CN111233481A - 一种块孔式无压烧结碳化硅换热模块及工艺 - Google Patents

一种块孔式无压烧结碳化硅换热模块及工艺 Download PDF

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CN111233481A
CN111233481A CN202010111033.9A CN202010111033A CN111233481A CN 111233481 A CN111233481 A CN 111233481A CN 202010111033 A CN202010111033 A CN 202010111033A CN 111233481 A CN111233481 A CN 111233481A
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李清华
张仁升
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Weihai Huaporcelain New Material Co Ltd
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Abstract

本发明属于工程陶瓷材料技术领域，尤其涉及一种块孔式无压烧结碳化硅换热模块及工艺。包括至少一个烧结单元，所述烧结单元从下往上依次包括下板、横向格条、中板、竖向格条、上板，所述横向格条、竖向格条均设有若干个并间隔一定距离设置，在所述横向格条、竖向格条的边界均设置边条。本发明采用下板、横向格条、中板、竖向格条、上板粘接在一起烧结，有效解决了传统换热管和折流板之间存在间隙的问题，避免换热管因共振而发生断裂；和列管式换热器采用的O型圈密封不同，块孔式换热器采用端面密封；大大增加了碳化硅换热器的使用安全性和稳定性。本发明具有强度高、耐冲击、密封可靠、不易破裂等优点，有效提高了碳化硅换热模块的使用性能。

Description

一种块孔式无压烧结碳化硅换热模块及工艺
技术领域
本发明属于工程陶瓷材料技术领域，尤其涉及一种块孔式无压烧结碳化硅换热模块及工艺。
背景技术
碳化硅是一种单相、无压烧结碳化硅陶瓷，具有高纯度、细晶和极低气孔率等优良特性，可以作为石墨、不锈钢、金属钽、哈氏金、氟塑料和其他传统材料的绝佳替代品。碳化硅广泛的用在化工、医药、冶金等行业的高温、高压、强腐蚀、高磨损的极端环境中，尤其是碳化硅换热器。
目前，无压烧结碳化硅换热器普遍采用列管式的设计。而碳化硅部件无法有效焊接，所以普遍采用O型圈和管板密封的方式。但是O型圈密封方式不稳定，在高压、高温、高腐蚀的情况下，经常出现密封泄露。再者，列管式设计在安装的时候，由于碳化硅换热管的直线度、安装应力、换热管和折流板之间的间隙，最终导致在一些工况下极易产生断管泄露，以上问题在实际的工作过程中给操作人员带来极大的不便，生产成本升高。
发明内容
为了克服现有技术领域存在的上述技术问题，本发明目的在于提供一种块孔式无压烧结碳化硅换热模块，具有强度高、耐冲击、密封可靠、不易破裂等。
本发明解决其技术问题所采用的技术方案是：一种块孔式无压烧结碳化硅换热模块，包括至少一个烧结单元，所述烧结单元从下往上依次包括下板、横向格条、中板、竖向格条、上板，所述横向格条、竖向格条均设有若干个并间隔一定距离设置，在所述横向格条、竖向格条的边界均设置边条；所述边条的宽度大于所述横向格条、竖向格条的宽度。
本发明更进一步地技术方案是：一种块孔式无压烧结碳化硅换热模块的工艺，包括以下步骤：（1）制造无压烧结碳化硅生坯，将下板、横向格条、中板、竖向格条、边条、上板的生坯分别制作完成；
（2）将粘结料手工涂布在横向格条、边条、竖向格条的上下面，涂布厚度为0.3-0.6毫米，将下板、横向格条、中板、竖向格条、边条、上板按照顺序组装好；
（3）将组装好的块孔式碳化硅生坯件置于真空炉内烧结，烧结气氛为氩气，烧结温度为2000-2200℃，保温时间为0.5-3h；
（4）烧结完成后，继续置于真空炉内退火处理，退火气氛为氮气，温度为1600-1900℃，退火时间为2-6 h，退火完成得到模块成品。
本发明更进一步地技术方案是：步骤（2）中的粘结料为：10-20%聚碳硅烷溶液、70-80%碳化硅粉、5-10%硅粉、0.6-1.4%碳化硼混合而成的混合物。
本发明更进一步地技术方案是：所述粘结料的制备步骤：（1）首先将块状的聚碳硅烷研磨成粉末，将重量份数为50份的聚碳硅烷粉末放入重量份数为50份的二甲苯中，于60℃搅拌混匀，制备成聚碳硅烷溶液；（2）取重量份数为20份的聚碳硅烷溶液、70份的碳化硅粉末、9份的硅粉、1份的碳化硼粉混合成粘接料，将混合好的粘接料在真空环境下脱泡备用。
本发明采用下板、横向格条、边条、中板、竖向格条、边条、上板粘接在一起烧结，有效解决了传统换热管和折流板之间存在间隙的问题，避免换热管因共振而发生断裂，大大增加了碳化硅换热器的使用安全性。此外，本发明具有强度高、耐冲击、密封可靠、不易破裂等优点，有效提高了碳化硅换热模块的使用性能。本发明块孔式无压烧结碳化硅换热模块的工艺，技术巧妙，科学合理，是本领域技术的一大进步，促进了技术的更新换代。
附图说明
下面结合附图和实施例对本发明作进一步说明。
图1是本发明块孔式无压烧结碳化硅换热模块结构分解示意图；
图2是本发明块孔式无压烧结碳化硅换热模块整体结构示意图。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合具体实施例对本发明进行进一步详细说明。
实施例1
如图1所示，为一种块孔式无压烧结碳化硅换热模块，包括一个烧结单元，该烧结单元从下往上依次为下板1、横向格条2、中板3、竖向格条4、上板5。所述横向格条2、竖向格条4均设有若干个并间隔一定距离设置，在所述横向格条2、竖向格条4的边界均设置边条6。本实施例中边条6的宽度大于所述横向格条2、竖向格条4的宽度。
在上述的横向格条2、竖向格条4、边条6的上下表面均设置粘结料，便于粘接烧结。如图2所示，为多个烧结单元组合一起，组成块孔式无压烧结碳化硅换热模块。
实施例2
针对实施例1中的块孔式无压烧结碳化硅换热模块的制备工艺包括以下步骤：（1）制造无压烧结碳化硅生坯，将下板、横向格条、中板、竖向格条、上板的生坯分别制作完成；
（2）将粘结料手工涂布在横向格条、边条、竖向格条的上下面，涂布厚度为0.3-0.6毫米，将下板、横向格条、中板、竖向格条、上板、边条组装好；
（3）将组装好的块孔式碳化硅生坯件，置于真空炉内烧结，烧结气氛为氩气，烧结温度为2000-2200℃，保温时间为0.5-3h；
（4）烧结完成后，继续置于真空炉内退火处理，退火气氛为氮气，温度为1600-1900℃，退火时间为2-6 h，退火完成得到模块成品。
上述中步骤（2）中粘结料的制备过程如下：（1）首先将块状的聚碳硅烷研磨成粉末，将重量份数为50份的聚碳硅烷粉末放入重量份数为50份的二甲苯中，于60℃搅拌混匀，制备成聚碳硅烷溶液；（2）取重量份数为20份的聚碳硅烷溶液、70份的碳化硅粉末、9份的硅粉、1份的碳化硼粉混合成粘接料，将混合好的粘接料在真空环境下脱泡备用。
实施例3
为1平方米小孔换热器，孔通道截面积4*28.7=118mm2
Figure 475369DEST_PATH_IMAGE002
上述为一个实施例按照实施例2工艺的烧结尺寸和烧结后尺寸数据统计表。
实施例4
为2平方米大孔换热器，孔通道截面积6.6*36.9=302mm2
Figure 64613DEST_PATH_IMAGE004
上述为另一个实施例按照实施例2工艺的烧结尺寸和烧结后尺寸数据统计表。
综上所述，本发明一种块孔式无压烧结碳化硅换热模块结构科学合理，对碳化硅的烧结起到很好的稳固和定型作用。再者，块孔式无压烧结碳化硅换热模块的工艺制作简单、高温耐热，改变了传统的模块制作流程，提高了操作人员的工作效率。
上述实施例只是为了说明本发明的技术构思及特点，其目的是在于让本领域内的普通技术人员能够了解本发明的内容并据以实施，并不能以此限制本发明的保护范围。凡是根据本发明内容的实质所做出的等效的变化或修饰，都应涵盖在本发明的保护范围内。

Claims (4)

1.一种块孔式无压烧结碳化硅换热模块，包括至少一个烧结单元，其特征在于：所述烧结单元从下往上依次包括下板、横向格条、中板、竖向格条、上板，所述横向格条、竖向格条均设有若干个并间隔一定距离设置，在所述横向格条、竖向格条的边界均设置边条；所述边条的宽度大于所述横向格条、竖向格条的宽度。
2.根据权利要求1所述的一种块孔式无压烧结碳化硅换热模块的工艺，其特征在于：包括以下步骤：（1）制造无压烧结碳化硅生坯，将下板、横向格条、中板、竖向格条、边条、上板的生坯分别制作完成；
（2）将粘结料手工涂布在横向格条、边条、竖向格条的上下面，涂布厚度为0.3-0.6毫米，将下板、横向格条、中板、竖向格条、边条、上板按照顺序组装好；
（3）将组装好的块孔式碳化硅生坯件置于真空炉内烧结，烧结气氛为氩气，烧结温度为2000-2200℃，保温时间为0.5-3h；
（4）烧结完成后，继续置于真空炉内退火处理，退火气氛为氮气，温度为1600-1900℃，退火时间为2-6 h，退火完成得到模块成品。
3.根据权利要求2所述的一种块孔式无压烧结碳化硅换热模块的工艺，其特征在于：步骤（2）中的粘结料为10-20%聚碳硅烷溶液、70-80%碳化硅粉、5-10%硅粉、0.6-1.4%碳化硼混合而成的混合物。
4.根据权利要求3所述的一种块孔式无压烧结碳化硅换热模块的工艺，其特征在于：所述粘结料的制备步骤：（1）首先将块状的聚碳硅烷研磨成粉末，将重量份数为50份的聚碳硅烷粉末放入重量份数为50份的二甲苯中，于60℃搅拌混匀，制备成聚碳硅烷溶液；（2）取重量份数为20份的聚碳硅烷溶液、70份的碳化硅粉末、9份的硅粉、1份的碳化硼粉混合成粘接料，将混合好的粘接料在真空环境下脱泡备用。
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