Expansion sliding block base plate and manufacturing process thereof

Abstract

The invention relates to the technical field of auxiliary parts of high-temperature equipment, in particular to an expansion sliding block base plate and a manufacturing process of the expansion sliding block base plate. The middle layer is a fluororubber layer and is used for buffering interaction force between the surface layer and the bottom layer; and the bottom layer is a T2 red copper plate and is used for conducting heat and assisting in self-lubrication. According to the base plate, all layers of materials have excellent high temperature resistance, the PEEK on the surface layer, the fluororubber on the middle layer and the T2 red copper plate on the bottom layer can stably work for a long time in the high-temperature environment of the high-temperature expansion boiler, and the problem that a traditional base plate is prone to deformation and failure at the high temperature is effectively solved.

Description

Technical Field

[0001] The invention relates to the technical field of auxiliary components of high-temperature equipment, and in particular to an expansion slider pad and a manufacturing process thereof. Background Art

[0002] During the operation of a high-temperature expansion boiler, due to the thermal expansion and contraction characteristics of metal materials, boiler components will expand and contract. Traditional pad materials and structures have many shortcomings when dealing with dimensional changes under such high-temperature conditions. For example, previous products used PVC heating galvanizing. Under high-temperature conditions, PVC materials are prone to softening, deformation, or even decomposition, and the performance of the pad cannot be effectively maintained, resulting in the stability and safety of equipment operation being affected. In addition, ordinary pads are difficult to achieve good self-lubricating function under high temperatures, which increases the sliding resistance between components, which not only aggravates the wear of components, but also may lead to increased energy consumption. In severe cases, it may even affect the normal operation of the boiler. Therefore, the present invention proposes a pad that can work stably in a high-temperature environment, has self-lubricating properties, and adapts to the expansion and contraction requirements of the boiler. Summary of the invention

[0003] The purpose of the present invention is to provide an expansion slider pad and its manufacturing process to solve the problems of performance degradation and shortened life of existing products in high temperature environments due to the material's non-high temperature resistance and easy corrosion. By adopting a special material combination and manufacturing process, the expansion slider pad can operate stably in high temperature environments such as high temperature expansion boilers and maintain good self-lubricating properties and mechanical properties.

[0004] An expansion slider pad, the pad comprising:

[0005] Surface layer: made of a composite material of PEEK and graphite;

[0006] The middle layer is a fluororubber layer, which is used to buffer the interaction force between the surface layer and the bottom layer;

[0007] The bottom layer is T2 copper plate, which is used to conduct heat and assist in self-lubrication.

[0008] Preferably, the glass transition temperature of the PEEK material is not lower than 143° C., the melting point is not lower than 334° C., and the thickness of the surface layer is in the range of 2-5 mm.

[0009] Preferably, the thickness of the intermediate layer is in the range of 1-3 mm.

[0010] Preferably, the thickness of the T2 copper plate is in the range of 3-6 mm.

[0011] Preferably, the surface layer, the middle layer and the bottom layer are bonded by a high temperature resistant adhesive.

[0012] Preferably, the manufacturing process includes the following steps:

[0013] Raw material preparation: Prepare PEEK material and graphite powder that meet the quality standards, and mix them in proportion; Select a copper plate of T2 purity and clean its surface; Prepare raw rubber of fluororubber (AFLAS) and corresponding vulcanizing agents and accelerators, and weigh them accurately;

[0014] Surface material forming: Put the mixed PEEK + graphite material into a mold, and adopt a hot pressing forming process. The hot pressing temperature is controlled at 380°C - 400°C, the pressure is controlled at 10MPa - 15MPa, and the pressure holding time is determined to be 15min - 30min according to the thickness and size of the backing plate. After forming, carry out grinding and polishing treatments;

[0015] Fluororubber layer preparation: Add the raw rubber of fluororubber and additives to a kneader for kneading. The kneading temperature is 100°C - 120°C, and the kneading time is 15min - 20min. Then, carry out thin passing treatment through an open mill, with the number of thin passing times being 5 - 8 times, and then cut it into a suitable shape and size;

[0016] Backing plate assembly and vulcanization: Apply an adhesive on the surface-treated T2 copper plate, bond the fluororubber compound, and roll to remove air bubbles. Apply an adhesive on the other side of the fluororubber layer, bond the formed PEEK + graphite surface material, and roll firmly. Then, put it into a vulcanization mold for vulcanization. The vulcanization temperature is controlled at 180°C - 200°C, the vulcanization pressure is 5MPa - 8MPa, and the vulcanization time is determined to be 20min - 40min according to the thickness of the backing plate and the fluororubber formula;

[0017] Post-treatment and inspection: After vulcanization, demold the backing plate, conduct appearance inspection and dimension measurement on the backing plate to ensure compliance with the design requirements. At the same time, conduct high-temperature resistance performance testing, self-lubrication performance testing, and bonding strength testing on the backing plate. If it is qualified, it is judged as a finished product.

[0018] Preferably, after the surface material is hot pressed and formed, its thickness tolerance is controlled within ±0.05mm - ±0.08mm, and the surface roughness reaches below Ra0.6μm - Ra0.8μm.

[0019] Preferably, when assembling the backing plate, during the bonding process of the T2 copper plate and the fluororubber compound, and the fluororubber layer and the PEEK + graphite surface material, the adhesive used is chloroprene rubber adhesive or polyurethane adhesive.

[0020] The beneficial effects of the present invention are:

[0021] Superior high-temperature resistance: Each layer of the backing plate of the present invention has excellent high-temperature resistance. The PEEK on the surface layer, the fluororubber in the middle layer, and the T2 copper plate at the bottom layer can work stably for a long time in the high-temperature environment of a high-temperature expansion boiler, effectively solving the problems of easy deformation and failure of traditional backing plates at high temperatures.

[0022] Good self-lubricating performance: The combined action of the composite surface layer of PEEK and graphite, the fluororubber in the middle layer, and the copper at the bottom layer realizes good self-lubricating performance of the backing plate in a high-temperature environment, greatly reducing the friction coefficient between components, reducing wear, and improving the operation efficiency and service life of the equipment.

[0023] Adapt to thermal expansion and contraction: The structural design and material selection of the backing plate fully consider the thermal expansion and contraction characteristics of a high-temperature expansion boiler. During the expansion and contraction of the boiler, the backing plate can ensure the smooth sliding out and retraction of the slider through its own structural changes and material properties, ensuring the stability and reliability of the boiler operation.

[0024] Chemical corrosion resistance: The fluororubber in the middle layer has the property of chemical corrosion resistance, which can effectively resist the erosion of the complex chemical environment inside the high-temperature expansion boiler, extend the service life of the backing plate, and improve the overall safety of the equipment. Brief Description of the Drawings

[0025] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention, and therefore should not be regarded as limiting the scope. For those of ordinary skill in the art, without creative efforts, other related drawings can also be obtained based on these drawings.

[0026] Figure 1 Is a three-dimensional schematic diagram of the present invention;

[0027] Figure 2 Is an internal structure schematic diagram of the present invention. Detailed Embodiments

[0028] To make the objectives, 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 in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. Usually, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0029] In the description of the embodiments of the present invention, it should be noted that if terms such as "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. are used to indicate the orientation or positional relationship, it is based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship in which the invention product is usually placed during use. This is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation to the present invention.

[0030] As shown in the figure, an expansion slider backing plate 100 includes a surface layer 101, an intermediate layer 102, and a bottom layer 103. The surface layer 101 is made of a composite material of PEEK (polyetheretherketone) and graphite, and this material has excellent self-lubricating properties. PEEK itself has excellent high-temperature resistance, with a glass transition temperature as high as 143 °C and a melting point of 334 °C, and can maintain stable physical and chemical properties in a high-temperature environment. Graphite has good lubricating properties and can effectively reduce the friction coefficient between components. After the two are compounded, even in the harsh working environment of a high-temperature expansion boiler, it can ensure that the surface of the backing plate always maintains good self-lubricating state and reduces component wear.

[0031] The intermediate layer 102 is an Aflas fluororubber layer. Aflas fluororubber has excellent high-temperature resistance and can be used for a long time in an environment up to 200 °C. At the same time, it has good self-lubricating properties. It can effectively buffer the interaction force between the surface layer and the bottom layer, and maintain good elasticity and sealing performance at high temperatures to prevent external impurities from entering the interior of the backing plate and affecting the performance of the backing plate. In addition, fluororubber also has the characteristic of chemical corrosion resistance and can adapt to the complex chemical environment inside the high-temperature expansion boiler.

[0032] The bottom layer 103 is made of T2 copper plate. T2 copper plate has good electrical and thermal conductivity, with a high thermal conductivity coefficient, which can quickly transfer the heat generated on the surface of the backing plate, thereby reducing the temperature of the backing plate and improving its stability in a high-temperature environment. At the same time, copper itself also has certain self-lubricating properties, which cooperate with the surface layer and the intermediate layer to further improve the self-lubricating effect of the backing plate. In addition, T2 copper plate also has good corrosion resistance and processing performance, and can meet the use requirements of the backing plate under different working conditions.

[0033] Manufacturing process steps

[0034] Raw material preparation:

[0035] Prepare PEEK materials and graphite powder that meet the quality standards, and mix them in a certain proportion to ensure uniform mixing to guarantee the consistency of the surface material properties.

[0036] Select a T2 copper plate with high purity, and conduct surface cleaning treatment on it to remove impurities such as oil stains and oxide layers on the surface, so as to ensure the subsequent bonding effect with fluororubber.

[0037] Prepare raw fluororubber (AFLAS) and corresponding vulcanizing agents, accelerators and other additives, and accurately weigh them according to the formula.

[0038] Surface material forming:

[0039] Put the mixed PEEK + graphite material into the mold and adopt the hot pressing forming process. Under certain temperature and pressure, make the material form the required shape and size. The hot pressing temperature is controlled above the melting point of the PEEK material, generally 380°C - 400°C, the pressure is controlled at 10MPa - 15MPa, and the pressure holding time is determined according to the thickness and size of the backing plate, generally 15min - 30min, to ensure that the material is fully melted and compacted to form a dense structure.

[0040] After forming, grind and polish the surface material to remove surface defects and burrs, and ensure the surface flatness and smoothness to meet the requirements of self-lubrication and bonding with fluororubber.

[0041] Fluororubber layer preparation:

[0042] Add the prepared raw fluororubber and additives into the internal mixer for mixing. The mixing temperature is controlled at 100°C - 120°C, and the mixing time is 15min - 20min to make the additives fully disperse in the raw rubber to form a uniform mixed rubber.

[0043] Pass the mixed fluororubber compound through the open mill for thin pass treatment to further improve the uniformity and plasticity of the compound. The number of thin passes is generally 5 - 8 times.

[0044] According to the size of the expansion slider backing plate, cut the fluororubber compound after thin pass into appropriate shapes and sizes for standby.

[0045] Backing plate assembly and vulcanization:

[0046] Evenly apply a layer of adhesive on the surface-treated T2 copper plate, attach the cut fluororubber compound to the copper plate, and ensure the tight bonding between the fluororubber and the copper plate through methods such as rolling to remove the air bubbles between the two.

[0047] Evenly apply a layer of adhesive on the other side of the fluororubber layer, and then attach the formed and treated PEEK + graphite surface material to the fluororubber, and also ensure firm bonding through methods such as rolling.

[0048] Put the assembled backing plate into the vulcanization mold for vulcanization treatment. The vulcanization temperature is controlled at 180°C - 200°C, the vulcanization pressure is 5MPa - 8MPa, and the vulcanization time is determined according to the thickness of the backing plate and the formula of fluororubber, generally 20min - 40min. Through the vulcanization reaction, the fluororubber crosslinks and cures to form a stable rubber layer, firmly bonding the surface material and the back material together to form an integral expansion slider backing plate.

[0049] Post-treatment and inspection:

[0050] After vulcanization is completed, take the backing plate out of the mold for demolding treatment. Conduct an appearance inspection on the demolded backing plate to ensure that there are no defects such as air bubbles, cracks, and lack of rubber on the surface.

[0051] Measure the dimensions of the backing plate to check whether it meets the design requirements. For key dimensions such as thickness, length, and width, use measuring tools with higher precision to measure and ensure that the dimensional accuracy is within the allowable tolerance range.

[0052] Detect the performance of the backing plate, including high-temperature resistance test, self-lubrication performance test, bond strength test, etc. For the high-temperature resistance test, the backing plate can be placed in a high-temperature environmental chamber for simulation testing according to the actual use temperature, and observe the deformation and performance changes of the backing plate at high temperature; for the self-lubrication performance test, the friction coefficient between the backing plate and other materials can be measured through a friction testing machine; for the bond strength test, methods such as peel test can be used to detect the bond strength between the surface material, fluororubber layer, and back material.

[0053] Working principle:

[0054] When the high-temperature expansion boiler is working, due to the thermal expansion and contraction of metals, the boiler components will expand. At this time, the surface layer of the self-lubricating sliding backing plate of the present invention can maintain self-lubrication in a high-temperature environment under the action of PEEK and graphite, enabling the slider to slide out smoothly to meet the expansion requirements of the boiler. At the same time, the fluororubber in the middle layer can effectively buffer the stress generated by expansion, protecting the surface layer and the bottom layer from excessive stress damage. The copper plate at the bottom layer quickly conducts heat through its good thermal conductivity to maintain the overall temperature balance of the backing plate.

[0055] Under the cooling condition of the boiler, the components contract, and the slider of the backing plate can retract smoothly under the action of its own elasticity and the coordination of various layer materials. The materials of the surface layer, middle layer, and bottom layer can still maintain good physical properties in a low-temperature environment, ensuring that the backing plate can work normally without performance failure problems caused by temperature changes.

[0056] Example 1

[0057] The expansion slider backing plate of the present invention is applied to a certain type of high-temperature expansion boiler, and the operating temperature range of this boiler is 150 - 250 °C. After installing the backing plate and through long-term operation monitoring, it is found that during the expansion and contraction process of the boiler, the slider can smoothly slide out and retract, the surface of the backing plate always maintains a good self-lubricating state, and the wear between components is significantly reduced. The operating stability of the equipment has been significantly improved, and the energy consumption has also decreased. The good application effect of the self-lubricating sliding backing plate of the present invention in the high-temperature expansion boiler.

[0058] The above are only the preferred embodiments of the present invention for patent, and are not intended to limit the present invention for patent. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention for patent shall be included within the protection scope of the present invention for patent.

Claims

1. An expansion slider pad, characterized in that: The backing plate (100) comprises: Surface layer (101): made of a composite material of PEEK and graphite; The middle layer (102) is a fluororubber layer used to buffer the interaction force between the surface layer (101) and the bottom layer (103); The bottom layer (103) is a T2 copper plate, which is used for conducting heat and assisting self-lubrication.

2. The expansion slider pad according to claim 1, characterized in that: The glass transition temperature of the PEEK material is not lower than 143° C., the melting point is not lower than 334° C., and the thickness of the surface layer (101) is in the range of 2-5 mm.

3. The expansion slider pad according to claim 1, characterized in that: The thickness of the intermediate layer (102) is in the range of 1-3 mm.

4. The expansion slider pad according to claim 1, characterized in that: The thickness of the T2 copper plate ranges from 3 to 6 mm.

5. The expansion slider pad according to claim 1, characterized in that: The surface layer, the middle layer and the bottom layer are bonded together by a high temperature resistant adhesive.

6. The expansion slider pad according to claim 1, characterized in that: The production process includes the following steps: Raw material preparation: Prepare PEEK materials and graphite powder that meet quality standards and mix them in proportion; Select a copper plate with purity T2 and clean its surface; Prepare fluororubber (AFLAS) raw rubber and corresponding vulcanizing agent and accelerator and weigh them accurately; Surface material molding: put the mixed PEEK + graphite material into the mold, adopt hot pressing molding process, the hot pressing temperature is controlled at 380℃-400℃, the pressure is controlled at 10MPa-15MPa, and the holding time is determined to be 15min-30min according to the thickness and size of the pad. After molding, it is ground and polished; Preparation of fluororubber layer: Add fluororubber raw rubber and additives into internal mixer for mixing at a mixing temperature of 100℃-120℃ for 15min-20min, then pass through open mixer for thinning treatment for 5-8 times, and then cut into suitable shape and size; Pad assembly and vulcanization: Apply adhesive to the surface treated T2 copper plate, attach fluororubber rubber and roll to remove bubbles, apply adhesive to the other side of the fluororubber layer, attach the formed PEEK+graphite surface material and roll firmly, then put it into the vulcanization mold for vulcanization. The vulcanization temperature is controlled at 180℃-200℃, the vulcanization pressure is 5MPa-8MPa, and the vulcanization time is determined to be 20min-40min according to the pad thickness and fluororubber formula; Post-processing and testing: After vulcanization is completed, demoulding is carried out, and the pad is inspected for appearance and measured for size to ensure that it meets the design requirements. At the same time, the pad is tested for high temperature resistance, self-lubricating performance, and bonding strength. If it passes the test, it will be determined as a finished product.

7. The expansion slider pad according to claim 6, characterized in that: After the surface material is hot-pressed, its thickness tolerance is controlled within ±0.05mm-±0.08mm, and the surface roughness reaches below Ra0.6μm-Ra0.8μm.

8. The expansion slider pad according to claim 6, characterized in that: When the pad is assembled, in the process of laminating the T2 copper plate with the fluororubber rubber material, and the fluororubber layer with the PEEK+graphite surface material, the adhesive used is a chloroprene rubber adhesive or a polyurethane adhesive.

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