CN111923556B - 一种大型复杂异形曲面复合保温层及其制备方法 - Google Patents
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Abstract
一种大型复杂异形曲面复合保温层,为多个曲面模块组成,每个曲面模块中依次包括内保温层、粘结层、固形保温层及保护层,其特征在于:每个曲面模块中所述内保温层是棉状材料,所述固形保温层是多层纸状或毡状材料保温层与多层反射层相互交叉叠加形成,上述固形保温层中相互交叉叠加的保温层和反射层从内到外依次增加1~5mm的轮廓尺寸,各保温层和反射层的相同边的轮廓边缘对齐贴合在一个平面上。使用弧面拼接拟合曲面,形成与曲面相同的外形轮廓,减少了拼接缝隙,制得的曲面流畅,曲面之间的拼接缝隙减小,降低漏热,提高了保温性能。延长了使用寿命。
Description
技术领域
本发明涉及隔热材料技术领域,具体涉及一种大型复杂异形曲面复合保温层及其制备方法。
背景技术
在热动力工程中常常使用大型罐体用作热能转换装置,罐体两端通常为半球形、半椭球形等曲面结构。为减少热能损失,常在罐体表面包覆一层隔热材料,现使用的隔热材料多为棉状、毡状、纸状等。棉状保温材料在使用一段时间后,容易坍塌并堆积在底部,严重影响隔热性能。毡状和纸状保温层为平板状材料,不能与曲面良好贴合,保温层与罐体曲面之间存在较大缝隙,使得隔热保温效果降低,若采用上述平板材料剪裁成小平面拼接成近弧形结构,这样会导致拼接缝密集,保温性能急剧下降,同时加工时间长,且工艺复杂不易控制,且利用小块平板材料拼接成弧形整体结构的抗弯性能低。
发明内容
本发明目的在于提供一种隔热性能优异的大型复杂异形曲面复合保温层。
本发明目的在于提供复合保温层的制备方法。该方法制备的保温层与罐体曲面良好贴合,具有优异的保温效果。
本发明目的通过以下技术方案实现:
一种大型复杂异形曲面复合保温层,为多个曲面模块组成,每个曲面模块中依次包括内保温层、粘结层、固形保温层及保护层,其特征在于:每个曲面模块中所述内保温层是棉状材料,厚度为3~10mm,所述粘结层是厚度为0.1~1.5mm的粘结剂,所述固形保温层是多层纸状或毡状材料保温层与多层反射层相互交叉叠加形成,所述保温层的单层厚度为0.3~8mm,所述反射层为不锈钢、铝、镍、钛金属箔或聚酰亚胺镀金属薄膜材料,单层厚度为0.005~0.03mm;上述固形保温层中相互交叉叠加的保温层和反射层从内到外依次增加1~5mm的轮廓尺寸,各保温层和反射层的相同边的轮廓边缘对齐贴合在一个平面上。
进一步,上述固形保温层具体是n层保温层和n-1层反射层交叉叠加形成,使用粘结剂粘剂密封,其中 n≥3。
考虑到制备时间和成本,以及实用价值,本发明中n的取值可为3≦n≦8。
一种大型复杂异形曲面复合保温层的制备方法,其特征在于:具体是将保温层分型,根据曲面外形尺寸剪裁材料,采用棉状保温材料作为内保温层,在其表面涂覆一层粘接层,将固形保温层与内保温层粘接固定,再通过相同外形轮廓尺寸的模具压合成型,所述固形保温层为多层纸状或毡状材料保温层与多层反射层相互交叉叠加形成。
进一步,上述固形保温层具体是n层保温层和n-1层反射层交叉叠加形成,n≥3,曲面模块中各保温层结构从内到外依次增加1~5mm的轮廓尺寸余量,各保温层和反射层轮廓边沿对齐,使用粘结剂粘剂密封,保温层单层厚度为0.3~8mm,反射层为不锈钢、铝、镍、钛金属箔或聚酰亚胺镀金属薄膜材料,单层厚度为0.005~0.03mm。
进一步,上述棉状材料单层厚度为3~5mm,形成的内保温层总厚度为3~10mm。
进一步,上述粘接层是在内保温层表面均匀涂覆一层粘结剂,涂覆厚度为0.1~1.5mm,所述粘结剂具体是由苯基硅橡胶和Fe2O3按16~18:1质量比混炼硫化制得。
采用棉状材料作为保温材料时,其和曲面的贴合度高,保温效果好,但是一段时间后容易坍塌、堆积到曲面底部,无法继续实现保温功能;由于纸状或毡状保温材料为板状材料,通过压合成一定弧度结构,该结构不稳定,在使用过程中,会出现回弹、变形的现象,导致保温材料与曲面缝隙变大,保温效果下降。
本发明采用棉状材料作为内保温层实现与曲面的高度贴合,将纸状或毡状保温材料与反射层形成交叉叠加,并通过各层结构之间的尺寸差,层与层之间形成一定的弧度,使其形状进一步固定,作为固形保温层复合在内保温层表面,起到支撑内保温层的作用,且在长期使用过程中,固形保温层不发生回弹变形。
进一步,保温层模块固定在固形工装中,并在100~150℃温度下,固化20~30min时间。
进一步,在固化成型后的保温层模块外封装一层保护层,所述保护层是高硅氧纤维布、防水玻璃布或防水硅胶布。
最具体的,一种大型复杂异形曲面复合保温层的制备方法,其特征在于,按如下步骤进行:
S1:分型下料:根据曲面形状,确定保温层的分型结构,得到每一块保温层模块的外形尺寸,根据尺寸进行下料;
S2:加工工装:根据保温层模块的外形尺寸,制作出与保温层模块轮廓的凹腔,凹腔底面的凸起轮廓与设备曲面外形轮廓相同;
S3:层叠修型:在工装凹腔底面铺上一层棉状保温层,单层厚度为3~5mm,总厚度为3~10mm,在其表面均匀涂覆一层厚度为0.1~1.5mm的粘结剂,再覆上一层厚度为0.3~8mm的纸状或毡状保温层,再使用反射层与保温层交替叠加,叠加过程中,各层有下至上尺寸增加1~5mm,边缘对齐并处采用粘结剂密封粘结,所述粘结剂是苯基硅橡胶和Fe2O3按16~18:1质量比混炼硫化制得,所述反射层为不锈钢、铝、镍、钛金属箔或聚酰亚胺镀金属薄膜材料,单层厚度为0.005~0.03mm;
S4:固化成型:将S3中的层叠结构在工装模具中进行压合,在100~150℃温度下固化20~30min时间;
S5:封装:将成型后的保温层模块组装完整的成曲面结构后,在表面封装一层高硅氧纤维布、防水玻璃布或防水硅胶布作为保护层。
在保温层使用过程中,由于保温层是多种材料组成的复合结构,各层材料受热变形不同,且在粘结剂的作用下,较高的温度会使得复合保温层中的内保温层、粘结层及固形保温层变形加剧,发生分层、脱落甚至各层结构破裂的现象,本发明采用棉状保温材料作为内保温层,选用阻燃硅橡胶作为粘结剂,结合上述结构的固形保温层,形成一个整体,在高温环境中具有较高的弹性应变能力。
本发明采用棉状保温材料制作的内保温层作为过渡层,使得保温层与设备罐体表面贴合更紧密,毡状或纸状保温材料与反射层交叉叠加具有支撑作用,防止过渡层坍塌堆积。
本发明具有如下技术效果:
使用弧面拼接拟合曲面,形成与曲面相同的外形轮廓,减少了拼接缝隙,制得的曲面流畅,曲面之间的拼接缝隙减小,降低漏热,提高了保温性能。棉状保温层材料作为过渡层使得保温层与曲面紧密贴合,毡状或纸状保温材料与反射层的交替叠加结构,提高了保温层的整体保温隔热性能,并高效固定了其拟合的曲面结构,防止了棉状材料的坍塌堆积,在高温环境下结构稳定,不易发生分层、回弹、变形等现象,延长了使用寿命。
附图说明
图1:本发明实施例1曲面分型结构示意图。
图2:本发明实施例1曲面的轮廓尺寸差示意图。
图3:本发明实施例1形成的曲面固定保温层模块截面示意图;
01-保温层、02-反射层。
具体实施方式
下面通过实施例对本发明进行具体的描述,有必要在此指出的是,以下实施例只用于对本发明进行进一步说明,不能理解为对本发明保护范围的限制,该领域的技术人员可以根据上述本发明内容对本发明作出一些非本质的改进和调整。
实施例1
一种外表温度为220℃的大型复杂半椭球曲面复合保温层的制备方法,按如下步骤进行:
如附图1所示:d=1.5m,L=0.75m,L1=0.15m,保温层总厚度b约40mm;
S1:分型下料:根据曲面形状,确定保温层的分型结构,并沿轴向分为同等的12块类扇形四边形曲面和1块直径d1=200mm的圆形曲面,得到每一块保温层模块的外形尺寸,根据尺寸进行下料;
本发明可以根据曲面尺寸结构,调整分型结构的扇形数量和圆形曲面的直径。
S2:加工工装:根据每一块保温层模块的外形尺寸,制作出与保温层模块轮廓的凹腔,凹腔底面的凸起轮廓与设备曲面单块外形轮廓相同;
S3:层叠修型:在工装凹腔底面铺上一层棉状保温层,单层厚度为5mm,总厚度厚度为10mm,在其表面均匀涂覆一层1mm厚的阻燃硅橡胶层,所述阻燃硅橡胶层是由苯基硅橡胶和Fe2O3按18:1质量比混炼硫化制得;再覆上一层厚度为5mm的毡状保温层,再使用厚度为0.02mm的钛金属箔反射层与保温层交替叠加,叠加过程中,各保温层和反射层由下至上轮廓尺寸增加2.6mm,各保温层和反射层的四条边边缘对齐,调整并采用粘结剂密封粘结,最终固形为4层保温层, 3层反射层;
S4:固化成型:将S3中的层叠结构在工装模具中进行压合,在150℃下固化25min时间;
S5:封装:将成型后的保温层模块组装成完整的曲面结构后,在表面封装一层10mm厚的保护层。
不安装保温层时,罐体表面温度检测为220℃,安装了本发明制备的保温层以后,其表面温度分布均匀,漏热减少,表面温度约为32℃。
Claims (8)
1.一种大型复杂异形曲面复合保温层,由多个曲面模块组成,每个曲面模块依次包括内保温层、粘结层、固形保温层及保护层,其特征在于:所述内保温层是棉状材料,厚度为3~10mm,所述粘结层是厚度为0.1~1.5mm的粘结剂,所述固形保温层是单层厚度为0.3~8mm的多层纸状或毡状材料保温层与多层反射层相互交叉叠加形成,曲面模块的固形保温层中的各保温层与反射层由内到外依次轮廓尺寸依次增加1~5mm,各保温层和反射层轮廓边缘对齐固定,所述反射层为不锈钢、铝、镍、钛金属箔或聚酰亚胺镀金属薄膜材料,单层厚度为0.005~0.03mm;所述固形保温层具体是n层保温层和n-1层反射层交叉叠加形成,使用粘结剂粘剂密封,其中3≤n≤8。
2.如权利要求1所述的一种大型复杂异形曲面复合保温层的制备方法,其特征在于:具体是将保温层分型为多个曲面模块,根据确定的外形尺寸剪裁材料,采用棉状保温材料作为内保温层,在其表面涂覆一层粘接层,将固形保温层与内保温层粘接固定,再通过相同外形轮廓尺寸的模具压合成型,所述固形保温层为多层纸状或毡状材料保温层与多层反射层相互交叉叠加形成。
3.如权利要求2所述的一种大型复杂异形曲面复合保温层的制备方法,其特征在于:所述固形保温层具体是n层保温层和n-1层反射层交叉叠加形成,3≤n≤8,曲面模块中各保温层结构从内到外依次增加1~5mm的轮廓尺寸余量,各保温层和反射层轮廓边沿对齐,使用粘结剂粘剂密封,保温层单层厚度为0.3~8mm,反射层为不锈钢、铝、镍、钛金属箔或聚酰亚胺镀金属薄膜材料,单层厚度为0.005~0.03mm。
4.如权利要求2或3所述的一种大型复杂异形曲面复合保温层的制备方法,其特征在于:所述棉状材料单层厚度为3~5mm,形成的内保温层总厚度为3~10mm。
5.如权利要求2或3所述的一种大型复杂异形曲面复合保温层的制备方法,其特征在于:所述粘接层是在内保温层表面均匀涂覆一层粘结剂,涂覆厚度为0.1~1.5mm,所述粘结剂具体是由苯基硅橡胶和Fe2O3按16~18:1质量比混炼硫化制得。
6.如权利要求4所述的一种大型复杂异形曲面复合保温层的制备方法,其特征在于:所述粘接层是在内保温层表面均匀涂覆一层粘结剂,涂覆厚度为0.1~1.5mm,所述粘结剂具体是由苯基硅橡胶和Fe2O3按16~18:1质量比混炼硫化制得。
7.如权利要求6所述的一种大型复杂异形曲面复合保温层的制备方法,其特征在于:保温层模块固定在固形工装中,并在100~150℃温度下,固化20~30min时间。
8.一种如权利要求1所述的大型复杂异形曲面复合保温层的制备方法,其特征在于,按如下步骤进行:
S1:分型下料:根据曲面形状,确定保温层的分型结构,得到每一块保温层模块的外形尺寸,根据尺寸进行下料;
S2:加工工装:根据保温层模块的外形尺寸,制作出与保温层模块轮廓的凹腔,凹腔底面的凸起轮廓与设备曲面外形轮廓相同;
S3:层叠修型:在工装凹腔底面铺上一层棉状保温层,单层厚度为3~5mm,总厚度为3~10mm,在其表面均匀涂覆一层厚度为0.1~1.5mm的粘结剂,再覆上一层厚度为0.3~8mm的纸状或毡状保温层,再使用反射层与保温层交替叠加,各保温层和反射层层由下至上轮廓尺寸依次增加1~5mm,各保温层和反射层边缘对齐并处采用粘结剂密封粘结,所述粘结剂是苯基硅橡胶和Fe2O3按16~18:1质量比混炼硫化制得,所述反射层为不锈钢、铝、镍、钛金属箔或聚酰亚胺镀金属薄膜材料,单层厚度为0.005~0.03mm;
S4:固化成型:将S3中的层叠结构在工装模具中进行压合,在100~150℃温度下固化20~30min时间;
S5:封装:将成型后的保温层模块组装成完整的曲面结构后,在表面封装一层保护层。
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