Fabrication of Reflective Insulation Coating with Medium Brightness for Controlling Track Slab Temperature
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摘要:
为缓解高速铁路纵连结构型无砟轨道结构在高温环境下易出现的形变上拱病害，使用自制氟改性黑色颜料，配制一种兼具中明度值和高反射性能的反射隔热涂料. 该涂料在实现高效控温的同时，可避免常规高明度白色反射涂料对目视人员造成的视觉损伤. 采用红外光谱对自制氟改性黑色颜料的分子结构进行表征，并利用紫外-可见-近红外分光光度计揭示其高太阳光反射性能作用机制，同时与常规冷颜料进行对比分析；在此基础上，配制相应的中明度反射隔热涂料，对成膜后涂层的控温、黏结、耐久等性能进行测试；进一步在自然暴露环境下的实尺轨道板结构进行表面涂装，通过长期温度监测评估其现场控温效果. 试验结果表明：自制氟改性黑色颜料凭借其近红外波段的透明特性，提升了中明度反射隔热涂层的太阳光反射性能；与常规颜料中明度涂层相比，自制涂层的太阳光反射率提升7.2%以上，在模拟太阳辐射下隔热温差可提升3.0 ℃以上，并具有较好的匀质性、黏结力和耐紫外老化性能；在典型晴朗天气条件下，自制涂层可将实尺轨道板结构表面峰值温度降低10.0 ℃以上，表面日温差减小5.0～10.0 ℃，并将轨道板纵向正温度梯度降低约50%.
Abstract:To mitigate the deformation and upward arching defects prone to occur in the longitudinally continuous ballastless track structures of high-speed railway under high-temperature conditions, a reflective insulation coating with medium brightness and high reflective properties was formulated by using self-made fluorine-modified black pigments. This coating can effectively control the temperature while avoiding the visual damage caused by conventional white reflective coating with high brightness to people seeing it. The molecular structure of the self-made fluorine-modified black pigment was characterized by infrared spectroscopy. The mechanism underlying the high solar reflectance performance of the self-made black pigment was elucidated by using a UV-VIS-NIR spectrophotometer, with a comparison made against conventional cool pigments. Based on this, a reflective thermal insulation coating with medium brightness was developed, and the properties of the film-formed coating, including temperature control, adhesion, and durability, were tested. Furthermore, the full-scale track slab structures under natural exposure conditions were coated, and long-term temperature monitoring and analysis were conducted to evaluate the actual temperature control effect of the coating. The results show that the self-made fluorine-modified black pigment can effectively improve the solar reflectance performance of the reflective thermal insulation coating with medium brightness through the transparency characteristics of its near-infrared band. The solar reflectivity of the self-made coating can be increased by more than 7.2% compared to the coating with medium brightness by using conventional pigments. The insulation temperature difference under simulated solar radiation can be increased by more than 3 ℃. The coating possesses good uniformity, adhesion, and resistance to ultraviolet-induced aging. Under typical sunny conditions, it can reduce the surface peak temperature of a full-scale track slab structure by more than 10 ℃, the daily temperature difference on the surface by 5–10 ℃, and the longitudinal positive temperature gradient of the track slab by about 50%.
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Key words:
- reflective insulation coating /
- pigment /
- brightness /
- temperature /
- solar radiation
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图 2 不同PCF掺量反射隔热涂层的L、a、b值和太阳光反射性能
Figure 2. L, a, and b values and solar reflectance performance of reflective insulation coatings with different PCF dosages
图 3 不同PCF掺量反射隔热涂层和不同颜料种类反射隔热涂层的紫外-可见-近红外反射光谱
Figure 3. UV-VIS-NIR reflectance spectra of reflective insulation coatings with different PCF dosages and pigment types
图 4 不同颜料反射隔热涂层模拟太阳光温升试验的热成像图及温升曲线
Figure 4. Thermal image and temperature rise curves of simulated solar temperature rise test for reflective insulation coatings with different pigments
图 5 PCF涂层的微观形貌、黏结性能及耐紫外老化性能
Figure 5. Microscopic morphology, adhesion properties, and resistance to ultraviolet-induced aging of PCF coating
图 6 典型时刻实尺轨道板的热成像图及温度分布统计
Figure 6. Thermal image and temperature distribution statistics of full-scale track slab at typical moments
图 7 2023年9月12日–20日涂装轨道板与对照轨道板的表面温度、表面最大日温差和纵向温度梯度随时间变化曲线
Figure 7. Variation curves of surface temperature, maximum daily temperature difference, and longitudinal temperature gradient of coated and control track slabs from September 12th to 20th, 2023
图 8 轨道板在不同季节的表面温度随时间变化曲线
Figure 8. Surface temperature variation curves of track slab at different seasons
表 1 反射隔热涂料基础配方
Table 1. Basic formula of reflective insulation coating
序号 种类 牌号 用量/份 1 氟碳树脂 GK570 60 2 钛白粉 R930 13 3 玻璃微珠 H26 13 4 醋酸丁酯 10 5 流平剂 B354 1 6 消泡剂 B066 0.5 7 分散剂 B110 1.5 8 触变剂 R974 1 
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表 2 不同颜料制备涂层及混凝土试样的颜色与太阳光反射性能
Table 2. Colors and solar reflectance performance of coatings and concrete specimens fabricated by different pigments
材料 掺量/% L值 a值 b值 TSR NIR VLR PCF 0.36 72.17 0.602 0.864 0.655 0.824 0.463 ICB 0.95% 71.88 1.228 −3.163 0.583 0.717 0.450 ICNB 1.96% 72.34 −0.474 −4.556 0.543 0.656 0.437 CB 0.20% 72.22 −0.294 −2.065 0.347 0.303 0.401 混凝土 / 65.21 0.520 4.790 0.248 0.224 0.268
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