A heating and thermal insulation integrated member and a method for manufacturing the same

Abstract

This invention relates to an integrated heating and insulation component and its manufacturing method. The component includes a heating circuit layer and a super insulation layer stacked together. The heating circuit layer comprises a polytetrafluoroethylene-coated fiberglass base layer, a metal foil etched circuit layer, and a thermoplastic FEP (fluoroethylene propylene) film layer stacked sequentially. The super insulation layer comprises a super insulation material layer and an outer protective material layer. The super insulation material layer is stacked on the thermoplastic FEP film layer, and the outer protective material layer is the outermost layer, stacked on the super insulation material layer. This integrated component fits tightly, occupies little magnet space, meets thickness requirements, and eliminates the need to install the heating structure first and then the insulation structure during installation, simplifying installation and reducing the workload.

Description

Technical Field

[0001] This invention relates to an integrated heating and insulation component and its manufacturing method, belonging to the field of heating and insulation technology for heavy ion accelerators. Background Technology

[0002] To achieve extremely high vacuum levels, heavy ion accelerator vacuum systems require various vacuum pumps and simultaneous high-temperature heating of the vacuum pipes to completely release adsorbed gas molecules such as water vapor, carbon monoxide, and hydrogen from the pipe walls. To accelerate this release, heating structures are installed on the pipes within the ultra-high vacuum system, while also ensuring insulation, minimizing heat loss, and maintaining uniform temperature. To reduce construction costs, the space for heating and insulation structures within the vacuum pipes, located inside the magnets, is extremely limited. Therefore, a highly insulated, ultra-thin heating and insulation structure is needed to meet these requirements. Currently, the traditional structure involves uniformly sewing nickel-cadmium alloy wires onto a high-temperature fabric, then wrapping it with a thin insulating material. This structure has a total thickness greater than 5.5 mm, and the two components cannot fit tightly together, occupying significant magnet space and failing to meet the required thickness. Furthermore, installation requires first installing the heating structure and then the insulation structure, which is difficult and involves a large workload. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention provides an integrated heating and insulation component and its manufacturing method. This integrated component fits tightly, occupies little space in the magnet, meets thickness requirements, and eliminates the need to install the heating structure first and then the insulation structure during installation, making installation simple and reducing the workload.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A heating and insulation integrated component, comprising:

[0006] The integrated heating and insulation component includes a heating circuit layer and a super insulation layer stacked together. The heating circuit layer includes a polytetrafluoroethylene-coated fiberglass base cloth layer, a metal foil etched circuit layer, and a thermoplastic FEP (fluoroethylene propylene) film layer stacked sequentially. The super insulation layer includes a super insulation material layer and an outer protective material layer. The super insulation material layer is stacked on the thermoplastic FEP film layer, and the outer protective material layer is located as the outermost layer and is stacked on the super insulation material layer.

[0007] Preferably, in the integrated heating and insulation component, the raw material of the metal foil in the metal foil etched circuit layer includes stainless steel foil, copper foil, or gold foil, with a thickness of 0.02-0.1 mm.

[0008] Preferably, in the integrated heating and insulation component, the super insulation material in the super insulation material layer includes a nano-aerogel blanket or a nanoporous super insulation sheet.

[0009] Preferably, in the integrated heating and insulation component, the outer protective material in the outer protective material layer includes polytetrafluoroethylene-coated fiberglass cloth.

[0010] Preferably, in the integrated heating and insulation component, the PTFE-coated fiberglass base fabric layer has a thickness of 0.1 mm, uses 2116# electronic grade fiberglass base fabric, and has a PTFE content of 170 g / m². 2 .

[0011] Preferably, in the integrated heating and insulation component, the thickness of the thermoplastic FEP (fluoroethylene propylene) film layer is 0.03 mm.

[0012] Preferably, the total thickness of the integrated heating and insulation component is 1.5-3mm.

[0013] A second aspect of the present invention provides a method for manufacturing the above-mentioned integrated heating and insulation component, comprising the following steps:

[0014] The polytetrafluoroethylene-coated fiberglass base fabric layer, the thermoplastic FEP polytetrafluoroethylene propylene film layer, and the metal foil are cut to the specified size according to the design requirements and stacked in sequence according to the order of the polytetrafluoroethylene-coated fiberglass base fabric layer, the metal foil, and the thermoplastic FEP polytetrafluoroethylene propylene film layer.

[0015] Then it is placed in a flatbed hot press for pressurization and heating. When it is heated to a certain temperature, it is kept at a constant temperature for a certain time, then the heating is stopped, and the pressure is maintained and the temperature is lowered until it reaches room temperature. Then the polytetrafluoroethylene-coated fiberglass base cloth layer coated with metal foil is subjected to a photosensitive imaging process and an etching process to etch the designed heating circuit onto the metal foil to form the heating circuit layer.

[0016] The super thermal insulation material layer is cut to the specified size according to the design requirements, wrapped with the outer protective material layer and sealed; the sealed super thermal insulation material layer semi-finished product is sewn into an enhanced super thermal insulation material layer using a sewing machine with polytetrafluoroethylene coated glass fiber sewing thread.

[0017] The prepared metal foil etched circuit layer, the thermoplastic FEP polytetrafluoroethylene propylene film layer, and the super heat insulation material layer are stacked sequentially. During stacking, the metal foil etched circuit layer is exposed on one side of the heating circuit and in contact with the thermoplastic FEP polytetrafluoroethylene propylene film layer, while the side with the polytetrafluoroethylene coated fiberglass base cloth layer is in direct contact with the hot plate of the hot press. Then, it is placed in a flat plate hot press for pressurization and heating again. When the temperature is reached, it is kept constant for a certain time, and then the heating is stopped and the pressure is maintained and the temperature is lowered until room temperature is reached. Finally, the integrated heating and heat insulation component is obtained.

[0018] The preferred method for manufacturing the product involves heating at a temperature of 280-290℃ and maintaining that temperature for 10-20 minutes.

[0019] The present invention has the following advantages due to the adoption of the above technical solutions:

[0020] 1. The integrated heating and insulation component provided by this invention has each layer of structure tightly fitted together, with a total thickness of less than 3mm. This effectively solves the problem of limited installation space for the vacuum pipe inside the magnet, reduces the gap between magnets, and significantly saves on costs.

[0021] 2. This invention effectively combines the heating circuit layer and the super insulation layer, solving the inconvenience caused by using the heating structure and insulation structure separately in the traditional way. The installation steps are quick and simple.

[0022] 3. All materials used in this invention can withstand a high temperature environment of 300℃. When the vacuum pipe is baked, it is easier to achieve the requirements of extremely high vacuum degree at this temperature, which meets the requirements of extremely high vacuum environment for beam operation. Attached Figure Description

[0023] Figure 1 An exploded view of an integrated heating and insulation component provided in an embodiment of the present invention;

[0024] Figure 2 This is a schematic diagram of a circuit layer etched from a metal foil.

[0025] Figure 3 This is an external view of the integrated heating and insulation component provided in this embodiment of the present invention;

[0026] The markings in the diagram are as follows:

[0027] 1- Polytetrafluoroethylene coated fiberglass base layer; 2- Metal foil etched circuit layer; 3- Thermoplastic FEP polytetrafluoroethylene propylene film layer; 4- Super heat insulation material layer; 5- Outer protective material layer. Detailed Implementation

[0028] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention are described clearly and completely below. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0029] Unless otherwise defined, the technical or scientific terms used in this invention shall have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," "third," "fourth," and similar terms used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect.

[0030] For ease of description, spatial relative terms may be used in the text to describe the relationship of one element or feature relative to another element or feature as shown in the figure. These relative terms include, for example, "inside," "outside," "middle," "outer," "below," "above," etc. Such spatial relative terms are intended to include different orientations of the device in use or operation, other than those depicted in the figure.

[0031] The current traditional structure involves uniformly sewing nickel-cadmium alloy wire onto a high-temperature fabric, then wrapping it with a thin insulating material. This heating and insulation structure has a total thickness greater than 5.5mm, and the two cannot be tightly bonded together, occupying a significant amount of space for the magnets, thus failing to meet thickness requirements. Furthermore, installation requires first installing the heating structure and then the insulation structure, making installation difficult and resulting in a large workload.

[0032] To address the aforementioned issues, this invention provides an integrated heating and insulation component and its manufacturing method. This integrated component fits tightly, occupies little space in the magnet, meets thickness requirements, and eliminates the need to install the heating structure first and then the insulation structure during installation, making installation simple and reducing the workload.

[0033] The technical solution of the present invention will be described in detail below with reference to specific examples.

[0034] like Figure 1As shown, the integrated heating and insulation component of this invention includes, from top to bottom, an outer protective material layer 5, a super insulation material layer 4, a thermoplastic FEP (fluoropolymer ethylene propylene) film layer 3, a metal foil etched circuit layer 2, and a polytetrafluoroethylene-coated fiberglass base layer 1. The polytetrafluoroethylene-coated fiberglass base layer 1 serves as the base layer, supporting the metal foil etched circuit layer 2. The thermoplastic FEP film layer 3 is located above the metal foil etched circuit layer 2. Together, these three layers form the heating circuit layer. The super insulation material layer 4 and the outer protective material layer 5 form the super insulation layer.

[0035] like Figure 2 As shown, the metal foil etched circuit layer 2 is obtained by the following method: a polytetrafluoroethylene-coated fiberglass base cloth coated with metal foil is etched onto the metal foil through a photosensitive imaging process and an etching process. Further, the raw materials for the metal foil include stainless steel foil, copper foil, or gold foil, with a thickness of 0.02-0.1 mm.

[0036] In a preferred embodiment of the present invention, the super thermal insulation material in the super thermal insulation material layer 4 includes a nano-aerogel blanket or a nanoporous super thermal insulation thin plate (the nanoporous super thermal insulation thin plate is specifically a silica plate), and the outer protective material in the outer protective material layer 5 includes polytetrafluoroethylene coated fiberglass cloth.

[0037] Furthermore, such as Figure 1 As shown, the thickness of the polytetrafluoroethylene (PTFE) coated fiberglass base fabric is 0.1 mm, using 2116# electronic grade fiberglass base fabric, with a PTFE content of 170 g / m². 2 .

[0038] Furthermore, such as Figure 1 As shown, the thickness of the thermoplastic FEP polyfluoroethylene propylene film layer 3 is 0.03 mm.

[0039] Furthermore, such as Figure 1 As shown, the total thickness of the integrated heating and insulation component is 1.5-3mm.

[0040] A second aspect of the present invention provides a method for manufacturing the above-mentioned integrated heating and insulation component, comprising the following steps:

[0041] I. Fabrication method of heating circuit layer

[0042] 1) Cut the PTFE-coated fiberglass base cloth, thermoplastic FEP (fluoroethylene propylene) film, and metal foil to the specified dimensions according to the design requirements; 2) Stack the PTFE-coated fiberglass base cloth, metal foil, and thermoplastic FEP film in a neat order; 3) Place them in a 200-ton flatbed hot press for pressurization and heating. When heated to 285℃, hold the temperature for 15 minutes, then stop heating and begin pressure holding and cooling until room temperature; 4) Then, etch the designed heating circuit onto the metal foil through a photosensitive imaging process and an etching process to form the heating circuit layer.

[0043] II. Method for Manufacturing Super Insulation Layers

[0044] 1) Cut the super insulation material to the specified size according to the design requirements; 2) Wrap it with the outer protective material and seal it; 3) Use a special sewing machine to sew the sealed super insulation material semi-finished product into 20×20mm squares with 0.24mm diameter polytetrafluoroethylene coated glass fiber sewing thread to form an enhanced super insulation layer.

[0045] III) Manufacturing Method of High-Insulation Ultra-Thin Integrated Heating and Insulation Components

[0046] 1) The fabricated metal etched circuit, thermoplastic FEP (fluoropolymer ethylene propylene) film, and super insulation layer are neatly stacked in sequence. During stacking, the side of the metal etched circuit with the exposed heating circuit contacts the thermoplastic FEP film, while the side with the PTFE-coated fiberglass base fabric directly contacts the hot plate of the hot press. 2) The circuit is placed in a 200-ton flatbed hot press for further pressurization and heating. When heated to 285℃, it is held at that temperature for 15 minutes, then heating is stopped, and pressure is maintained to allow cooling until room temperature is reached. Finally, a high-insulation, ultra-thin integrated heating and insulation component is obtained.

[0047] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for manufacturing an integrated heating and insulation component, wherein the integrated heating and insulation component comprises a heating circuit layer and a super insulation layer stacked in layers, the heating circuit layer comprising a polytetrafluoroethylene coated fiberglass base layer (1), a metal foil etched circuit layer (2), and a thermoplastic FEP polytetrafluoroethylene propylene film layer (3) stacked in sequence, the super insulation layer comprising a super insulation material layer (4) and an outer protective material layer (5), the super insulation material layer (4) being stacked on the thermoplastic FEP polytetrafluoroethylene propylene film layer (3), and the outer protective material layer (5) being the outermost layer and stacked on the super insulation material layer (4); Its features are, The manufacturing method includes the following steps: The polytetrafluoroethylene-coated fiberglass base fabric layer (1), the thermoplastic FEP polytetrafluoroethylene propylene film layer (3), and the metal foil are cut to the specified size according to the design requirements, and the polytetrafluoroethylene-coated fiberglass base fabric layer (1) and the metal foil are stacked. Then, the stacked polytetrafluoroethylene-coated fiberglass base fabric layer (1) and metal foil are placed in a flat plate hot press for pressurization and heating. When the temperature reaches a certain level, the temperature is kept constant for a certain time, the heating is stopped, and the pressure is maintained and the temperature is lowered until room temperature. Then, the polytetrafluoroethylene-coated fiberglass base fabric layer (1) coated with metal foil is subjected to a photosensitive imaging process and an etching process to etch the designed heating circuit onto the metal foil to form the metal foil etched circuit layer (2). The super heat insulation material layer (4) is cut to the specified size according to the design requirements, wrapped with the outer protective material layer (5), and the super heat insulation material layer (4) is sealed; the sealed super heat insulation material layer (4) semi-finished product is sewn into an enhanced super heat insulation material layer using a sewing machine with polytetrafluoroethylene coated glass fiber sewing thread. The metal foil etched circuit layer (2), the thermoplastic FEP polytetrafluoroethylene propylene film layer (3), and the reinforced super insulation material layer are stacked in sequence. When stacking, the metal foil etched circuit layer (2) is exposed on one side of the heating circuit and is in contact with the thermoplastic FEP polytetrafluoroethylene propylene film layer (3). The side with the polytetrafluoroethylene coated glass fiber base cloth layer (1) is in direct contact with the hot plate of the hot press. Then it is placed in a flat plate hot press for pressurization and heating again. When it is heated to a certain temperature, it is kept at a constant temperature for a certain time. Then the heating is stopped and the pressure is maintained and the temperature is reduced until the room temperature is reached. Finally, the integrated heating and insulation component is obtained.

2. The manufacturing method according to claim 1, characterized in that, The heating temperature is 280-290℃, and the holding time is 10-20 minutes.

3. The manufacturing method according to claim 1, characterized in that, The raw materials of the metal foil in the metal foil etched circuit layer (2) include stainless steel foil, copper foil or gold foil, with a thickness of 0.02-0.1 mm.

4. The manufacturing method according to claim 1, characterized in that, The super insulation material in the super insulation material layer (4) includes a nano aerogel blanket or a nanoporous super insulation sheet.

5. The manufacturing method according to claim 1, characterized in that, The outer protective material in the outer protective material layer (5) includes polytetrafluoroethylene coated fiberglass cloth.

6. The manufacturing method according to claim 1, characterized in that, The polytetrafluoroethylene (PTFE) coated fiberglass base fabric layer (1) has a thickness of 0.1 mm, uses 2116# electronic grade fiberglass base fabric, and has a PTFE content of 170 g / m². 2 .

7. The manufacturing method according to claim 1, characterized in that, The thickness of the thermoplastic FEP polyfluoroethylene propylene film layer (3) is 0.03 mm.

8. The manufacturing method according to claim 1, characterized in that, The total thickness of the integrated heating and insulation component is 1.5-3mm.

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