CN112129131A - 一种双层高效耐蚀回字型换热管及其制造方法 - Google Patents

一种双层高效耐蚀回字型换热管及其制造方法 Download PDF

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CN112129131A
CN112129131A CN202011039622.7A CN202011039622A CN112129131A CN 112129131 A CN112129131 A CN 112129131A CN 202011039622 A CN202011039622 A CN 202011039622A CN 112129131 A CN112129131 A CN 112129131A
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刘明军
张昭志
柳磊
张敬敏
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Zhuixin Digital Technology Co ltd
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Abstract

本发明公开了一种双层高效耐蚀回字型换热管及其制造方法，该回字型换热管具体为包括内层管和外套管双层结构、通路截面类“回”字型的复合管，其中外套管为本体导热率低的PVC且内层固化有SiO2气凝胶热反射膜层的PVC塑料/SiO2气凝胶复合材料，内套层为纯铜管镀镍后喷涂哈氏合金的高导热耐蚀复合材料。本发明双层结构的、空间占位小、换热效率高、可工业化生产。

Description

一种双层高效耐蚀回字型换热管及其制造方法
技术领域
本发明涉及导热材料技术领域，尤其涉及一种双层高效耐蚀回字型换热管及其制造方法。
背景技术
管式(又称管壳式、列管式)换热器是最典型的间壁式换热器，它在工业上的应用有着悠久的历史，而且至今仍在所有换热器中占据主导地位，管式换热器主要有壳体、管束、管板和封头等部分组成，壳体多呈圆形，内部装有平行管束，管束两端固定于管板上。传统的管式换热器虽然换热介质流量大，但整个设备的换热效果不够好，换热器的换热效率比较低，不能满足生产中的需求。而且目前没有内置于汽车发动仓的高效换热器。
因此，市面上急需一种双层结构的、空间占位小、换热效率高、可工业化生产的一种双层高效耐蚀回字型换热管及其制造方法。
发明内容
本发明旨在提供一种双层结构的、空间占位小、换热效率高、可工业化生产的一种双层高效耐蚀回字型换热管及其制造方法。
为了实现上述目的，本发明采用以下技术方案：一种双层高效耐蚀回字型换热管，该回字型换热管具体为包括内层管和外套管的双层结构、通路截面类“回”字型的复合管，其中外套管为本体导热率低的PVC且内层固化有SiO2气凝胶热反射膜层的PVC塑料/SiO2气凝胶复合材料，内套层为纯铜管镀镍后喷涂哈氏合金的高导热耐蚀复合材料；
该回字型换热管的制造方法包括以下阶段：
S1：原材料及辅材准备
①原材料准备：准备设计需求的PVC管体和纯铜管体，按重量份准备镍粉2份-3份、铬粉1份-1.2份、钼粉0.3份-0.4份、铜粉0.04份-0.06份、工业级SiO2气凝胶2.5份-3份、阴离子聚丙烯酸钠盐分散剂3.5份-4.5份、聚氧乙烯脂肪醇醚润湿剂1.8份-2.2份、钙锌复合热稳定剂3.5份-4.5份、水性硅丙乳液56份-58份、乙二醇3.5份-4.5份、空心玻璃微珠18份-22份、消泡剂0.3份-0.5份、钛白粉18份-20份、滑石粉12份-14份、方解石粉38份-43份、三甲基戊二醇单异丁酸酯3.5份-4.5份；
②辅材准备：准备足量乙醇、足量氨水、足量去离子水、足量电镀镍槽液；
S2：预处理
①将阶段S1步骤①准备的纯铜管体采用浸入阶段S1步骤②准备的乙醇清洗干净后，采用橡胶塞封堵铜管两端，然后对铜管外表面进行酸浸蚀表面处理，再浸入阶段S1步骤②准备的电镀镍槽液中，控制槽液PH值范围在4-4.5，温度控制在80℃-90℃进行化学镀镍，镍层厚度控制在0.03mm-0.05mm，获得预镀镍铜管；
②将步骤①获得的预镀镍铜管浸泡于阶段S1步骤②准备的乙醇中防止氧化，获得待用铜管；
③将阶段S1步骤①准备的阴离子聚丙烯酸钠盐分散剂、聚氧乙烯脂肪醇醚润湿剂、钙锌复合热稳定剂和去离子水放入容器中，以400rpm-600rpm的机械搅拌速率15min-18min，再加入阶段S1步骤①准备的工业级SiO2气凝胶，再次搅拌均匀后，采用氨水调节混合液的pH至7-8，然后以12000rpm-15000rpm的机械搅拌速率对混合液处理6min-8min，即得待用浆料；
④将阶段S1步骤①准备的钛白粉、滑石粉和方解石粉加入适量去离子水中混合均匀，再加入本阶段步骤③获得的待用浆料，400rpm-600rpm的机械搅拌速率15min-18min，再依次加入阶段S1步骤①准备的消泡剂、成膜助剂、水性硅丙乳液、乙二醇和空心玻璃微珠，形成混合液，然后以12000rpm-15000rpm的机械搅拌速率对混合液处理32min-35min，制得SiO2气凝胶反射隔热涂料；
S3：材料制备
①以阶段S1步骤①准备的镍粉、铬粉、钼粉、铜粉为喷涂原料，采用真空磁控溅射镀膜机，以阶段S2步骤②获得的待用铜管外表面为靶材进行合氏合金镀膜处理，获得粗制高导热耐蚀复合材料；
②以机械方式抛光步骤①获得的粗制高导热耐蚀复合材料，获得所需内层管；
③采用阶段S1步骤②准备的乙醇将阶段S1步骤①准备的PVC管体清洗干净，然后采用阶段S2步骤④准备的SiO2气凝胶反射隔热涂料灌刷其内腔，使该膜层在室温下逐渐干燥固化，固化后重复灌刷及静置固化至干燥固化后膜层厚度0.3mm-0.4mm，获得外套管；
④将步骤②获得的内层管与步骤③获得的外套管套装起来，然后采用对应本发明内层管、外套管对应的双通路接头将套装的通路截面类“回”字型的复合管的两端封装起来，获得内层管、外套管两条独立液体通路的结构，即获得所需的双层换热管。
与现有技术相比较，本发明具有以下优点：(1)本发明内层管的导热原理为，开创性地将高耐蚀高导热的哈氏合金以粉末冶金的形式，固化在镀镍铜管基体外表面，获得了哈氏合金本身不具备的易成型性能和与铜的高结合力，同时赋予了基体材料高耐蚀、高导热的技术效果，本发明的热导率为82W/(m·K)-97W/(m·K)，是同时申请的两个方案中性能更优的一个，但成本同样是更高的一个，仅需12cm-15cm的一小段换热管即能实现本发明将一方90℃的热量传导至另一方30℃-50℃的技术目的，客观上控制了成本不至于太高。(2)根据本发明的方法制备的外套层中的热反射层气凝胶膜，其导热系数仅
Figure BDA0002706245500000041
光热反射率约为93％，膜层内壁与PVC管的温差20℃-25℃(即在内液温度50℃的情况下，PVC管的温度在25℃-30℃)，不仅隔热效果较好，而且SiO2气凝胶的用量较少，降低了涂料的成本，有利于实际的应用与推广。(3)本发明在汽车液体循环结构中首创性地使用了冷却水与玻璃水的直接交替换热结构，且对两者的空间结构几乎不造成任何影响，是具有很好的前瞻价值的。因此，本发明具有双层结构的、空间占位小、换热效率高、可工业化生产的特性。
附图说明
图1为本发明的结构示意图；
图中：内层管1、外套管2。
具体实施方式
实施例1：
如图1所示的一种双层高效耐蚀回字型换热管，其特征在于：该回字型换热管具体为包括内层管1和外套管2的双层结构、通路截面类“回”字型的复合管，其中外套管为本体导热率低的PVC且内层固化有SiO2气凝胶热反射膜层的PVC塑料/SiO2气凝胶复合材料，内套层为纯铜管镀镍后喷涂哈氏合金的高导热耐蚀复合材料；
该回字型换热管的制造方法包括以下阶段：
S1：原材料及辅材准备
①原材料准备：准备设计需求的PVC管体和纯铜管体，按重量份准备镍粉27g、铬粉11.3g、钼粉3.4g、铜粉0.5g、工业级SiO2气凝胶30g、阴离子聚丙烯酸钠盐分散剂45g、聚氧乙烯脂肪醇醚润湿剂22g、钙锌复合热稳定剂45g、水性硅丙乳液560g、乙二醇45g、空心玻璃微珠220g、消泡剂5g、钛白粉200g、滑石粉140g、方解石粉430g、三甲基戊二醇单异丁酸酯成膜助剂45g；
②辅材准备：准备足量乙醇、足量氨水、足量去离子水、足量电镀镍槽液；
S2：预处理
①将阶段S1步骤①准备的纯铜管体采用浸入阶段S1步骤②准备的乙醇清洗干净后，采用橡胶塞封堵铜管两端，然后对铜管外表面进行酸浸蚀表面处理，再浸入阶段S1步骤②准备的电镀镍槽液中，控制槽液PH值范围在4-4.5，温度控制在80℃-90℃进行化学镀镍，镍层厚度控制在0.03mm-0.05mm，获得预镀镍铜管；
②将步骤①获得的预镀镍铜管浸泡于阶段S1步骤②准备的乙醇中防止氧化，获得待用铜管；
③将阶段S1步骤①准备的阴离子聚丙烯酸钠盐分散剂、聚氧乙烯脂肪醇醚润湿剂、钙锌复合热稳定剂和去离子水放入容器中，以400rpm-600rpm的机械搅拌速率15min-18min，再加入阶段S1步骤①准备的工业级SiO2气凝胶，再次搅拌均匀后，采用氨水调节混合液的pH至7-8，然后以12000rpm-15000rpm的机械搅拌速率对混合液处理6min-8min，即得待用浆料；
④将阶段S1步骤①准备的钛白粉、滑石粉和方解石粉加入适量去离子水中混合均匀，再加入本阶段步骤③获得的待用浆料，400rpm-600rpm的机械搅拌速率15min-18min，再依次加入阶段S1步骤①准备的消泡剂、成膜助剂、水性硅丙乳液、乙二醇和空心玻璃微珠，形成混合液，然后以12000rpm-15000rpm的机械搅拌速率对混合液处理32min-35min，制得SiO2气凝胶反射隔热涂料；
S3：材料制备
①以阶段S1步骤①准备的镍粉、铬粉、钼粉、铜粉为喷涂原料，采用真空磁控溅射镀膜机，以阶段S2步骤②获得的待用铜管外表面为靶材进行合氏合金镀膜处理，获得粗制高导热耐蚀复合材料；
②以机械方式抛光步骤①获得的粗制高导热耐蚀复合材料，获得所需内层管1；
③采用阶段S1步骤②准备的乙醇将阶段S1步骤①准备的PVC管体清洗干净，然后采用阶段S2步骤④准备的SiO2气凝胶反射隔热涂料灌刷其内腔，使该膜层在室温下逐渐干燥固化，固化后重复灌刷及静置固化至干燥固化后膜层厚度0.3mm-0.4mm，获得外套管2；
④将步骤②获得的内层管1与步骤③获得的外套管2套装起来，然后采用对应本发明内层管1、外套管2对应的双通路接头将套装的通路截面类“回”字型的复合管的两端封装起来，获得内层管1、外套管2两条独立液体通路的结构，即获得所需的双层换热管。
根据本实施例生产的高导热输液管1，其内层管1的热导率为82W/(m·K)-97W/(m·K)，外套层2中的热反射层气凝胶膜，其导热系数仅
Figure BDA0002706245500000061
光热反射率约为93％，膜层内壁与PVC管的温差20℃-25℃(即在内液温度50℃的情况下，PVC管的温度在25℃-30℃)，不仅隔热效果较好，而且SiO2气凝胶的用量较少，降低了涂料的成本，有利于实际的应用与推广，下同。
实施例2：
具体与实施例1近似，差异之处在于：
①原材料准备：准备设计需求的PVC管体和纯铜管体，按重量准备镍粉20g、铬粉10g、钼粉3g、铜粉0.4g、工业级SiO2气凝胶30g、阴离子聚丙烯酸钠盐分散剂45g、聚氧乙烯脂肪醇醚润湿剂22g、钙锌复合热稳定剂45g、水性硅丙乳液560g、乙二醇45g、空心玻璃微珠220g、消泡剂5g、钛白粉200g、滑石粉140g、方解石粉430g、三甲基戊二醇单异丁酸酯成膜助剂45g；
实施例3：
具体与实施例1近似，差异之处在于：
①原材料准备：准备设计需求的PVC管体和纯铜管体，按重量准备镍粉30g、铬粉12g、钼粉4g、铜粉0.6g、工业级SiO2气凝胶25g、阴离子聚丙烯酸钠盐分散剂35g、聚氧乙烯脂肪醇醚润湿剂18g、钙锌复合热稳定剂35g、水性硅丙乳液580g、乙二醇35g、空心玻璃微珠180g、消泡剂3g、钛白粉180g、滑石粉120g、方解石粉380g、三甲基戊二醇单异丁酸酯成膜助剂35g；
对所公开的实施例的上述说明，仅为了使本领域专业技术人员能够实现或使用本发明。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的，本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下，在其它实施例中实现。因此，本发明将不会被限制于本文所示的这些实施例，而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。

Claims (1)

1.一种双层高效耐蚀回字型换热管，其特征在于：该回字型换热管具体为包括内层管(1)和外套管(2)的双层结构、通路截面类“回”字型的复合管，其中外套管为本体导热率低的PVC且内层固化有SiO2气凝胶热反射膜层的PVC塑料/SiO2气凝胶复合材料，内套层为纯铜管镀镍后喷涂哈氏合金的高导热耐蚀复合材料；
该回字型换热管的制造方法包括以下阶段：
S1：原材料及辅材准备
①原材料准备：准备设计需求的PVC管体和纯铜管体，按重量份准备镍粉2份-3份、铬粉1份-1.2份、钼粉0.3份-0.4份、铜粉0.04份-0.06份、工业级SiO2气凝胶2.5份-3份、阴离子聚丙烯酸钠盐分散剂3.5份-4.5份、聚氧乙烯脂肪醇醚润湿剂1.8份-2.2份、钙锌复合热稳定剂3.5份-4.5份、水性硅丙乳液56份-58份、乙二醇3.5份-4.5份、空心玻璃微珠18份-22份、消泡剂0.3份-0.5份、钛白粉18份-20份、滑石粉12份-14份、方解石粉38份-43份、三甲基戊二醇单异丁酸酯3.5份-4.5份；
②辅材准备：准备足量乙醇、足量氨水、足量去离子水、足量电镀镍槽液；
S2：预处理
①将阶段S1步骤①准备的纯铜管体采用浸入阶段S1步骤②准备的乙醇清洗干净后，采用橡胶塞封堵铜管两端，然后对铜管外表面进行酸浸蚀表面处理，再浸入阶段S1步骤②准备的电镀镍槽液中，控制槽液PH值范围在4-4.5，温度控制在80℃-90℃进行化学镀镍，镍层厚度控制在0.03mm-0.05mm，获得预镀镍铜管；
②将步骤①获得的预镀镍铜管浸泡于阶段S1步骤②准备的乙醇中防止氧化，获得待用铜管；
③将阶段S1步骤①准备的阴离子聚丙烯酸钠盐分散剂、聚氧乙烯脂肪醇醚润湿剂、钙锌复合热稳定剂和去离子水放入容器中，以400rpm-600rpm的机械搅拌速率15min-18min，再加入阶段S1步骤①准备的工业级SiO2气凝胶，再次搅拌均匀后，采用氨水调节混合液的pH至7-8，然后以12000rpm-15000rpm的机械搅拌速率对混合液处理6min-8min，即得待用浆料；
④将阶段S1步骤①准备的钛白粉、滑石粉和方解石粉加入适量去离子水中混合均匀，再加入本阶段步骤③获得的待用浆料，400rpm-600rpm的机械搅拌速率15min-18min，再依次加入阶段S1步骤①准备的消泡剂、成膜助剂、水性硅丙乳液、乙二醇和空心玻璃微珠，形成混合液，然后以12000rpm-15000rpm的机械搅拌速率对混合液处理32min-35min，制得SiO2气凝胶反射隔热涂料；
S3：材料制备
①以阶段S1步骤①准备的镍粉、铬粉、钼粉、铜粉为喷涂原料，采用真空磁控溅射镀膜机，以阶段S2步骤②获得的待用铜管外表面为靶材进行合氏合金镀膜处理，获得粗制高导热耐蚀复合材料；
②以机械方式抛光步骤①获得的粗制高导热耐蚀复合材料，获得所需内层管(1)；
③采用阶段S1步骤②准备的乙醇将阶段S1步骤①准备的PVC管体清洗干净，然后采用阶段S2步骤④准备的SiO2气凝胶反射隔热涂料灌刷其内腔，使该膜层在室温下逐渐干燥固化，固化后重复灌刷及静置固化至干燥固化后膜层厚度0.3mm-0.4mm，获得外套管(2)；
④将步骤②获得的内层管(1)与步骤③获得的外套管(2)套装起来，然后采用对应本发明内层管(1)、外套管(2)对应的双通路接头将套装的通路截面类“回”字型的复合管的两端封装起来，获得内层管(1)、外套管(2)两条独立液体通路的结构，即获得所需的双层换热管。
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