CN107318179A - 一种增韧氧化铝制作高温共烧发热管的方法 - Google Patents
一种增韧氧化铝制作高温共烧发热管的方法 Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 19
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 title claims abstract description 17
- 238000010344 co-firing Methods 0.000 title claims abstract description 15
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 19
- 238000004080 punching Methods 0.000 claims abstract description 7
- 239000000919 ceramic Substances 0.000 claims abstract description 6
- 238000007639 printing Methods 0.000 claims abstract description 4
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- 239000000843 powder Substances 0.000 claims description 15
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 12
- 239000002002 slurry Substances 0.000 claims description 12
- 238000005266 casting Methods 0.000 claims description 9
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 6
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 6
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 6
- 239000012298 atmosphere Substances 0.000 claims description 6
- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 claims description 6
- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical compound O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 claims description 6
- 238000000465 moulding Methods 0.000 claims description 6
- 229910052757 nitrogen Inorganic materials 0.000 claims description 6
- 238000005245 sintering Methods 0.000 claims description 5
- 239000002270 dispersing agent Substances 0.000 claims description 4
- PCEXQRKSUSSDFT-UHFFFAOYSA-N [Mn].[Mo] Chemical compound [Mn].[Mo] PCEXQRKSUSSDFT-UHFFFAOYSA-N 0.000 claims description 3
- 238000000498 ball milling Methods 0.000 claims description 3
- 239000011230 binding agent Substances 0.000 claims description 3
- 239000007767 bonding agent Substances 0.000 claims description 3
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 claims description 3
- 239000000292 calcium oxide Substances 0.000 claims description 3
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 claims description 3
- 238000007766 curtain coating Methods 0.000 claims description 3
- 239000011267 electrode slurry Substances 0.000 claims description 3
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- 239000007924 injection Substances 0.000 claims description 3
- 238000003801 milling Methods 0.000 claims description 3
- 229910052759 nickel Inorganic materials 0.000 claims description 3
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- 239000000377 silicon dioxide Substances 0.000 claims description 3
- 239000002904 solvent Substances 0.000 claims description 3
- 239000004408 titanium dioxide Substances 0.000 claims description 3
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical group [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 3
- 229910052721 tungsten Inorganic materials 0.000 claims description 3
- 239000010937 tungsten Substances 0.000 claims description 3
- 238000000227 grinding Methods 0.000 claims 1
- 238000005476 soldering Methods 0.000 claims 1
- 238000010438 heat treatment Methods 0.000 abstract description 15
- 238000005516 engineering process Methods 0.000 abstract description 4
- 238000005238 degreasing Methods 0.000 abstract description 3
- 238000009413 insulation Methods 0.000 abstract description 3
- 238000004134 energy conservation Methods 0.000 abstract description 2
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Abstract
本发明公开了发热管加工技术领域的一种增韧氧化铝制作高温共烧发热管的方法，其具体步骤如下：S1：加工素烧管；S2流延生片；S3：冲床冲压并打孔；S4：正面印刷发热电阻及背面电极；S5：生片卷管；S6：预先脱脂烧结；S7：钎焊引线，本发明与普通电热丝制作的发热管相比，发热效率提升30％，耐压可达到4000V以上，与普通氧化铝陶瓷共烧发热体对比，可靠性大幅度提高，寿命大幅度提升，本发明技术成熟、且可靠性高，在相同条件下，比PTC发热组件节能20％以上，无启动冲击电流、可控性好，散热体表面高绝缘，安全性高，升温比电炉丝或PTC发热组件快，长期使用功率衰减低于4％，工作寿命长。
Description
技术领域
本发明涉及发热管技术领域，具体为一种增韧氧化铝制作高温共烧发热管的方法。
背景技术
普通电热丝或PTC等发热体，发热效率不高，功率大，热量损失大，绝缘难以达到标准等问题。一般氧化铝陶瓷与金属浆料高温共烧，制成的氧化铝陶瓷发热体，在急冷急热环境易产生不可预见爆裂。为此，我们提出了一种增韧氧化铝制作高温共烧发热管的方法投入使用，以解决上述问题。
发明内容
本发明的目的在于提供一种增韧氧化铝制作高温共烧发热管的方法，以解决上述背景技术中提出的问题。
为实现上述目的，本发明提供如下技术方案：一种增韧氧化铝制作高温共烧发热管的方法，该方法的具体步骤如下：
S1：用等静压、注射和热压铸工艺，制作95氧化铝陶瓷管(或棒)，素烧至1000-1300度，外圆磨加工至需要的直径，长度加工至需要的长度，备用；
S2：在95氧化铝粉中加入微量纳米氮化铝粉体，随后加入溶剂、粘结剂和分散剂，在球磨机中球磨，使粉体均匀分散，制成合适粘度的浆料，流延成型；
S3：流延好的生带，冲床冲压成片并打孔，以保证电极部分电极浆料印刷时过孔；
S4：流延生片正面印刷电阻浆料，背面印刷电极，保证电极与电阻通过孔导通；
S5：将印好的生片，电极朝外，卷在素烧管上，使流延生片边缘刚好重合，为方便卷边，可提前在电阻面再次印刷粘接剂；
S6：将卷好的管用等静压加压，保证生片与素烧管紧密结合，中间无空气残留，预先脱脂，在氮气保护气氛下烧结致密；
S7：将烧结好的管状发热体，外露电极部分电镀镍并在氮气保护气氛下，将引线钎焊在电极上，制作成增韧陶瓷共烧发热体。
优选的，所述步骤S2中，95氧化铝粉与纳米氮化铝粉体的添加比例为97：3。
优选的，所述步骤S2中，助烧剂为二氧化硅、氧化钙、二氧化钛或三氧化二硼中的一种。
优选的，所述步骤S2中，浆料流延成型的厚度为0.3-1mm。
优选的，所述步骤S3中，冲床冲压成片的长宽尺寸，以刚好可卷满氧化铝素烧管为宜。
优选的，所述步骤S4中，电阻浆料为钨钼或钼锰。
与现有技术相比，本发明的有益效果是：本发明与普通电热丝制作的发热管相比，发热效率提升30％，耐压可达到4000V以上，与普通氧化铝陶瓷共烧发热体对比，可靠性大幅度提高，寿命大幅度提升，本发明技术成熟、且可靠性高，在相同条件下，比PTC发热组件节能20％以上，无启动冲击电流、可控性好，散热体表面高绝缘，安全性高，升温比电炉丝或PTC发热组件快，长期使用功率衰减低于4％，工作寿命长。
附图说明
图1为本发明工作流程图。
具体实施方式
下面将结合本发明实施例中的附图，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一部分实施例，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做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。
请参阅图1，本发明提供一种技术方案：一种增韧氧化铝制作高温共烧发热管的方法，该方法的具体步骤如下：
S1：用等静压、注射和热压铸工艺，制作95氧化铝陶瓷管(或棒)，素烧至1000-1300度，外圆磨加工至需要的直径，长度加工至需要的长度，备用；
S2：在95氧化铝粉中加入微量纳米氮化铝粉体，95氧化铝粉与纳米氮化铝粉体的添加比例为97：3，随后加入溶剂、粘结剂和分散剂，分散剂为二氧化硅、氧化钙、二氧化钛或三氧化二硼中的一种，在球磨机中球磨，使粉体均匀分散，制成合适粘度的浆料，流延成型，浆料流延成型的厚度为0.3-1mm；
S3：流延好的生带，冲床冲压成片并打孔，冲床冲压成片的长宽尺寸，以刚好可卷满氧化铝素烧管为宜，以保证电极部分电极浆料印刷时过孔；
S4：流延生片正面印刷电阻浆料，电阻浆料为钨钼或钼锰，背面印刷电极，保证电极与电阻通过孔导通；
S5：将印好的生片，电极朝外，卷在素烧管上，使流延生片边缘刚好重合，为方便卷边，可提前在电阻面再次印刷粘接剂；
S6：将卷好的管用等静压加压，保证生片与素烧管紧密结合，中间无空气残留，预先脱脂，在氮气保护气氛下烧结致密；
S7：将烧结好的管状发热体，外露电极部分电镀镍并在氮气保护气氛下，将引线钎焊在电极上，制作成增韧陶瓷共烧发热体。
本发明可同样制作素烧棒、素烧片，或其他异形素烧陶瓷坯体，制作各种类型其他发热体，本发明与外加电路、温度传感器、压力传感器制成发热控制器，并应用于智能马桶盖、即热式水龙头、即热式热水器和电子烟等。
尽管已经示出和描述了本发明的实施例，对于本领域的普通技术人员而言，可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的范围由所附权利要求及其等同物限定。
Claims (6)
1.一种增韧氧化铝制作高温共烧发热管的方法，其特征在于：该方法的具体步骤如下：
S1：用等静压、注射和热压铸工艺，制作95氧化铝陶瓷管(或棒)，素烧至1000-1300度，外圆磨加工至需要的直径，长度加工至需要的长度，备用；
S2：在95氧化铝粉中加入微量纳米氮化铝粉体，随后加入溶剂、粘结剂和分散剂，在球磨机中球磨，使粉体均匀分散，制成合适粘度的浆料，流延成型；
S3：流延好的生带，冲床冲压成片并打孔，以保证电极部分电极浆料印刷时过孔；
S4：流延生片正面印刷电阻浆料，背面印刷电极，保证电极与电阻通过孔导通；
S5：将印好的生片，电极朝外，卷在素烧管上，使流延生片边缘刚好重合，为方便卷边，可提前在电阻面再次印刷粘接剂；
S6：将卷好的管用等静压加压，保证生片与素烧管紧密结合，中间无空气残留，预先脱脂，在氮气保护气氛下烧结致密；
S7：将烧结好的管状发热体，外露电极部分电镀镍并在氮气保护气氛下，将引线钎焊在电极上，制作成增韧陶瓷共烧发热体。
2.根据权利要求1所述的一种增韧氧化铝制作高温共烧发热管的方法，其特征在于：所述步骤S2中，95氧化铝粉与纳米氮化铝粉体的添加比例为97：3。
3.根据权利要求1所述的一种增韧氧化铝制作高温共烧发热管的方法，其特征在于：所述步骤S2中，助烧剂为二氧化硅、氧化钙、二氧化钛或三氧化二硼中的一种。
4.根据权利要求1所述的一种增韧氧化铝制作高温共烧发热管的方法，其特征在于：所述步骤S2中，浆料流延成型的厚度为0.3-1mm。
5.根据权利要求1所述的一种增韧氧化铝制作高温共烧发热管的方法，其特征在于：所述步骤S3中，冲床冲压成片的长宽尺寸，以刚好可卷满氧化铝素烧管为宜。
6.根据权利要求1所述的一种增韧氧化铝制作高温共烧发热管的方法，其特征在于：所述步骤S4中，电阻浆料为钨钼或钼锰。
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