阅读说明：本技术 一种电化学腐蚀传感器及其制备方法 (Electrochemical corrosion sensor and preparation method thereof ) 是由 宋恩雨 徐洪涛 于 2021-07-15 设计创作，主要内容包括：本发明涉及金属电化学腐蚀监测技术领域,具体涉及一种电化学腐蚀传感器及其制备方法,电化学腐蚀传感器包括金属基板、叠加在基板上的绝缘层及叠加在绝缘层上的电极层；所述绝缘层和电极层的厚度为微米级；制备方法为通过超声喷涂在金属基板表面喷涂UV胶形成绝缘层,然后通过超声喷涂在绝缘层表面喷涂纳米碳层或纳米金层形成电极层。电化学腐蚀传感器结构简单,加工工艺先进,适合批量生产,绝缘层和电极层均采用超声纳米喷涂的方式加工,加工时绝缘层和电极层厚度可进行精密控制,最小可做到纳米级别的区分,从而保证了传感器检测灵敏度和检测参数一致性,使得本发明的电化学腐蚀传感器具有很好的一致性和高灵敏度。(The invention relates to the technical field of metal electrochemical corrosion monitoring, in particular to an electrochemical corrosion sensor and a preparation method thereof, wherein the electrochemical corrosion sensor comprises a metal substrate, an insulating layer superposed on the substrate and an electrode layer superposed on the insulating layer; the thicknesses of the insulating layer and the electrode layer are in a micron order; the preparation method comprises the steps of spraying UV glue on the surface of the metal substrate through ultrasonic spraying to form an insulating layer, and then spraying a nano carbon layer or a nano gold layer on the surface of the insulating layer through ultrasonic spraying to form an electrode layer. The electrochemical corrosion sensor has the advantages of simple structure, advanced processing technology and suitability for batch production, the insulating layer and the electrode layer are processed in an ultrasonic nano-spraying mode, the thicknesses of the insulating layer and the electrode layer can be precisely controlled during processing, and nano-level distinguishing can be realized at minimum, so that the detection sensitivity and the detection parameter consistency of the sensor are ensured, and the electrochemical corrosion sensor has good consistency and high sensitivity.)

1. An electrochemical corrosion sensor comprising a metal substrate, an insulating layer overlying the substrate, and an electrode layer overlying the insulating layer; the thickness of the insulating layer and the electrode layer is micron-sized.

2. The electrochemical corrosion sensor according to claim 1, wherein said insulating layer has a thickness of 10 ± 0.2 microns and said electrode layer has a thickness of 25 ± 0.2 microns.

3. The electrochemical corrosion sensor according to claim 1, wherein said metal substrate is a pure metal having a purity of greater than 99.9%; or the insulating layer adopts UV glue; or the electrode layer is a nano carbon layer or a nano gold layer.

4. The electrochemical corrosion sensor according to claim 1, wherein a plurality of through holes are uniformly distributed on the metal substrate, the insulating layer and the electrode layer, and preferably, the number of the through holes is 28; the diameter of the through hole is 3 mm.

5. The electrochemical corrosion sensor of claim 1, wherein the metal substrate of the electrochemical corrosion sensor is well insulated from the electrode layer and has an insulation resistance between the two layers of greater than 200M ohms.

6. A method for preparing an electrochemical corrosion sensor according to any one of claims 1 to 5, wherein an insulating layer is formed by spraying UV glue on the surface of a metal substrate by ultrasonic spraying, and then an electrode layer is formed by spraying a nano carbon layer or a nano gold layer on the surface of the insulating layer by ultrasonic spraying.

7. The preparation method of claim 6, which is characterized by comprising the following steps:

(1) processing the metal substrate to obtain the metal substrate with certain appearance and through holes;

(2) ultrasonically spraying the insulating layer on a metal substrate, and curing by adopting an ultraviolet lamp to form a complete and uniform insulating layer film with the thickness of (10 +/-0.2) microns;

(3) and ultrasonically spraying the electrode layer on the insulating layer, and drying in a high-temperature oven after spraying to form a complete electrode layer film with the thickness of (25 +/-0.2) microns and the surface resistance of the film within 2 ohms.

8. The preparation method of claim 7, wherein in the step (1), the processed dimensional errors of the metal substrate are less than 0.05 mm;

preferably, the step (1) further comprises a step of polishing the surface of the processed metal substrate, wherein the oxide film on the surface of the metal substrate is removed by surface polishing, the surface of the polished metal substrate is free of rust, the flatness is less than 0.01mm, and no burr is left on the periphery of the metal substrate and the periphery of the through hole.

9. A preparation method according to claim 7, characterized in that, in the step (2), the micro fab high-precision nano material deposition inkjet printing system is adopted to spray UV water-based glue on the metal substrate, preferably, the viscosity of the used UV water-based glue is required to be less than 100 cps;

or in the step (2), the ultraviolet lamp curing time is 20-40 minutes, and more preferably 30 minutes.

10. A preparation method according to claim 7, characterized in that, in the step (3), the micro fab high precision nanomaterial deposition ink jet printing system is used to spray carbon nano slurry on the insulating layer, preferably, the carbon nano slurry is aqueous slurry, and the viscosity is required to be less than 100 cps;

or, in the step (3), the drying condition is 115-135 ℃ for 20-40 min, and preferably 125 ℃ for 30 min.

Technical Field

The invention relates to the technical field of metal electrochemical corrosion monitoring, in particular to an electrochemical corrosion sensor and a preparation method thereof.

Background

The information in this background section is only for enhancement of understanding of the general background of the invention and is not necessarily to be construed as an admission or any form of suggestion that this information forms the prior art that is already known to a person of ordinary skill in the art.

Monitoring of metal corrosion conditions, especially corrosion conditions of iron bars, grounding terminal strips and the like in the power industry is an important link for guaranteeing the safety of power operation. Metal parts such as power transmission iron towers and grounding terminal strips are exposed in various natural environments and are subject to various corrosion damages, and the mechanical properties and the conductivity of rusted iron towers and terminal strips are greatly reduced, so that the safety of power operation is directly influenced, and therefore, effective measures are adopted to monitor the corrosion conditions of the metal parts such as the power transmission iron towers and the grounding terminal strips in real time.

The metal electrochemical corrosion sensor is an effective means for realizing the real-time monitoring, the metal substrate of the sensor is made of the same metal material as an iron tower, a terminal strip and the like, and is arranged on the same use site as the iron tower and the terminal strip, the iron tower and the terminal strip are in the same natural environment, and the corrosion condition of the iron tower and the terminal strip can be truly reflected by monitoring the corrosion of the sensor.

The prior art discloses a metal material atmospheric corrosion electrochemical sensor and application thereof, the whole sensor is packaged by epoxy daub, an interlayer material is arranged between working electrodes, and a gap between the working electrodes and the interlayer material is filled by the epoxy daub and an insulating material so as to ensure the insulating state of the working electrodes and the interlayer material in the whole package; the upper surface of the interlayer material is provided with a drainage material which is used for draining liquid providing conductivity into the interlayer material so as to enable the surface of the interlayer material to provide conductivity and conduct the working areas of the working electrodes positioned at the two sides of the interlayer material; a hole for fixing the reference electrode is formed in the middle of the interlayer material; although the electrochemical sensor of the technology can effectively detect the real-time electrochemical corrosion behavior of the metal material in the atmospheric environment, the corrosion monitoring surface consisting of the working electrode, the interlayer material and the reference electrode of the sensor is positioned on the same plane, and when corrosion occurs, corrosion products are attached to the surface of the sensor, so that the monitoring precision and the service life of the sensor are seriously influenced.

Also, the prior art discloses a galvanic couple type corrosion sensor, which comprises a body, wherein the body consists of a metal electrode, an insulating sheet and a carbon film electrode which are sequentially overlapped together from top to bottom, the metal electrode and the carbon film electrode are electrically connected with electrode lead-out wires, and the body is provided with a plurality of through holes which penetrate through the metal electrode, the insulating sheet and the carbon film electrode; due to the limitation of the processing mode of the galvanic couple type corrosion sensor, the thicknesses of the two layers of the insulating sheet and the carbon film electrode are both in millimeter level, and when corrosion occurs, the sensitivity of the sensor is greatly reduced.

Therefore, the inventor finds out how to provide an electrochemical corrosion sensor which has high sensitivity and advanced processing technology and can ensure good parameter consistency in batch production, and the electrochemical corrosion sensor is a problem to be solved by the technical personnel in the field.

Disclosure of Invention

Aiming at the technical problems in the prior art, the invention aims to provide an electrochemical corrosion sensor and a preparation method thereof, wherein the electrochemical corrosion sensor comprises a metal substrate, an insulating layer superposed on the substrate and an electrode layer superposed on the insulating layer; the insulating layer and the electrode layer are processed in an ultrasonic spraying mode, and the thickness of the insulating layer and the thickness of the electrode layer reach the micron level; the sensor has good sensitivity and consistency, and the manufacturing method can meet the requirements of low cost and large-scale production.

In order to achieve the above object, the technical solution of the present invention is as follows:

in a first aspect of the present invention, a novel electrochemical corrosion sensor is provided, the sensor comprising a metal substrate, an insulating layer overlying the substrate, and an electrode layer overlying the insulating layer; the thicknesses of the insulating layer and the electrode layer are in a micron order;

preferably, the thickness of the insulating layer is 10 +/-0.2 microns, and the thickness of the electrode layer is 25 +/-0.2 microns.

Due to the limitation of a processing mode, the thicknesses of two layers of an insulating sheet and a carbon film electrode of the electrochemical corrosion sensor in the prior art are both in millimeter level, and when corrosion occurs, the sensitivity of the sensor is greatly reduced; the invention improves the insulating layer on the substrate and the electrode layer superposed on the insulating layer into micron level, so that the electrochemical corrosion sensor has good consistency and high sensitivity.

Preferably, the metal substrate is made of pure metal with the purity higher than 99.9%, so that the consistency of corrosion monitoring in the whole life cycle of the sensor can be ensured;

preferably, the insulating layer is sprayed on the metal substrate by adopting UV glue in an ultrasonic spraying mode; the UV adhesive is easy to spray and cure and has good insulating property;

preferably, the electrode layer is a nano carbon layer or a nano gold layer, and is sprayed on the insulating layer in an ultrasonic spraying mode; the nano carbon layer or the nano gold layer selected in the invention has good inertia, and the electrode layer has good corrosion resistance as a reference electrode;

in a second aspect of the present invention, a method for manufacturing the electrochemical corrosion sensor is provided, in which a metal substrate is first formed, then a UV glue is sprayed on a surface of the metal substrate by ultrasonic spraying to form an insulating layer, and finally a nano carbon layer or a nano gold layer is sprayed on a surface of the insulating layer by ultrasonic spraying to form an electrode layer.

The insulating layer and the electrode layer are processed by adopting an ultrasonic spraying mode, and the ultrasonic sensor has the advantages that the thicknesses of the insulating layer and the electrode layer can be precisely controlled according to different requirements, the precision can be distinguished in a nanometer level, and the total thickness can be in a micrometer level, so that the detection sensitivity and the detection parameter consistency of the sensor are ensured.

Specifically, the preparation method comprises the following steps:

(1) processing the metal substrate to obtain the metal substrate with certain appearance and through holes;

(2) ultrasonically spraying the insulating layer on a metal substrate, and curing by adopting an ultraviolet lamp to form a complete and uniform insulating layer film with the thickness of (10 +/-0.2) microns;

(3) and ultrasonically spraying the electrode layer on the insulating layer, and drying in a high-temperature oven after spraying to form a complete electrode layer film with the thickness of (25 +/-0.2) microns and the surface resistance of the film within 2 ohms.

Further, ultrasonically spraying the insulating layer on the metal substrate in the step (2), specifically spraying UV (ultraviolet) water-based glue on the metal substrate by using a MicroFab (micro fab high-precision nano material deposition ink-jet printing system), wherein preferably, the viscosity requirement of the used UV water-based glue is not more than 100cps, and the selection of the condition is selected based on the requirement of an ultrasonic spraying process;

further, the electrode layer is ultrasonically sprayed on the insulating layer in the step (3), specifically, a carbon nano-slurry is sprayed on the insulating layer by using a micro fab high-precision nano-material deposition ink-jet printing system, preferably, the carbon nano-slurry is an aqueous slurry, the viscosity requirement is not more than 100cps, and the selection of the condition is selected based on the requirements of the ultrasonic spraying process.

The specific embodiment of the invention has the following beneficial effects:

the electrochemical corrosion sensor provided by the invention has the advantages of simple structure, advanced processing technology and the like, is suitable for batch production, and can ensure good consistency;

the insulating layer and the electrode layer are processed by adopting an ultrasonic nano spraying mode, the thickness of the insulating layer and the thickness of the electrode layer can be precisely controlled during processing, and nano-level differentiation can be realized at minimum, so that the detection sensitivity and the detection parameter consistency of the sensor are ensured, and the electrochemical corrosion sensor disclosed by the invention has good consistency and high sensitivity.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this specification, are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the invention and together with the description serve to explain the invention and not to limit the invention.

FIG. 1 is a structural view of an electrochemical corrosion sensor according to example 2 of the present invention;

FIG. 2 is a graph of electrochemical corrosion sensor test data for example 2 of the present invention.

Detailed Description

It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.

It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present application. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.

As discussed in the background art, the electrochemical corrosion sensor in the prior art has the limitations of the processing mode, and the thicknesses of the two layers of the insulating sheet and the carbon film electrode layer are both in millimeter level, so that when corrosion occurs, the sensitivity of the sensor is greatly reduced; in view of this, the present invention improves the insulating layer on the substrate and the electrode layer stacked on the insulating layer to the micrometer level, so that the electrochemical corrosion sensor of the present invention has good consistency and high sensitivity.

In one embodiment of the present invention, an electrochemical corrosion sensor is provided, the sensor comprising a metal substrate, an insulating layer overlying the substrate, and an electrode layer overlying the insulating layer; the thickness of the insulating layer and the electrode layer is micron-sized.

In one or more embodiments of the present invention, the insulating layer has a thickness of 10 ± 0.2 micrometers, and the electrode layer has a thickness of 25 ± 0.2 micrometers.

Due to the limitation of a processing mode, the thicknesses of two layers of an insulating sheet and a carbon film electrode of the electrochemical corrosion sensor in the prior art are both in a millimeter level, and when corrosion occurs, the sensitivity of the sensor is greatly reduced. The invention improves the insulating layer on the substrate and the electrode layer superposed on the insulating layer into micron level, so that the electrochemical corrosion sensor has good consistency and high sensitivity.

Preferably, the metal substrate is made of pure metal with the purity higher than 99.9%, so that the consistency of corrosion monitoring in the whole life cycle of the sensor can be ensured;

preferably, the insulating layer is sprayed on the metal substrate by adopting UV glue in an ultrasonic spraying mode; the UV adhesive is easy to spray and cure and has good insulating property;

preferably, the electrode layer is a nano carbon layer or a nano gold layer, and is sprayed on the insulating layer in an ultrasonic spraying mode; the nano carbon layer or the nano gold layer selected in the invention has good inertia, and the electrode layer has good corrosion resistance as a reference electrode;

preferably, a plurality of through holes are uniformly distributed on the metal substrate, the insulating layer and the electrode layer, and the corrosion current of the metal substrate during corrosion is amplified by means of the edge adsorption effect of the thin liquid film around the through holes;

further preferably, the number of the through holes is 28; the diameter of the through hole is 3 mm;

furthermore, the metal substrate of the electrochemical corrosion sensor is well insulated from the electrode layer, and the insulation resistance between the two layers is more than 200M ohm.

In an embodiment of the invention, a preparation method of the electrochemical corrosion sensor is provided, and the preparation method includes spraying UV glue on the surface of a metal substrate by ultrasonic spraying to form an insulating layer, and then spraying a nano carbon layer or a nano gold layer on the surface of the insulating layer by ultrasonic spraying to form an electrode layer.

The insulating layer and the electrode layer are processed by adopting an ultrasonic spraying mode, and the ultrasonic sensor has the advantages that the thicknesses of the insulating layer and the electrode layer can be precisely controlled according to different requirements, the precision can be distinguished in a nanometer level, the total thickness can be in a micrometer level, the detection sensitivity and the detection parameter consistency of the sensor are ensured, and the detection sensitivity is high.

Specifically, the preparation method comprises the following steps:

(1) processing the metal substrate to obtain the metal substrate with certain appearance and through holes;

(2) ultrasonically spraying the insulating layer on a metal substrate, and curing by adopting an ultraviolet lamp to form a complete and uniform insulating layer film with the thickness of (10 +/-0.2) microns;

(3) and ultrasonically spraying the electrode layer on the insulating layer, and drying in a high-temperature oven after spraying to form a complete electrode layer film with the thickness of (25 +/-0.2) microns and the surface resistance of the film within 2 ohms.

Preferably, in the step (1), the shape of the metal substrate, the number of the through holes and the distribution are designed according to the range of the corrosion current detected by the sensor; further preferably, the number of the through holes is 28; the diameter of the through hole is 3 mm;

preferably, during the specific manufacturing, the metal substrate is processed and molded firstly, and then the insulating layer and the electrode layer are formed by spraying through an ultrasonic spraying process;

preferably, in the step (1), the processed dimension errors of the metal substrate are all less than 0.05 mm;

preferably, the step (1) further comprises a step of polishing the surface of the processed metal substrate, wherein the oxide film on the surface of the metal substrate is removed by surface polishing, the surface of the polished metal substrate is free of rust, the flatness is less than 0.01mm, and no burr is left on the periphery of the metal substrate and the periphery of the through hole;

further, ultrasonically spraying the insulating layer on the metal substrate in the step (2), specifically spraying a UV (ultraviolet) water-based glue on the metal substrate by using a MicroFab (micro fab high-precision nano material deposition ink-jet printing system), wherein preferably, the viscosity requirement of the used UV water-based glue is less than 100cps, and the selection of the condition is selected based on the requirement of an ultrasonic spraying process;

further, ultrasonically spraying the electrode layer on the insulating layer in the step (3), specifically, spraying carbon nano-slurry on the insulating layer by using a micro fab high-precision nano-material deposition inkjet printing system, preferably, the carbon nano-slurry is aqueous slurry, the viscosity requirement is less than 100cps, and the selection of the condition is selected based on the requirements of the ultrasonic spraying process;

preferably, in the step (2), the ultraviolet lamp curing time is 20-40 minutes, and further preferably 30 minutes, so as to form a complete and uniform insulating layer film;

preferably, in the step (3), the drying condition is 115-135 ℃, 20-40 min, further preferably 125 ℃, 30min, so as to form a complete electrode layer film;

the invention will be further explained and illustrated with reference to specific examples.

Example 1

Preparing an electrochemical corrosion sensor:

1. machining and forming of metal substrate

The metal substrate is a zinc plate with the purity higher than 99.9% and the thickness of 1 mm; the metal substrate is firstly processed according to the design requirement, the processed metal substrate is subjected to surface polishing, the whole body is flat after polishing, the surface is free of corrosion, and the edges and the periphery of the through hole are free of burrs;

2. preparation of insulating layer

At present, each through hole on the metal substrate is plugged in advance, so that UV glue is prevented from being sprayed on the inner wall of the through hole in the spraying process;

the ultrasonic spraying adopts a MicroFab high-precision nano material deposition ink-jet printing system, and is provided with a moving platform with an error not more than 1 μm, so that the high-precision high-density spraying and printing functions can be realized;

before spraying, relevant parameters of a MicroFab system are adjusted, the size of a base station is 210 x 260mm, and the maximum stroke is 300 x 300 mm; selecting nozzle diameter of 5 μm, setting nozzle frequency at 25kHz, speed at 50mm/s, and acceleration at 1500mm/s²The spraying flow rate is 35 mul/min; the pressure of the nitrogen is precisely controlled to be 0.06 multiplied by 10⁶Pa；

Before an insulating layer is sprayed, a sensor metal substrate is fixed on a micro Fab system base station, and high-precision and high-density pattern drawing of the overall dimension of the metal substrate is realized through a vertical CCD camera;

adjusting the viscosity of the UV adhesive to 100cps, setting operation parameters of a MicroFab system, and spraying (10 +/-0.2) micron insulating layers on the surface layer of the metal substrate under the common monitoring of a horizontal CCD camera and a vertical CCD camera;

curing the sprayed UV adhesive insulating layer for 30 minutes by adopting an ultraviolet lamp to form a complete and uniform insulating layer film;

3. preparation of the electrode layer

After the sensor insulating layer is completely cured, spraying an electrode layer by using a MicroFab system;

the electrode layer adopts carbon nano slurry, the viscosity of the carbon nano slurry is 100cps, the micro Fab system adopts a 5-micron caliber spray head, and the same operation parameters of the micro Fab system and the insulating layer are set for spraying;

and placing the sprayed electrode layer carbon nano slurry in a high-temperature oven, and drying at 125 ℃/30min to form a complete electrode layer film.

Example 2

As shown in fig. 1, a novel electrochemical corrosion sensor comprises a metal substrate 1, an insulating layer 2 and an electrode layer 3; 28 through holes 11 with the diameter of 3mm are uniformly distributed on the metal substrate 1, the insulating layer 2 and the electrode layer 3, and the corrosion current when the metal substrate is corroded is amplified by means of the edge adsorption effect of the thin liquid film around the through holes 11.

Preferably, the metal substrate 1 is a zinc plate with a purity higher than 99.9% and a thickness of 1 mm; the insulating layer 2 adopts UV glue, and the thickness is (10 +/-0.2) microns; the electrode layer 3 adopts a nano carbon layer, and the thickness is (25 +/-0.2) microns; the metal substrate 1 and the electrode layer 3 are well insulated, and the insulation resistance between the two layers needs to be more than 200M ohm.

Preparing a plurality of electrochemical corrosion sensors by adopting the preparation method of the electrochemical corrosion sensor in the embodiment 1, placing the electrochemical corrosion sensors in a high-precision humidity box, setting different humidity in the humidity box body, and then collecting corrosion current generated by the corrosion sensors; randomly selecting 4 electrochemical corrosion sensors from the plurality of electrochemical corrosion sensors for testing:

as can be seen from fig. 2, 4 electrochemical corrosion sensors selected at random were tested, in which 1 curve labeled with humidity represents a humidity change curve, and 4 curves labeled with current represent corrosion circuit curves of the corrosion sensors; as can be seen from the figure, the humidity box is set to have the relative humidity ranging from 50% to 100% to 50%, the sensors have good responsivity and sensitivity to the humidity change, and the corrosion currents of the 4 sensors have good consistency; the sensitivity and consistency of the sensor far exceed those of similar products; therefore, the preparation method has obvious advantages and can meet the requirements of low cost and large-scale production.

The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.