CN112746242A

CN112746242A - Electric heating coating for improving electric energy utilization efficiency and temperature control and preparation method thereof

Info

Publication number: CN112746242A
Application number: CN202011597473.6A
Authority: CN
Inventors: 谭僖; 朱晖朝; 王枫; 陈志坤; 李福球
Original assignee: Guangdong Yueke New Material Technology Co ltd; Foshan Taoyuan Advanced Manufacturing Research Institute
Current assignee: Guangdong Yueke New Material Technology Co ltd; Foshan Taoyuan Advanced Manufacturing Research Institute
Priority date: 2020-12-29
Filing date: 2020-12-29
Publication date: 2021-05-04
Also published as: WO2022142091A1

Abstract

The invention discloses an electric heating coating for improving electric energy utilization efficiency and temperature control, which sequentially comprises the following components: 1) a substrate; 2) al (Al)₂O₃A thin film layer; 3) circuit layers (including metallic copper coatings and integrated circuit layers). The invention also provides a preparation method based on the electric heating coating, which comprises the following steps: a) inspecting and surface-pretreating the substrate, b) aluminizing the substrate surface, c) converting the surface aluminum into Al₂O₃Film, d) coating Al by cold spraying₂O₃Depositing a copper coating on the film and annealing; e) etching the copper circuit after the annealing treatment in the step d); f) the sensor and other electronic components are soldered and encapsulated in designated areas of the electrically heated coating. The electric heating coating has a coating heating function, can have good functions of temperature monitoring, regulation and control and the like after passing through the integrated control circuit, can integrate high-power electronic components, and improves the stability of the electronic components and the utilization efficiency of heat energy.

Description

Electric heating coating for improving electric energy utilization efficiency and temperature control and preparation method thereof

Technical Field

The invention relates to the technical field of electric heating coatings, in particular to an electric heating coating for improving electric energy utilization efficiency and temperature control and a preparation method thereof.

Background

With the continuous development and popularization of hybrid vehicles and electric vehicles, the function of electric heaters is increasingly prominent. The electric heater has high requirements mainly on heating efficiency, quality, size, cost, safety and the like. The current mainstream electric heating technology is mainly wire-wound resistance heating technology and positive temperature coefficient heating technology, however, the electric heating efficiency of the two technologies needs to be improved, the size and the quality need to be further reduced, and in addition, the technologies have the defects of difficult temperature control, slow thermal response time and the like. The occurrence of the thermal layer technology is promoted because the mainstream electric heating technology has larger defects.

For example, an electrically heated anti-icing coating and method of making the same (application No. 201610489651.0), an electrically heated technology for aircraft anti-icing/deicing (application No. 201710248415.4), and the like all provide a multi-layer electrically heated coating system; a novel electric heating coating and a preparation method thereof (application number 201910940041.1) also disclose an electric heating coating system with a 3-layer structure. However, these techniques only relate to how to realize the thermal layer technique, i.e. how to realize the purpose of heating by designing the coating; but does not relate to the practical problems of how to control the temperature, how to utilize the electric energy more effectively and the like.

On the other hand, the related technologies (including the related technologies of electric vehicles) related to the field of electric heating are developed towards light weight, high efficiency, intelligence and integration, and how to realize the electric heating technology from a more macroscopic and practical level is particularly urgent.

In view of the above, the invention provides a preparation technology of the electric heating coating, and provides a design idea considering the problems of how to control the temperature, how to effectively utilize the electric energy and the like from the viewpoint of integration and intellectualization.

Disclosure of Invention

The invention aims to provide a preparation method of an electric heating coating, which is a brand new design idea, takes a thermal layer technology as a basic function, has core functions of temperature monitoring, regulation and control and the like, can integrate high-power electronic components, improves the stability of the electronic components and improves the utilization efficiency of heat energy. The method is suitable for the fields including but not limited to automobiles, high-speed rails, aviation, new energy and the like.

In order to achieve the purpose, the invention adopts the following technical scheme:

an electrical heating coating for improving electrical energy utilization efficiency and temperature control, the electrical heating coating comprising in sequence:

1) a substrate;

2)Al₂O₃a thin film layer;

3) and a circuit layer.

Alternatively, Al₂O₃The thickness of the thin film layer is 2-15 mu m.

Optionally, the circuit layer includes a metallic copper coating and an integrated circuit layer. Preferably, the thickness of the metallic copper coating is 10 to 1000 μm, and most preferably 10 to 100 μm.

The preparation method and the design idea of the electric heating coating based on the improvement of the electric energy utilization efficiency and the temperature control are as follows:

a) the base material is inspected by means of naked eyes, optical microscope sampling and the like to confirm that the equipment has no defects such as holes, impurities and the like, and oil removal treatment is carried out by adopting one or more modes of flame burning, alcohol cleaning and acetone cleaning according to the specific conditions of the base material.

b) And carrying out aluminum plating treatment on the surface of the base material by adopting methods such as magnetron sputtering and the like.

Alternatively, if the substrate itself is Al or an Al alloy, this step may be omitted;

optionally, the thickness of the aluminum plating layer is 2-20 μm.

c) Forming a layer of Al on the surface of the base material by adopting an anodic oxidation method₂O₃A film.

Alternatively, Al₂O₃The layer can also be obtained by thermal spraying, chemical deposition, etc., in which case the optimum thickness depends on the application.

Alternatively, Al₂O₃The film may be replaced by an insulating material such as resin, glass, or an organic film, and the optimum thickness depends on the use.

d) By cold spraying on Al₂O₃And continuously depositing a copper coating on the surface of the film, and then carrying out annealing treatment.

Optionally, the thickness of the copper coating is matched with the design power of the electric heater, and is usually 10-1000 μm; preferably, the thickness of the copper coating is 10 to 100 μm.

Optionally, the annealing temperature is about 400 ℃ or 350-450 ℃.

e) The copper coating is etched in a certain way to form a copper circuit with a desired characteristic loop.

Optionally, the etching method includes, but is not limited to, electrochemical etching, and the like.

In particular, the above step e) can also be achieved by: before the step d), according to the shape of the required copper circuit, by designing a corresponding clamp or adding a certain protective layer on the surface of the ceramic coating, the copper circuit with the required specific shape is directly deposited in the step d) without being corroded again.

f) According to the actual function and design of the electric heater, the sensor and other electronic components are welded on the designated area of the electric heating coating and are packaged properly to obtain the integrated circuit layer.

Optionally, the step is to provide a design idea, and does not limit the specific implementation approach;

optionally, any number of designated areas on the coating surface can be set, depending on the actual function and design of the electric heater;

alternatively, the designated area may be located anywhere on the entire coating surface, and its size and shape are also not fixed, depending also on the actual function and design of the electric heater.

The embodiment of the invention also provides an electric heating coating which is obtained based on any one of the preparation methods or the design ideas.

Based on the electric heating coating provided by the invention, better temperature control can be realized through an integrated control circuit, and the utilization rate of electric energy can be greatly improved by utilizing the overall design of the integrated circuit layer and adopting a copper conducting layer material with lower resistance.

Drawings

Fig. 1 is a schematic view of an electrically heated coating provided by the present invention. Wherein, 1-coolant, 2-Al substrate, 3-Al₂O₃Membrane, 4-copper circuit, 5-high power device, 6-sensor.

Fig. 2 is a schematic view of another electrically heated coating provided by the present invention. Wherein 1 ' ' -coolant, 2 ' -stainless steel substrate, 3 ' -aluminized film, 4 ' -Al₂O₃Membrane, 5 '-copper circuit, 6' -sensor.

Fig. 3 is a schematic view of another electrically heated coating provided by the present invention.Wherein, 1 ' -coolant, 2 ' -Al alloy substrate, 3 ' -Al₂O₃Membrane, 4 "-copper circuit, 5" -sensor.

Detailed Description

In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. The examples, in which specific conditions are not specified, were conducted under conventional conditions or conditions recommended by the manufacturer. The reagents or instruments used are not indicated by the manufacturer, and are all conventional products available commercially.

The preparation method and design concept of the electric heating coating provided by the invention are specifically explained below.

It is first pointed out that the thermal layer technology that has emerged in recent years is quite different from the heating principles and modes of the conventional wire-wound resistance heating technology and the ptc heating technology, and has significant advantages in terms of electrical heating efficiency, size and mass reduction, temperature control, thermal response time, etc., so that the conventional wire-wound resistance heating technology and the ptc heating technology are no longer specifically compared with the technology of the present invention.

Secondly, the inventor finds that the thermal layer technology is disclosed to a certain extent in recent years, however, the related technologies (including the related technologies of electric vehicles) related to the electric heating field are developed towards the directions of light weight, high efficiency, intellectualization and integration, and how to design and manufacture the electric heating coating with higher performance and more integrated functions is very important, and from the viewpoint, the invention provides a design idea of the structure design and the preparation method of the electric heating coating with higher performance and more functions compared with the prior public reports. The invention adopts a large number of modern surface engineering technical means, relates to a plurality of fields of vacuum coating, anodic oxidation, cold spraying, integrated circuits and the like, is a multidisciplinary and multi-technology comprehensive innovation, aims to realize the basic function of electric heating, has core functions of temperature monitoring, regulation and control and the like, can integrate high-power electronic components, improves the stability of the electronic components and improves the utilization efficiency of heat energy. It is contemplated that the technology may be applied to fields including, but not limited to, automotive, high-speed rail, aerospace, and new energy.

Some embodiments of the present invention provide an electrically heated coating, a method of preparing the same, and design considerations, which may specifically include:

a) the base material is inspected and surface-pretreated to confirm that no specific defect exists on the surface of the base body, and the surface of the base material is cleaned.

The base material is inspected by means of naked eyes, optical microscope sampling and the like to confirm that the equipment has no defects such as holes, impurities and the like, and oil removal treatment is carried out by adopting one or more modes of flame burning, alcohol cleaning and acetone cleaning according to the specific conditions of the base material.

The above are some conventional pretreatments of the substrate and their use is not specifically described here.

b) The surface of the substrate is subjected to aluminum plating by magnetron sputtering or the like, and this step can be omitted if the substrate itself is Al or an Al alloy.

In some preferred implementation methods, the substrate is made of Al or Al alloy, so that the magnetron sputtering process can be omitted, the process is simplified, and the cost is reduced; of course, the substrate may be metal of other materials, even ceramic, composite material, etc., and then a layer of aluminum is plated on the surface of the substrate by magnetron sputtering, preferably, the thickness of the aluminum plated layer is 2 to 20 μm.

In some preferred embodiments, a layer of Al is formed on the surface of the Al/Al alloy substrate or the aluminum-plated substrate by anodic oxidation₂O₃Film of Al formed by magnetron sputtering aluminum-plated + anodic oxidation₂O₃A film of Al as a component₂O₃Gradually changed into a gradient film of Al/Al alloy, the gradient film has the advantages of good bonding property, less defects, low porosity, good high-temperature resistance and the like, so that the heat transfer efficiency is higher, the electric energy utilization efficiency of the electric heating coating can be improved, the thermal response speed of the coating is improved, and preferably, Al₂O₃The thickness of the film is 2 to 15 μm.

In some preferred embodiments, Al₂O₃The layer can also be obtained by deposition on the surface of the substrate by thermal spraying, chemical deposition and the like, but Al obtained by anodic oxidation₂O₃The film is more compact, and the thickness is better controlled, so that the film has better insulation and heat conduction effects; however, if under special requirements, for example, Al is required₂O₃When the film thickness is thick, or for Al₂O₃When the requirements on the insulating and heat conducting effects of the film are not strict, other methods for depositing Al on the surface of the substrate can be considered₂O₃And (3) a layer.

In some preferred embodiments, Al is used when insulation and thermal conductivity are not critical₂O₃The film may be replaced by an insulating material such as resin, glass, or organic thin film, and these insulating materials may have insufficient heat resistance and poor insulating and heat conducting effects, but these materials are used instead of Al₂O₃Thin films tend to be cost effective and are therefore also possible.

d) And a compact copper coating is deposited on the surface by adopting a cold spraying technology, and the electrical property of the copper coating is improved by annealing treatment.

In some preferred embodiments, a copper coating layer is formed by depositing copper by cold spraying and annealing the copper coating layer. This is because copper itself is a metal with good conductivity and is relatively inexpensive. The copper coating obtained by cold spraying copper and annealing treatment is compact (porosity is less than 0.5%), and has conductivity equivalent to that of cast copper, so that extremely low resistance is obtained (which is different from that of a comparative technology by orders of magnitude). From electrical knowledge, it can be known that the lower the resistance, the higher the power at the same voltage. This means that in voltage-limited application scenarios like automobiles, aircrafts, etc., the electrically heated coating of the present invention will have a much higher maximum electrical heating power than the comparative technology; alternatively, with the same output power, there is a lower end voltage, which means that less power is lost during transmission. It can be seen that the present invention has significant advantages in increasing the maximum electric heating power and reducing the electric energy loss compared with other comparative examples (CN201610489651.0, CN201710248415.4, CN 201910940041.1).

e) The copper coating is etched to obtain the desired copper circuit.

In some preferred embodiments, this is accomplished by chemical or electrochemical etching.

It should be noted that here too, a method for obtaining copper circuits is proposed, but not limited to this route of etching:

in some preferred embodiments, before cold spraying the copper coating, according to the shape of the required copper circuit, by designing a corresponding clamp or adding a certain protective layer on the surface of the ceramic coating, the copper circuit with the required specific shape can be directly deposited in the process of cold spraying the copper coating without carrying out corrosion again;

in some preferred embodiments, non-corrosive means such as laser engraving may be considered for obtaining copper circuitry.

f) The sensor and other electronic components are soldered at designated areas of the electrically heated coating and appropriately packaged to obtain an integrated circuit layer.

The content included in this step is actually a design idea, and is not limited to one or some specific embodiments, and it needs to be properly matched with steps d) and e) to achieve this purpose. The step is closely related to the design of the electric heater and the heat exchanger, one or more groups of integrated circuits are designed according to the specific functions required by the electric heater and the heat exchanger, and then the electric heating coating is used as an insulating substrate of the integrated circuits to endow more functions to the electric heating coating. The benefits of this are: firstly, the integration level of the electric heater and the heat exchanger is improved, so that the size and the weight of related structures are reduced; the electric heater and the heat exchanger are combined into a whole, so that the heat of the heat exchanger can be used for electric heating, the electric energy consumption of the electric heater can be greatly reduced under a specific application way, and the electric heat conversion efficiency is greatly improved; and thirdly, the heating power of the electric heater can be regulated and controlled in real time by combining the integrated sensor with a related control circuit, so that more stable and stable temperature control is obtained. Of course, more functions related to the electric heater and the heat exchanger can be realized by suitable integrated circuit design, and the invention is not listed here.

Some embodiments of the present invention also provide electrically heated coatings, obtained according to the manufacturing methods and design considerations provided in any of the examples above.

The features and properties of the present invention are described in further detail below with reference to specific examples.

Example 1

a) And (3) detecting the Al substrate by naked eyes to see whether the substrate has defects such as scratches, holes, miscellaneous clips and the like. Then, the surface of the Al substrate was wiped with acetone to remove oil.

b) This step is omitted in view of the fact that the base material is an Al substrate.

c) Oxidizing Al with the thickness of 10 mu m on the surface of the Al substrate by anodic oxidation₂O₃A film.

d) Spraying a copper coating on the ceramic layer by using pure copper powder as raw material powder and adopting a cold spraying technology, wherein the thickness of the copper coating is 10 mu m, and then carrying out annealing treatment at 400 ℃;

e) corroding the copper coating into an electric circuit with a specific shape by using a chemical corrosion method;

f) soldering sensors and other electronic components in designated areas of the electrically heated coating and appropriate packaging, as shown in FIG. 1; and (5) obtaining the product.

Example 2

a) And (3) detecting the stainless steel substrate by naked eyes to see whether the substrate has defects such as scratches, holes, miscellaneous clips and the like. Then, the surface of the stainless steel substrate was wiped with acetone to remove oil.

b) And plating an aluminum plating layer with the thickness of 15 mu m on the surface of the base material by adopting a magnetron sputtering method and the like.

c) Al of 10 μm thickness is oxidized on the aluminized film by anodic oxidation₂O₃A film.

f) soldering sensors and other electronic components in designated areas of the electrically heated coating and appropriate packaging, as shown in FIG. 2; and (5) obtaining the product.

Example 3

a) And (3) detecting the Al alloy substrate by naked eyes to see whether the substrate has defects such as scratches, holes, impurities and the like. Then, the surface of the Al alloy substrate was wiped with acetone to remove oil.

b) This step is omitted in view of the fact that the base material is an Al alloy substrate.

c) Oxidizing Al with the thickness of 10 mu m on the surface of the Al alloy substrate by anodic oxidation₂O₃A film.

e) corroding the copper coating into an electric circuit with a specific shape by using a laser engraving method;

f) soldering sensors and other electronic components in designated areas of the electrically heated coating and appropriate packaging, as shown in FIG. 3; and (5) obtaining the product.

The above description is only a preferred embodiment of the present application and is not intended to limit the present application, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. The utility model provides an promote electric energy utilization efficiency and temperature control's electrical heating coating which characterized in that, electrical heating coating includes in proper order:

1) a substrate;

2)Al₂O₃a thin film layer;

3) and a circuit layer.

2. The electrically heated coating for improved electrical energy utilization efficiency and temperature control of claim 1, wherein Al is₂O₃The thickness of the thin film layer is 2-15 mu m.

3. The electrically heated coating for improved power efficiency and temperature control of claim 1 wherein the circuit layer comprises a metallic copper coating and an integrated circuit layer.

4. An electric heating coating for improving electric energy utilization efficiency and temperature control as claimed in claim 3, wherein the thickness of the metallic copper coating is 10-1000 μm, preferably 10-100 μm.

5. A method for preparing an electrically heated coating for improving electrical energy utilization efficiency and temperature control according to claim 1, comprising:

a) inspecting and surface-pretreating the base material to confirm that no specific defect exists on the surface of the base body and clean the surface of the base material;

b) performing aluminum plating treatment on the surface of the base material by adopting magnetron sputtering, wherein if the base material is Al or Al alloy, the step can be omitted;

c) forming a layer of Al on the surface of the base material by adopting an anodic oxidation method₂O₃A film;

d) depositing a compact copper coating on the surface by adopting a cold spraying technology, and annealing;

e) etching the copper coating to obtain the desired copper circuit;

f) the sensor and other electronic components are soldered and encapsulated in designated areas of the electrically heated coating.

6. The method for preparing an electrically heated coating for improving efficiency of electric energy utilization and temperature control as claimed in claim 5, wherein the examination in step a) includes but is not limited to visual observation, optical microscope sampling observation; the specific defects include, but are not limited to, holes, inclusions; the surface pretreatment is oil removal treatment.

7. The method for preparing an electric heating coating for improving the electric energy utilization efficiency and controlling the temperature according to claim 5, wherein the thickness of the aluminum plating layer in the step b) is 2 to 20 μm.

8. The method for preparing an electrically heated coating for improving electrical energy utilization efficiency and temperature control of claim 5, wherein said Al in step c)₂O₃The thin film may also be obtained by thermal spraying or chemical deposition, in which case step b) may be omitted.

9. The method for preparing an electrically heated coating for improving efficiency of electric energy utilization and temperature control as claimed in claim 5, wherein the temperature of the annealing treatment in step d) is 350 ℃ to 450 ℃.

10. The method for preparing an electrically heated coating with improved electrical energy utilization efficiency and temperature control as claimed in claim 5, wherein the corrosion in step e) includes but is not limited to chemical corrosion.