CN104529180B - 一种电热膜板的生产方法及生产设备 - Google Patents

一种电热膜板的生产方法及生产设备 Download PDF

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CN104529180B
CN104529180B CN201410846108.2A CN201410846108A CN104529180B CN 104529180 B CN104529180 B CN 104529180B CN 201410846108 A CN201410846108 A CN 201410846108A CN 104529180 B CN104529180 B CN 104529180B
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邱洁华
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Tianjin guona New Material Co., Ltd
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Abstract

本发明提供了一种电热膜板的生产方法及生产设备，其生产方法包括如下步骤：1）提供待喷涂基板；2）将所述基板先后送入温度为0‑200℃的升温区、201‑600℃的固温区、601‑620℃的稳定区调节温度；3）将所述基板送入温度为601‑620℃的喷涂区接受电热膜处理液喷涂，在所述基板的至少一面形成电热膜，获得半成品；4）将所述半成品送入固化区固化所述电热膜；5）冷却，获得成品。本发明在喷涂前对基板分段调节温度，待基板温度均匀后喷涂，形成的电热膜与基板连接性能好，膜厚度均匀、表面平滑，避免了出现起泡、凹凸不平等缺陷；并且通过一次喷涂即可，生产效率高，采用移动式喷涂，使得喷涂全面、膜层均匀。

Description

一种电热膜板的生产方法及生产设备
技术领域
本发明涉及一种电热膜板的生产方法及生产设备，属于发热器件技术领域。
背景技术
纳米电热膜板是对耐高温绝缘载体在高温条件下喷涂电热膜液而形成的电发热体，绝缘载体一般为微晶玻璃，陶瓷等。纳米电热板工作时，有效放射5.6um-15um的远红外线，占整体波长90%以上。高达98%的热效率让纳米电热膜发热板在发热领域首屈一指，使用过程无发红，灼热现象，物理和化学性能稳定，热稳定性、耐酸碱性、耐磨性好。发热膜自身熔点高达1000℃，纳米电热膜无毒性物质，无磁场辐射，零污染，且有远红外理疗作用。用纳米电热膜取代电热丝，电热盘，电热管等传统电热产品元件，只需改变载体基材，任何几何形状都可，既压缩了体积又轻薄化，且比传统发热丝发热盘节电40%，是新一代电热的最好选择。
以公开号为 CN1529534A 的发明专利公开了一种电热膜及其制造方法，该电热膜处理液配比(质量百分比)为：A：四氯化锡，40～50 ；B ：三氯化钛，30～40 ；C ：三氯化锑，0.1～0.3 ；D ：二氯化钙，0.1～0.3 ；E ：异丙醇，2～3 ；F ：乙醇，10～13 ；G ：纯水，2～5。其不足之处是最高工作温度仅仅为450℃，应用范围相对比较狭窄，且这种电热膜制造过程中直接将基材放入600-800℃炉内加热喷涂，喷涂时基材内部温度很难达到与外部温度一致，影响了成膜质量，容易出现成膜厚度不均匀、凹凸不平、起泡等，缺陷较多，并且需要多次重复喷入电热膜处理液，工程繁琐、常温电阻大、效率低。
发明内容
针对上述问题，本发明的主要目的在于提供一种电热膜板的生产方法及生产设备，其在喷涂前对基板分段调节温度，待基板温度均匀后喷涂，形成的电热膜与基板连接性能好，膜厚度均匀、表面平滑，避免了出现起泡、凹凸不平等缺陷；并且通过一次喷涂即可，生产效率高，采用移动式喷涂，使得喷涂全面、膜层均匀。
为了达到上述目的，本发明采用如下技术方案：一种电热膜板的生产方法，包括如下步骤：
1）提供待喷涂基板；
2）将所述基板先后送入温度为0-200℃的升温区、201-600℃的固温区、601-620℃的稳定区调节温度；
3）将所述基板送入温度为601-620℃的喷涂区接受电热膜处理液喷涂，在所述基板的至少一面形成电热膜，获得半成品；
4）将所述半成品送入固化区固化所述电热膜，所述固化区温度高于喷涂区温度；
5）冷却，获得成品。
作为进一步的优选，所述步骤4）中固化区温度为621-650℃。
作为进一步的优选，所述升温区、固温区、稳定区、喷涂区和固化区的温度分别独立控制。为了达到较好的保温、控温效果，所述升温区、固温区、稳定区、喷涂区和固化区是相对封闭的空间。
作为进一步的优选，所述基板经过升温区的时间为5-10分钟，经过固温区和稳定区的时间各为1-10分钟，经过喷涂区的时间为3-10分钟，经过固化区的时间为1-5分钟。
作为进一步的优选，喷涂时，喷涂方向与基板表面的夹角小于90度。
作为进一步的优选，在与基板的前进方向垂直的方向上水平移动喷涂。
作为进一步的优选，所述基板为玻璃、搪瓷、陶瓷或云母片。
作为进一步的优选，所述电热膜板为纳米电热膜板，喷涂纳米电热膜处理液。
一种电热膜板的生产设备，包括用于使基板前进的输送装置，按基板的前进方向，还依次包括进料口、升温腔室、固温腔室、稳定腔室、喷涂腔室、固化腔室以及出料口，所述各腔室工作时的温度范围为：升温腔室0-200℃、固温腔室201-600℃、稳定腔室601-620℃、喷涂腔室601-620℃、固化腔室621-650℃。
作为进一步的优选，所述升温腔室、固温腔室、稳定腔室、喷涂腔室以及固化腔室各具有独立的温控系统。
作为进一步的优选，所述升温腔室、固温腔室、稳定腔室、喷涂腔室以及固化腔室均由保温砖或耐火纤维制成的上、下两腔室组成，位于输送装置上面和下面，以构成相对封闭的空间，以此达到更好的保温、控温效果。
作为进一步的优选，所述升温腔室、固温腔室、稳定腔室、喷涂腔室以及固化腔室内均设置有电加热管，各腔室电热管的根数、层数和功率可根据需要达到的目标温度来设置。
作为进一步的优选，所述升温腔室、固温腔室、稳定腔室、喷涂腔室以及固化腔室中具有各自的测温热电偶。通过热电偶测得各腔室的温度后，反馈给各自的温控系统进行控制。
作为进一步的优选，所述喷涂腔室下腔室的下方设置有喷涂基板下表面的喷涂装置，所述喷涂装置包括喷头、丝杠和电机，喷头在丝杠的作用下受控地移动喷施电热膜处理液，使得处理液在基板表面分布均匀。
作为进一步的优选，所述喷涂腔室下腔室底部开有斜向通道，喷头喷出的处理液经过斜向通道后到基板表面，对喷头喷出的处理液进行了导向，而且使得处理液倾斜喷涂在前进的基板表面，增加了处理液与基板的接触面积，并且即使处理液掉落，也不会直接落在喷头上。
作为进一步的优选，所述喷头在与基板的前进方向垂直的方向上水平移动。
作为进一步的优选，所述输送装置为电机带动的链条或转动的陶瓷辊，承载并运输基板。其中陶瓷辊具有耐腐蚀、耐高温的优点。
作为进一步的优选，所述喷涂腔室对应的输送装置开有喷涂孔，用于更好的喷涂基板下表面。
作为进一步的优选，所述喷涂腔室上方引出抽气装置，用于吸走喷涂过程中挥发的气体和部分雾化液体。
作为进一步的优选，所述出料口上方还设置有风扇，用于加速冷却成品。
本发明的有益效果如下：本发明基板放置在输送装置上，在其前进过程中，先后通过各腔室调节温度，待基板内外温度均匀后开始喷涂，形成的电热膜与基板连接性能好，膜厚度均匀、表面平滑，避免了出现起泡、凹凸不平等缺陷；并且雾化喷头在丝杠的作用下受控地来回喷施处理液，使得处理液在基板上分布均匀，制得的膜层均匀，喷涂方向与基板表面的夹角小于90度，使得处理液倾斜喷涂在前进的基板表面，增加了处理液与基板的接触面积，并且即使处理液掉落，也不会直接落在喷头上；另外，喷涂后加热固化，使得处理液干化，制得电热模板。本发明通过一次喷涂即可，生产效率高、喷涂全面，膜的质量好，制得的电热膜板使用寿命长。
附图说明
图1为本发明实施例电热膜板的生产设备结构示意图。
图2为图1中喷涂腔室A-A向的剖面示意图。
图3为图2中B-B向的剖面示意图。
附图中标记的说明如下：1-基板、2-输送辊、3-进料口、4-升温腔室、5-固温腔室、6-稳定腔室、7-喷涂腔室、8-固化腔室、9-出料口、10-电加热管、11-热电偶、12-喷涂装置、13-喷头、14-丝杠、15-电机、16-斜向通道、17-喷涂孔、18-抽气装置、19-风扇。
具体实施方式
本发明目的的实现、功能特点及有益效果，下面将结合具体实施例以及附图做进一步的说明。
下面结合附图和具体实施例对本发明所述技术方案作进一步的详细描述，以使本领域的技术人员可以更好的理解本发明并能予以实施，但所举实施例不作为对本发明的限定。
如图1-3所示，本发明实施例纳米电热膜板的生产设备，包括用于使玻璃基板1前进的陶瓷输送辊2，转动的陶瓷输送辊2上承载并运输基板1，按基板1的前进方向，还依次包括进料口3、升温腔室4、固温腔室5、稳定腔室6、喷涂腔室7、固化腔室8以及出料口9，所述升温腔室4、固温腔室5、稳定腔室6、喷涂腔室7和固化腔室8均由保温砖或耐火纤维制成的上、下两腔室组成，位于输送辊2上面和下面；进料口3和出料口9位于输送辊2上面。
所述各腔室的温度范围为：升温腔室4为0-200℃、固温腔室5为201-600℃、稳定腔室6为601-620℃、喷涂腔室7为601-620℃、固化腔室8为621-650℃。
所述升温腔室4、固温腔室5、稳定腔室6、喷涂腔室7和固化腔室8内设置有电加热管10，电加热管10可设置在各腔室的上和/或下腔室，也可设置单层或多层电加热管10，各腔室电热管10的位置排布、根数、层数和功率可根据需要达到的目标温度以及保温效果来设置。
所述升温腔室4、固温腔室5、稳定腔室6、喷涂腔室7和固化腔室8各具有独立的温控系统，各腔室顶部设置一个或多个测温热电偶11，通过热电偶11测得各腔室的温度后，由各自的温控系统（例如PLC控制柜等）进行控制。
所述喷涂腔室7的下腔室的下方设置有喷涂基板1下表面的喷涂装置12；所述喷涂装置12包括雾化喷头13、丝杠14、电机15，雾化喷头13在丝杠14的作用下受控地来回喷施电热膜处理液，使得处理液在基板1下表面分布均匀，所述喷头13在输送辊2的长度方向上移动；所述喷涂腔室7的下腔室底部开设有斜向通道16，喷涂装置12喷出的处理液经过斜向通道16后到基板1下表面，斜向通道16对喷出的处理液进行了导向，使得喷涂方向与基板表面的夹角小于90度，处理液倾斜喷涂在前进的基板1下表面。
如图3所示，所述喷涂腔室7内的中间区域可以适当减少输送辊2的长度或数量，形成喷涂孔17，以使基板1下表面和处理液更好地接触。
所述喷涂腔室6上方引出抽气装置18，用于吸走喷涂过程中挥发的气体和少部分雾化液体。所述出料口9上方还设置有风扇19，用于加速冷却电热膜板成品。
本发明实施例纳米电热膜板的生产方法，包括如下步骤：
1）提供待喷涂玻璃基板1；
2）将所述基板1先后送入温度为0-200℃的升温区、201-600℃的固温区、601-620℃的稳定区调节温度；
3）将所述基板送入温度为601-620℃的喷涂区接受纳米电热膜处理液喷涂，在所述基板的至少一面形成电热膜，获得半成品；
4）将所述半成品送入温度为621-650℃的固化区固化所述纳米电热膜；
5）冷却，获得成品。
所述基板经过升温区的时间为5-10分钟，经过固温区和稳定区的时间各为1-10分钟，经过喷涂区的时间为3-10分钟，经过固化区的时间为1-5分钟。
本发明实施例所用纳米电热膜处理液为现有技术。

Claims (5)

1.一种电热膜板的生产方法，其特征在于：包括如下步骤：
提供待喷涂基板；
将所述基板先后送入温度为0-200℃的升温区、201-600℃的固温区、601-620℃的稳定区调节温度；
将所述基板送入温度为601-620℃的喷涂区接受电热膜处理液喷涂，在所述基板的至少一面形成电热膜，获得半成品；
将所述半成品送入固化区固化所述电热膜，所述固化区温度高于喷涂区温度；
冷却，获得成品；
所述基板经过升温区的时间为5-10分钟，经过固温区和稳定区的时间各为1-10分钟，经过喷涂区的时间为3-10分钟，经过固化区的时间为1-5分钟。
2.根据权利要求1所述的电热膜板的生产方法，其特征在于：所述固化区温度为621-650℃。
3.根据权利要求1所述的电热膜板的生产方法，其特征在于：所述升温区、固温区、稳定区、喷涂区和固化区的温度分别独立控制。
4.根据权利要求1所述的电热膜板的生产方法，其特征在于：喷涂时，喷涂方向与基板表面的夹角小于90度。
5.根据权利要求1所述的电热膜板的生产方法，其特征在于：喷涂时，在与基板的前进方向垂直的方向上水平移动喷涂。
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