WO2011136278A1 - 熱交換用プレートの元板材、及び熱交換用プレートの元板材の製造方法 - Google Patents
熱交換用プレートの元板材、及び熱交換用プレートの元板材の製造方法 Download PDFInfo
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- WO2011136278A1 WO2011136278A1 PCT/JP2011/060281 JP2011060281W WO2011136278A1 WO 2011136278 A1 WO2011136278 A1 WO 2011136278A1 JP 2011060281 W JP2011060281 W JP 2011060281W WO 2011136278 A1 WO2011136278 A1 WO 2011136278A1
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- plate material
- plate
- heat exchange
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- base plate
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D13/00—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form
- B21D13/04—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form by rolling
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/02—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations
- F28F3/04—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being integral with the element
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/02—Stamping using rigid devices or tools
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D31/00—Other methods for working sheet metal, metal tubes, metal profiles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D53/00—Making other particular articles
- B21D53/02—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
- F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D53/00—Making other particular articles
- B21D53/02—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers
- B21D53/04—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers of sheet metal
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4935—Heat exchanger or boiler making
Definitions
- the present invention relates to a base plate material for a heat exchange plate and a method for manufacturing a base plate material for a heat exchange plate.
- a heat exchange plate incorporated in a heat exchanger or the like has high heat conductivity.
- a technique as disclosed in Patent Document 1 has been developed. In the transfer method to the metal plate surface shown in Patent Document 1, the uneven transfer portion formed on the outer peripheral surface of the transfer roll is pressed against the metal sheet transferred by the rotation of the transfer roll. As a result, on the surface of the metal sheet, an uneven portion to be transferred that is substantially the same as the transfer portion of the transfer roll is formed.
- Patent Document 2 discloses a plate heat exchanger.
- a plate set formed by stacking two plates each having a predetermined pattern of aperture rows crossing the aperture rows, and a partition plate having communication holes in the four corners are stacked alternately.
- a plate heat exchanger in which fluid circulation layers formed by partition plates are formed, and each circulation layer is communicated with a circulation layer that is separated from the upper and lower layers.
- a chevron-shaped groove having a height of several millimeters to several centimeters called “herringbone” is press-formed on the heat exchange plate itself used in the heat exchanger. Thereafter, the heat exchange plate is incorporated into the heat exchanger.
- Japanese Unexamined Patent Publication No. 2006-239744 Japanese Unexamined Patent Publication No. 2009-192140 (for example, FIG. 6)
- the heat transfer is improved by increasing the surface area by forming microscopic irregularities on the surface of the flat plate.
- flat plates having fine irregularities on the surface are rarely used as heat exchange plates as they are. That is, as disclosed in FIG. 6 of Patent Document 2, a flat plate material on which fine irregularities are formed is usually a mountain-shaped groove having a height of several mm to several cm called “herringbone” on its plane. Is press-molded. Thereafter, the flat plate material is incorporated into the heat exchanger. Therefore, the press formability is desired for the flat plate material after fine irregularities are formed.
- the flat plate material may be manufactured from titanium.
- Titanium is a material having anisotropy, and the anisotropy of the material affects deformation behavior such as reduction of the plate thickness and strain gradient in the stress concentration portion. Therefore, titanium is remarkably poor in press formability as compared with other materials having no anisotropy.
- titanium is a material that tends to seize, if the oil film of the lubricating oil breaks during pressing, flaws are likely to occur due to material breakage or contact with a press die or tool.
- Patent Documents 1 and 2 do not disclose a technique for manufacturing a heat exchange plate that overcomes the difficulty of a flat plate made of titanium.
- the present invention has been made in view of the above-described problems, and has a heat transfer plate that is extremely excellent in heat conductivity and can be easily formed into a heat exchange plate. It aims to provide a method.
- the present invention comprises the following technical means. That is, the base plate material of the heat exchange plate in the present invention is formed by forming fine concave portions and convex portions on the surface of the titanium flat plate material, and is a base plate that becomes the heat exchange plate after being subjected to press working.
- the height of the convex portion is Rz ( ⁇ m)
- the width of the concave portion is L ( ⁇ m)
- the pitch between the adjacent convex portions is P ( ⁇ m)
- it is (Rz ⁇ L / P).
- the concave portion and the convex portion are formed so that the shape parameter defined in (1) is 12 ⁇ m or less.
- the concave portion and the convex portion are formed so that the shape parameter is 4 ⁇ m or more.
- the said convex part is circular shape by planar view, Comprising: It forms in the zigzag form on the surface of the said flat plate material. Further, the height Rz of the convex part is 5 ⁇ m or more in terms of 10-point average roughness, and 0.1 ⁇ t ( ⁇ m) or less when the thickness of the flat plate material is t ( ⁇ m). Is preferred.
- the manufacturing method of the base plate material of the heat exchange plate in the present invention is formed by forming fine concave and convex portions on the surface of the titanium flat plate material, and after the press working, the heat exchange plate A manufacturing method of the original plate material,
- Rz the height of the convex portion
- L the width of the concave portion
- P the pitch between the adjacent convex portions
- the concave portion and the convex portion so that the shape parameter is 4 ⁇ m or more. Further, it is preferable that the convex portions are formed in a circular shape in plan view, and the convex portions are formed in a staggered manner on the surface of the flat plate material. Further, the flat plate is formed such that the height Rz of the convex portion is 5 ⁇ m or more in terms of 10-point average roughness, and 0.1 ⁇ t ( ⁇ m) or less when the thickness of the flat plate material is t ( ⁇ m). It is preferable to form the convex portions on the surface of the material.
- the base plate material By using the base plate material according to the technique of the present invention, it is possible to easily manufacture a heat exchange plate without causing cracks or the like during post-processing press processing. In addition, by forming the concave and convex portions on the surface of the base plate material, it is possible to manufacture a heat exchange plate having very excellent heat conductivity.
- (A)-(c) is a figure which shows the manufacturing method of the plate for heat exchange
- (d) is the I section enlarged view of (b). It is the figure which showed the recessed part and convex part which were formed in the surface of the original board
- FIG. 1 is the schematic of the apparatus which forms a recessed part and a convex part on the surface of a base plate material, (b) is an enlarged view of VI part of (a), (c) is an enlarged view of VI 'part of (a).
- FIG. 1 is a conceptual diagram showing a method for manufacturing a heat exchange plate.
- a flat plate 1 which is a material having a predetermined size is prepared.
- a base plate 2 (base plate material) is created.
- the plate 4 for heat exchange is manufactured by pressing the plate base plate 2 (base plate material) to form, for example, a mountain-shaped groove (herringbone) 3.
- the flat plate 1 shown in FIG. 1 (a) is a titanium material, and its dimensions and plate thickness are determined in consideration of the dimensions and plate thickness desired for the heat exchange plate 4 which is the final product.
- a plate 2 is formed.
- the plate base plate 2 on which the irregular shape is formed has a very high heat transfer property and a very high heat transfer rate.
- the plate base plate 2 of the present invention is made of titanium, characteristics such as corrosion resistance, strength, and weight reduction are superior to other metals. Therefore, it is suitable for products that require corrosion resistance and strength, such as plates of plate heat exchangers.
- the herringbone 3 is a plurality of grooves having a skeleton shape, and the height of the grooves is several mm to several cm.
- the base plate 2 is incorporated into a heat exchanger. Even when the flow of the working fluid inside the heat exchanger is non-uniform, the oblique lattice-shaped irregularities represented by the herringbone 3 and the like can be a wall orthogonal to the working fluid flowing from any direction. It will contribute to the improvement of heat transfer by turbulent flow.
- the convex portion 5 formed on the surface 2a of the plate base plate 2 is circular in plan view, and its diameter D is 400 ⁇ m or more.
- the arrangement of the projections 5 in plan view is staggered.
- the staggered arrangement includes a straight line connecting the centers of the convex portions 5 and 5 adjacent in the horizontal direction (X direction) and the convex portions 5 and 5 adjacent in the vertical direction (Y direction). This means that the straight line connecting the centers is not orthogonal.
- the term “adjacent” means being located at the shortest distance.
- the convex portions 5 and 5 adjacent in the vertical direction (Y direction) are shifted by a half pitch in the horizontal direction (X direction).
- the convex portion 5 is arranged so that the angle ⁇ formed by the chain line (B) is 60 °.
- the convex portion 5 is directed to the flow of the working fluid from any direction.
- the walls can be orthogonal to each other, it contributes to the improvement of heat transfer by turbulent flow.
- the convex portions 5 are arranged in a staggered manner, stress concentration due to anisotropy can be dealt with even with anisotropic materials such as titanium.
- the distance L between the convex portions 5 adjacent in the vertical direction or the horizontal direction is preferably 200 ⁇ m or more.
- the width L of the concave portion 6 means the shortest distance between the convex portions 5 adjacent in the horizontal direction or the vertical direction.
- the pitch between adjacent convex portions 5 is P and the diameter of the convex portions 5 is D
- the pitch P between the adjacent convex parts 5 means the distance between the centers of the convex parts 5 adjacent in the horizontal direction or the vertical direction (the distance between the centers of the convex parts 5 at the shortest distance from each other).
- the width L of the recess 6 shown in FIG. 2A has the same value in both the vertical direction and the horizontal direction. That is, the shortest distance between the convex parts 5 adjacent in the vertical direction and the shortest distance between the convex parts 5 adjacent in the horizontal direction both have the same value.
- the pitch P between the adjacent convex portions 5 is preferably 600 ⁇ m or more.
- the convex portion 5 is formed in a trapezoidal shape from an upper wall 8 that rises upward in a cross-sectional view, and a front wall 9 that horizontally connects the upper edges of the upper wall 8. ing.
- the height of the convex portion 5 (upper wall 8) indicated by the ten-point average roughness Rz (hereinafter sometimes referred to as height Rz) is 5 ⁇ m or more, and the plate thickness t of the plate base plate 2 is 1/10 or less, that is, 0.1 ⁇ t or less.
- the flatness (shape) cannot be ensured at the time of rolling transfer in the processing apparatus 10 described later, and the rolling stability is high. It is determined not to be obtained. Further, in a plate in which the flatness cannot be ensured, a stress distribution is generated at the time of press forming in a subsequent process, so that a crack is generated at a location where the stress is high. That is, if the height Rz of the convex portion 5 is too large, it causes cracking (starting point) during press working and causes flaws. On the other hand, if the height Rz is too small (5 ⁇ m or less), the heat transfer efficiency cannot be improved.
- the convex part 5 does not have to be a perfect circular shape in plan view, and includes an elliptical shape with a flatness ratio of up to about 0.2.
- a planar view shape of the convex part 5 although various shapes, such as a square, can be considered, it is preferable that it is substantially circular from a viewpoint of the stress concentration avoidance at the time of the press work performed by a post process.
- positioning state of the convex part 5 is not limited to the shape shown by FIG.
- the convex part 5 may be arrange
- the angle ⁇ may be another value.
- the press molding is performed in the same manner as when the width L of the concave portion 6 and the pitch P between the adjacent convex portions 5 are changed.
- the press formability of the plate base plate 2 it is considered optimal that the height Rz of the convex portion 5 or the width L of the concave portion 6 is not too large and the pitch P of the convex portion is not too narrow. Therefore, it is considered that there is an upper limit for the shape parameters representing these.
- the present inventors perform computer simulation on the titanium plate base plate 2 on which irregularities of various shapes are formed, and the shape parameter [Rz ⁇ (L / P)] and the press formability score Pf Clarified the relationship.
- the “press formability score” (Pf) is an index used for evaluation of formability in press working. If the value of the press formability score Pf is 60 points or more, it is said that cracking or the like does not occur due to press forming, and it can be reliably formed into a desired shape. In the present embodiment, as shown in FIG. 7, 30 points are assigned to the heat exchange plate 4 after forming (after pressing), and the press formability score Pf is calculated by collecting these points.
- FIG. 5 shows the relationship between the shape parameter and the press formability score Pf.
- the press formability score Pf decreases as the shape parameter increases. However, if the shape parameter is 12 ⁇ m or less, the press formability score Pf is 60 or more. That is, if the shape parameter is 12 ⁇ m or less, a decrease in press formability Pf can be avoided.
- the plate base plate 2 of the present invention is a source of a plate constituting the heat exchanger, and serves as a partition wall for performing heat exchange. Therefore, the plate base plate 2 of the present invention is also required to have a high heat transfer coefficient (high heat transfer efficiency).
- the heat transfer efficiency of the flat plate on which the concave portions and the convex portions are not formed is 1.00
- the heat transfer efficiency Ht in the plate (heat exchange plate) on which the concave portions and the convex portions are formed is preferably 1.05 or more.
- the relationship between the heat transfer efficiency Ht and the shape parameter is considered. As shown in FIG. 5, for example, the shape parameter is gradually increased from 12 ⁇ m by decreasing the height Rz of the convex portion 5, decreasing the width L of the concave portion 6, or increasing the pitch P of the convex portion. Get smaller.
- the heat transfer efficiency is also gradually reduced, and approaches the heat transfer efficiency of the flat plate on which the concave portion and the convex portion are not formed.
- the shape parameter is 4 ⁇ m or more, the heat transfer efficiency (1.05 or more) required for an actual heat exchanger can be ensured.
- the shape parameter is 4 ⁇ m or more when the plate base plate 2 is manufactured.
- the shape parameter needs to be secured to some extent. Specifically, it is considered that the shape parameter needs to be 4 ⁇ m or more as described above. As described above, the shape parameter is set to any value within the range of 4 ⁇ m to 12 ⁇ m, the height Rz of the convex portion 5 is 5 ⁇ m or more with a 10-point average roughness, and 0.1 ⁇ t with respect to the thickness t of the flat plate material. ( ⁇ m) or less. Thereby, the width L of the concave portion 6 and the pitch P of the convex portion 5 are inevitably determined (derived).
- the crimping area ratio S satisfies the formula (1).
- the pressure-bonding area ratio S in the plate base plate 2 is the concavo-convex shape in FIG. It is preferable to satisfy the formula (1).
- the plate 4 for heat exchange which comprises an exchanger can be manufactured.
- the heat exchange plate 4 manufactured in this way has a heat exchange rate of 1.05 or more and has a very excellent heat transfer property.
- the heat exchanger in which the heat exchange plate 4 is incorporated has very high heat exchange efficiency.
- the processing apparatus 10 includes a transfer roll 11, a processing roll 12, and a support roll 13.
- the transfer roll 11 is disposed on the upstream side and the downstream side of the processing roll 12 and transfers the flat plate material 1.
- the processing roll 12 forms irregularities of micron order (several ⁇ m to several hundred ⁇ m) on the surface of the flat plate 1 being transferred.
- the processing roll 12 includes a flat plate 1 having a convex portion 5 having a height Rz and a pitch P and a concave portion 6 having a width L so that the shape parameter of the plate base plate 2 is 4 ⁇ m to 12 ⁇ m. Formed on the surface 1a.
- a processed portion 14 having a convex shape is formed by etching or discharge dull on the entire circumference of the outer peripheral surface of the processing roll 12 (see FIG. 6B).
- the height of the processed portion 14 is such that the height Rz of the convex portion 5 in the plate base plate 2 obtained after processing is 5 ⁇ m or more, and the height Rz of the convex portion 5 with respect to the thickness t of the flat plate material. Is set to be 0.1 ⁇ t ( ⁇ m) or less.
- the surface layer of the work roll 12 is preferably subjected to Cr plating or tungsten carbide treatment from the viewpoint of load resistance and wear resistance.
- the processing apparatus 10 presses the processing portion 14 provided on the processing roll 12 against the surface of the flat plate 1 while rotating the processing roll 12. As a result, the concave portion 6 having a shape obtained by inverting the processed portion 14 is formed on the surface of the flat plate 1, and the convex portion 5 is formed.
- the processing apparatus 10 sets the shape parameter of the plate base plate 2 to 4 ⁇ m to 12 ⁇ m or less, the height Rz of the convex portion 5 of the plate base plate 2 to 5 ⁇ m or more, and the plate thickness t of the plate base plate 2. And 10% or less (see FIG. 6C).
- the apparatus which forms the convex part 5 is not limited to an above-described processing apparatus.
- the heat exchanging plate 4 is manufactured by pressing the plate base plate 2, but this pressing may be anything, and may not form the herringbone as described above. Good.
- the “press formability score” used as the evaluation standard for press formability in the present invention has a good correlation with the Erichsen value (Ericsen test), which is regarded as a general press formability evaluation method. It has been known. Therefore, the press formability can be accurately evaluated also by the press formability score used in the present invention.
- the base plate material of the heat exchange plate of the present invention is suitable as a base plate of a plate constituting a heat exchanger used for offshore power generation or the like.
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- Shaping Metal By Deep-Drawing, Or The Like (AREA)
- Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
Abstract
Description
特許文献1に示される金属板表面への転写方法では、移送ロールの回転によって移送される金属シートに対して、転写ロールの外周面に形成された凹凸状の転写部が押圧される。これによって、金属シートの表面に、転写ロールの転写部と略同じ凹凸状の被転写部が形成される。
すなわち、特許文献2の図6に開示されているように、微細な凹凸が形成された平板材は、通常、その平面に例えば「ヘリンボーン」と言われる高さ数mm~数cmの山形の溝がプレス成形される。その後、平板材が熱交換器内へ組み込まれる。そのため、微細な凹凸が形成された後の平板材は、プレス成形性が望まれている。
すなわち、本発明における熱交換用プレートの元板材は、チタン製の平板材の表面に微細な凹部及び凸部を形成することによって形成され、プレス加工が施された後に熱交換用プレートとなる元板材であって、前記凸部の高さをRz(μm)、前記凹部の幅をL(μm)、隣り合う前記凸部間のピッチをP(μm)としたとき、(Rz×L/P)で定義される形状パラメータが12μm以下となるように、前記凹部及び前記凸部が形成されていることを特徴とする。
また、前記凸部は平面視で円形状であって、前記平板材の表面に千鳥状に形成されることが好ましい。
さらに、前記凸部の高さRzは、十点平均粗さで5μm以上であり、且つ、前記平板材の厚みをt(μm)としたとき、0.1×t(μm)以下であることが好ましい。
前記凸部の高さをRz(μm)、前記凹部の幅をL(μm)、隣り合う前記凸部間のピッチをP(μm)としたとき、(Rz×L/P)で定義される形状パラメータが12μm以下となるように、前記凹部及び凸部を形成することを特徴とする。
また、前記凸部を平面視で円形状に形成すると共に、前記凸部を平板材の表面に千鳥状に配置して形成することが好ましい。
さらに、前記凸部の高さRzが十点平均粗さで5μm以上、且つ前記平板材の厚みをt(μm)としたときに0.1×t(μm)以下となるように、前記平板材の表面に前記凸部を形成することが好ましい。
図1は、熱交換用プレートの製造方法を示した概念図である。
熱交換用プレートを製造するにあたっては、まず、図1(a)に示されるように、所定の大きさを有する素材である平板材1を用意する。そして、図1(b)に示されるように、平板材1をプレス加工して平板材1の表面1aに微細な凹凸形状を形成することにより、表面2aに微細な凹凸形状が形成されたプレート元板2(元板材)が作成される。次に、図1(c)に示されるように、プレート元板2(元板材)をプレス加工して、例えば山形の溝(ヘリンボーン)3を形成することにより、熱交換用プレート4が製造される。
この平板材1の表面1aに対して、後述する加工装置10を用いて微細な凹凸形状(複数の凸部5と、これら凸部5に挟まれた凹部6)を形成することにより、プレート元板2が形成される。凹凸形状が形成されたプレート元板2は、伝熱性が非常に向上し、熱伝達率が非常に高い。加えて、本発明のプレート元板2はチタン製であるため、他金属と比較して、耐食性、強度、軽量化などの特性が優れている。それゆえに、プレート式熱交換器のプレートなど、耐食性、強度が必要となる製品に対して好適である。
図2(a)に示されるように、プレート元板2の表面2aに形成された凸部5は、平面視で円形であって、その直径Dは400μm以上である。凸部5の平面視での配置は、千鳥状となっている。ここで、千鳥状の配置(千鳥配置)は、横方向(X方向)に隣接する凸部5、5の中心を結んだ直線と、縦方向(Y方向)に隣接する凸部5、5の中心を結んだ直線と、が直交しないことを意味する。また、ここで、用語「隣接する」は、最短距離に位置することを意味する。
このように、凸部5の配置が千鳥状であることにより、熱交換器内の作動流体の流れが不均一である場合であっても、凸部5がどの方向からの作動流体の流れに対しても直交する壁となり得るため、乱流による伝熱性向上に寄与する。また、凸部5の配置が千鳥状であることにより、チタン等の異方性のある材料に対しても、異方性起因の応力集中に対応できる。
L=P-(D/2)×2
ここで、隣り合う凸部5間のピッチPは、横方向又は縦方向に隣接する凸部5の中心間の距離(互いに対して最短距離にある凸部5の中心間の距離)を意味する。
図2(b)に示されるように、凸部5は、断面視にて上方に立ち上がる上壁8と、この上壁8の上縁を水平に結ぶ表壁9と、から台形状に構成されている。十点平均粗さRzにて示される凸部5(上壁8)の高さ(以降、高さRzと示すことがある)は、5μm以上であって、プレート元板2の板厚tの1/10以下、すなわち0.1×t以下となっている。
したがって、プレート元板2のプレス成形性を考えると、凸部5の高さRz又は凹部6の幅Lが大きすぎず、凸部のピッチPは狭すぎないことが最適であると考えられる。したがって、これらを表す形状パラメータには上限値があると考えられる。
詳しくは、熱交換用プレート4において、縦方向(Y方向)に向くA線、C線、E線と交わる各部分では、割れが生じず健全なら2点、ネッキング傾向があれば1点、割れが生じていれば0点とする。また、縦方向(Y方向)に向くB線、D線と交わる各部分では、健全なら1点、ネッキング傾向があれば0.5点、割れが生じていれば0点とする。そして、各部分の点数に、図7に示されるRの値の逆数を掛けることによって、割れの状態を数値化する。そして、全体の総点数に対する、割れが生じていない割合を計算し、その値をプレス成形性スコアPfとする。
ここで、伝熱効率Htと形状パラメータとの関係を考える。図5に示されるように、例えば、凸部5の高さRzを小さくしたり、凹部6の幅Lを小さくしたり、凸部のピッチPを大きくすることによって、形状パラメータは12μmから徐々に小さくなる。このように、形状パラメータを徐々に小さくすると伝熱効率も徐々に小さくなり、凹部及び凸部が形成されていない平板の伝熱効率に近づくことになる。しかしながら、形状パラメータが4μm以上であれば、現実の熱交換器で必要とされる伝熱効率(1.05以上)を確保することができる。
さて、凹部6の幅Lが小さくなるほど、形状パラメータは小さくなる。流体を流したときの温度境界層の観点から考えると、凹部6の幅Lが小さ過ぎると伝熱性の低下を招いてしまう。このため、凹部6の幅Lもある程度確保されるほうが良く、形状パラメータも、ある程度大きい必要があると思われる。
前述したように、形状パラメータを4μm~12μm内のいずれかの値とし、凸部5の高さRzを十点平均粗さで5μm以上、且つ平板材の厚みtに対して0.1×t(μm)以下とする。これにより、凹部6の幅L及び凸部5のピッチPは必然的に決定される(導出される)。
加えて、後工程で実施されるプレス作業での加工性や凹凸部5の変形防止を考えるのであれば、プレート元板2における圧着面積比Sが、図2(a)の凹凸形状においては、式(1)を満たすようにすることが好ましい。
平板材1(チタン)の降伏応力σy>プレス時に凸部5にかかる面圧(F/S) (1)
ここで、
S1=P・P・tan(θ/180・π)/4
S2=π/4・D・D/2
整理すると、
S1=P2・tan(πθ/180)/4
S2=πD2/8
また、
S=圧着面積比=S2/S1
F=プレス加工時の荷重
D=凸部5の直径
上記S1は、図2(a)における平面の面積(図2(a)における直線A及び直線Bにより囲まれる三角形の面積)である。上記S2は、図2(a)における凸部5の面積(前述の三角形内に存在する凸部5の面積)である。
加工装置10は、移送ロール11と、加工ロール12と、支持ロール13と、を備えている。移送ロール11は、加工ロール12の上流側及び下流側に配置され、平板材1を移送する。
例えば、上記実施形態では、熱交換用のプレート4が、プレート元板2をプレス加工することにより製造されるが、このプレス加工は何でも良く、上述したようなヘリンボーンを形成するものでなくてもよい。
1a 平板材の表面
2 プレート元板(元板材)
2a プレート元板の表面
3 溝
4 熱交換用プレート
5 凸部
6 凹部
8 上壁
9 表壁
10 加工装置
11 移送ロール
12 加工ロール
13 支持ロール
Claims (8)
- チタン製の平板材の表面に凹部及び凸部を形成することによって形成され、プレス加工が施された後に熱交換用プレートとなる元板材であって、
前記凸部の高さをRz(μm)、前記凹部の幅をL(μm)、隣り合う前記凸部間のピッチをP(μm)としたとき、(Rz×L/P)で定義される形状パラメータが12μm以下となるように、前記凹部及び前記凸部が形成されていることを特徴とする熱交換用プレートの元板材。 - 前記形状パラメータが4μm以上となるように、前記凹部及び前記凸部が形成されることを特徴とする請求項1に記載の熱交換用プレートの元板材。
- 前記凸部は平面視で円形状であって、前記平板材の表面に千鳥状に形成されることを特徴とする請求項1に記載の熱交換用プレートの元板材。
- 前記凸部の高さRzは、十点平均粗さで5μm以上であり、且つ、前記平板材の厚みをt(μm)としたとき、(0.1×t)μm以下であることを特徴とする請求項1に記載の熱交換用プレートの元板材。
- チタン製の平板材の表面に凹部及び凸部を形成することによって形成され、プレス加工が施された後に熱交換用プレートとなる元板材の製造方法であって、
前記凸部の高さをRz(μm)、前記凹部の幅をL(μm)、隣り合う前記凸部間のピッチをP(μm)としたとき、(Rz×L/P)で定義される形状パラメータが12μm以下となるように、前記凹部及び凸部を形成することを特徴とする熱交換用プレートの元板材の製造方法。 - 前記形状パラメータが4μm以上となるように、前記凹部及び前記凸部を形成することを特徴とする請求項5に記載の熱交換用プレートの元板材の製造方法。
- 前記凸部を平面視で円形状に形成すると共に、前記凸部を平板材の表面に千鳥状に配置して形成することを特徴とする請求項5に記載の熱交換用プレートの元板材の製造方法。
- 前記凸部の高さRzが十点平均粗さで5μm以上、且つ前記平板材の厚みをt(μm)としたときに(0.1×t)μm以下となるように、前記平板材の表面に前記凸部を形成することを特徴とする請求項5に記載の熱交換用プレートの元板材の製造方法。
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