanical shearing and cavitation. S14. Initial quality inspection and transfer: After processing, samples are taken to test the fineness and viscosity of the slurry to confirm that the nanoparticles have been fully dispersed and formed a stable suspension system for use in subsequent processes.

5. The method for preparing a quick-setting anti-corrosion coating for power transmission equipment in cold regions according to claim 3, characterized in that: The specific implementation steps of S2 are as follows: S21. Material pretreatment: The powder mixture of nano-modified zinc phosphate and precipitated barium sulfate is pretreated in a drying oven at 110 degrees Celsius for 2 hours to ensure complete drying; S22. Plasma treatment preparation: The dried powder mixture is evenly spread in the quartz tray of the low-temperature plasma treatment equipment and then sent into the vacuum reaction chamber. S23. Surface activation implementation: After the reaction chamber is evacuated by starting the equipment, argon gas is introduced as the process gas. Radio frequency plasma is started at the set power to bombard the powder surface for 3 minutes. S24. Activation material integration: Immediately after processing, the activated powder is added to the previously prepared resin base and sheared and dispersed for 40 minutes at a speed of 1200 rpm using a high-speed dispersing disc.

6. The method for preparing a quick-setting anti-corrosion coating for power transmission equipment in cold regions according to claim 3, characterized in that: The specific implementation steps of S3 are as follows: S31. System preheating control: The temperature of the slurry system after pigment dispersion is controlled by the jacket of the reactor to keep it stable at 40 degrees Celsius. S32. Preliminary Accelerator Addition: Add the first part of the accelerator, which accounts for 60% of the total mass of DMP-30, to the constant temperature system, and stir continuously at a medium stirring speed of 500-600 rpm for 15 minutes to allow it to be preliminarily mixed and activated. S33, Cooling and Addition of Main Curing Agent: The temperature of the material system is then reduced to below 25 degrees Celsius by cooling jacket, and then all the metered modified polyamide curing agent is added to the system. S34. Dispersion of main curing agent: Increase the stirring speed to 800 rpm and continue stirring for 20 minutes to ensure that the curing agent is completely and evenly dispersed; S35. Final Catalytic System Completion: Finally, while maintaining a temperature of 25 degrees Celsius, add the remaining DMP-30 promoter and all of the dibutyltin dilaurate catalyst to the system, and continue stirring for 15 minutes to end the process.

7. The method for preparing a quick-setting anti-corrosion coating for power transmission equipment in cold regions according to claim 3, characterized in that: The specific implementation steps of S4 are as follows: S41. Preparation of microcapsule additives: Microcapsule additives with polyurea as the wall material and encapsulated with polyacrylate leveling agent and silicone defoamer are prepared in advance by in-situ polymerization. S42. Stirring conditions setting: After all liquid components of the coating system have been added, adjust the stirring speed of the reactor to a medium speed of 500 rpm. S43. Microcapsule feeding: The measured amount of microcapsule additive is slowly and evenly added into the paint mixing tank through the powder feeding port; S44. Homogenization and dispersion: Maintain the current stirring speed and continue stirring for 30 minutes to ensure that the microcapsules are evenly distributed in the coating system without significant damage.

8. The method for preparing a quick-setting anti-corrosion coating for power transmission equipment in cold regions according to claim 3, characterized in that: The specific implementation steps of S5 are as follows: S51. Pressure equipment preparation: Transfer the coating material that has undergone the previous steps to a pressure-resistant supercritical carbon dioxide treatment vessel and seal the equipment. S52. Creation of supercritical environment: Start the equipment to pump a predetermined mass of liquid carbon dioxide into the treatment vessel, and then increase the temperature and pressure to make the carbon dioxide in the vessel reach a supercritical state. S53, Dynamic Circulation Processing: Maintain the system pressure at 15 MPa and start the in-vessel circulating agitator to ensure that the supercritical fluid and coating materials are in full contact and continuously circulate for 30 minutes. S54. Controllable pressure relief discharge: After the process is completed, the system pressure is slowly released at a rate of 0.5 MPa per minute through a precisely controlled pressure relief valve until it returns to normal pressure; S55. Product index verification: Discharge the material and immediately test the viscosity and bubble content of the coating to confirm that it meets the product standards.

9. The method for preparing a quick-setting anti-corrosion coating for power transmission equipment in cold regions according to claim 3, characterized in that: The specific implementation steps of S6 are as follows: S61. Monitoring system installation: Install a flow detection pool with a transparent window in parallel on the conveying pipeline before the coating product is filled and packaged; S62, Photoelectric sensor calibration: A semiconductor laser emitter of a specific wavelength is installed on one side of the detection cell, and photoelectric sensors are installed on the other side and at a 90-degree angle to the first side to receive transmitted light and scattered light signals. S63. Online monitoring start-up: Start the delivery pump to make the coating flow through the detection pool at a constant flow rate, and simultaneously start the photoelectric sensor system to collect and record light intensity data in real time; S64. Data comparison and judgment: The collected optical data signals are transmitted to the central processing unit and compared and judged in real time with the preset quality qualification threshold database. S65. Quality Report Generation: The system dynamically displays the real-time status of product quality based on the comparison results and generates a unique quality monitoring report for each batch of coating products. Coatings that have passed online monitoring and are confirmed to be qualified are filtered and sealed for packaging.

10. The method for preparing a quick-setting anti-corrosion coating for power transmission equipment in cold regions according to claim 8, characterized in that: The nano-scale inorganic thermally conductive filler in S1 is nano-alumina with an average particle size in the range of 10-100 nm and a specific surface area between 50-150 m² / g; the nano-modified zinc phosphate anticorrosive pigment in S2 has an average particle size of 50-200 nm and a phosphorus-zinc mass ratio controlled between 1:1.5 and 1:2.5; the predetermined standard in S2 is that the slurry fineness is not greater than 20 μm and the particle size distribution span is less than 3.0; the product standard in S5 is that the viscosity of the coating at 23°C is 70-100 cP, the bubble content is less than 0.2%, and the coating shows no phase separation or gelation after being placed at -40°C for 24 hours; the online quality monitoring system in S6 determines the fineness and dispersion uniformity by analyzing the transmittance and scattered light intensity of the coating in real time, wherein the transmittance deviation of qualified coating does not exceed ±5% of the standard value, and the coefficient of variation of scattered light intensity is less than 10%.

Images