CN104757863B - 等离子不粘锅及其制造方法 - Google Patents

等离子不粘锅及其制造方法 Download PDF

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CN104757863B
CN104757863B CN201510116150.3A CN201510116150A CN104757863B CN 104757863 B CN104757863 B CN 104757863B CN 201510116150 A CN201510116150 A CN 201510116150A CN 104757863 B CN104757863 B CN 104757863B
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mcraly
layer
plasmasphere
oxide
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CN104757863A (zh
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方成
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ZHEJIANG SANHO KITCHENWARE Co Ltd
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ZHEJIANG SANHO KITCHENWARE Co Ltd
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Priority to PCT/CN2015/078603 priority patent/WO2016145731A1/zh
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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47J—KITCHEN EQUIPMENT; COFFEE MILLS; SPICE MILLS; APPARATUS FOR MAKING BEVERAGES
    • A47J36/00—Parts, details or accessories of cooking-vessels
    • A47J36/02—Selection of specific materials, e.g. heavy bottoms with copper inlay or with insulating inlay
    • A47J36/025—Vessels with non-stick features, e.g. coatings
    • A—HUMAN NECESSITIES
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    • A47J27/00—Cooking-vessels
    • A—HUMAN NECESSITIES
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Abstract

本发明公开了一种等离子不粘锅及其制备方法，包括锅体，所述锅体具有由铝基材构成的内表面，该内表面上涂覆有不粘涂层，所述不粘涂层与锅体内表面之间设有等离子层，该等离子层包括涂覆于锅体内表面的MCrALY层和涂覆于所述MCrALY层外的混合物层，该混合物层由MCrALY颗粒和金属氧化物颗粒构成。MCrALY层的韧性较好，粘接力强，与基材之间易结合，且结合后的牢固度高，很好地充当了一个缓冲的作用，为后续涂覆混合物层做好基础；而混合物层融合了MCrALY颗粒和金属氧化物颗粒，具有更强的硬度和脆性，大大提升了锅体表面的硬度和耐磨性能；通过MCrALY层的缓冲作用，混合物层在保证高硬度和脆度的情况下，与MCrALY层实现牢固可靠的持久粘接。

Description

等离子不粘锅及其制造方法
技术领域
本发明属于厨房用具领域，尤其是涉及一种等离子不粘锅及其制造方法。
背景技术
锅是厨房常用的烹饪工具。为了方便清洗和烧制菜肴，越来越多的人使用不粘锅，但现有的不粘锅存在诸多缺陷，如目前压铸锅体需进行多次压铸，才能成型，费时费力，工作效率低；又如中国专利CN102871529公开了一种具有硬质表面的铝合金不粘锅及其加工工艺，其操作过程为成型→精车→氧化→喷涂→烧结，其精车操作只对锅体进行简单的清洗，无法彻底清除制造过程中携带的油污和毛刺，虽然现有技术中虽有部分除油、清洗操作，但其由于步骤不合理及配置液体效果不佳等原因均无法达到很好的去油和去毛刺的效果，影响锅体后期的使用效果和安全；且其制膜过程的温度较高，氧化之后就进行喷漆和烧结操作，影响制膜的速度和制成膜体的使用效果。
再者，现有铝合金不粘锅存在诸多缺陷，如由于铝合金基材较软，在铝合金上喷涂一层更软的不粘涂层。在实际使用中，由于涂层和基材都较软,难以抵抗磨损,抗刮耐磨性能极差；后经过改良，增加了铝合金硬质氧化技术，氧化膜硬度达到400HV(裸铝硬度为250HV)，适当提高了基材硬度，提高整体的抗刮耐磨性能。但相对来说，硬质氧化硬度相对于我们家庭日常使用的铁铲，炒田螺等较硬物质时，还是难以抵挡。通过实验方法，硬质氧化涂层炊具，用铁铲炒田螺，15分钟后就可视明显划伤。而后行业内有人员就尝试在铝基材上通过等离子技术喷涂一层陶瓷涂层来提高硬度，因为等离子陶瓷涂层具有硬度极高(硬度达到1800HV)和高耐腐蚀效果；但该工艺存在两个致命问题，一是等离子陶瓷氧化物层太脆，结合到铝基材上存在脆性强，用铁铲撞击容易崩裂；二是等离子层与不粘涂层结合力太差，等离子层非常致密，与PTFE涂层根本无法有效结合，涂层喷上去后使用寿命反而更短。
发明内容
本发明为了克服现有技术的不足，提供一种耐刮耐磨的等离子不粘锅及其制造方法。
为了实现上述目的，本发明采用以下技术方案：一种等离子不粘锅，包括锅体，所述锅体具有由铝基材构成的内表面，该内表面上涂覆有不粘涂层，所述不粘涂层与锅体内表面之间设有等离子层，该等离子层包括涂覆于锅体内表面的MCrALY层和涂覆于所述MCrALY层外的混合物层，该混合物层由MCrALY颗粒和金属氧化物颗粒构成。MCrALY层的韧性较好，粘接力强，与基材之间易结合，且结合后的牢固度高，很好地充当了一个缓冲的作用，为后续涂覆混合物层做好基础；而混合物层融合了MCrALY颗粒和金属氧化物颗粒，具有更强的硬度和脆性，大大提升了锅体表面的硬度和耐磨性能；通过MCrALY层的缓冲作用，混合物层在保证高硬度和脆度的情况下，与MCrALY层实现牢固可靠的持久粘接。
进一步的，所述MCrALY层和混合物层之间还设有缓冲层，该缓冲层由70-80％的MCrALY和20-30％的金属氧化物颗粒混合而成。缓冲层的设置，产生更缓慢的过渡和缓冲作用，更加有利于提高各涂层之间的粘接力和持久性，进一步提高了整个等离子涂层的硬度和厚度，将锅体整体的耐磨性和硬度调试到最佳状态。
作为优选，所述混合物层由40-50％的MCrALY颗粒和50-60％的金属氧化物颗粒混合而成；该比例搭配形成的等离子涂层，兼具了最佳表面硬度和最佳附着力。50-60％金属氧化物在表层，起到了主要硬度支撑作用，硬度达到1800-2000HV；若含量低于50％，覆盖率不够，硬度不够；含量高于60％，则会出现局部堆积，导致过脆。经大量实验验证，该范围下的MCrALY和金属氧化物的混合为最佳分布。
本发明还公开了一种等离子不粘锅的制造方法，其包括如下步骤：
(1)成型；
(2)除油：除去锅体表面的油污和氧化皮并吹干；
(3)热覆底；
(4)清洗锅体，吹干；
(5)喷砂：用20#与46#混合的棕刚玉对锅体表面进行喷砂处理，使锅体表面粗糙度达到Ra＝7.0-10.0μm；该粗糙度可以使30-60μm等离子涂层具有最佳的附着力；
(6)预热，将锅体加热到220-280℃；该温度下预热，使得铝基材软化，软化后的基材与等离子层更好地粘结、融合在一起，相比稳态下的基材，软化后的基材具有更好的融合性和吸附性；
(7)喷涂等离子层：用由直流电驱动的等离子电弧作为热源，将粉末状的MCrALY颗粒加热到熔融或半熔融状态，并以150m/s的速度喷向锅体表面而形成附着牢固的MCrALY层；然后将粉末状的MCrALY颗粒和金属氧化物颗粒的混合物加热到熔融或半熔融状态，并以150m/s的速度喷向锅体表面而形成附着于MCrALY层外的混合物层；
(8)打底层喷涂：待喷涂完等离子层后，采用改型树脂涂料喷涂锅体内表面，在120-280℃下烘烤5-10分钟，形成厚度为3-5μm的打底层；该打底层可与等离子层非常可靠地粘接；
(9)内喷涂：在锅体内表面喷涂PTFE涂料，在380-440℃下烘烤10分钟，形成厚度为30-45μm的PTFE涂料层。通过在等离子层外喷涂一层特殊材质的打底层，该打底层不仅可与等离子层有效粘合，还可以与PTFE涂料可靠地粘接，有效解决了PTFE涂料易脱落的问题，保证了不粘锅的使用寿命。
进一步的，所述金属氧化物选自氧化铝、氧化锆、氧化钛、氧化铬、氮化钛、MCrALY中的一种或几种的混合，所述MCrALY和金属氧化物的颗粒粒径为60-80μm。
作为优选，所述步骤(7)中等离子层的喷涂厚度为30-60μm，粗糙度范围为：Ra＝10-15μm,Rz＝50-70μm。该数值下实现了最佳表面粗糙度，该粗糙度可增强PTFE涂料与等离子喷涂的混合物层的牢固性，同时在表面形成微观的波峰波谷表面，在烹饪过程中，此种波峰波谷结构可有效抵抗外来物的刮擦；实现20％的波峰与食物接触，80％的涂层被有效的保护，极大延长不粘涂层的使用寿命和持久不粘性能。
作为优选，所述步骤(7)中，等离子层的喷涂电流为400-800A，电压为25-45V，送粉量为50-80g/min，喷涂距离为10-20mm，喷涂时间为90-120s。
本等离子不粘锅，成型操作利用4800吨压力一次成型，成型效果好，效率高，表面更平整使锅体受热更均匀，传热更快；而在成型操作后设置除油操作，该设置的浓度为5％的脱脂粉可快速溶解锅体表面的油脂，除油彻底，速度快，然后用抛光剂清洗，即可对碱性液体进行中和，又可对锅体表面进行抛光处理；而热覆底可在锅体底面再增加一层保护层，增强锅体的牢固性和使用寿命，在热覆底后增加再次清洗操作，用氢氧化钠对锅体进行清洗，在用稀硝酸对锅体表面的氢氧化钠进行中和清洗，而该设置对氢氧化钠的浓度、温度及PH值进行了设定，使氢氧化钠的去污效果最好，最快，更少的氢氧化钠使用量，更好的去污效果，且节约了成本，而无需很多的稀硝酸即可去除氢氧化钠，且稀硝酸对氢氧化钠的中和效果好；
喷砂操作可使锅体表面达到一定的粗糙度提高固体的附着力和耐磨力，且可使锅体表面形成微观的波峰波谷表面；使锅体的牢固性和抗疲劳性能更高；且锅体经等离子喷涂形成的表面层硬度可达到1500-2000HV，相比之前的氧化膜硬度提高了3-4倍，进一步增强锅体的耐久性，同时耐酸、耐碱及耐盐水能力都比氧化膜提升2倍以上；且喷涂的PTFE涂料，由于打底层的过渡作用，突破了现有技术难题，不仅可以与等离子层持久地粘接，而且只需要喷涂很薄的一层即可实现非常好的不粘附性能；短时间锅体可以耐高温到300℃，一般在240～260℃之间可以连续使用，有显著的热稳定性，在高温下不融化，在冷冻的温度下不脆化；可使锅体表面具有不沾水和油污，如粘有少量的污垢，简单的擦拭也可以去除干净；不受药品和其他化学药品的侵蚀；即使涂料脱落，由于等离子涂层的粗糙度设置，也只是在波峰尖点位置造成断层破损，不会牵连到其他区域，保持其他区域涂层的完整性.
综上所述，本发明制得的等离子不粘锅具有显著的热稳定性和不粘性，锅体硬度高，不粘涂层不易脱落，耐磨损时间长，使用寿命明显提高。
附图说明
图1为本发明的结构示意图。
图2为图1的A处放大图。
具体实施方式
为了使本技术领域的人员更好的理解本发明方案，下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整的描述。
如图1、2所示，图2中各涂层表示的厚度并非实际比例，是为了便于理解而做出放大；一种等离子不粘锅，包括锅体1，所述锅体具有由铝基材构成的内表面，该内表面上涂覆有不粘涂层11，所述不粘涂层与锅体内表面之间设有等离子层2，该等离子层包括涂覆于锅体1内表面的MCrALY层21和涂覆于所述MCrALY层21外的混合物层22，该混合物层由MCrALY颗粒和金属氧化物颗粒构成。通过在不粘涂层与锅体之间设置了特殊的等离子层，使得锅体表面硬度明显提高；该等离子层为双层结构，由MCrALY颗粒构成的MCrALY层与锅体基材相粘接，其具有较强韧性，与基材粘接力强；混合物层由MCrALY颗粒和金属氧化物颗粒混合而成，其具有更强的硬度，通过MCrALY层的过渡和衔接作用，混合物层可以牢固的附着于基材上。
为了更好的提高个涂层的粘接力度和耐磨性，在所述MCrALY层21和混合物层22之间再喷涂一层缓冲层23，该缓冲层由70-80％的MCrALY和20-30％的金属氧化物颗粒混合而成，缓冲层起到一个承接的作用，形成一个很好的过渡作用，保证了整个等离子层再最优的厚度下，具有最优的硬度和粘接力；
具体的，所述混合物层22由40-50％的MCrALY颗粒和50-60％的金属氧化物颗粒混合而成。
所述的等离子不粘锅的制备方法如下，
(1)成型，利用4800吨压力将锅体一次压铸成型；质地致密，比普通拉升锅受热更均匀，传热更快，真正无油烟。
(2)除油，用浓度为5％SCD脱脂粉清洗锅体，PH为13，温度控制在40-50℃，除去锅体表面的油污和氧化皮；然后将锅体放入浓度为3-5％SCD抛光剂中进行中和清洗，温度是室温，PH值为2-3；再用水洗净锅体，然后再吹干锅体表面。
(3)热覆底；利用压力为2500吨的锻压机对锅体进行热覆底。使底部更致密均匀，超导热覆底技术比普通冷覆底(有孔)热效率提升20％以上，节能更省时。
(4)清洗，用浓度为2-3％，温度为30-40℃，PH值为12-14的氢氧化钠清洗锅体；然后用水净锅体，再用浓度为1-2％的稀硝酸，温度为室温，PH值为1-3，对锅体进行中和清洗；再用水洗净锅体，然后吹干锅体表面；
(5)喷砂：用20#与46#混合的棕刚玉对锅体表面进行喷砂处理，使锅体表面粗糙度达到Ra＝7.0-10.0μm；
(6)预热，将锅体加热到220-280℃；该温度下铝锅表面硬度开始下降，表面张力降到较低状态，可有效与后面的涂覆的等离子层的结合。
(7)喷涂等离子层：用由直流电驱动的等离子电弧作为热源，将粉末状的MCrALY颗粒加热到熔融或半熔融状态，并以150m/s的速度喷向锅体表面，在锅体表面形成附着牢固的MCrALY层；然后将粉末状的70-80％的MCrALY颗粒和20-30％的金属氧化物颗粒的混合物加热到熔融或半熔融状态，并以150m/s的速度喷向锅体表面而形成附着于MCrALY层外的缓冲层；最后将40-50％的粉末状MCrALY颗粒和50-60％的粉末状金属氧化物颗粒的混合物加热到熔融或半熔融状态，并以150m/s的速度喷向锅体表面而形成附着于缓冲层外的混合物层；经大量实验验证，40-50％的粉末状MCrALY颗粒和50-60％的粉末状金属氧化物颗粒的混合而成的混合物层，兼具了最佳表面硬度和最佳附着力；50-60％金属氧化物在表层，起到了主要硬度支撑作用，硬度达到1800-2000HV；若含量低于50％，覆盖率不够，硬度不够；含量高于60％，则会出现局部堆积，导致过脆。经大量实验验证，该范围下的MCrALY和金属氧化物的混合为最佳分布。
具体的，该等离子层喷涂过程中的电流为400-800A，电压为25-45V，主气压为氮气，压力为40-60psi；辅气压为氢气，压力随电压变化而变化，载气也为氮气，压力为40-60psi，送粉量为50-80g/min，喷涂距离为10-20mm，喷涂时间为90-120s；
等离子层喷涂后形成的厚度为30-60μm，粗糙度范围为：Ra＝10-15μm,Rz＝50-70μm，通过以上工艺锅体与等离子喷涂层的结合力≥110N/mm2；
具体的，金属氧化物可以选自氧化铝、氧化锆、氧化钛、氧化铬、氮化钛、MCrALY中的一种或几种的混合，所述MCrALY和金属氧化物的颗粒粒径为60-80μm，本实施例中选用氧化锆；
(8)打底层喷涂：待喷涂完等离子层后，采用改型树脂涂料喷涂锅体内表面，在120-280℃下烘烤5-10分钟，形成厚度为3-5μm的打底层；具体的，所述改性改型树脂涂料包括30-50％的peek(聚醚醚酮)和35-40％的pes(聚醚砜)，再搭配常规粘接涂料的其他组分均匀混合即可制得，本领域技术人员根据需要可以对配料的种类和配比作调整，不再赘述，只需要控制好peek(聚醚醚酮)和pes(聚醚砜)的含量即可实现；该打底层可提高PTFE涂层与等离子层的结合力；
(9)内喷涂：在锅体内表面喷涂PTFE涂料，在380-440℃下烘烤10分钟，形成厚度为30-45μm的PTFE涂料层。即制得本发明等离子不粘锅。
为了验证本发明等离子不粘锅的性能，对锅体进行了一系列测试，该测试过程如下：
测试一：用冷热冲击锅体。将锅体加热到400℃，维持1min，后放入到0℃冷热中，连续冲击30次后，对锅体表面的涂层进行观察，未发现脱落和崩裂；
测试二：钢球冲击锅体。将锅体用250g钢球，从高1.2mm空中垂直跌落在锅体表面，冲击，随意冲击锅体表面5个点以上，观察锅体表面未出现崩裂或脱落现象。
测试三：煮盐水。将锅体放入到采用10％盐水溶液中进行沸腾24小时，观察锅体表面，未发现腐蚀现象。
测试四：煮热油。在锅体中加入500g大豆油，恒温在220度煮30min后，观察锅体表面未发现腐蚀或脱落现象。
测试五：煮醋酸。在锅体中加入5％醋酸溶液，恒温在100度煮15min后，观察锅体表面未发生腐蚀或脱落现象。
经过上述测试后，锅体仍然能正常使用，因而证实了本发明的不粘锅的各项性能得到了很大的提高：
(1)不粘性：很薄的PTFE涂料层也具有很好的不粘附性能；
(2)耐热性：PTFE涂料层具有优良的耐热和耐低温特性，短时间可以耐高温到300℃，一般在240～260℃之间可以连续的使用，有显著的热稳定性，在高温下不融化，在冷冻的温度下不脆化；
(3)抗湿性：PTFE涂料层表面具有不沾水和油污，如粘有少量的污垢，简单的擦拭也可以去除干净；
(4)耐磨损性：具有耐磨损和不粘附的双重性能优点；
(5)耐腐蚀性：不受药品和其他化学药品的侵蚀；
(6)抗脱落性：即使涂料脱落，也只是在波峰尖点位置造成断层破损，不会牵连到其他区域，保持其他区域涂层的完整性。
此外本锅体还具备下述优点：1)锅体表面也是呈现均匀的波峰波谷状态，且更致密更联系；2)锅体硬度达到1500-2000HV，硬度相比于硬质氧化膜提升了3-4倍；3)抗刮耐磨硬度比现有的不粘锅提升了3-4倍，使用寿命更长；4)更强的耐腐蚀能力。金属陶瓷膜耐酸、耐碱及耐盐水能力都比氧化膜提升2倍以上。
显然，所描述的实施例仅仅是本发明的一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都应当属于本发明保护的范围。

Claims (7)

1.一种等离子不粘锅，包括锅体(1)，所述锅体具有由铝基材构成的内表面，该内表面上涂覆有不粘涂层(11)，其特征在于：所述不粘涂层与锅体内表面之间设有等离子层(2)，该等离子层包括涂覆于锅体(1)内表面的MCrALY层(21)和涂覆于所述MCrALY层(21)外的混合物层(22)，该混合物层由MCrALY颗粒和金属氧化物颗粒构成。
2.如权利要求1所述的等离子不粘锅，其特征在于：所述MCrALY层(21)和混合物层(22)之间还设有缓冲层(23)，该缓冲层由70-80％的MCrALY和20-30％的金属氧化物颗粒混合而成。
3.如权利要求1或2所述的等离子不粘锅，其特征在于：所述混合物层(22)由40-50％的MCrALY颗粒和50-60％的金属氧化物颗粒混合而成。
4.一种制备如权利要求1-3中任一项所述的等离子不粘锅的方法，其特征在于：包括如下步骤：
(1)成型；
(2)除油：除去锅体表面的油污和氧化皮并吹干；
(3)热覆底；
(4)清洗锅体，吹干；
(5)喷砂：用20#与46#混合的棕刚玉对锅体表面进行喷砂处理，使锅体表面粗糙度达到Ra＝7.0-10.0μm；
(6)预热，将锅体加热到220-280℃；
(7)喷涂等离子层：用由直流电驱动的等离子电弧作为热源，将粉末状的MCrALY颗粒加热到熔融或半熔融状态，并以150m/s的速度喷向锅体表面，在锅体表面形成附着牢固的MCrALY层；然后将粉末状MCrALY颗粒和金属氧化物颗粒的混合物加热到熔融或半熔融状态，并以150m/s的速度喷向锅体表面而形成附着于MCrALY层外的混合物层；
(8)打底层喷涂：待喷涂完等离子层后，采用改型树脂涂料在120-280℃下烘烤5-10分钟，形成厚度为3-5μm的打底层；
(9)内喷涂：在锅体内表面喷涂PTFE涂料，在380-440℃下烘烤10分钟，形成厚度为30-45μm的PTFE涂料层。
5.根据权利要求4所述的制备方法，其特征在于：所述金属氧化物选自氧化铝、氧化锆、氧化钛、氧化铬、氮化钛、MCrALY中的一种或几种的混合，所述MCrALY和金属氧化物的颗粒粒径为60-80μm。
6.根据权利要求4所述的制备方法，其特征在于：所述步骤(7)中等离子层的喷涂厚度为30-60μm，粗糙度范围为：Ra＝10-15μm,Rz＝50-70μm。
7.如权利要求4所述的制造方法，其特征在于：所述步骤(7)中，等离子层的喷涂电流为400-800A，电压为25-45V，送粉量为50-80g/min，喷涂距离为10-20mm，喷涂时间为90-120s。
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