CN107523405A - 一种环保型换热器翅片成形加工液及其制备方法 - Google Patents
一种环保型换热器翅片成形加工液及其制备方法 Download PDFInfo
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Classifications
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- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
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- C—CHEMISTRY; METALLURGY
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- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
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- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
- C10M2227/00—Organic non-macromolecular compounds containing atoms of elements not provided for in groups C10M2203/00, C10M2207/00, C10M2211/00, C10M2215/00, C10M2219/00 or C10M2223/00 as ingredients in lubricant compositions
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
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- C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
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- C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
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- C10N2040/24—Metal working without essential removal of material, e.g. forming, gorging, drawing, pressing, stamping, rolling or extruding; Punching metal
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- C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
- C10N2040/00—Specified use or application for which the lubricating composition is intended
- C10N2040/20—Metal working
- C10N2040/244—Metal working of specific metals
- C10N2040/245—Soft metals, e.g. aluminum
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Abstract
本发明公开了一种用于空调换热器的环保型换热器翅片成形加工液及其制备方法。所述的环保型换热器翅片成形加工液,由下列重量百分比的组份配制而成:聚醚3.5%~7.5%、三乙醇胺硼酸酯2.4%~5.0%、二甲基硅氧烷2.0%~5.0%、苯丙三氮唑0.1%~0.5%、去离子蒸馏水85%~92%。本发明提供的加工液可代替现有的烷烃类换热器翅片加工液,并在换热器翅片生产过程中无VOCs排放问题。在满足金属加工润滑冷却的前提下,具有无毒无害、微生物有效降解、无挥发和无气味等优势为主的环境友好型产品特点,同时还具有防腐蚀的能力且成本低之优势。
Description
技术领域
本发明涉及机加工使用的润滑冷却液体,尤其涉及一种环保型换热器翅片成形加工液及其制备方法。
背景技术
换热器翅片由铝箔加工而成,采用级进模式冲床进行加工。翅片的成形过程主要涉及以下几个步骤:一次拉深——二次拉深——三次拉深——冲孔——变薄拉伸——翅片开窗——纵切——横切等几个步骤。其每一个步骤由于模具与工件之间的接触、工件的塑性变形,发热量非常大,故在翅片成形过程中,需要使用润滑液进行润滑冷却。由于空调的换热器,特别是内机,在使用过程中不允许散发出异味,以免而对客户造成不适感,故在生产换热器翅片时,使用的换热器翅片润滑液,必须是容易被清除的。
目前,换热器行业使用的润滑液主要是轻质白油,该种润滑液是一种矿物油基润滑液,主要由C8~C20的烷烃与极性添加剂混合而成,其中烷烃占比达到80%~98%之间。该种物质具有以下特点:
1、挥发性强,挥发性强有利于其从翅片表面清除,但是也造成生产环境恶劣,甚至污染空气,影响大气中PM2.5的含量;另外由于挥发性油基本上完全排放到空气中,造成的VOCs排放极高。VOCs与小分子烷烃直接氧化产生的碳粉弥漫空气中,对空气质量、操作人员身体造成一定的伤害。
2、安全性低,其闪点在50℃~80℃之间,属于易燃易爆品,过程控制要求非常严格,所到之处安装自动灭火系统;
3、低毒性问题,环己烷在该种矿物油中基本无法去除,对人体造成危害,且矿物油溶解人体皮肤油脂层,造成皮肤干涩开裂。
鉴于以上问题严重地影响了环保,为解决其使用不环保、不安全的技术问题,亟需一种新型的安全环保的空调换热器翅片加工用润滑冷却液。
发明内容
本发明为了解决现有空调换热器翅片加工冷却液即不环保、又不安全的技术问题,提出一种安全的环保型换热器翅片成形加工液,用其代替现有轻质白油应用于换热器翅片加工过程中的润滑与冷却,如此可以有效地降低加工过程中的污染与排放。这是换热器实现绿色制造的关键所在。
本发明提出的一种环保型换热器翅片成形加工液,由下列重量百分比的组份配制而成:
聚醚 3.5% ~ 7.5%、三乙醇胺硼酸酯2.4% ~5.0%、二甲基硅氧烷 2.0% ~5.0%、
苯丙三氮唑 0.1% ~ 0.5%、去离子蒸馏水85% ~ 92%。
其中,所述环保型换热器翅片成形加工液的运动粘度为1.05~1.5 mm2/s。
所述环保型换热器翅片成形加工液的极压性大于Pb270N。
本发明还提出了一种环保型换热器翅片成形加工液的制备方法,步骤如下:
步骤1:根据所述环保型翅片成形加工液的配方,按比例秤取组分聚醚、三乙醇胺硼酸酯、二甲基硅氧烷、苯丙三氮唑和去离子蒸馏水;
步骤2:先将所述的去离子蒸馏水,加入搅拌器中,再逐一添加所述的聚醚、三乙醇胺硼酸酯、二甲基硅氧烷、苯并三氮唑,搅拌至均匀。
较优的,所述的环保型翅片成形加工液在150℃下彻底干燥,残余量低于1%。
本发明提供的加工液可代替现有的烷烃类换热器翅片加工液,并在换热器翅片生产过程中无VOCs排放问题。加工液以水基为主要溶剂,避免了油基材料造成皮肤过敏和皮脂溶解开裂现象,保护了员工身体健康;还降低了设备能耗,减少了因油性添加剂残留导致的腐蚀等产品质量事故。解决了现有加工液的爆燃与碳化问题,净化了车间环境。即在满足金属加工润滑冷却的前提下,具有无毒无害、微生物有效降解、无挥发和无气味等优势为主的环境友好型产品特点,同时还具有防腐蚀的能力且成本低之优势。
具体实施方式
下面通过实施例对本发明作进一步的说明。
本发明提出的一种环保型换热器翅片成形加工液,由下列重量百分比的组份配制而成:
聚醚 3.5% ~ 7.5%、三乙醇胺硼酸酯2.4% ~5.0%、二甲基硅氧烷 2.0% ~5.0%、
苯丙三氮唑 0.1% ~ 0.5%、去离子蒸馏水85% ~ 92%。
根据需要,环保型换热器翅片成形加工液可以按以下不同实施例的配方表进行配制 :
本发明使用的组分有:
1、聚醚:通过其良好的润滑性在工件表面形成一层润滑薄膜,能维持润滑膜的均匀性,而在加工过程中由于其水溶性降低,将聚集在铝箔表面。
本发明的加工液中,聚醚含量为3.5%~7.5%,主要是环氧乙烷和四氢呋喃为基单元,利用C-O键可变因子调节支链R基团的位置,同时控制C/O键比例小于3,使之保留润滑性并可以被生物降解,避免高温下炭化积聚和残留的问题。
2、三乙醇胺硼酸酯:作为抗磨添加剂溶解在润滑剂中,加工过程中吸附在工件、模具表面形成稳定的抗磨层,具有良好的防止工件、冲头磨损的作用。三乙醇胺硼酸酯在溶液中作为一种储碱物质应用于铜管润滑液中,可以保证润滑液长期处于弱碱性状态,提高润滑液的防锈能力。3%左右的三乙醇胺硼酸酯可以作为铜、铝的防锈剂剂。
本发明的加工液中,三乙醇胺硼酸酯的含量为2.4%~5.0%,是先以硼酸和丙三醇进行皂化反应,在催化剂和一定压力条件下加入三乙醇胺,充分反应并搅拌后生成的物质具有良好的环境友好性,在水溶液中能够在金属表面形成一层不发粘的保护膜,该膜能够在工件表面形成可塑的线性膜,同时有效的将水基与金属隔绝开,抑制了细菌的生长于繁殖,延长了水性润滑液的使用寿命。
3、二甲基硅氧烷:能与铝合金的切断面络合反应,形成稳定的反应层,从而避免翅片在使用中从边部往内渗蚀。从加工上解决了换热器断面腐蚀的问题。
本发明的加工液中,二甲基硅氧烷的含量为2.0%~5.0%,是以聚有机硅氧烷中的聚二甲基硅氧烷(PDMS)结构中的Si-O键为主体,利用其螺旋型的不对称特点,改变侧链的结构,减小因为键角大于90°发生的内旋转现象,引入硅梯型小分子聚合物,降低其生成低分子环状物的趋势,从而提高分子集团的热稳定性,能够提高材料整体的力学性能,将固体粒子迁移到柔性基体,搭载无机-有机的流体界面。
4、苯丙三氮唑:作为一种防锈添加剂,能与金属材料形成反应层,特别的,苯丙三氮唑是铜的最佳防锈剂,由于加工过程中残留在翅片的杯口,在穿管之后粘附在铜管表面,起到防止铜管腐蚀的作用。
本发明的加工液中,苯丙三氮唑的含量为0.1%~0.5%,作为优良的铜制品缓蚀剂,尤其是在水环境中能够抑制氢离子的产生,从根本上阻止腐蚀因子的存在,以苯丙三氮唑产生的负离子和亚铜离子在金属表面生成的非常稳定的络合物,将分子中N原子的H进行置换,与孤立电子对结合成链状聚合物,该层膜在200℃温度下不会改变性能且有效地保护铜的氧化。
5、去离子蒸馏水:作为溶剂,能在无杂质介入的状态下提高润滑液的品级,去除水中氯离子、含硫离子之后,其对换热器的铜管、铝箔的腐蚀性大幅度降低。水的防锈性大幅度上升。同时也提高溶液的使用寿命。
本发明的加工液中,去离子蒸馏水的含量为85%~92%,其主要起到冷却与溶剂的作用,同时蒸馏水由于无卤素离子等,具有非常好的耐防腐性,可以避免由于水中含有的腐蚀性离子导致工件腐蚀。蒸馏水中不含有活性菌类,可以避免润滑剂出现变质的可能性。
本发明环保型换热器翅片成形加工液的制备方法,可以按如下方法进行:
1、根据所述环保型翅片成形加工液的配方,按比例秤取组分聚醚、三乙醇胺硼酸酯、二甲基硅氧烷、苯丙三氮唑和去离子蒸馏水;
2、先将所述的去离子蒸馏水,加入搅拌器中,再逐一添加所述的聚醚、三乙醇胺硼酸酯、二甲基硅氧烷、苯并三氮唑,搅拌至均匀。
本发明提供的加工液具有润滑、冷却、防腐性能,同时具有一定的钝化作用。加工剂可以在翅片的切断面形成稳定的钝化层,从而起到翅片断面防腐的作用。环保型翅片加工液中的添加剂在干燥之后不会为液体状,能彻底干爽,不易挥发,绿色环保。加工液还具有良好的润滑性能,选用聚醚C/O的适当比例,调整碳键上氧原子的端部位置,容易与水形成较强的氢键,因此与水或其他组分混合时不会燃烧,稳定安全。同时加强了与非极性有机物等的溶解性,可以满足各种不同产品的使用需求。
本发明提供的加工液通过物理方式将聚醚、三乙醇胺硼酸酯、二甲基硅氧烷、苯丙三氮唑和去离子蒸馏水进行混合,在150℃下彻底干燥,残余量低于1%。即按行业规定,采用φ56mm的蒸发皿,加入10g加工液,在150℃的烘箱中干燥2h,称重残余量应低于0.1g。加热干燥之后蒸发皿底部无肉眼可见的液态残留物。加工液在满足金属加工润滑的前提下,具有无毒无害、微生物有效降解、无挥发和无气味等优势为主的环境友好型产品特点,同时具有防腐蚀的能力且成本低廉之优势。
使用本发明提供的加工液,可以使得绿色换热器翅片成形具有无VOCs排放,不使用轻质白油润滑的特点。其中换热器翅片加工设备采用涂抹式预涂方式对铝箔进行预润滑冷却,并通过润滑管道将加工液输送到每一个变形位置的模具腔体,在模具加工前,通过气体将其喷淋到铝箔表面,并起到降低模具温度的作用。这种环保型换热器翅片成形加工液具有良好的冷却、润滑、防锈作用。并且,由于环保型翅片冷却液中的特殊成分,在翅片的切断面,其中的成分会吸附在翅片切断面,与铝箔形成钝化膜,从而解决换热器翅片由于切断而造成的断面防腐能力下降的问题。新型环保型翅片冷却液具有无VOCs污染,不燃无毒,不含会费性矿物油的特点。
以上所述实施例主要是为了说明本发明的创作构思,应当指出的是,对于本领域的普通技术人员来说,在不脱离本发明构思的前提下,还可以做出若干变形和改进,这些都属于本发明的保护范围。
Claims (5)
1.一种环保型换热器翅片成形加工液,由下列重量百分比的组份配制而成:
聚醚 3.5% ~ 7.5%、三乙醇胺硼酸酯2.4% ~5.0%、二甲基硅氧烷 2.0% ~5.0%、
苯丙三氮唑 0.1% ~ 0.5%、去离子蒸馏水85% ~ 92%。
2.如权利要求1所述的环保型换热器翅片成形加工液,其特征在于,其运动粘度为1.05~1.5 mm2/s。
3.如权利要求1所述的环保型换热器翅片成形加工液,其特征在于,其极压性大于Pb270N。
4.一种如权利要求1所述环保型换热器翅片成形加工液的制备方法,步骤如下:
步骤1:根据所述环保型翅片成形加工液的配方,按比例秤取聚醚、三乙醇胺硼酸酯、二甲基硅氧烷、苯丙三氮唑和去离子蒸馏水;
步骤2:先将所述的去离子蒸馏水,加入搅拌器中,再逐一添加所述的聚醚、三乙醇胺硼酸酯、二甲基硅氧烷、苯并三氮唑,搅拌至均匀。
5.如权利要求4所述的制备方法,其特征在于,所述的环保型翅片成形加工液在150℃下彻底干燥,残余量低于1%。
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