Method for synergistically preparing wear-resistant coating slurry based on high and low molecular weight surface activity

Abstract

The invention discloses a method for synergistically preparing wear-resistant coating slurry based on high and low molecular weight surface activity, which comprises the following steps: compounding sodium methylene bis-naphthalene sulfonate, DOE120, SPAN-40 and PEO4000 into a synergistic active agent, adding Al (HPO) and ZrOCl8HO, carrying out 80W ultrasonic deagglomeration for 10 minutes, carrying out 300rmin planetary ball milling for 60 minutes, adjusting the pH value to 6-7, and standing for 24 hours to obtain the slurry. The average particle size of the slurry is 0.21-0.24 [mu] m, the hardness of the coating is 2-3H, and the wear resistance reaches 0.12-0.15 g. When the coating is applied to a wind power blade, the annual abrasion loss is reduced to 0.15 mm, and the maintenance period is prolonged by 300%; the abrasion of the power battery bottom plate is greatly reduced, and the service life exceeds 5 years. The problems that traditional slurry is poor in stability and high in wear rate are solved, the slurry adapts to extreme working conditions, the equipment operation and maintenance cost is remarkably reduced, and the slurry has important industrial application value.

Description

Technical Field

[0001] This invention belongs to the field of reinforced ceramic coating products, and specifically relates to a method for preparing wear-resistant coating slurry based on the synergistic preparation of high and low molecular weight surface activity. Background Technology

[0002] As an important type of protective coating, wear-resistant coatings have the characteristics of low surface friction coefficient, strong load-bearing capacity, and excellent resistance to mechanical impact. When subjected to external forces, they can effectively reduce friction loss between interfaces, reduce wear, and thus protect the substrate from damage and extend its service life. They have been widely used in aerospace vehicles, vehicles, ships, instruments, machine tools and many other industries.

[0003] In recent years, with the rapid development of the renewable energy industry, the market demand for wear-resistant coatings in the energy sector has grown dramatically, especially in the protection of critical equipment such as wind turbine blades, nuclear reactor containment vessels, dam structures, and turbines. However, existing wear-resistant slurries formulated with low molecular weight surfactants suffer from problems such as poor stability, short suspension time, and unsatisfactory surface tension. Furthermore, the uneven particle size distribution of the slurry affects the wear resistance and reliability of the coating, making it difficult to meet the high standards required for protective coatings on power battery substrates. Therefore, developing a method for preparing a coating slurry with good stability and excellent wear resistance for power battery substrates is of significant practical importance. Summary of the Invention

[0004] The purpose of this invention is to provide a method for preparing wear-resistant coating slurries based on the synergistic effect of high and low molecular weight surfactants, so as to solve the problems of poor stability and insufficient wear resistance of coatings in the existing technology of slurries prepared by low molecular weight surfactants.

[0005] The technical solution of the present invention to solve the above-mentioned technical problems is as follows: A method for preparing wear-resistant slurry for power battery substrates using high and low molecular weight surfactants in synergistic processes includes the following steps: S1: Preparation of the compound surfactant solution The compound surfactant solution is prepared by mixing sodium methylene bis(naphthalene) sulfonate, methyl glucoside dioleate polyoxyethylene (120) ether (DOE120), SPAN-40, PEO4000 and deionized water; wherein, the amount of sodium methylene bis(naphthalene) sulfonate is 0.5g / L to 1g / L, the amount of methyl glucoside dioleate polyoxyethylene (120) ether (DOE120) is 0.5g / L to 1g / L, the amount of SPAN-40 is 0.5g / L to 1g / L, and the amount of PEO4000 is 0.5g / L to 1g / L.

[0006] S2: Raw material mixing and deagglomeration. Al(H2PO4)3 and ZrOCl2・8H2O were added to the compound activator solution prepared in S1, and the concentration of Al(H2PO4)3 was controlled at 1 g / L and the concentration of ZrOCl2・8H2O was controlled at 50 g / L. Then, a JY92-IIN high-energy ultrasonic cell disruptor (Ningbo Kesi Biotechnology Co., Ltd.) was used to ultrasonically treat the raw materials for 10 min with an output power of 80W to achieve deagglomeration of the raw materials.

[0007] S3: Ball milling treatment. The mixed slurry after deagglomeration treatment in S2 is added to the ball mill jar, and the ball mill jar is transferred to the QM-SP planetary ball mill. The ball mill speed is set to 300 r・min⁻¹. First, it rotates forward for 30 min, and then rotates in reverse at the same speed for 30 min to complete the ball milling and refining.

[0008] S4: Adjust pH and let stand. Take out the ball-milled slurry, add ammonia water and stir to adjust the pH value of the slurry to 6-7, and then let it stand at room temperature for 24 hours to obtain the target wear-resistant coating slurry.

[0009] The present invention has the following beneficial effects: 1. This invention uses high and low molecular weight surfactants to synergistically prepare wear-resistant slurries, effectively improving the instability of slurries prepared with low molecular weight surfactants; and improving the stabilization time and surface tension of the slurry.

[0010] 2. The slurry prepared by this invention can effectively improve the particle size distribution of the slurry particles. The micron-level particle size distribution can fully enhance the wear resistance of the coating. Attached Figure Description

[0011] Figure 1 The surface tension index of surfactant solutions is given for three implementation examples; Figure 2 The average particle size index of the wear-resistant slurry in three implementation examples; Figure 3 The stability of the wear-resistant slurry suspension in three implementation examples. Detailed Implementation

[0012] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0013] Example 1 A method for preparing wear-resistant slurry for power battery substrates using high and low molecular weight surfactants in synergistic processes includes the following steps: S1: Preparation of Compound Surfactant Solution The compound surfactant solution is prepared by mixing sodium methylene bisnaphthalene sulfonate, methyl glucoside dioleate polyoxyethylene (120) ether (DOE120), SPAN-40, PEO4000 and deionized water; wherein, the amount of sodium methylene bisnaphthalene sulfonate is 0.5 g / L, the amount of methyl glucoside dioleate polyoxyethylene (120) ether (DOE120) is 1 g / L, the amount of SPAN-40 is 0.5 g / L and the amount of PEO4000 is 0.5 g / L.

[0014] S2: Raw material mixing and deagglomeration. Al(H2PO4)3 and ZrOCl2・8H2O were added to the compound activator solution prepared in S1, and the concentration of Al(H2PO4)3 was controlled at 1 g / L and the concentration of ZrOCl2・8H2O was controlled at 50 g / L. Then, a JY92-IIN high-energy ultrasonic cell disruptor (Ningbo Kesi Biotechnology Co., Ltd.) was used to ultrasonically treat the raw materials for 10 min with an output power of 80W to achieve deagglomeration of the raw materials.

[0015] S3: Ball milling treatment. The mixed slurry after deagglomeration treatment in S2 is added to the ball mill jar, and the ball mill jar is transferred to the QM-SP planetary ball mill. The ball mill speed is set to 300 r・min⁻¹. First, it rotates forward for 30 min, and then rotates in reverse at the same speed for 30 min to complete the ball milling and refining.

[0016] S4: Adjust pH and let stand. Take out the ball-milled slurry, add ammonia water and stir to adjust the pH value of the slurry to 6, and then let it stand at room temperature for 24 hours to obtain the target wear-resistant coating slurry.

[0017] The slurry prepared in this embodiment has an average particle size of 0.24 μm, a coating interface peel rate of 22%, an abrasion resistance (ASTM D4060-2019) of 0.12 g, a hardness (GB / T6739-2006 pencil method) of 2H, a surface drying time of 8-10 h, a complete drying time of 24-30 h, and exhibits good kerosene and gasoline resistance (232℃, 14 d) without softening, bubbling, wrinkling, or cracking.

[0018] Example 2 A method for preparing wear-resistant slurry for power battery substrates using high and low molecular weight surfactants in synergistic processes includes the following steps: S1: Preparation of Compound Surfactant Solution The compound surfactant solution is prepared by mixing sodium methylene bis(naphthalene) sulfonate, methyl glucoside dioleate polyoxyethylene (120) ether (DOE120), SPAN-40, PEO4000 and deionized water; wherein, the amount of sodium methylene bis(naphthalene) sulfonate is 1 g / L, the amount of methyl glucoside dioleate polyoxyethylene (120) ether (DOE120) is 0.5 g / L, the amount of SPAN-40 is 1 g / L and the amount of PEO4000 is 1 g / L.

[0019] S2: Raw material mixing and deagglomeration. Al(H2PO4)3 and ZrOCl2・8H2O were added to the compound activator solution prepared in S1, and the concentration of Al(H2PO4)3 was controlled at 1 g / L and the concentration of ZrOCl2・8H2O was controlled at 50 g / L. Then, a JY92-IIN high-energy ultrasonic cell disruptor (Ningbo Kesi Biotechnology Co., Ltd.) was used to ultrasonically treat the raw materials for 10 min with an output power of 80W to achieve deagglomeration of the raw materials.

[0020] S3: Ball milling treatment. The mixed slurry after deagglomeration treatment in S2 is added to the ball mill jar, and the ball mill jar is transferred to the QM-SP planetary ball mill. The ball mill speed is set to 300 r・min⁻¹. First, it rotates forward for 30 min, and then rotates in reverse at the same speed for 30 min to complete the ball milling and refining.

[0021] S4: Adjust pH and let stand. Take out the ball-milled slurry, add ammonia water and stir to adjust the pH value of the slurry to 6-7, and then let it stand at room temperature for 24 hours to obtain the target wear-resistant coating slurry.

[0022] The slurry prepared in this embodiment has an average particle size of 0.23 μm, a coating interface peel rate of 25%, an abrasion resistance (ASTM D4060-2019) of 0.14 g, a hardness (GB / T6739-2006 pencil method) of 3H, a surface drying time of 8-10 h, a complete drying time of 24-30 h, and exhibits good kerosene and gasoline resistance (232℃, 14 d) without softening, bubbling, wrinkling, or cracking.

[0023] Example 3 A method for preparing wear-resistant slurry for power battery substrates using high and low molecular weight surfactants in synergistic processes includes the following steps: S1: Preparation of Compound Surfactant Solution The compound surfactant solution is prepared by mixing sodium methylene bisnaphthalene sulfonate, methyl glucoside dioleate polyoxyethylene (120) ether (DOE120), SPAN-40, PEO4000 and deionized water; wherein, the amount of sodium methylene bisnaphthalene sulfonate is 1g / L, the amount of methyl glucoside dioleate polyoxyethylene (120) ether (DOE120) is 1g / L, the amount of SPAN-40 is 1g / L and the amount of PEO4000 is 1g / L.

[0024] S2: Raw material mixing and deagglomeration. Al(H2PO4)3 and ZrOCl2・8H2O were added to the compound activator solution prepared in S1, and the concentration of Al(H2PO4)3 was controlled at 1 g / L and the concentration of ZrOCl2・8H2O was controlled at 50 g / L. Then, a JY92-IIN high-energy ultrasonic cell disruptor (Ningbo Kesi Biotechnology Co., Ltd.) was used to ultrasonically treat the raw materials for 10 min with an output power of 80W to achieve deagglomeration of the raw materials.

[0025] S3: Ball milling treatment. The mixed slurry after deagglomeration treatment in S2 is added to the ball mill jar, and the ball mill jar is transferred to the QM-SP planetary ball mill. The ball mill speed is set to 300 r・min⁻¹. First, it rotates forward for 30 min, and then rotates in reverse at the same speed for 30 min to complete the ball milling and refining.

[0026] S4: Adjust pH and let stand. Take out the ball-milled slurry, add ammonia water and stir to adjust the pH value of the slurry to 6-7, and then let it stand at room temperature for 24 hours to obtain the target wear-resistant coating slurry.

[0027] The slurry prepared in this embodiment has an average particle size of 0.21 μm, a coating interface peel rate of 28%, an abrasion resistance (ASTM D4060-2019) of 0.15 g, a hardness (GB / T6739-2006 pencil method) of 3H, a surface drying time of 10-12 h, a complete drying time of 28-36 h, and exhibits good kerosene and gasoline resistance (232℃, 14d) without softening, bubbling, wrinkling, or cracking. The effectiveness of the technical solution of the present invention is further illustrated by the coating performance data of the three implementation examples in Table 1: Interface peeling rate: Example 1 (22%) < Example 2 (25%) < Example 3 (28%). This difference is related to the amount of sodium methylene bisnaphthalene sulfonate in the compounded surfactant (the amount of sodium methylene bisnaphthalene sulfonate in Example 1 is 0.5 g / L, which is lower than 1 g / L in Examples 2 and 3), indicating that the low proportion of this component is more conducive to improving the interfacial bonding between the coating and the substrate.

[0028] Wear resistance: Example 1 (0.12g) has the best wear resistance, while Example 3 (0.15g) is slightly weaker. Combined with the average particle size of the slurry (Example 1: 0.24μm, Example 3: 0.21μm), it can be seen that in addition to particle size, the compounding ratio of surfactant is also a key factor affecting wear resistance. The compounding scheme of the present invention can control the wear amount within 0.15g, which meets the high wear resistance requirements of the power battery base plate.

[0029] Hardness: The coating hardness of Examples 2 and 3 reached 3H (higher than 2H in Example 1), which corresponds to the increased use of SPAN-40 and PEO4000 in Examples 2 and 3. This shows that adjusting the ratio of compound surfactants can optimize coating hardness and cover the protection requirements of different scenarios.

[0030] Drying time: The surface drying time (10-12h) and actual drying time (28-36h) of Example 3 were slightly longer than those of Examples 1 and 2. This is related to the higher total amount of surfactant used in Example 3 (1g / L for each component), but it is still within the acceptable range for industrial applications.

[0031] Media resistance and appearance: The coatings in the three embodiments were free of appearance defects such as cratering and blistering, and their resistance to kerosene and gasoline (232℃, 14d) was "no softening, no blistering, no wrinkling, and no cracking", indicating that the formulation and process of the present invention have good stability and can stably prepare high-performance protective coatings.

[0032] I. Comparison Table of Actual Application Verification Data II. In-depth Data Analysis 1. Wind turbine blade applications: Long-term protection advantages in extreme environments Core of wear control: The annual wear of the coating of this invention is only 0.15mm, which is much lower than the 0.8mm of the traditional coating. The key reason is that after the slurry is treated by ultrasonic deagglomeration (80W, 10min) and planetary ball milling, the average particle size is controlled at 0.21-0.24μm, the dispersion uniformity is significantly improved, and combined with the synergistic stabilizing effect of high and low molecular weight surfactants, a dense and wear-resistant structure is formed.

[0033] Environmental adaptability verification: The interface peeling rate under salt spray environment is ≤25%, which meets the advanced requirement of ≤15% adhesion loss after salt spray corrosion in ISO4587 standard. This is better than traditional coatings (peeling rate ≥40%), proving that the compounded activator system effectively enhances the adhesion strength between the coating and the blade substrate.

[0034] The economic benefits are evident: the maintenance cycle has been extended from 6 months to 24 months, which meets the core demand of the wind power industry to "reduce operation and maintenance costs". According to industry data, the annual maintenance cost of a single wind turbine can be reduced by 18%-30%, which is especially suitable for difficult-to-maintain scenarios such as offshore wind power.

[0035] 2. Application of power battery base plate: Safety protection upgrade under complex working conditions Synergistic wear resistance and impact resistance: The wear depth is only 0.02mm after 12 months, and there is no cracking under 10J impact, which meets the safety requirements of the electric vehicle power battery bottom impact test (GB / T31498-2021), and solves the pain point of traditional coatings being easily damaged under the coupled action of vibration and impact.

[0036] Key role in corrosion protection: No corrosion points were observed in the environment of minor electrolyte leakage, and the insulation resistance retention rate was ≥98%, which verified the corrosion inhibition effect of the inorganic phase composed of Al(H2PO4)3 and ZrOCl2・8H2O, and avoided safety hazards caused by the corrosion of the power battery base plate.

[0037] Lifecycle optimization: The service life is extended from 3 years to more than 5 years, covering the design service life of core components of new energy vehicles, reducing user replacement costs, and reducing the consumption of coating materials, thus possessing both environmental and economic value.

[0038] 3. Verification of the correlation between technical solutions and performance data Surfactant synergistic effect: The combination of sodium methylene bis(naphthalene) sulfonate (low molecular weight) and PEO4000 (high molecular weight) not only ensures the dispersion stability of the slurry (avoiding particle agglomeration leading to uneven wear), but also improves the elastic modulus of the coating through the flexible polymer segments, thereby improving the impact resistance by 40%.

[0039] The key role of process parameters: 80W ultrasonic deagglomeration effectively breaks up particle aggregates, and 300r・min⁻¹ planetary ball milling further refines the particle size. The combination of the two results in uniform distribution of slurry particles, which directly supports the low wear performance of the coating in different application scenarios.

[0040] Industry benchmarks for performance indicators: The coating abrasion resistance (ASTM D4060-2019) is as low as 0.12g, and the hardness reaches 2-3H (GB / T6739-2006), both of which are better than the conventional requirements for industrial abrasion-resistant coatings (abrasion amount ≤0.5g, hardness ≥2H), and have broad application potential.

[0041] III. Summary This invention's coating slurry, through technological innovation of "synergistic use of high and low molecular weight surfactants + ultrasonic-ball milling composite process," achieves "low wear, high stability, and long service life" protection in core energy equipment such as wind turbine blades and power battery base plates. All practical application data significantly outperform traditional coatings, and performance reliability has been verified through benchmarking against industry standards. It not only reduces equipment maintenance costs but also improves the safe service level of core components, possessing clear industrial application value and market competitiveness.

[0042] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for preparing wear-resistant coating slurry based on the synergistic effect of high and low molecular weight surface activity, characterized in that, The preparation process includes mixing a compound surfactant solution with inorganic raw materials, followed by ultrasonic deagglomeration, ball milling, pH adjustment, and settling. The specific process is as follows: S1: The compound surfactant solution is prepared by mixing sodium methylene bisnaphthalene sulfonate, methyl glucoside dioleate polyoxyethylene ether, SPAN-40, PEO4000 and deionized water. S2: Add Al(H2PO4)3 and ZrOCl2・8H2O to the compound activator solution, wherein the concentration of Al(H2PO4)3 is 1g / L and the concentration of ZrOCl2・8H2O is 50g / L. Then, use a JY92-IIN high-energy ultrasonic cell disruptor to sonicate for 10 minutes at an output power of 80W to deagglomerate. S3: Add the mixed slurry treated by S2 into the ball mill jar, transfer it to the QM-SP planetary ball mill, set the speed to 300 r・min⁻¹, first rotate forward for 30 min, and then rotate in reverse at the same speed for 30 min to perform ball milling; S4: Take out the ball-milled slurry, add ammonia water and stir to adjust the pH to 6-7, let it stand at room temperature for 24 hours to obtain the target wear-resistant slurry.

2. The method for preparing wear-resistant coating slurry based on the synergistic effect of high and low molecular weight surface activity according to claim 1, characterized in that, The amount of sodium methylene bis(naphthalene) sulfonate described in S1 is 0.5 g / L to 1 g / L.

3. The method for preparing wear-resistant coating slurry based on the synergistic effect of high and low molecular weight surface activity according to claim 1, characterized in that, The amount of methyl glucoside dioleate polyoxyethylene ether described in S1 is 0.5 g / L to 1 g / L.

4. The method for preparing wear-resistant coating slurry based on the synergistic effect of high and low molecular weight surface activity according to claim 1, characterized in that, The dosage of SPAN-40 mentioned in S1 is 0.5 g / L to 1 g / L.

5. The method for preparing wear-resistant coating slurry based on the synergistic effect of high and low molecular weight surface activity according to claim 4, characterized in that, The dosage of PEO4000 mentioned in S1 is 0.5 g / L to 1 g / L.

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