METHOD OF PREPARING INSULATION COATING

Abstract

The present invention discloses a method of preparing insulation coating. The method comprises: providing a powder of polymer material, a graphite powder, and a substrate, wherein the powder of the polymer material is an epoxy powder or a polyethylene (PE) powder. Next, forming a mixture via mixing the powder of polymer material and the graphite powder. Then, utilizing a thermal spray device to spray the mixture on the substrate and then cooling the substrate to form an insulation coating. The method possesses advantages of increased production efficiency and reduced cost, and provides an insulation coating with good sound insulation properties.

Claims

1. A method of preparing insulation coating, the method comprising the steps of: providing a powder of polymer material, a graphite powder, and a substrate, wherein the powder of polymer material comprises an epoxy powder or a polyethylene (PE) powder; forming a mixture via mixing the powder of polymer material and the graphite powder, wherein the volume percentage concentration of the graphite powder is between 525 vol %; heating the mixture to a temperature between 350650 C.; spraying the mixture on the substrate; and cooling the mixture to form an insulation coating.

2. The method of preparing insulation coating as claimed in claim 1, wherein the graphite powder comprises an expanded graphite powder.

3. The method of preparing insulation coating as claimed in claim 1, wherein spraying the mixture on the substrate utilizes a spray device to spray the mixture on the substrate.

4. The method of preparing insulation coating as claimed in claim 3, wherein the spray device is a thermal spray device.

5. The method of preparing insulation coating as claimed in claim 1, wherein the method further comprises the step of: forming a resist coating to increase corrosion resistance via spraying a zinc-aluminum alloy on the substrate.

6. The method of preparing insulation coating as claimed in claim 5, wherein the thickness of the resist coating is between 200700 m.

7. The method of preparing insulation coating as claimed in claim 1, wherein cooling the substrate to form an insulation coating further comprises the step of: spraying the mixture on the insulation coating and cooling the mixture to form a second insulation coating.

8. The method of preparing insulation coating as claimed in claim 5, wherein cooling the substrate to form an insulation coating further comprises the step of: spraying the mixture on the insulation coating and cooling the mixture to form a second insulation coating.

9. The method of preparing insulation coating as claimed in claim 6, wherein cooling the substrate to form an insulation coating further comprises the step of: spraying the mixture on the insulation coating and cooling the mixture to form a second insulation coating.

10. The method of preparing insulation coating as claimed in claim 7, wherein the thickness of the second insulation coating is between 0.41.3 cm.

11. The method of preparing insulation coating as claimed in claim 8, wherein the thickness of the second insulation coating is between 0.41.3 cm.

12. The method of preparing insulation coating as claimed in claim 9, wherein the thickness of the second insulation coating is between 0.41.3 cm.

13. The method of preparing insulation coating as claimed in claim 1, wherein the thickness of the insulation coating is between 0.41.3 cm.

14. The method of preparing insulation coating as claimed in claim 1, wherein cooling the substrate to form an insulation coating further comprises the steps of: heating the surface of the insulation coating to a temperature between 350650 C.; and cooling the mixture to room temperature.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1 is a flowchart of a first embodiment of the present invention;

[0012] FIG. 2 is a schematic view of the first embodiment of the present invention;

[0013] FIG. 3a is a flowchart of a second embodiment of the present invention;

[0014] FIG. 3b is a schematic view of the second embodiment of the present invention;

[0015] FIG. 4a is an absorption coefficient-frequency view of an epoxy powder mixed with a normal graphite powder of the present invention;

[0016] FIG. 4b is an absorption coefficient-frequency view of an epoxy powder mixed with an expanded graphite powder of the present invention;

[0017] FIG. 5a is an absorption coefficient-frequency view of a polyethylene powder mixed with a normal graphite powder of the present invention; and

[0018] FIG. 5b is an absorption coefficient-frequency view of a polyethylene powder mixed with an expanded graphite powder of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0019] In order to describe details of preferred embodiments of the present invention, description of the structure, and the application as well as the steps are made with reference to the accompanying drawings. It is learned that after the description, any variation, modification or the like to the structure and the steps of the embodiments of the preferred embodiments of the present invention is easily made available to any person skilled in the art. Thus, the following description is only for illustrative purpose and does not, in any way, try to limit the scope of the present invention.

[0020] With reference to FIGS. 1 and 2 of a first embodiment of the present invention, the method of preparing an insulation coating 5 comprises the following steps:

[0021] Step 91: providing a powder of polymer material 1, a graphite powder 2, and a substrate 3. In the first embodiment, the powder of polymer material 1 is an epoxy powder or a polyethylene (PE) powder, the graphite powder 2 is a normal graphite powder or an expanded graphite powder, and the substrate 3 is a metal substrate, a stone substrate or a cement substrate.

[0022] Step 92: forming a mixture 4 via mixing the powder of polymer material 1 and the graphite powder 2. The present invention forms the mixture 4 via utilizing different volume percentage concentrations of the normal graphite powder or the expanded graphite powder respectively mixed into the epoxy powder or the polyethylene powder. The ingredients of the mixture 4 as shown in table one, are preferably, with a volume percentage concentration of the graphite powder 2 between 525 vol %.

TABLE-US-00001 TABLE ONE normal graphite expanded graphite powder (vol %) powder (vol %) epoxy powder 5 vol % 10 vol % 20 vol % 5 vol % 10 20 vol % vol % polyethylene 5 vol % 10 vol % 20 vol % 5 vol % 10 20 powder vol % vol %

[0023] Step 93: heating the mixture 4 to a temperature between 350650 C.

[0024] Step 94: spraying the mixture 4 on the substrate 3. The present invention utilizes a spray device 6 that heats the mixture 4 to a temperature between 350650 C. and sprays the molten mixture 4 on the substrate 3, wherein the spray device 6 is a thermal spray device. It is noted that the surface of the substrate 3 may be sand sprayed to remove oxides or impurities and increase adhesion to the substrate 3.

[0025] Step 95: cooling the mixture 4 to form an insulation coating 5. The mixture 4 is cooled to room temperature and forms an insulation coating 5, preferably the thickness of the insulation coating 5 is between 0.41.3 cm.

[0026] With reference to FIGS. 3a and 3b of a second embodiment of the present invention comprises, before Step 92: forming a mixture 4 via mixing the powder of polymer material 1 and the graphite powder 2 further comprising a step 911: forming a resist coating 7 to increase corrosion resistance via spraying a zinc-aluminum alloy on the substrate 3. The resist coating 7 is used for increasing corrosion resistance and extending the life of the substrate 3, preferably the thickness of the resist coating 7 is between 200700 m.

[0027] In the second embodiment of the present invention, after Step 95 comprises: cooling the mixture 4 to form an insulation coating 5 further comprising a step 96: spraying the mixture 4 on the insulation coating 5 and cooling the mixture 4 to form a second insulation coating 51. The thickness of the second insulation coating 51 is preferably between 0.41.3 cm.

[0028] With reference to FIG. 4a of an absorption coefficient-frequency view of an epoxy powder mixed with a normal graphite powder of the present invention. The epoxy has a network structure. The network structure may enhance the viscoelastic and sound insulation properties. According to FIG. 4a, the absorption coefficient of the epoxy is better than the substrate, and the epoxy mixed with normal graphite can change the absorption frequency of the sound waves.

[0029] With reference to FIG. 4b of an absorption coefficient-frequency view of an epoxy powder mixed with an expanded graphite powder of the present invention. Since the granule of the expanded graphite powder is bigger than the normal graphite powder, the structure and absorption coefficient of the insulation coating with expanded graphite powder is different than the insulation coating with normal graphite powder. According to FIG. 4b, the maximum of the absorption coefficient of epoxy powder mixed with 5 vol % expanded graphite powder is located at 4000 Hz, and the maximum of the absorption coefficient of epoxy powder mixed with 20 vol % expanded graphite powder is located at 5000 Hz.

[0030] With reference to FIG. 5a of an absorption coefficient-frequency view of a polyethylene powder mixed with a normal graphite powder of the present invention. The polyethylene powder mixed with different volume percentage concentrations of the normal graphite powder with good sound insulation at 1700 Hz and 3700 Hz. The reason is that the situation varies with different volume percentage concentrations of the normal graphite powder dispersed in the mixture. In higher concentrations, the normal graphite powder agglomerates in the mixture to form larger particles of graphite powder which can correspond to the low-frequency sound waves. In lower concentrations, the normal graphite powder spread evenly in the mixture can correspond to the high-frequency sound waves.

[0031] With reference to FIGS. 1, 2 and 5b, FIG. 5b is an absorption coefficient-frequency view of a polyethylene powder mixed with an expanded graphite powder of the present invention. The volume percentage concentration of the expanded graphite powder will influence the frequency bands of the sound insulation.

[0032] In an embodiment of the present invention, after Step 95 comprises: cooling the mixture 4 to form an insulation coating 5 further comprising the following step: heating the surface of the insulation coating 5 to a temperature between 350650 C.; and cooling the mixture 4 to room temperature. According to FIG. 5b, reheating the surface of the insulation coating 5 can influence the frequency bands and promote the sound insulation property.

[0033] As mentioned above, the present invention provides preparing an insulation coating that has numerous advantages such as simple structure, ease of manufacturing, longer service life, relatively low cost, and good sound insulation properties.

[0034] While the invention has been described in connection with what is considered the most practical and preferred embodiments, it is understood that this invention is not limited to the disclosed embodiments but is intended to cover various arrangements included within the spirit and scope of the broadest interpretation so as to encompass all such modifications and equivalent arrangements.