CN108382021A - 一种耐高温金属箔真空绝热材料及其制备方法 - Google Patents
一种耐高温金属箔真空绝热材料及其制备方法 Download PDFInfo
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Abstract
本发明公开一种耐高温金属箔真空绝热材料及其制备方法,其特征在于该真空绝热材料包括:平面箔层(1)、凹面箔层(2)、连接层(3)、真空封口(4)、低导热填充材料(5);所述平面箔层(1)与凹面箔层(2)为上下搭接结构,通过一圈连接层(3)将平面箔层(1)与凹面箔层(2)紧密连接。该真空绝热材料可耐400℃以上的高温,并且保温绝热性能优异,常温导热系数可低至0.0012W/(m·K),高温(400℃)导热系数可低至0.003W/(m·K)。可以使真空绝热材料应用在航天、钢铁、石化、电力、高温工业设备等的高温绝热保温领域。
Description
技术领域
本发明专利涉及一种真空绝热材料及其制备方法,尤其是涉及一种耐高温金属箔真空绝热材料及其制备方法。
背景资料
真空绝热板是真空保温材料中的一种,也是目前世界上最先进的高效保温材料,它主要由芯材、吸气剂和阻气膜三部分组成。真空绝热材料基于真空绝热原理,通过在阻气膜内填充芯材和吸气剂,通过最大限度的提高膜内部真空度来降低热对流、热传导和热辐射,以此实现高效绝热。真空绝热材料的阻气膜显得尤为重要,一旦阻气膜发生穿孔或破损,真空绝热板将失去其优异的保温性能。
专利号为CN101767448B的发明专利上公开了一种真空绝热板用隔气膜制作方法。该专利所述的阻气薄膜包括上层料、中间层料和下层料,上层料选自PDVC(聚偏二氯乙烯)、PS(聚苯乙烯)或PET(聚对苯二甲酸乙二醇酯),中间层料选自PE(聚乙烯)、PVOH(聚乙烯醇)、PA(尼龙)、EVOH(乙烯-乙烯醇共聚物)、EVA(乙烯-醋酸乙烯共聚物)、PET或PP(聚丙烯),下层料为PE。
专利号为CN105970742B的发明专利公开了一种真空绝热板的制备方法。该专利所述的薄膜是以PE为内粘层,与Al、VMPET、PA通过干式复合的工艺高温高频热贴合而成。
专利号为ZL200420053407.2的实用新型专利上公开了一种真空绝热板。该专利所述的阻气薄膜自芯材由内而外分别为PA层、PET层、铝箔层和PE层。
专利号为CN202248332U的实用新型专利上公开了一种真空绝热建筑保温板。该专利所述的阻气薄膜包括层状结构和热合层,层状结构为PA膜或PET膜或PVDC膜或EVOH膜,热合层为PE膜、CPP膜或者BOPP膜。
专利号为CN201680117U的实用新型专利上公开了一种便于应用的真空绝热板。该专利所述的阻气薄膜为金属、玻璃、PA、PI(聚亚酰胺)、PE、PP。
目前国内的真空绝热板产品,无论是家电用、冷冻冷藏用、工业用还是建筑用真空绝热板,都是采用铝箔金属层复合高分子层薄膜结构(建筑用真空绝热板最外层还附有一层无机玻纤布),并都是以高温熔融PE的方式来热压封装真空绝热板。PE是乙烯经聚合制得的一种热塑性树脂,其熔点范围为112~135℃。当外界温度高于135℃时,真空绝热板阻气薄膜中的PE热封层熔融,即真空绝热板失效,并且这种铝箔金属层复合高分子层薄膜结构强度较低、抗穿刺性能低。导致目前国内的真空绝热板保温绝热材料在航天、钢铁、石化、电力、高温工业设备等的高温绝热保温领域尚无应用。
发明内容
发明目的:为了解决现有技术中真空绝热材料不耐高温的问题,本发明提供了一种耐高温金属箔真空绝热材料及其制备方法,该耐高温金属箔真空绝热材料可耐400℃以上的高温,并且保温绝热性能优异,常温导热系数可低至0.0012W/(m∶K),高温(400℃)导热系数可低至0.003W/(m·K)。
技术方案:为了实现上述目的,本发明所述的一种耐高温金属箔真空绝热材料,其特征在于它包括:平面箔层(1)、凹面箔层(2)、连接层(3)、真空封口(4)、低导热填充材料(5);所述平面箔层(1)与凹面箔层(2)为上下搭接结构,通过一圈连接层(3)将平面箔层(1)与凹面箔层(2)紧密连接;真空封口(4)可以在平面箔层(1)上或凹面箔层(2)上,优选凹面箔层(2);低导热填充材料(5)位于平面箔层(1)与凹面箔层(2)搭接形成的空腔内。
所述平面箔层(1)为平板状金属箔,可以是由以下物质组成的群中选择的1种或1种以上的组合:银箔、铝箔、铜箔、不锈钢箔;平面箔层(1)厚度为50μm~200μm。
所述凹面箔层(2)为四边突起、中间下陷的凹形金属箔,可以是由以下物质组成的群中选择的1种或1种以上的组合:银箔、铝箔、铜箔、不锈钢箔;凹面箔层(2)厚度为50μm~200μm。
所述连接层(3)为平面箔层(1)和凹面箔层(2)的熔融重叠层。
所述真空封口(4)为熔化填缝的金属焊料。
所述低导热填充材料(5)为多孔保温材料,可以是由以下物质组成的群中选择的1种或1种以上的组合:如玻璃棉、岩/矿棉、陶瓷纤维、气凝胶、纳米无机颗粒等无机保温材料;聚氨酯、聚苯乙烯、酚醛树脂等有机保温材料,并且低导热填充材料(5)中可以选择添加H2O或O2和N2的吸收剂。
本发明还公开了一种制备上述耐高温金属箔真空绝热材料的方法,其特征在于包括下述顺序的步骤:
(1)将金属箔按所需尺寸裁切成平面箔层(1);
(2)将金属箔按所需尺寸裁切后,采用延展法将金属箔加工成四边突起、中间下陷的凹面箔层(2);
(3)在上述平面箔层(1)或凹面箔层(2)上开孔,孔径为5mm~100mm,预留真空封口(4)位置;
(4)根据上述凹面箔层(2)内部形状填充低导热填充材料(5)后,将平面箔层(1)覆盖在凹面箔层(2)上,采用激光焊接或电阻焊方法形成连接层(3),连接层宽度为0.5mm~5mm;
(5)封住预留真空封口(4),采用氦气检漏仪测试连接层(3)的焊缝气密性;
(6)确定连接层(3)无漏点后,将金属焊料放在真空封口(4)上,采用真空钎焊方法真空密封真空封口(4),得到耐高温金属箔真空绝热材料,真空腔体内压力为0.001Pa~1.0Pa,温度为600℃~1200℃。
本发明优点在于:耐高温金属箔真空绝热材料可耐400℃以上的高温,并且保温绝热性能优异,常温导热系数可低至0.0012W/(m·K),高温(400℃)导热系数可低至0.003W/(m·K)。可以使真空绝热材料应用在航天、钢铁、石化、电力、高温工业设备等的高温绝热保温领域。
附图说明
图1为本发明的一种耐高温金属箔真空绝热材料结构示意图,其中1为平面箔层、2为凹面箔层、3为连接层、4为真空封口、5为低导热填充材料。
图2为一种耐高温金属箔真空绝热材料的侧面示意图,其中1为平面箔层、2为凹面箔层。
图3为另外一种耐高温金属箔真空绝热材料的侧面示意图,其中1为平面箔层、2为凹面箔层。
具体实施方式
下面结合具体实施例,进一步阐明本发明,应理解这些实施例仅用于说明本发明而不用于限制本发明的范围,在阅读了本发明之后,本领域技术人员对本发明的各种等价形式的修改均落于本申请所附权利要求所限定。
实施例1
如图1和图2所示,一种耐高温金属箔真空绝热材料包括:50μm厚平面铝箔层(1)、50μm厚凹面铝箔层(2)、连接层(3)为铝箔焊缝、真空封口(4)为镍-铜焊料、低导热填充材料(5)为玻璃棉;真空封口(4)在凹面箔层(2)上。上述耐高温金属箔真空绝热材料的制备方法包括下述顺序的步骤:
(1)将50μm厚的铝箔裁切成长×宽为420mm×420mm的平面箔层(1);
(2)将50μm厚的铝箔裁切成长×宽为430mm×430mm,采用延展法将铝箔加工成中间底面尺寸为400mm×400mm,四边与底面呈135°角的凹面箔层(2);
(3)在上述凹面箔层(2)上开孔,孔径为10mm;
(4)根据上述凹面箔层(2)内部形状填充玻璃棉后,将平面箔层(1)覆盖在凹面箔层(2)上,采用激光焊接形成连接层(3)焊缝,缝宽为1mm;
(5)封住预留真空封口(4),采用氦气检漏仪测试连接层(3)的焊缝气密性;
(6)确定连接层(3)无漏点后,将镍-铜焊料放在真空封口(4)上,采用真空钎焊方法真空密封真空封口(4),得到耐高温金属箔真空绝热材料,真空腔体内压力为0.1Pa,温度为600℃。
实施例2
如图1和图3所示,一种耐高温金属箔真空绝热材料包括:100μm厚不锈钢箔(1)、100μm厚不锈钢箔层(2)、连接层(3)为不锈钢箔焊缝、真空封口(4)为镍基合金焊料、低导热填充材料(5)为含吸气剂的陶瓷纤维棉毡;真空封口(4)在凹面箔层(2)上。上述耐高温金属箔真空绝热材料的制备方法包括下述顺序的步骤:
(1)将100μm厚的不锈钢箔裁切成长×宽为820mm×820mm的平面箔层(1);
(2)将100μm厚的不锈钢箔裁切成长×宽为830mm×830mm,采用延展法将不锈钢箔加工成中间底面尺寸为800mm×800mm,四边与底面呈90°角的凹面箔层(2);
(3)在上述凹面箔层(2)上开孔,孔径为30mm;
(4)根据上述凹面箔层(2)内部形状填充陶瓷纤维棉毡后,将平面箔层(1)覆盖在凹面箔层(2)上,采用电阻缝焊方法形成连接层(3)焊缝,缝宽为2mm;
(5)封住预留真空封口(4),采用氦气检漏仪测试连接层(3)的焊缝气密性;
(6)确定连接层(3)无漏点后,将镍基焊料放在真空封口(4)上,采用真空钎焊方法真空密封真空封口(4),得到耐高温金属箔真空绝热材料,真空腔体内压力为0.3Pa,温度为900℃。
上述仅为本发明的单个具体实施方式,但本发明的设计构思并不局限于此,凡利用此构思对本发明进行非实质性的改动,均应属于侵犯本发明保护的范围的行为。但凡是未脱离本发明技术方案的内容,依据本发明的技术实质对以上实施例所作的任何形式的简单修改、等同变化与改型,仍属于本发明技术方案的保护范围。
Claims (7)
1.一种耐高温金属箔真空绝热材料,其特征在于所述真空绝热材料包括:平面箔层(1)、凹面箔层(2)、连接层(3)、真空封口(4)、低导热填充材料(5);所述平面箔层(1)与凹面箔层(2)为上下搭接结构,通过一圈连接层(3)将平面箔层(1)与凹面箔层(2)紧密连接;真空封口(4)可以在平面箔层(1)上或凹面箔层(2)上,优选凹面箔层(2);低导热填充材料(5)位于平面箔层(1)与凹面箔层(2)搭接形成的空腔内。
2.依据权利要求1所述的耐高温金属箔真空绝热材料,其特征在于所述平面箔层(1)为平板状金属箔,可以是由以下物质组成的群中选择的1种或1种以上的组合:银箔、铝箔、铜箔、不锈钢箔;平面箔层(1)厚度为50μm~200μm。
3.依据权利要求1所述的耐高温金属箔真空绝热材料,其特征在于所述凹面箔层(2)为四边突起、中间下陷的凹形金属箔,可以是由以下物质组成的群中选择的1种或1种以上的组合:银箔、铝箔、铜箔、不锈钢箔;凹面箔层(2)厚度为50μm~200μm。
4.依据权利要求1所述的耐高温金属箔真空绝热材料,其特征在于所述连接层(3)为平面箔层(1)和凹面箔层(2)的熔融重叠层。
5.依据权利要求1所述的耐高温金属箔真空绝热材料,其特征在于所述真空封口(4)为熔化填缝的金属焊料。
6.依据权利要求1所述的耐高温金属箔真空绝热材料,其特征在于所述低导热填充材料(5)为多孔保温材料,可以是由以下物质组成的群中选择的1种或1种以上的组合:如玻璃棉、岩/矿棉、陶瓷纤维、气凝胶、纳米无机颗粒等无机保温材料;聚氨酯、聚苯乙烯、酚醛树脂等有机保温材料,并且低导热填充材料(5)中可以选择添加H2O或O2和N2的吸收剂。
7.本发明还公开了一种制备上述耐高温金属箔真空绝热材料的方法,其特征在于包括下述顺序的步骤:
(1)将金属箔按所需尺寸裁切成平面箔层(1);
(2)将金属箔按所需尺寸裁切后,采用延展法将金属箔加工成四边突起、中间下陷的凹面箔层(2);
(3)在上述平面箔层(1)或凹面箔层(2)上开孔,孔径为5mm~100mm,预留真空封口(4)位置;
(4)根据上述凹面箔层(2)内部形状填充低导热填充材料(5)后,将平面箔层(1)覆盖在凹面箔层(2)上,采用激光焊接或电阻焊方法形成连接层(3),连接层宽度为0.5mm~5mm;
(5)封住预留真空封口(4),采用氦气检漏仪测试连接层(3)的焊缝气密性;
(6)确定连接层(3)无漏点后,将金属焊料放在真空封口(4)上,采用真空钎焊方法真空密封真空封口(4),得到耐高温金属箔真空绝热材料,真空腔体内压力为0.001Pa~1.0Pa,温度为600℃~1200℃。
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