CN112746237A - 一种新型电加热涂层以及制备方法和应用 - Google Patents
一种新型电加热涂层以及制备方法和应用 Download PDFInfo
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Abstract
本发明公开了一种新型电加热涂层，所述新型电加热涂层依次包括：1)基材；2)合金层；3)陶瓷层；4)金属铜层；所述合金层厚度为30～50μm；陶瓷层厚度为90～130μm；金属铜层厚度为10～1000μm，可用于汽车等领域的除冰、空调制热等。该制备方法包括：a)对基材进行检验及表面预处理，b)使用热喷涂的办法在基材表面沉积合金层，c)使用热喷涂技术在粘结层上沉积陶瓷层，d)使用冷喷涂技术在陶瓷层上沉积铜涂层并进行退火处理；e)最后采用化学腐蚀等技术腐蚀出所需的铜电路。其中，采用冷喷涂技术喷涂的涂层具有与纯铜相当的电学性能，因而具有较高的加热效率和较好的节能效果。
Description
技术领域
本发明涉及热喷涂、冷喷涂技术领域，具体而言，涉及一种电加热涂层以及制备方法和应用，可用于汽车等领域的除冰、空调制热等。
背景技术
车辆加热主要用于驾驶室调温、挡风玻璃的除冰和除霜等，随着混合动力车和电动车的不断发展和普及，推动了电加热技术的发展。目前常用的电加热技术主要是线绕电阻或正温度系数(PTC)加热，然而这些技术加热响应时间过长、热能利用较低、空间占用大，给对电能利用效率要求较高的混合动力车和电动车带来了新的挑战。
本发明所述新型电加热涂层直接覆盖于电加热器外侧，涂层与基材之间结合紧密，不存在配合间隙，且采用纯铜涂层作为加热元件，这样就能使用更大的通电电流来快速制热，从而极大地提高热能利用率，大幅减少加热相应时间，更有利于温度的调控。此外，所述新型电加热涂层还具有厚度较小的优势，占用空间小，有利于电加热器及汽车的空间结构优化设计。
目前新型电加热涂层已有一些相关的专利，一种电加热防冰涂层及其制备方法(申请号为201610489651.0)、一种用于飞行器防/除冰的电加热技术(申请号为201710248415.4)等都提供了多层电加热涂层体系，相对于上述专利，本发明专利采用了更为简便的3层涂层，在涂层设计思路上有所创新，且实现相同目的时，本发明涂层的厚度更薄、制热效果更好；一种新型电加热涂层及其制备方法(申请号为201910940041.1)也公开了一种3层结构的电加热涂层，然而上述专利电加热层为NiCr涂层，且基体限定为Al合金，热喷涂的NiCr涂层孔隙率较高，加热效率会受到影响，且NiCr涂层本身电性能不佳，不适合在较低的电压下产生较大的电流，而本发明采用冷喷涂沉积纯铜涂层具有接近纯铜涂层的致密结构和电学性能，在最大加热功率方面有着明显的优势，此外，本发明所述电加热涂层不再局限于Al合金基体，也拓展了加热器的用途。
发明内容
本发明的目的在于提供涉及一种电加热涂层以及制备方法和应用，具有加热相应时间短、热能利用率高、涂层设计简单紧凑等优点，可以更为广泛地应用于汽车等领域的电加热器，提供除冰、空调制热等用途。
为达到此发明目的，本发明采用以下技术方案：
一种新型电加热涂层，所述新型电加热涂层依次包括：
1)基材；2)合金层；3)陶瓷层；4)金属铜层；所述合金层厚度为30～50μm；陶瓷层厚度为90～130μm；金属铜层厚度为10～1000μm。
可选地，合金层的材料包括但不限于NiCr、Si、CoCrAlY或NiCrAlY。
可选地，陶瓷层的材料为Al2O3。
可选地，金属铜层上还设置集成电路层。
本发明还提供了上述新型电加热涂层的制备方法，具体如下：
a)采用肉眼、光学显微镜取样等手段对基材进行检验，以确认器材无孔洞、夹杂等缺陷，根据基材的具体情况，采用火焰灼烧、酒精清洗、丙酮清洗中的一种或多种方式进行除油处理，然后采用12-45#的白刚玉对基材进行喷砂处理以提高表面粗糙度，其中，喷砂压力为：0.25-0.65MPa。
b)根据基材和即将喷涂的陶瓷层的成分，选择具有合适成分的合金粉末，采用热喷涂的方法在基材表面沉积合金粘结层。
可选地，热喷涂方法包括但不限于超音速火焰喷涂及等离子喷涂；
可选地，常用的合金粉末包括但不限于NiCr、Si、CoCrAlY、NiCrAlY等；
可选地，合金粘结层的厚度为30-50μm。
c)采用热喷涂技术在金属粘结层表面继续沉积陶瓷涂层。
可选地，可采用Al2O3、Cr2O3等粉末作为喷涂原材料；
可选地，采用Al2O3作为喷涂原料时，涂层厚度为90～130μm；采用Cr2O3作为喷涂原料时，涂层厚度为100～200μm。
d)采用冷喷涂技术在陶瓷层表面继续沉积铜涂层，然后进行退火处理。
可选地，铜涂层厚度与电加热器的设计功率匹配，通常为10～1000μm；优选地，铜涂层厚度为10～100μm。
e)用一定的方法将铜涂层腐蚀成所需特性回路的铜电路。
可选地，所述腐蚀方法包括但不限于电化学腐蚀，刻蚀等。
特别地，上述步骤e)还可通过以下方式实现：在进行步骤d)前，根据所需铜电路的形状、通过设计相应的夹具或在陶瓷涂层表面添加一定的防护层，使得步骤d)直接沉积出所需特定形状的铜电路、而无需再次进行腐蚀。
本发明实施例还提供了上述电加热涂层在汽车领域中的应用。
具体实施方式
下面将结合本发明实施例，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明实施例的一部分，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例1
一种新型电加热涂层的制备方法，包括如下步骤：
a)使用肉眼检测Al基板，看基板是否存在划痕、孔洞、杂夹等缺陷。然后使用丙酮擦拭上述Al基板表面的油渍，然后使用45#的白刚玉，0.5MPa的压力对上述Al基板进行喷砂；
b)使用NiCr粉作为原料粉末，采用HVAF在Al基板上表面喷涂厚度为30μm的NiCr涂层；
c)使用Al2O3粉作为原料粉末，使用HVAF在NiCr涂层上喷涂陶瓷层，厚度为100μm；
d)使用纯铜粉末作为原料粉末，采用冷喷涂技术在陶瓷层上喷涂铜涂层，厚度为10μm；
e)使用化学腐蚀的手段将铜涂层腐蚀成具有特定形状的电回路；即得。
实施例2
一种新型电加热涂层的制备方法，包括如下步骤：
a)使用肉眼检测不锈钢基板，看基板是否存在划痕、孔洞、杂夹等缺陷。然后使用丙酮擦拭上述不锈钢基板表面的油渍，然后使用12#的白刚玉，0.5MPa的压力对上述不锈钢基板进行喷砂；
b)使用CoCrAlY粉作为原料粉末，采用大气等离子喷涂(APS)在不锈钢基板上表面喷涂厚度为30μm的CoCrAlY涂层；
c)使用Al2O3粉作为原料粉末，使用HVAF在CoCrAlY涂层上喷涂陶瓷层，厚度为100μm；
d)使用纯铜粉末作为原料粉末，采用冷喷涂技术在陶瓷层上喷涂铜涂层，厚度为10μm；
e)使用化学腐蚀的手段将铜涂层腐蚀成具有特定形状的电回路；即得。
实施例3
一种新型电加热涂层的制备方法，包括如下步骤：
a)使用肉眼检测陶瓷基板(或陶瓷基复合材料基板)，看基板是否存在划痕、孔洞、杂夹等缺陷。然后使用丙酮擦拭上述陶瓷基板表面的油渍，然后使用12#的白刚玉，0.5MPa的压力对上述陶瓷基板进行喷砂；
b)使用Si粉作为原料粉末，采用大气等离子喷涂(APS)在不锈钢基板上表面喷涂厚度为50μm的Si涂层；
c)使用Al2O3粉作为原料粉末，使用HVAF在Si涂层上喷涂陶瓷层，厚度为100μm；
d)使用纯铜粉末作为原料粉末，采用冷喷涂技术在陶瓷层上喷涂铜涂层，厚度为10μm；
e)使用化学腐蚀的手段将铜涂层腐蚀成具有特定形状的电回路；即得。
实施例4
一种新型电加热涂层的制备方法，包括如下步骤：
a)使用肉眼检测Al基板，看基板是否存在划痕、孔洞、杂夹等缺陷。然后使用丙酮擦拭上述Al基板表面的油渍，然后使用45#的白刚玉，0.5MPa的压力对上述Al基板进行喷砂；
b)使用NiCr粉作为原料粉末，采用HVAF在Al基板上表面喷涂厚度为30μm的NiCr涂层；
c)使用Cr2O3粉作为原料粉末，使用HVAF在NiCr涂层上喷涂陶瓷层，厚度为150μm；
d)使用纯铜粉末作为原料粉末，采用冷喷涂技术在陶瓷层上喷涂铜涂层，厚度为10μm；
e)使用化学腐蚀的手段将铜涂层腐蚀成具有特定形状的电回路；即得。
实施例5
一种新型电加热涂层的制备方法，包括如下步骤：
a)使用肉眼检测Al基板，看基板是否存在划痕、孔洞、杂夹等缺陷。然后使用丙酮擦拭上述Al基板表面的油渍，然后使用45#的白刚玉，0.5MPa的压力对上述Al基板进行喷砂；
b)使用NiCr粉作为原料粉末，采用HVAF在Al基板上表面喷涂厚度为30μm的NiCr涂层；
c)使用Al2O3粉作为原料粉末，使用HVAF在NiCr涂层上喷涂陶瓷层，厚度为100μm；
d)根据电路形状设计专用的夹具，对电路中无需覆盖Cu涂层的地方进行防护；然后使用纯铜粉末作为原料粉末，采用冷喷涂技术在陶瓷层上喷涂铜涂层，厚度为10μm；除去夹具，即得。
以上具体实施方式部分对本发明所涉及的分析方法进行了具体的介绍。应当注意的是，上述介绍仅是为了帮助本领域技术人员更好地理解本发明的方法及思路，而不是对相关内容的限制。对于本领域的技术人员来说，本发明可以有各种更改和变化。凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。
Claims (9)
1.一种新型电加热涂层，其特征在于，所述新型电加热涂层依次包括：
1)基材；2)合金层；3)陶瓷层；4)金属铜层；
所述合金层厚度为30～50μm；陶瓷层厚度为90～130μm；金属铜层厚度为10～1000μm。
2.根据权利要求1所述新型电加热涂层，其特征在于，合金层的材料包括但不限于NiCr、Si、CoCrAlY或NiCrAlY。
3.根据权利要求1所述新型电加热涂层，其特征在于，陶瓷层的材料为Al2O3。
4.根据权利要求1所述新型电加热涂层，其特征在于，金属铜层上还设置集成电路层。
5.一种权利要求1所述新型电加热涂层的制备方法，其特征在于，包括如下步骤：
S1、对基材进行检验及表面预处理，确认基体表面不存在特定缺陷，然后对基材表面进行清洁，提高基材表面粗糙度；
S2、采用热喷涂技术在基材表面喷涂合金粘结层涂层；
S3、采用冷喷涂技术在步骤S2涂层上表面沉积铜涂层，并退火处理；
S4、腐蚀步骤S3形成的铜涂层，以获得所需的铜电路。
6.根据权利要求5所述新型电加热涂层的制备方法，其特征在于，步骤S1中所述检验包括但不限于肉眼观察、光学显微镜取样观察；所述特定缺陷包括但不限于孔洞、夹杂等；所述预处理包括除油及喷砂处理。
7.根据权利要求6所述新型电加热涂层的制备方法，其特征在于，所述除油方法包括但不限于火焰灼烧、酒精清洗、丙酮清洗中的一种或多种，所述喷砂所用砂粒选自12-45#的白刚玉，喷砂压力为0.25-0.65MPa。
8.根据权利要求5所述新型电加热涂层的制备方法，其特征在于，金属铜层上还设置集成电路层。
9.权利要求1所述新型电加热涂层在汽车领域加热元件中的应用。
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