WO2015125831A1 - プレート式熱交換器およびその製造方法 - Google Patents
プレート式熱交換器およびその製造方法 Download PDFInfo
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- WO2015125831A1 WO2015125831A1 PCT/JP2015/054465 JP2015054465W WO2015125831A1 WO 2015125831 A1 WO2015125831 A1 WO 2015125831A1 JP 2015054465 W JP2015054465 W JP 2015054465W WO 2015125831 A1 WO2015125831 A1 WO 2015125831A1
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- Prior art keywords
- box
- heat exchanger
- vertical wall
- plate
- laminated
- Prior art date
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Classifications
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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
- F28F19/00—Preventing the formation of deposits or corrosion, e.g. by using filters or scrapers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K1/00—Soldering, e.g. brazing, or unsoldering
- B23K1/0008—Soldering, e.g. brazing, or unsoldering specially adapted for particular articles or work
- B23K1/0012—Brazing heat exchangers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/02—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of a press ; Diffusion bonding
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D9/0031—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other
- F28D9/0043—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other the plates having openings therein for circulation of at least one heat-exchange medium from one conduit to another
- F28D9/005—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other the plates having openings therein for circulation of at least one heat-exchange medium from one conduit to another the plates having openings therein for both heat-exchange media
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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
- F28F19/00—Preventing the formation of deposits or corrosion, e.g. by using filters or scrapers
- F28F19/02—Preventing the formation of deposits or corrosion, e.g. by using filters or scrapers by using coatings, e.g. vitreous or enamel coatings
- F28F19/06—Preventing the formation of deposits or corrosion, e.g. by using filters or scrapers by using coatings, e.g. vitreous or enamel coatings of metal
-
- 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
- F28F3/025—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being corrugated, plate-like elements
-
- 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
- F28F3/12—Elements constructed in the shape of a hollow panel, e.g. with channels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/04—Tubular or hollow articles
- B23K2101/14—Heat exchangers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2275/00—Fastening; Joining
- F28F2275/04—Fastening; Joining by brazing
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2275/00—Fastening; Joining
- F28F2275/06—Fastening; Joining by welding
- F28F2275/061—Fastening; Joining by welding by diffusion bonding
Definitions
- the present invention relates to a plate heat exchanger in which a plurality of heat transfer plates are stacked.
- plate heat exchangers have extremely high heat exchange performance, and are therefore used in electric water heaters, industrial equipment, automobile air conditioners, and the like.
- a heat exchange medium passage that is, a hot medium passage and a low temperature medium passage are formed adjacent to each other by stacked plates, and a medium having a temperature difference flowing between the high temperature medium passage and the low temperature medium passage. It is configured to exchange heat with each other by transferring heat.
- Patent Document 1 a high-temperature flow path and a low-temperature flow path are obtained by laminating plates with wave shapes serving as flow paths and joining them by various joining methods (fastening with gaskets and screws, welding, brazing). Has created a structure that exists alternately.
- a stainless steel plate excellent in corrosion resistance is used as a material metal plate.
- small and medium heat exchangers are often joined by brazing in consideration of pressure resistance.
- brazing material such as melting damage, cracking of the brazing part, deterioration of corrosion resistance, channel burial due to molten brazing, etc.
- a bonding failure may occur.
- the cost of using brazing material is also high.
- solid phase diffusion bonding is a bonding method that utilizes mutual diffusion of base material atoms generated at the bonding interface under high temperature pressure, and the bonded portion exhibits the same strength and corrosion resistance as the base material.
- the bonding force by solid phase diffusion is affected by the applied pressure and temperature at the bonding surface.
- the additive element when a stainless steel plate is used as the material metal plate, the additive element has a strong influence on diffusion bonding of stainless steel, and when a large amount of easily oxidizable elements Al, Ti, Si are contained, a strong oxide or An oxide film may be formed to inhibit bonding.
- solid phase diffusion bonding when trying to apply solid phase diffusion bonding by pressing the stacked plate-type parts from above and below, solid phase diffusion bonding is sufficiently performed on the vertical joint surfaces, but the pressing force from the side surface direction is not sufficient. Since it tends to be sufficient, the joining of the side end surfaces of the upper and lower plates tends to be insufficient.
- the present invention has been devised to solve such problems, and defines the shape of the side end face of the plate-type component constituting the plate heat exchanger, and the side end face and the upper and lower plate-type parts.
- solid phase diffusion bonding instead of brazing, the plate-type heat exchanger that ensures airtightness can be easily manufactured even when stainless steel is used as the material.
- it is allowed to supply a part of the brazing material to a region where it is difficult to apply weight.
- the rectangular plate-type component constituting the heat exchanger case is a box-type component having a vertical wall portion on the periphery, and is the same shape as the box-type component
- the box-shaped parts are stacked on the box-shaped parts by reversing the direction of the horizontal plane, and the upper part of the vertical wall part of the laminated lower part is inserted into the lower part of the vertical wall part of the laminated upper part.
- the angle ( ⁇ ) of the vertical wall portion is ⁇ ⁇ 30 °, and at least a part of the vertical wall portion is in solid phase diffusion bonding at a contact portion between the upper portion of the vertical wall portion and the lower portion of the vertical wall portion. It is characterized by. Further, depending on the required bonding strength, brazing bonding can be applied to at least a part of the contact portion. It is preferable that other contact portions between the upper part and the lower part are also joined by solid phase diffusion bonding or brazing.
- the box-shaped part has two types of openings at the target position on the upper surface thereof, one of which opens above the box-shaped part and opens the other, and the other of the box-shaped part projects at the same height inside the box-shaped part.
- a fin having a cross-sectional shape of a triangle, trapezoid or quadrangle and a height equal to the height of the flange is formed on the top flat portion of the laminated box-type component, and the tip piece of the upper laminated component is near the punch shoulder of the lower laminated component
- the tips of the fins contact each other, and the flow path joint formed by solid-phase diffusion bonding or brazing at the contact part is equivalent to the strength of the base material. It is preferable to have good bonding strength.
- a fin part with a triangular, trapezoidal, or quadrangular cross section and the same height as the flange height is inserted between the two stacked box-shaped parts, and the top piece of the upper part of the laminated part is a flat part near the punch shoulder of the lower part of the laminated part
- the tip of the fin part comes into contact with the upper flat part of the box-type part when the contact is made, and both are solid-phase diffusion bonded or brazed at the contact part to form a flow path joint. It may be a thing.
- a ferritic single-phase stainless steel plate or austenite system having chemical components of 0.1 Si + Ti + Al ⁇ 0.15 mass% and a surface roughness Ra ⁇ 0.3 ⁇ m
- Solid-phase diffusion bonding is performed by heating a laminated assembly using a stainless steel plate or a martensitic stainless steel plate in an atmosphere having a heating temperature of 1100 ° C. or higher and a pressure of 0.3 MPa or more and 1 ⁇ 10 ⁇ 2 Pa or less.
- 1 ⁇ 10 ⁇ 2 Pa or less indicates the atmospheric pressure when the heating temperature is reached.
- the furnace may contain an inert gas such as Ar or N 2 .
- an inert gas such as Ar or N 2 .
- At least a part of the joining of the side end faces of the plate-type parts constituting the plate heat exchanger and the joining of the flow paths of the upper and lower plate-type parts uses a brazing material such as Cu or Ni. Since it is performed by solid phase diffusion bonding, a plate type heat exchanger with sufficient airtightness is provided at low cost. Moreover, the plate type heat exchanger excellent in durability can be provided at low cost by using a stainless steel plate as a raw steel plate.
- the plate-type heat exchanger is configured such that the heat exchange medium passages, that is, the passages of the high temperature medium and the low temperature medium are adjacent to each other by the stacked plates, and the temperature difference flowing between the passages of the high temperature medium and the low temperature medium.
- the mediums having the above are configured to exchange heat with each other by transferring heat.
- a simple structure for example, as shown in FIGS. 1 and 2, a plurality of box-shaped parts having the same shape are manufactured, and the box-shaped parts rotated about 180 ° in a horizontal plane and reversed in direction to the box-shaped parts. It is assumed that a heat exchanger is constructed by repeatedly stacking and further stacking box-shaped parts.
- the parts to be hermetically joined include the contact portion between the lower opening end serving as the flow path for the upper part and the upper opening end serving as the flow path for the lower part, and the peripheral vertical wall of the upper box part and the lower box part. It is a lap
- the contact portion between the lower opening end of the upper part and the upper opening end of the lower part performs solid phase diffusion bonding
- the peripheral vertical wall part of the upper box part and the peripheral vertical part of the lower box part The lap portion of the wall portion is intended to define the shape and secure the bondability.
- the steel sheet is subjected to press work and has a vertical wall portion at the periphery, and two types of openings are provided at the target position on the upper surface, one above the box-shaped part.
- a box-shaped part formed by press molding was formed in which the other was extended and opened, and the other was extended inward at the same height inside the box-shaped part.
- the box-shaped part 1 and the box-shaped part 2 are obtained by simply inverting the direction of the horizontal plane and have the same shape. And the height which added the height of the opening part which extended and opened upwards and below becomes the height of a box-shaped rectangular plate type component single item.
- the same-shaped box-shaped parts were rotated on the horizontal plane by about 180 ° on the horizontal plane, and the operation of placing them in the opposite direction was repeated and separately prepared.
- a heat exchanger structure as shown in FIG. 3A is obtained.
- the peripheral vertical wall part of the upper box-shaped component is configured to be inserted so as to wrap around the peripheral vertical wall part of the lower box-shaped component. For this reason, the height of the vertical wall portion needs to be higher than the sum of the heights of the opening portions projecting upward and downward.
- the opening angle of the peripheral vertical wall of the upper box-shaped part and the downward opening angle of the lower box-shaped part that is, the vertical wall angle ( ⁇ ) shown in FIG. It is desirable that 15 ° ⁇ ⁇ ⁇ 30 ° so that the weight from the direction is applied to the vertical wall portion.
- the vertical wall part is slightly open downward and the size of the plate heat exchanger itself does not increase. It is preferable to make it as small as possible, 0 ⁇ ⁇ ⁇ 15 °.
- solid phase diffusion bonding is performed at the sites indicated by a, b, c, and d in FIG.
- a heat exchange medium passage that is, a high-temperature medium passage and a low-temperature medium passage are formed adjacent to each other, and heat exchange is performed with a medium having a temperature difference flowing between the high-temperature medium passage and the low-temperature medium passage. It is configured to perform a heat exchange action. For this reason, in order to increase the efficiency of the heat exchange action, it is effective to widen the partition wall surface that separates the passage of the high temperature medium and the low temperature medium.
- fins having a cross-sectional shape of a triangle, a trapezoid, or a quadrangle and a height that is the same as the height of the box-shaped part are provided on the upper flat portion of the laminated box-shaped part.
- a fin having the same cross-sectional shape as a triangle, trapezoid, or quadrangle and having the same height as the height of the box-shaped part is placed on the flat upper surface of the box-shaped part and inward of the box-shaped part.
- Box-shaped components in which fins are formed on the upper flat portion are stacked.
- the box-shaped component 2 is a box-shaped component 1 whose direction is reversed, and the box-shaped component 3 is arranged in the same direction as the box-shaped component 1 in the same direction.
- the brazing material When brazing a part of the vertical wall, the brazing material includes Ni brazing BNi-5 specified in JISZ3265, P based on BNi-5 and Cu brazing specified in JISZ3262. BCu-1 (oxygen-free copper) can be mainly used.
- BCu-1 oxygen-free copper
- the type, form and amount of brazing material can be selected according to the material and shape of the box-shaped part. For example, it is preferable that 0.1 g / cm 2 or more and 1.0 g / cm 2 or less of brazing material is applied to the gap between the vertical wall portions formed when the box-shaped components on which the fin components are arranged are stacked.
- the plate heat exchanger of the present invention has durability in an environment where corrosion resistance is required.
- the additive elements strongly influence the diffusion bonding of stainless steel, and if there are a lot of easily oxidizable elements such as Al, Ti, Si, a strong oxide or oxide on the surface of the joint interface May form a film and inhibit bonding.
- the plate heat exchanger of the present invention when producing the plate heat exchanger of the present invention using a stainless steel plate as a raw material, the content of the easily oxidizable elements Al, Ti, Si is limited, and the surface properties and solid phase of the material stainless steel plate are limited. It was decided to define the pressure and heating temperature during diffusion bonding.
- Ferrite single-phase stainless steel sheet, austenitic stainless steel sheet, martensitic stainless steel sheet, or duplex stainless steel sheet having a general composition defined by JIS or the like can be used. If a large amount of easily oxidizable elements such as Al, Ti, and Si is contained, a strong oxide or oxide film is formed on the surface of the bonding interface and the bonding is inhibited. Therefore, the total amount is limited. Details will be given in the description of the examples. However, when 0.1Si + Ti + Al is 0.15% or more, the inside of the joined product is in a state of advanced oxidation, and bonding becomes insufficient.
- C 0.0001 to 0.15%
- Si less than 1.5%
- Mn 0.001 to 1.2%
- P 0.001 to 0.045% in mass%.
- S 0.0005 to 0.03%
- Cr 11.5 to 32.0%
- Cu 0 to 1.0%
- Mo 0 to 2.5%
- Al less than 0.15%
- Ti less than 0.15%
- Nb 0 to 1.0%
- V 0 to 0.5%
- N 0 to 0.025%
- balance Fe and unavoidable impurities A ferrite single phase type is preferable.
- C 0.0001 to 0.15%
- Si less than 1.5%
- Mn 0.001 to 2.5%
- P 0.001 to 0.045%
- S 0 .0005 to 0.03%
- Cr 15.0 to 26.0%
- Cu 0 to 3.5%
- Mo 0 to 7.0%
- Al Austenite comprising less than 0.15%
- Nb 0 to 1.0%
- V 0 to 0.5%
- N 0 to 0.3%
- C 0.15 to 1.5%
- Si less than 1.5%
- Mn 0.001 to 1.0%
- P 0.001 to 0.045%
- S 0 .0005 to 0.03%
- Ni 0.05 to 2.5%
- Cr 13.0 to 18.5%
- Cu 0 to 0.2%
- Mo 0 to 0.5%
- Al Less than 0.15%
- Ti less than 0.15%
- Nb 0 to 0.2%
- V 0 to 0.2%
- C 0.0001 to 0.15%
- Si less than 1.5%
- Mn 0.001 to 1.0%
- P 0.001 to 0.045%
- S 0.0005 to 0.03%
- Ni 0.05 to 6.0%
- Cr 13.0 to 25.0%
- Cu 0 to 0.2%
- Mo 0 to 4.0%
- Al Less than 0.15%
- Ti less than 0.15%
- Nb 0 to 0.2%
- V 0 to 0.2%
- N 0.005 to 0.2%
- balance Fe and inevitable impurities A ferrite + martensite two-phase system or a ferrite + austenite two-phase system may be used.
- the stainless steel described above can be added with 0 to 0.01% B and 0 to 0.1% with one or more of Ca, Mg, and REM in order to ensure manufacturability.
- the surface roughness of both of them affects the bondability.
- the details of this surface roughness will be given in the description of the examples, but depending on the contact surface pressure between the metals to be joined, in the case of solid phase diffusion joining with a pressure of 0.3 MPa, relatively diffusion joining is performed.
- the surface roughness is Ra ⁇ 2.0 ⁇ m for the two-phase stainless steel plate that is easily deformed, and Ra ⁇ 0.3 ⁇ m for the other ferritic single-phase stainless steel plate, austenitic stainless steel plate, or martensitic stainless steel plate that is difficult to be diffusion bonded. There is a need.
- the pressure applied between the two stainless steel plates used for diffusion bonding is 0.1 MPa or more for the duplex stainless steel, and 0.3 MPa or more for the ferrite single phase, austenitic, or martensitic stainless steel plate. If the applied pressure is less than these values, heating to a higher temperature is required to form a sound joint interface, which is not preferable as a product as described later. If the applied pressure is more than these values, diffusion bonding can be performed with relatively simple equipment. It is preferable to use a metal weight for applying the pressing force in the vertical direction. The weight is preferably made of heat-resistant ferritic stainless steel having excellent heat resistance and low thermal expansion. The applied pressure is obtained by dividing the weight load by the vertical joint area.
- the atomic diffusion range is expanded and diffusion bonding becomes easy.
- load collapse due to instability of the center of gravity and shape defects due to uneven load are likely to occur.
- the applied pressure is 0.8 MPa or less, which is the minimum value necessary for joining.
- the heating temperature for diffusion bonding is 1000 ° C. or higher for duplex stainless steel, and 1100 ° C. or higher for ferrite single-phase, austenitic, or martensitic stainless steel sheets. If these temperatures are not reached, sufficient diffusion bonding cannot be performed.
- the solid phase diffusion of the stainless steel surface layer starts around 900 ° C.
- atomic diffusion becomes active and diffusion bonding is facilitated in a short time, but when heated to 1200 ° C. or higher, high-temperature strength is lowered and crystal grains are easily coarsened.
- the joined parts undergo significant thermal deformation during heating.
- the inventors have studied a heating temperature that allows diffusion bonding at as low a temperature as possible.
- the chemical composition, surface roughness, and applied pressure are followed, and the heating temperature at the time of joining is 1100 ° C. to 1200 ° C. for ferrite single-phase, austenitic, or martensitic stainless steel plates, and for two-phase stainless steel plates. It has been found that a temperature range of 1000 ° C. to 1200 ° C. and the range of 1100 ° C. to 1200 ° C. may be used in the bonding of these different materials.
- Diffusion bonding between stainless steel plates can be performed by heating and holding the members to be bonded in an atmosphere in which the pressure is set to 1 ⁇ 10 ⁇ 2 Pa or less by evacuation. Sufficient diffusion bonding cannot be performed in an atmosphere exceeding 1 ⁇ 10 ⁇ 2 Pa.
- the atmospheric pressure is higher than 1 ⁇ 10 ⁇ 2 Pa (> 1 ⁇ 10 ⁇ 2 Pa)
- oxygen contained in the gaps between the stainless steel plates to be bonded remains, and an oxide film is formed on the surface of the bonding surface during heating. Significantly inhibits sex.
- the atmospheric pressure is lower than 1 ⁇ 10 ⁇ 2 Pa, that is, the atmospheric pressure is 1 ⁇ 10 ⁇ 2 Pa or less, the surface oxide film becomes extremely thin, which is the optimum condition for diffusion bonding.
- an inert gas such as Ar, He, or N 2 can be sealed and bonded.
- the heating and holding time may be set in the range of 30 to 120 min. From the viewpoint of mass productivity, it is better that the heating and holding time is as short as possible. However, a heating time of 30 minutes or more is required to uniformly apply heat to the entire bonded component and sufficiently excite atomic diffusion. On the other hand, when a holding time of 120 min or more is given, crystal grains grow to such an extent that the strength of the base material is affected. Therefore, a preferable holding time was set to 30 to 120 min.
- Example 1 First, in order to confirm the bondability of the test material, only a box-shaped part having a thickness of 0.4 mm was formed using a steel plate having the composition shown in Table 1, as shown in FIG. Three sheets were laminated. The vertical wall angle ⁇ at this time was 30 °, and no brazing material was applied. Further, the surface roughness Ra of the molded part is 0.3 ⁇ m ⁇ .
- the temporarily assembled processed product was subjected to diffusion bonding under the conditions described in Table 2 and the conditions selected from the heat pattern in FIG. That is, after placing in a horizontal vacuum furnace and allowing the atmospheric pressure to reach 1 ⁇ 10 ⁇ 2 Pa or less, heating is performed with the heat pattern (3) shown in FIG.
- the heating temperature is 1200 ° C.
- the soaking time is 2.
- the load surface pressure was set to 0.5 MPa for 0 h. This condition is a temperature and a surface pressure that are considered to be upper limits from the viewpoint of mass productivity.
- the state of the internal oxidation state and the joining state of the vertical wall portion of the obtained three-layer processed product were confirmed.
- the internal oxidation state can be confirmed by cutting the cross section and judging from the coloration state by visual observation.
- the joining state of the vertical wall portion is not possible when there is one cross section where no cross section is observed by microscopic observation of five cross sections. It was judged.
- the results are shown in Table 3.
- Sample No. 7-11, no. 15-19, no. Inventive materials 21 to 28 did not show any oxidative coloring under the conditions of 1200 ° C., 2.0 h, and 0.5 MPa, and had good bonding properties.
- sample No. of the comparative material. 1-6, no. 12-14, no. No. 20 was colored and the bonding state was insufficient. Therefore, in the following experiment, a suitable joining state was confirmed using only the inventive material.
- Example 2 No. of Example 1 10, no. 16, no.
- two fin-shaped parts each having a cross section (1) a triangle, (2) a trapezoid, and (3) a quadrangle formed from a 0.4 mm steel plate were inserted.
- a top plate and a bottom plate having a plate thickness of 1.0 mm as shown in FIG. 3A were incorporated into the box-type component and the fin-type component to obtain a temporarily assembled heat exchanger.
- the angle ⁇ of the vertical wall was corrected by a press and changed variously.
- test body In order to perform diffusion bonding processing at each contact point indicated by a (top plate-box part), b (bottom plate-box part), c (fin part), and d (box part vertical wall part) in FIG.
- the test body was prepared.
- a test body in which pure Cu solder was applied to a part of the contact region was also produced.
- the Cu solder at this time was 0.3 g / cm 2 .
- the above temporarily assembled heat exchanger was subjected to bonding treatment under heating and pressing conditions of 1100 ° C., 2.0 h, and 0.3 MPa.
- a pressure test was used to measure the bonding strength.
- three of the four joints (openings) arranged on the upper flat portion of the box-shaped part shown in FIG. 4 are closed, and water pressure is applied to the inside of the heat exchanger from the remaining one place.
- the occurrence of leakage was grasped at a set pressure of 3 MPa.
- Table 4 No. included in the examples of the present invention. Nos. 1 to 9 did not cause any leakage in the 3 MPa pressure test, and had good bondability. On the other hand, no. 10 and no. No. 11 has a large vertical wall angle. No. 12 did not have fins inside, so that the box-shaped part was crushed during the test, and it did not have sufficient pressure resistance.
- No. No. 7 is an example in which diffusion bonding was performed at points a to c and partial brazing was performed at point d.
- 8 is an example in which diffusion bonding is performed at points a to d.
- suitable joining conditions were confirmed by changing the joining conditions of temperature, time, applied pressure, and atmospheric pressure. The results are shown in Table 5.
- No. 14 and no. No. 16 has a temperature and time deviated on the high temperature long time side.
- No. 18 was too high in pressure, was greatly deformed during heating and was inferior in pressure resistance.
- No. No. 17 is too low pressure, and no. No.
Abstract
Description
プレート式熱交換器は、積層したプレートにより熱交換媒体の通路、つまり高温媒体と低温媒体の通路を隣接して構成し、これら高温媒体の通路と低温媒体の通路に流す温度差を有する媒体に熱の授受により相互に熱交換作用を行うように構成されている。
一方、熱交換器そのものの耐久性向上の観点から、素材金属板として耐食性に優れたステンレス鋼板が用いられるようになっている。そして、小中型の熱交換器については耐圧性を考慮し、ろう付けで接合されることが多くなっている。
一方、接合部の耐食性低下を抑制する方法として、ろう付けに替えて固相拡散接合の適用が考えられる。固相拡散接合は高温圧力下で接合界面に生じる母材原子の相互拡散を利用した接合方法であり、接合部は母材なみの強度、耐食性を呈している。一方で、固相拡散による接合性は、接合面での加圧力や温度等が影響する。
また、積層したプレート型部品を上下方向から加圧して固相拡散接合させようとするとき、上下関係の接合面での固相拡散接合は十分に行われるが、側面方向からの押圧力が不十分になりやすいため、上下のプレートの側端面の接合が不十分になりやすい。
本発明は、このような問題点を解消するために案出されたものであり、プレート式熱交換器を構成するプレート型部品の側端面の形状を規定し、側端面および上下のプレート型部品の流路の接合を、ろう付けに替えて固相拡散接合で行うことにより、特に素材としてステンレス鋼板を用いたものであっても、気密性を確保したプレート式熱交換器を簡便に製造することを目的とする。なお、加重付与されにくい領域には、一部ろう材を供給することが許容される。
また、必要とする接合強度によっては、前記当接部位の少なくとも一部にろう付け接合を適用できる。その他の前記積層上部品と前記積層下部品との当接部においても、固相拡散接合またはろう付け接合により接合することが好ましい。
積層された二つの箱型部品の間に、断面形状が三角または台形または四角形で高さがフランジ高さと同じフィン部品が挿入され、積層上部品の先端片が積層下部品のパンチ肩近傍平坦部に当接させた際に、前記フィン部品の先端が箱型部品の上面平坦部に当接し、当該当接部で両者が固相拡散接合またはろう付けされて流路接合部が形成されているものであってもよい。
化学成分が0.1Si+Ti+Al<0.15質量%の2相系ステンレス鋼板を使用し、加熱温度が1000℃以上、加圧力が0.1MPa以上、雰囲気圧力1×10-2Pa以下の雰囲気で加熱する場合、表面粗さRa≦2.0μmのステンレス鋼板でも十分に固相拡散接合することができる。
また、素材鋼板としてステンレス鋼板を使用することにより、耐久性に優れたプレート式熱交換器が低コストで提供できることになる。
簡便な構造としては、例えば図1、2に見られるように、同形状の箱型部品を複数製造し、この箱型部品に水平面で180°程度回転し、向きを反転させた箱型部品を積み重ね、さらに箱型部品を積み重ねることを繰り返して、熱交換器を構築することが想定される。
箱型部品として、鋼板にプレス加工を施し、周縁縦壁部を僅かに下開きにするとともに、対象位置に二種の開口が、一方は周縁縦壁部高さの1/2より低い高さで当該矩形プレート型部品の上方に開口し、他方は同じく周縁縦壁部高さの1/2より低い高さで当該矩形プレート型部品の内方に開口した形で形成された部品を作製し、この箱型部品を底板の上に載置した後、この箱型部品上に同形の箱型部品を水平面で180°程度回転し、向きを反転させて載置する操作を繰り返すと、図2に見られるような熱交換器構造が得られる。なお上側の箱型部品の周縁縦壁部は下側の箱型部品の周縁縦壁部にラップするように差し込まれる形態となっている。
前記各部位をろう付けはなく、固相拡散接合しようとすると、上記のような積層構造では、上部品の下方開口端と下部品の上方開口端との当接部への加重付与は問題ないが、周縁縦壁部のラップ部への加重付与が困難となる。すなわち、周縁縦壁部のラップ部に上下方向から加重を掛けることは極めて難しくなって、十分に固相拡散接合が行えなくなる。
したがって、周縁縦壁部のラップ部位について接合方法を再検討する必要がある。
具体的には、図3(b)に示すように、鋼板にプレス加工を施し周縁に縦壁部を有するとともに、その上面において対象位置に二種の開口が、一方は当該箱型部品の上方に張出して開口し、他方は当該箱型部品の内方に同じ高さで張出して開口した形で形成されたプレス成形で形成された箱型部品を作製した。なお、図3(a)中、箱型部品1と箱型部品2は、単に水平面の向きを反転させたものであり、同形状を有している。そして、上方及び下方に張出して開口した開口部の高さを足し合わせた高さが箱型の矩形プレート型部品単品の高さとなる。
なお、上側の箱型部品の周縁縦壁部は下側の箱型部品の周縁縦壁部にラップするように、差し込まれる形態となっている。このため、縦壁部の高さは前記上方及び下方に張出して開口した開口部の高さを足し合わせた高さよりも高くする必要がある。
そこで、本発明では、積層箱型部品の上面平坦部に、断面形状が三角または台形または四角形で高さが箱型部品の高さと同じフィンを設けることにした。
上側箱型部品の縦壁部に下側箱型部品の縦壁部が差し込まれるように積み重ねると、前記フィンの先端同士が当接することになる。したがって、この状態で上下方向から加重をかけた状態で高温下に保持すると、図5中、○部、□部で固相拡散接合される。なお、フィン部品同士をろう付け接合してもよい。
箱型部品自体にフィンを設けるのではなく、フィン部品と箱型部品を別々に作製し、積層した上下の箱型部品の間にフィン部品を挿入してもよい。
しかしながら、素材鋼板としてステンレス鋼板を用いる場合、ステンレス鋼の拡散接合には添加元素が強く影響し、易酸化元素であるAl、Ti、Siが多く含まれると接合界面表層に強固な酸化物または酸化皮膜を形成し接合を阻害することがある。
そこで、本発明のプレート式熱交換器を、ステンレス鋼板を素材として製造する際には、易酸化元素であるAl、Ti、Siの含有量を制限し、かつ素材ステンレス鋼板の表面性状や固相拡散接合時の加圧力と加熱温度を規定することにした。
易酸化元素であるAl、Ti、Siが多く含まれると接合界面表層に強固な酸化物または酸化皮膜を形成し、接合を阻害するので、その総量については制限する。詳細は実施例の記載に譲るが、0.1Si+Ti+Alが0.15%以上になると、接合品内部の酸化が進んだ状態となり、接合も不十分となる。
以上述べたステンレス鋼は、製造性を確保するためにBを0~0.01%、Ca、Mg、REMを1種以上で0~0.1%添加することが可能である。
この表面粗さについても詳細は実施例の記載に譲るが、接合しようとする金属間の接触面圧にもよるが、0.3MPaの加圧力で固相拡散接合する場合、比較的の拡散接合し易い2相系ステンレス鋼板では表面粗さはRa≦2.0μmに、拡散接合し難い他のフェライト単相系ステンレス鋼板またはオーステナイト系ステンレス鋼板またはマルテンサイト系ステンレス鋼板ではRa≦0.3μmにする必要がある。
上下方向への加圧力の付与には金属製の錘を使用することが好ましい。錘には耐熱性に優れ、熱膨張が小さい耐熱フェライト系ステンレス鋼の使用が好ましい。加圧力は錘の荷重を上下接合面積で除すことで求める。
一般的にステンレス鋼表層の固相拡散は900℃前後より始まる。とくに1100℃以上に加熱すると原子拡散が活発化するため短時間で拡散接合し易くなるが、1200℃以上に加熱すると高温強度が低下し、結晶粒も粗大化し易くなる。高温強度が低下すると接合部品は加熱中に著しい熱変形を生じる。また結晶粒が粗大化すると母材強度が低下し耐圧性が劣化する。そのため極力低温度で拡散接合できる加熱温度を検討するに至った。その結果、上述した化学成分、表面粗さ、加圧力に従うとともに、接合時の加熱温度をフェライト単相系またはオーステナイト系またはマルテンサイト系ステンレス鋼板においては1100℃~1200℃、2相系ステンレス鋼板では1000℃~1200℃、これらの異材接合においては1100℃~1200℃の範囲とすればよいことを知見した。なお、部分的にろう材を用いる場合には、ろう接の適正温度である1100℃以上とすることが好ましい。
雰囲気圧力が1×10-2Paより高いと(>1×10-2Pa)、接合するステンレス鋼板の隙間に内包する酸素が残存し、加熱時に接合面表層に酸化皮膜が生成することで接合性を著しく阻害する。雰囲気圧力を1×10-2Paより低く、すなわち雰囲気圧力を1×10-2Pa以下にすると表層の酸化皮膜は極薄となり拡散接合に最適な条件となる。なお、前述したように雰囲気圧力1×10-2Pa以下とした後にAr、He、N2、などの不活性ガスを封入して接合させることも可能である。
量産性の観点から、加熱保持時間は極力短い方が良い。ただし、接合部品全体へ均一に熱を付与し、原子拡散を十分に励起するためには30min以上の加熱時間が必要であった。一方、120min以上の保持時間を与えると母材強度に影響を及ぼす程度まで結晶粒が成長するため、好適な保持時間を30~120minとした。
まず、供試材の接合性を確認するために、表1に記載の成分組成を有する鋼板を用い、板厚0.4mmの箱型部品のみを成形し、図5(a)に示すように3枚積層させた。このときの縦壁角度θは、30°とし、ろう材の塗布は行わなかった。また、成形部の表面粗さRaは0.3μm≦である。
この仮組した加工品を表2に記載の条件および図6にヒートパターンより選択した条件で拡散接合を行った。すなわち、横型真空炉に入れ、雰囲気圧力を1×10-2Pa以下に到達させた後、図6に示すヒートパターン(3)にて加熱し、加熱温度を1200℃、均熱時間を2.0h、負荷面圧を0.5MPaとした。この条件は、量産性の観点から上限と考えられる温度、面圧である。
負荷は、加工品の上下をアルミナ製のセラミックス板で挟み、その上にSUS430製の錘を乗せることにより付与した。加圧力は縦壁部の接触総面積S(mm2),錘の重量P(N)よりPsinθ/S=0.5MPaとなるよう簡易的に調整した。
結果を表3に示す。
サンプルNo.7~11、No.15~19、No.21~28の発明材は、1200℃、2.0h、0.5MPaの条件において酸化する着色が認められず、また良好な接合性を有していた。一方、比較材のサンプルNo.1~6、No.12~14、No.20は、着色していたとともに接合状態も不十分であった。そこで、以下の実験には、発明材のみを用いて好適な接合状態を確認した。
実施例1のNo.10、No.16、No.24で作製した3枚の箱型部品の間に、0.4mmの鋼板を成形した断面が(1)三角形、(2)台形、(3)四角形からなるフィン型部品を2枚挿入した。そして、図3(a)に示すような板厚1.0mmの天板と底板を、前記箱型部品およびフィン型部品に組み込んで、仮組みの熱交換器とした。なお、縦壁の角度θをプレスにて矯正し種々変化させた。図3にa(天板-箱型部品)、b(底板-箱型部品)、c(フィン部)、d(箱型部品縦壁部)で示す各当接箇所において拡散接合処理を施すための試験体を作製した。また、前記c、dで示す当接箇所については、当接領域の一部に純Cuろうを塗布した試験体も作製した。このときのCuろうは、0.3g/cm2とした。
結果を表4にまとめて示す。本発明例に含まれるNo.1~9は、全て3MPaの耐圧試験にて漏れが発生せず、良好な接合性を有していた。一方、比較例のNo.10およびNo.11は、縦壁角度が大きく、また、No.12は、内部にフィンを用いなかったため、試験中に箱型部品が潰れてしまい、十分な耐圧性を有しなかった。
結果を表5に示す。No.13およびNo.15は、ろうの溶融が不十分で接合が不完全であった。また、No.14およびNo.16は、温度および時間が高温長時間側で外れており、No.18は、加圧力が高すぎ、加熱中の変形が大きく耐圧性に劣った。No.17は、加圧力が低すぎ、またNo.19は、雰囲気の雰囲気圧力が低すぎて、いずれも十分に接合できず、耐圧性に劣った。
このように接合条件が、本規定の範囲から外れると十分な耐圧性を有しないことがわかる。なお、本規定の範囲に含まれる条件で接合を行うと、表3およびNo.20に示すように十分な耐圧性を有することがわかる。
Claims (8)
- 熱交換器ケースを構成する矩形プレート型部品が、周縁に縦壁部を備えた箱型部品であり、当該箱型部品と同形の箱型部品が水平面の向きを反転させて前記箱型部品に積層されるとともに、当該積層された積層下部品の縦壁部上部が当該積層された積層上部品の縦壁部下部に嵌入されており、前記縦壁部の角度(θ)がθ≦30°であって、前記縦壁部上部と前記縦壁部下部との当接部位において少なくとも一部が固相拡散接合されていることを特徴とするプレート式熱交換器。
- 前記当接部位において少なくとも一部がろう付け接合されていることを含む請求項1に記載のプレート式熱交換器。
- 前記積層上部品と前記積層下部品との当接部が固相拡散接合またはろう付け接合されている請求項1または2に記載のプレート式熱交換器。
- 前記箱型部品は、その上面において対称位置に二種の開口が、一方は当該箱型部品の上方に張出して開口し、他方は当該箱型部品の内方に同じ高さで張出して開口した形で形成されたプレス成型品であり、前記積層下部品の上方張出開口部上面と前記積層上部品の下方張出開口部上下面の当接部において両者が固相拡散接合またはろう付け接合されている請求項1~3のいずれかに記載のプレート式熱交換器。
- 前記積層箱型部品の上面平坦部に、断面形状が三角形または台形または四角形で高さがフランジ高さと同じフィンが形成されており、積層上部品の先端片が積層下部品のパンチ肩近傍平坦部に当接させた際に、前記フィンの先端同士が当接し、当該当接部で両者が固相拡散接合またはろう付けされて形成された流路接合部が良好な接合強度を有する請求項1~4のいずれかに記載のプレート式熱交換器。
- 積層された二つの箱型部品の間に、断面形状が三角または台形または四角形で高さがフランジ高さと同じフィン部品が挿入され、積層上部品の先端片が積層下部品のパンチ肩近傍平坦部に当接させた際に、前記フィン部品の先端が箱型部品の上面平坦部に当接し、当該当接部で両者が固相拡散接合またはろう付けされた流路接合部が良好な接合強度を有する請求項1~4のいずれかに記載のプレート式熱交換器。
- 請求項1~6のいずれかに記載のプレート式熱交換器の製造方法であって、化学成分が0.1Si+Ti+Al<0.15質量%、表面粗さRa≦0.3μmのフェライト単相系ステンレス鋼板またはオーステナイト系ステンレス鋼板またはマルテンサイト系ステンレス鋼板を用いた箱型部品の積層組立体を、加熱温度が1100℃以上、加圧力が0.3MPa以上、雰囲気圧力10-2Pa以下の雰囲気で加熱して固相拡散接合することを特徴とするプレート式熱交換器の製造方法。
- 請求項1~6のいずれかに記載のプレート式熱交換器の製造方法であって、化学成分が0.1Si+Ti+Al<0.15質量%、表面粗さRa≦2.0μmの2相系ステンレス鋼板を用いた箱型部品の積層組立体を、加熱温度が1000℃以上、加圧力が0.1MPa以上、雰囲気圧力10-2Pa以下の雰囲気で加熱して固相拡散接合することを特徴とするプレート式熱交換器の製造方法。
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MY190700A (en) | 2022-05-11 |
US20170067700A1 (en) | 2017-03-09 |
CA2939817A1 (en) | 2015-08-27 |
US10502507B2 (en) | 2019-12-10 |
CN106062499B (zh) | 2019-12-06 |
EP3109582A4 (en) | 2017-01-25 |
ES2774033T3 (es) | 2020-07-16 |
EP3109582B1 (en) | 2020-02-12 |
KR102268451B1 (ko) | 2021-06-22 |
EP3109582A1 (en) | 2016-12-28 |
CA2939817C (en) | 2022-04-05 |
JP6192564B2 (ja) | 2017-09-06 |
MX2016010608A (es) | 2017-04-27 |
CN106062499A (zh) | 2016-10-26 |
SG11201606806QA (en) | 2016-09-29 |
JP2015152282A (ja) | 2015-08-24 |
KR20160121573A (ko) | 2016-10-19 |
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