CN113799470A - 一种全通孔多孔泡沫铝制备方法 - Google Patents
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- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 29
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 29
- 238000002360 preparation method Methods 0.000 title claims abstract description 23
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- 239000004721 Polyphenylene oxide Substances 0.000 claims abstract description 17
- 229920000570 polyether Polymers 0.000 claims abstract description 17
- 239000000463 material Substances 0.000 claims abstract description 13
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 claims abstract description 11
- 239000000853 adhesive Substances 0.000 claims abstract description 6
- 230000001070 adhesive effect Effects 0.000 claims abstract description 6
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- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 claims description 27
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 8
- 229910052799 carbon Inorganic materials 0.000 claims description 8
- 238000005238 degreasing Methods 0.000 claims description 8
- DOIRQSBPFJWKBE-UHFFFAOYSA-N dibutyl phthalate Chemical compound CCCCOC(=O)C1=CC=CC=C1C(=O)OCCCC DOIRQSBPFJWKBE-UHFFFAOYSA-N 0.000 claims description 8
- 238000001035 drying Methods 0.000 claims description 8
- 238000006386 neutralization reaction Methods 0.000 claims description 8
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- 239000003513 alkali Substances 0.000 claims description 4
- 239000007864 aqueous solution Substances 0.000 claims description 4
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 4
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- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
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- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
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Abstract
一种全通孔多孔泡沫铝制备方法,其特点是,包括步骤有:选用铝合金板材、聚醚泡绵填充物;铝合金板材裁剪和表面处理;环氧树脂胶配制;铝合金板表面喷涂环氧树脂胶;喷涂环氧树脂胶铝合金板和填充物聚醚泡绵呈90°依次顺序叠加摆放;固化制成铝合金及填充物复合薄板;切割后的铝合金及填充物复合薄板进行再次表面处理;在铝合金及填充物复合薄板的压合面涂覆铝硅钎焊料;压制后薄板放入钎焊炉内进行处理;出炉后清理;精整压制使其厚度满足设计要求;切割机或激光精裁,制成满足设计尺寸要求的全通孔多孔泡沫铝成品。其制备方法科学合理,简单实用,能够准确调整丝径和孔径几何尺寸,孔径方向性好,效果佳,特别适合散热领域应用,风阻小。
Description
技术领域
本发明属于泡沫铝的制备方法,涉及一种全通孔多孔泡沫铝制备方法。
背景技术
现有泡沫铝的制备方法与生产实体金属不尽相同,在制备过程中由于不同金属或合金所呈现的物理状态不同,制备的方法也不同。现有的制备方法有:散粉烧结法,粉末冶金法,浆料发泡法,中空球烧结法,熔模铸造法,渗流铸造法,气相沉积法,熔盐电沉积法。由于制备方法不同,致使制备的泡沫铝有闭孔结构和开孔结构,闭孔结构的泡沫铝含有大量独立存在的气泡,而开孔结构的泡沫铝则是呈连续贯通的三维网状,开孔结构的泡沫铝市场应用广泛。现有开孔结构的泡沫铝制备方法存在的质量问题是,以渗流法制备开孔结构的泡沫铝为例,有氯化钠残留在孔隙中,有此微小氯化钠残留颗粒包裹在泡沫铝孔隙中难以清除,特别是厚度较厚的氯化钠残留且堵塞微孔,无法清除,因有氯化钠残留影响泡沫铝的使用功能和寿命。而熔盐电沉积制备方法的能耗大,几何尺寸受限、变形量大、成本高。
发明内容
本发明的目的是,对现有的泡沫铝制备方法进行实质性改进和创新,提供一种科学合理,简单实用,效果佳,能够准确调整丝径和孔径几何尺寸的全通孔多孔泡沫铝制备方法。
本发明的目的是由以下技术方案来实现的:一种全通孔多孔泡沫铝制备方法,其特征是,它包括以下步骤:
1)选用铝合金板材,板长2.44m、宽1.2m,铝合金板材厚度按产品设计要求所规定的丝径确定;填充物选用聚醚泡绵30ppi-110ppi,填充物厚度按产品设计要求的孔径确定;
2)铝合金板材按产品长、宽要求下料,用氢氧化钠水溶液脱脂,氢氧化钠摩尔浓度2-3mol/L,温度50℃,再加入盐酸,盐酸含量8%进行中和反应,用清水漂洗、风干,铝合金板与聚醚泡绵胶合面采用宽带砂光机拉毛,其表面粗糙度Ra:15-50之间;
3)环氧树脂胶配制,环氧树脂水浴加热温度80℃,环氧树脂水浴后称重,按质量百分比,环氧树脂70%、环氧树脂固化剂T31为25%、二丁脂5%、丙酮适量,混合均匀、熟化15min;
4)铝合金板表面均匀喷涂环氧树脂胶,环氧树脂胶胶层厚度30-60μm;
5)将喷涂环氧树脂胶铝合金板和填充物聚醚泡绵交错叠加,叠加层数控制在7层或8层;
6)叠加后装入工装中,上表面加载荷0.2-0.8N/cm²,再锁紧,放入恒温箱内加温50℃,保温8h,固化制成铝合金及填充物复合薄板;
7)将铝合金及填充物复合薄板进行激光切割或机械切割,切割宽度是产品设计要求丝径尺寸2-3倍;
8)切割后的铝合金及填充物复合薄板进行二次脱脂、碱洗、酸中和、水洗、烘干、表面处理;
9)在铝合金及填充物复合薄板的压合面涂覆铝硅钎焊料;
10)将压合面涂覆铝硅钎焊料的铝合金及填充物复合薄板按设计要求,取若干片,按下一片、上一片呈90°顺序依次叠加摆放,叠加高度是设计厚度的1-2倍;
11)叠加后的薄片,用专用托盘放入四柱1500T压机中,压缩量为总叠加高度的1/3,压力为0.4-0.5kN/cm²;
12)压制后薄片装入烧结工装内锁紧,放入钎焊炉内,用99.999%纯度氩气洗炉,炉温调至60℃,当炉内含氧量小于10ppm时开始升温,将钎焊温度调整为620℃,升温速度135℃/min,保温15min,降温速度8-15℃/min,氩气流量设定为15-25m3 /h;
13)冷却段设定为三个温区,第一温区250℃,第二温区120℃,第三温区45℃,冷却水流量25-35 m3 /h,出炉温度35-45℃;
14)出炉后用6-8Kg/cm²压力压缩空气吹扫积碳,清水漂洗,烘干脱水;
15)再经压机精整压制,使薄片厚度满足设计要求;
16)切割机或激光精裁,制成满足设计尺寸要求的全通孔多孔泡沫铝成品。
本发明的一种全通孔多孔泡沫铝制备方法,由于采用包括:选用铝合金板材、聚醚泡绵填充物;铝合金板材裁剪和表面处理;环氧树脂胶配制;铝合金板表面喷涂环氧树脂胶;喷涂环氧树脂胶铝合金板和填充物聚醚泡绵呈90°依次顺序叠加摆放;固化制成铝合金及填充物复合薄板;切割后的铝合金及填充物复合薄板进行再次表面处理;在铝合金及填充物复合薄板的压合面涂覆铝硅钎焊料;压制后薄板放入钎焊炉内进行处理;出炉后清理;精整压制使其厚度满足设计要求;切割机或激光精裁,制成满足设计尺寸要求的全通孔多孔泡沫铝成品的流程步骤,其制备方法科学合理,简单实用,能够准确调整丝径和孔径几何尺寸,孔径方向性好,效果佳,特别适合散热领域应用,风阻小。
具体实施方式
本发明的一种全通孔多孔泡沫铝制备方法,包括以下步骤:
1)选用铝合金板材,板长2.44m、宽1.2m,铝合金板材厚度按产品设计要求所规定的丝径确定;填充物选用聚醚泡绵30ppi-110ppi,填充物厚度按产品设计要求的孔径确定;
2)铝合金板材按产品长、宽要求下料,用氢氧化钠水溶液脱脂,氢氧化钠摩尔浓度2-3mol/L,温度50℃,再加入盐酸,盐酸含量8%进行中和反应,用清水漂洗、风干,铝合金板与聚醚泡绵胶合面采用宽带砂光机拉毛,其表面粗糙度Ra:15-50之间;
3)环氧树脂胶配制,环氧树脂水浴加热温度80℃,环氧树脂水浴后称重,按质量百分比,环氧树脂70%、环氧树脂固化剂T31为25%、二丁脂5%、丙酮适量,混合均匀、熟化15min;
4)铝合金板表面均匀喷涂环氧树脂胶,环氧树脂胶胶层厚度30-60μm;
5)将喷涂环氧树脂胶铝合金板和填充物聚醚泡绵交错叠加,叠加层数控制在7层或8层;
6)叠加后装入工装中,上表面加载荷0.2-0.8N/cm²,再锁紧,放入恒温箱内加温50℃,保温8h,固化制成铝合金及填充物复合薄板;
7)将铝合金及填充物复合薄板进行激光切割或机械切割,切割宽度是产品设计要求丝径尺寸2-3倍;
8)切割后的铝合金及填充物复合薄板进行二次脱脂、碱洗、酸中和、水洗、烘干、表面处理;
9)在铝合金及填充物复合薄板的压合面涂覆铝硅钎焊料;
10)将压合面涂覆铝硅钎焊料的铝合金及填充物复合薄板按设计要求,取若干片,按下一片、上一片呈90°顺序依次叠加摆放,叠加高度是设计厚度的1-2倍;
11)叠加后的薄片,用专用托盘放入四柱1500T压机中,压缩量为总叠加高度的1/3,压力为0.4-0.5kN/cm²;
12)压制后薄片装入烧结工装内锁紧,放入钎焊炉内,用99.999%纯度氩气洗炉,炉温调至60℃,当炉内含氧量小于10ppm时开始升温,将钎焊温度调整为620℃,升温速度135℃/min,保温15min,降温速度8-15℃/min,氩气流量设定为15-25m3 /h;
13)冷却段设定为三个温区,第一温区250℃,第二温区120℃,第三温区45℃,冷却水流量25-35 m3 /h,出炉温度35-45℃;
14)出炉后用6-8Kg/cm²压力压缩空气吹扫积碳,清水漂洗,烘干脱水;
15)再经压机精整压制,使薄片厚度满足设计要求;
16)切割机或激光精裁,制成满足设计尺寸要求的全通孔多孔泡沫铝成品。
具体实施例1的一种全通孔多孔泡沫铝制备方法,包括以下步骤:
1)选用铝合金板材,板长2.44m、宽1.2m,铝合金板材厚度按产品设计要求所规定的丝径确定;填充物选用聚醚泡绵30ppi-110ppi,填充物厚度按产品设计要求的孔径确定;
2)铝合金板材按产品长、宽要求下料,用氢氧化钠水溶液脱脂,氢氧化钠摩尔浓度2-3mol/L,温度50℃,再加入盐酸,盐酸含量8%进行中和反应,用清水漂洗、风干,铝合金板与聚醚泡绵胶合面采用宽带砂光机拉毛,其表面粗糙度Ra:15-50之间;
3)环氧树脂胶配制,环氧树脂水浴加热温度80℃,环氧树脂水浴后称重,按质量百分比,环氧树脂70%、环氧树脂固化剂T31为25%、二丁脂5%、丙酮适量,混合均匀、熟化15min;
4)铝合金板表面均匀喷涂环氧树脂胶,环氧树脂胶胶层厚度30μm;
5)将喷涂环氧树脂胶铝合金板和填充物聚醚泡绵交错叠加,叠加层数控制在7层或8层;
6)叠加后装入工装中,上表面加载荷0.2N/cm²,再锁紧,放入恒温箱内加温50℃,保温8h,固化制成铝合金及填充物复合薄板;
7)将铝合金及填充物复合薄板进行激光切割或机械切割,切割宽度是产品设计要求丝径尺寸2-3倍;
8)切割后的铝合金及填充物复合薄板采用本领域常规处理技术,进行二次脱脂、碱洗、酸中和、水洗、烘干、表面处理;
9)在铝合金及填充物复合薄板的压合面涂覆铝硅钎焊料;
10)将压合面涂覆铝硅钎焊料的铝合金及填充物复合薄板按设计要求,取若干片,按下一片、上一片呈90°顺序依次叠加摆放,叠加高度是设计厚度的1-2倍;
11)叠加后的薄片,用专用托盘放入四柱1500T压机中,压缩量为总叠加高度的1/3,压力为0.4-0.5kN/cm²;
12)压制后薄片装入烧结工装内锁紧,放入钎焊炉内,用99.999%纯度氩气洗炉,炉温调至60℃,当炉内含氧量小于10ppm时开始升温,将钎焊温度调整为620℃,升温速度135℃/min,保温15min,降温速度8℃/min,氩气流量设定为15m3 /h;
13)冷却段设定为三个温区,第一温区250℃,第二温区120℃,第三温区45℃,冷却水流量25 m3 /h,出炉温度35℃;
14)出炉后用6-8Kg/cm²压力压缩空气吹扫积碳,清水漂洗,烘干脱水;
15)再经压机精整压制,使薄片厚度满足设计要求;
16)切割机或激光精裁,制成满足设计尺寸要求的全通孔多孔泡沫铝成品。
实施例2的一种全通孔多孔泡沫铝制备方法的步骤与实施例1基本相同,不同之处是,4)铝合金板表面均匀喷涂环氧树脂胶,环氧树脂胶胶层厚度45μm;6)叠加后装入工装中,上表面加载荷0.5N/cm²;12)降温速度12℃/min,氩气流量设定为20m3 /h;13)冷却水流量30 m3 /h,出炉温度40℃。
实施例3的一种全通孔多孔泡沫铝制备方法的步骤与实施例1基本相同,不同之处是,4)铝合金板表面均匀喷涂环氧树脂胶,环氧树脂胶胶层厚度60μm;6)叠加后装入工装中,上表面加载荷0.8N/cm²;12)降温速度15℃/min,氩气流量设定为25m3 /h;13)冷却水流量35 m3 /h,出炉温度45℃。
本发明的一种全通孔多孔泡沫铝制备方法所需材料易得,均为市售产品。
1.铝合金板,厚度范围:5-0.01mm,还可根据需要选择其它铝材;
2.填充物,多孔泡沫金属(镍边角料)或植物纤维体或多孔有机物(聚酯泡绵、聚醚泡绵);
3.有机胶(环氧树脂类)无机胶(磷酸盐类);
4.钎焊料,铝硅钎焊料或镁活化剂;
5.氢氧化钠,盐酸。
本发明具体实施方式并非穷举,并不构成对权利要求保护范围的限定,本领域技术人员根据本发明实施例获得的启示,不经过创造性劳动就能够想到其它实质上等同的替代,均在本发明保护范围内。
Claims (1)
1.一种全通孔多孔泡沫铝制备方法,其特征是,它包括以下步骤:
1)选用铝合金板材,板长2.44m、宽1.2m,铝合金板材厚度按产品设计要求所规定的丝径确定;填充物选用聚醚泡绵30ppi-110ppi,填充物厚度按产品设计要求的孔径确定;
2)铝合金板材按产品长、宽要求下料,用氢氧化钠水溶液脱脂,氢氧化钠摩尔浓度2-3mol/L,温度50℃,再加入盐酸,盐酸含量8%进行中和反应,用清水漂洗、风干,铝合金板与聚醚泡绵胶合面采用宽带砂光机拉毛,其表面粗糙度Ra:15-50之间;
3)环氧树脂胶配制,环氧树脂水浴加热温度80℃,环氧树脂水浴后称重,按质量百分比,环氧树脂70%、环氧树脂固化剂T31为25%、二丁脂5%、丙酮适量,混合均匀、熟化15min;
4)铝合金板表面均匀喷涂环氧树脂胶,环氧树脂胶胶层厚度30-60μm;
5)将喷涂环氧树脂胶铝合金板和填充物聚醚泡绵交错叠加,叠加层数控制在7层或8层;
6)叠加后装入工装中,上表面加载荷0.2-0.8N/cm²,再锁紧,放入恒温箱内加温50℃,保温8h,固化制成铝合金及填充物复合薄板;
7)将铝合金及填充物复合薄板进行激光切割或机械切割,切割宽度是产品设计要求丝径尺寸2-3倍;
8)切割后的铝合金及填充物复合薄板进行二次脱脂、碱洗、酸中和、水洗、烘干、表面处理;
9)在铝合金及填充物复合薄板的压合面涂覆铝硅钎焊料;
10)将压合面涂覆铝硅钎焊料的铝合金及填充物复合薄板按设计要求,取若干片,按下一片、上一片呈90°顺序依次叠加摆放,叠加高度是设计厚度的1-2倍;
11)叠加后的薄片,用专用托盘放入四柱1500T压机中,压缩量为总叠加高度的1/3,压力为0.4-0.5kN/cm²;
12)压制后薄片装入烧结工装内锁紧,放入钎焊炉内,用99.999%纯度氩气洗炉,炉温调至60℃,当炉内含氧量小于10ppm时开始升温,将钎焊温度调整为620℃,升温速度135℃/min,保温15min,降温速度8-15℃/min,氩气流量设定为15-25m3 /h;
13)冷却段设定为三个温区,第一温区250℃,第二温区120℃,第三温区45℃,冷却水流量25-35 m3 /h,出炉温度35-45℃;
14)出炉后用6-8Kg/cm²压力压缩空气吹扫积碳,清水漂洗,烘干脱水;
15)再经压机精整压制,使薄片厚度满足设计要求;
16)切割机或激光精裁,制成满足设计尺寸要求的全通孔多孔泡沫铝成品。
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