CN104169468A - 用于铝热交换器的多层保护性涂层 - Google Patents

用于铝热交换器的多层保护性涂层 Download PDF

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CN104169468A
CN104169468A CN201380014221.8A CN201380014221A CN104169468A CN 104169468 A CN104169468 A CN 104169468A CN 201380014221 A CN201380014221 A CN 201380014221A CN 104169468 A CN104169468 A CN 104169468A
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heat exchanger
coating
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trivalent chromium
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CN104169468B (zh
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M.帕特森
M.R.贾沃洛夫斯基
M.T.隆巴多
S.比林
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Abstract

一种用于涂布铝合金热交换器的方法包括：对所述热交换器的至少一个表面进行包括清洁在内的预处理工艺；用三价铬化合物转化涂布所述热交换器的所述至少一个表面；以及在含有有机腐蚀抑制剂的水溶液中对所述至少一个经过转化涂布的表面进行电泳涂布。

Description

用于铝热交换器的多层保护性涂层
技术领域
本文所公开的主题一般涉及在铝合金热交换器上沉积涂料的领域，并且更具体地涉及在铝合金热交换器上施加涂料和腐蚀抑制剂的多层沉积，其提供具有实质耐腐蚀性的粘附多层涂层。
背景技术
铝合金是铝与其他金属的混合物(称为合金)，通常为锌、锰、硅、铜、稀土和锆。铝合金质轻，具有高的比强度以及高的导热性。由于这些优异的机械特性，铝合金被用作用于在商业、工业和海洋应用中加热或冷却系统的热交换器。使用铝合金材料的典型的热交换器为散热片、管式和板式热交换器。
然而，铝合金热交换器具有相对高的易腐蚀性。特别是在条件严苛的海洋应用中，海水在这些热交换器中产生侵蚀性氯离子环境。这种氯离子环境迅速造成钎焊接头和散热片的点蚀和腐蚀以及制冷剂管破裂。腐蚀最终导致制冷剂损失以及加热或系统的失效。为了解决这个问题，通过常规方法如喷涂或浸渍对铝合金涂覆多层涂层以试图隔离表面与腐蚀性环境。然而，这些多层涂层不能提供令人满意的长期粘附耐久性。另外，这些铝涂布方法具有非视距局限性。通过涂料和抑制剂对铝合金热交换器提供多层保护的改进将在本领域中大受欢迎。
发明内容
根据本发明的一个方面，一种用于涂布铝合金热交换器的方法包括：对所述热交换器的至少一个表面进行包括清洁在内的预处理工艺；用三价铬化合物转化涂布所述热交换器的所述至少一个表面；以及在含有有机腐蚀抑制剂的水溶液中对所述至少一个经过转化涂布的表面进行电泳涂布。
根据本发明的另一个方面，一种用于涂布铝合金热交换器的方法包括：对所述热交换器的至少一个表面进行包括清洁在内的预处理工艺；用三价铬化合物转化涂布所述热交换器的所述至少一个表面；在含有有机腐蚀抑制剂的水溶液中对所述至少一个表面进行电泳涂布；以及对经过电泳涂布的热交换器进行包括施加含有腐蚀抑制性表涂层的溶剂型溶液的表面涂布。
根据结合附图作出的以下描述，本发明的其他方面、特征和技术将变得更显而易见。
附图说明
在本说明书结尾处的权利要求中特别指出并清楚地要求了被视为本发明的主题。根据结合附图作出的以下详细描述，本发明的前述和其他特征和优点是显而易见的，在所述附图中：
图1描绘了根据本发明的一个实施方案在铝合金热交换器上施加多层涂层的示例性工艺的流程图。
具体实施方式
在以下描述中更具体地描述本发明并且实施例意在仅具说明性，因为其中众多的修改和变化对于本领域的那些技术人员将是显而易见的。除非上下文另外明确指出，否则如本说明书和权利要求中所用的单数形式“一(a)”、“一(an)”和“所述(the)”可包括复数个指代物。此外，本文公开的所有范围都包括端点并且可独立地组合。
用于涂布铝热交换器的方法的实施方案包括通过表面处理和电泳沉积来施加转化涂料和腐蚀抑制剂的组合以向所述热交换器的基材提供具有实质耐腐蚀性的粘附多层涂层。在实施方案中，所述方法提供在铝合金热交换器上施加腐蚀抑制剂的多层涂层，这包括热交换器的表面预处理、热交换器的转化涂布、电泳涂布工艺和任选的表面涂布。所述表面预处理包括至少一个步骤以确保所述热交换器的表面是洁净的并且不含残留物和外来物质。使用自动催化转化涂布工艺，涂布过程使得含有三价铬化合物的膜能够均匀涂布在铝合金热交换器基材上。此外，通过在基材表面上施加含有腐蚀抑制剂的膜将热交换器电泳涂布(electro-coated/e-coated)。此外，在含有腐蚀抑制剂和聚氨酯的溶液中应用任选的面涂层涂覆以补充对于表面的腐蚀保护。
现参看附图，图1示出了在具有铝合金基材(或基材)的热交换器的表面上沉积多层腐蚀抑制剂的示例性工艺10。此类合金的实例包括1000、3000、5000、6000和7000系列铝合金。如以下描述中所用，热交换器的表面可包括(在一些非限制性实例中)散热片、管和/或板。如所示，通过基材的表面预处理12起始示例性工艺，在此期间基材经历各种处理以得到适于后续转化涂布工艺的表面特性。表面预处理不仅用于从铝合金基材的表面除去污物和有机污染物，而且用于除去在铝合金基材上形成的氧化物或氢氧化物，从而允许基材的表面暴露用于转化涂布。根据一个示例性工艺，基材准备包括使用合适的技术如(在一些非限制性实例中)溶剂冲洗、使用三氯乙烯或其他合适的溶剂的蒸气脱脂、溶剂乳液清洁等来除去表面污染物，以除去任何油脂或有机化合物。在一个示例性实施方案中，可利用具有含表面活性剂的水性、非硅酸盐碱性溶液的脱脂浴来清洁基材。在一个示例性实施方案中，脱脂浴的组成包括用于从基材的表面除去任何有机污染物的非硅酸盐化学试剂。在另一个非限制性实施方案中，表面预处理可包括在基本上纯水中高温浸泡。如本领域技术人员将了解，这些表面预处理程序容许广泛多种可选方案。因此，可考虑同样利用任何数目的其他程序和实践，例如通过机械方法或通过浸没或喷雾清洁器系统，以进行基材的预处理工艺。
在表面预处理12之后，用含三价铬的层对经过预处理的基材进行腐蚀抑制性转化涂布14以保护经过预处理的热交换器的表面免受腐蚀并增强腐蚀抑制性化合物在后续电泳涂布中的粘附性。转化处理工艺为自动催化转化涂布工艺，其通过在预定温度下将经过预处理的热交换器浸没于转化处理浴中持续预定的接触时间来进行。所述处理浴包括具有六氟锆酸盐和水溶性三价铬酸盐化合物的水溶液，其不含六价铬。在一个示例性实施方案中，三价铬酸盐化合物为三价硫酸铬。水溶性三价铬酸盐化合物以足够浓度存在于水溶液中以在经过预处理的热交换器的表面上涂布平均厚度为100 nm的一层均匀的三价铬。在一个示例性实施方案中，水溶液可以包括Surtec 650，其为获自CST-SurTec, Inc.的市售液体三价铬类化学试剂。在一个非限制性实施方案中，在约30℃(约303K)至约40℃(约313K)的周围温度下将经过预处理的热交换器浸没约10分钟以在表面上诱导转化涂层。在其他非限制性实施方案中，水溶液可包含氟化物和氟硼酸盐。应了解，转化涂布溶液的酸性氟化物特性除去天然氧化物膜并将其置换为水合的Al-Zr-O-F层，其增加了基材表面的亲水性并将表面活化用于有机涂布。在一个实施方案中，通过目测评价经过转化涂布的热交换器基材。其后，在一个示例性实施方案中，对经过转化涂布的热交换器基材(也称为经过转化涂布的热交换器)进行腐蚀抑制性电泳涂布16 (或“电泳涂布”16)。
在一个实施方案中，电泳涂布16为在去离子水浴中进行的阴极电泳涂布工艺。所述浴包括用于补充腐蚀保护的有机腐蚀抑制剂。经过转化涂布的热交换器被用作阴极，同时将有机腐蚀抑制剂悬浮于浴中。在一个非限制性实施方案中，所用的有机腐蚀抑制剂可获自PPG®，但在其他实施方案中，在不偏离本发明的范围的情况下还可使用其他类似的腐蚀抑制剂如铬酸锶颜料。可通过向被铬涂布的热交换器施加负DC电荷来进行电泳涂布16。浴中带相反电荷的聚合物分子被吸引到阴极热交换器并沉积在经过转化涂布的热交换器的表面上。在一个实施方案中，施加电荷以向经过转化涂布的热交换器涂布平均厚度为约25 μm的一层均匀的腐蚀抑制电泳涂料。在高温下干燥经过电泳涂布的热交换器，持续足够的时间以固化聚合物涂层。在一个实施方案中，在约160℃(约433K)至约170℃(约443K)下将热交换器干燥20分钟至30分钟的时间。在一个可选的实施方案中，还可使用阳极电泳涂布来代替阴极电泳涂布。
在一个示例性实施方案中，在电泳涂布16之后，对经过电泳涂布的热交换器进行包括施加含有腐蚀抑制性表涂层18的溶剂型溶液的表面涂布工艺。特别是，对经过电泳涂布的热交换器喷涂含有具有包括腐蚀抑制剂的颜料的液体聚氨酯涂料的溶液。在一个实施方案中，溶剂型溶液含有例如足够浓度的来自WPC Technologies, Inc的HybriCor™ 204以抑制腐蚀。在其他实施方案中，在不偏离本发明的范围的情况下还可使用类似的腐蚀抑制剂如铬酸锶颜料。此外，在周围环境中闪蒸出溶剂之后，在高温下将面涂层16固化(即，固化定型) 20分钟。在另一个实施方案中，在约60℃(约333 K)至约70℃(约343 K)下将面涂层16固化30分钟至45分钟的时间。如本领域的那些技术人员将了解，这些表面准备、涂布和后处理程序容许广泛多种可选方案。因此，可考虑同样利用任何数目的其他程序和实践来进行铝合金热交换器的这些工艺。在一个实施方案中，热交换器可包括化学蚀刻以除去表面上的任何氧化物层，接着转化涂布工艺14，接着电泳涂布16。最后，将热交换器表面干燥并浸渍于溶剂浴中用于腐蚀抑制性面涂布18。
示例性实施方案的技术效果和益处包括用于在热交换器的基材上提供具有实质耐腐蚀性的粘附多层涂层的方法。在实施方案中，所述方法包括热交换器的表面预处理、热交换器的转化涂布、电泳涂布工艺和任选的表面涂布。所述表面预处理包括至少一个步骤以确保所述热交换器的表面是洁净的并且不含残留物和外来物质。使用自动催化转化涂布工艺，另一个涂布过程使得三价铬化合物的膜能够均匀涂布在铝合金热交换器基材上。此外，通过在基材表面上施加腐蚀抑制性膜将热交换器电泳涂布。此外，在含有紫外颜料、腐蚀抑制剂和聚氨酯的溶液中使用任选的面涂层施加以补充对于表面的腐蚀保护。
本文所用的术语仅用于描述特定实施方案并且不旨在限制本发明。虽然本发明的描述已经出于说明和描述目的而呈现，但它不旨在为详尽的或以所公开的形式限制本发明。在不偏离本发明的范围和精神的情况下，到此为止还未描述的许多修改、变化、变更、取代或等效布置对于本领域的那些普通技术人员将是显而易见的。另外，虽然已经描述了本发明的各种实施方案，但应了解本发明的方面可能仅包括所述实施方案中的一些。因此，本发明不应被视为局限于前面的描述，而是仅受所附权利要求范围的限制。

Claims (20)

1. 一种用于涂布铝合金热交换器的方法，其包括：
对所述热交换器的至少一个表面进行包括清洁在内的预处理工艺；
用三价铬化合物转化涂布所述热交换器的所述至少一个表面；以及
在含有有机腐蚀抑制剂的水溶液中对所述至少一个经过转化涂布的表面进行电泳涂布。
2. 如权利要求1所述的方法，其进一步包括对所述至少一个表面进行包括施加含有腐蚀抑制性表涂层的溶剂型溶液的表面涂布。
3. 如权利要求2所述的方法，其中所述溶剂型溶液包括具有颜料和腐蚀抑制剂的液体聚氨酯涂料。
4. 如权利要求1所述的方法，其中所述转化涂布进一步包括将所述热交换器浸没于具有水溶性三价铬化合物和六氟锆酸盐的溶解物质的转化处理浴中。
5. 如权利要求4所述的方法，其中所述三价铬化合物为三价硫酸铬。
6. 如权利要求1所述的方法，其中所述转化涂布进一步包括在周围温度环境中将所述热交换器浸没于转化处理浴中持续预定的接触时间。
7. 如权利要求1所述的方法，其中所述预处理工艺包括对所述热交换器进行以下至少一种：使用三氯乙烯的蒸气脱脂、溶剂乳液清洁、和浸没于表面活性剂中。
8. 如权利要求1所述的方法，其中所述电泳涂布进一步包括对所述热交换器进行阴极电泳涂布，其中所述热交换器为阴极。
9. 如权利要求1所述的方法，其中所述水溶液为含有树脂和所述有机腐蚀抑制剂的去离子水。
10. 如权利要求1所述的方法，其中所述电泳涂布进一步包括对所述热交换器进行阳极电泳涂布，其中所述热交换器为阳极。
11. 一种用于涂布铝合金热交换器的方法，其包括：
对所述热交换器的至少一个表面进行包括清洁在内的预处理工艺；
用三价铬化合物转化涂布所述热交换器的所述至少一个表面；
在含有有机腐蚀抑制剂的水溶液中对所述至少一个表面进行电泳涂布；以及
对经过电泳涂布的热交换器进行包括施加含有腐蚀抑制性表涂层的溶剂型溶液的表面涂布。
12. 如权利要求11所述的方法，其中所述溶剂型溶液包括具有颜料和腐蚀抑制剂的液体聚氨酯涂料。
13. 如权利要求11所述的方法，其中所述转化涂布进一步包括将所述热交换器浸没于具有水溶性三价铬化合物和六氟锆酸盐的溶解物质的转化处理浴中。
14. 如权利要求13所述的方法，其中所述三价铬化合物为三价硫酸铬。
15. 如权利要求11所述的方法，其中所述转化涂布进一步包括在周围温度环境中将所述热交换器浸没于转化处理浴中持续预定的接触时间。
16. 如权利要求11所述的方法，其中所述转化涂布进一步包括将含有所述三价铬化合物的溶液喷涂至所述至少一个表面上。
17. 如权利要求11所述的方法，其中所述预处理工艺进一步包括以下至少一种：使用三氯乙烯的蒸气脱脂、溶剂乳液清洁、和浸没于表面活性剂中。
18. 如权利要求11所述的方法，其中所述水溶液为含有树脂和所述有机腐蚀抑制剂的去离子水。
19. 如权利要求11所述的方法，其中所述电泳涂布进一步包括对所述热交换器进行阴极电泳涂布，其中所述热交换器为阴极。
20. 如权利要求11所述的方法，其中所述电泳涂布进一步包括对所述热交换器进行阳极电泳涂布，其中所述热交换器为阳极。
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