Vacuum impregnation instrument with heating function

Abstract

The utility model discloses a vacuum impregnation instrument with a heating function. The vacuum impregnation instrument comprises a vacuum system, a heating system, a temperature sensor and a temperature controller, the heating system and the temperature sensor are arranged in the vacuum system; the heating system comprises a heat conducting plate embedded in the bottom of the vacuum system base; heating modules are distributed in the heat conducting plate; one end of the temperature sensor is connected with the heat-conducting plate; and the other end of the temperature sensor is connected with the temperature controller. The heating module adopts an electric heating wire or a PTC heating element. And the temperature controller adopts a PID control module. The heat insulation layer is arranged outside the base, the application range is wide, and the specific temperature requirements of different resin materials and samples can be met; the safety performance is high, and multiple temperature abnormity protection mechanisms are provided; the structure is compact, and function expansion is achieved on the basis of an original vacuum impregnation instrument.

Description

Technical Field

[0001] This utility model belongs to the field of material processing technology and relates to a vacuum impregnation apparatus with heating function. Background Technology

[0002] In the preparation of epoxy resin composites, vacuum impregnation equipment is an important tool, mainly used to remove air between the sample and the resin, thereby improving the material's density and interfacial bonding strength. However, traditional vacuum impregnation equipment suffers from problems such as long curing time and uneven curing. Existing equipment mainly relies on room temperature or external heating equipment for curing, lacking an integrated heating system and failing to control the temperature accurately and in real time during the impregnation process, resulting in low curing efficiency. Utility Model Content

[0003] To address the problem that existing vacuum impregnation devices lack heating functionality or exhibit uneven heating, the present invention provides a vacuum impregnation apparatus with heating functionality, comprising: a vacuum system, a heating system, a temperature sensor, and a temperature controller.

[0004] The heating system and temperature sensor are located inside the vacuum system;

[0005] The heating system includes a heat-conducting plate embedded in the bottom of the vacuum system base;

[0006] Heating modules are distributed inside the heat-conducting plate;

[0007] One end of the temperature sensor is connected to the heat-conducting plate;

[0008] The other end of the temperature sensor is connected to the temperature controller.

[0009] Furthermore, the heating module uses an electric heating wire or a PTC heating element.

[0010] Furthermore, the temperature controller employs a PID control module.

[0011] Furthermore, a heat insulation layer is provided on the outer layer of the base.

[0012] Furthermore, the upper surface of the heat-conducting plate is provided with heating points arranged in a matrix.

[0013] Furthermore, it also includes a control panel, which is connected to the PID control module.

[0014] Furthermore, the PID control module uses a Fuji PXF4 series temperature controller.

[0015] The vacuum impregnation apparatus with heating function provided by this utility model has the following advantages:

[0016] Precise temperature control was achieved during the vacuum impregnation process, with a temperature accuracy of ±1°C.

[0017] The heating process is highly integrated with the vacuum impregnation process, making operation more convenient;

[0018] It has a wide range of applications and can meet the specific temperature requirements of different resin materials and samples;

[0019] It boasts high safety performance and features multiple temperature anomaly protection mechanisms.

[0020] With a compact structure, it expands the functionality of the original vacuum impregnation machine. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a structural diagram of the device;

[0023] Figure 2 This is a structural diagram of an embodiment;

[0024] Reference numerals: 1. Vacuum system, 2. Heating system, 3. Temperature sensor, 4. Temperature controller, 5. Control panel, 6. Heat-conducting plate, 7. Insulation layer, 8. Vacuum oil pump, 9. Vacuum gauge, 10. Vacuum hose, 11. Vacuum valve, 12. Observation window, 13. Vacuum chamber. Detailed Implementation

[0025] It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of the present invention can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and embodiments.

[0026] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0027] Figure 1 This is a structural diagram of the device;

[0028] A vacuum impregnation apparatus with heating function includes: a vacuum system 1, a heating system 2, a temperature sensor 3, and a temperature controller 4;

[0029] The heating system 2 and the temperature sensor 3 are disposed inside the vacuum system 1;

[0030] The heating system 2 includes a heat-conducting plate 6 embedded in the bottom of the base of the vacuum system 1;

[0031] Heating modules are distributed inside the uniform heat-conducting plate 6;

[0032] One end of the temperature sensor 3 is connected to the heat-conducting plate 6; the temperature sensor 3 and the heat-conducting plate 6 are in close contact.

[0033] The other end of the temperature sensor 3 is connected to the temperature controller 4.

[0034] Furthermore, the heating module uses an electric heating wire or a PTC heating element.

[0035] Furthermore, the temperature controller 4 employs a PID control module.

[0036] Furthermore, the outer layer of the base is provided with a heat insulation layer 7, and it is recommended to select a finished glass wool board with aluminum foil side; use insulation materials with high temperature resistance and low thermal conductivity; and ensure that the surface temperature of the equipment shell is kept within a safe range during the heating process.

[0037] Furthermore, the heat-conducting plate 6 adopts a multi-point uniform heating design with a matrix layout to ensure uniform heat distribution; a temperature gradient compensation zone is set around the working plane of the heat-conducting plate 6 to ensure that the temperature error in different areas of the platform is controlled within ±2°C. This design, which counteracts edge heat dissipation and maintains overall temperature uniformity, ensures uniform temperature across the entire platform, making it particularly suitable for processes requiring uniform temperature, such as vacuum impregnation.

[0038] Furthermore, it also includes a control panel 5 with temperature setting, real-time display and constant temperature control functions, the control panel 5 being connected to the PID control module.

[0039] Furthermore, it also includes safety protection mechanisms: automatic power-off protection for over-temperature; temperature abnormality alarm function; and a self-diagnostic mechanism for heating system 2 faults.

[0040] The PID control module uses a Fuji PXF4 series temperature controller.

[0041] The vacuum system 1 includes a vacuum chamber 13, a vacuum oil pump 8, a vacuum gauge 9, a vacuum hose 10, and a vacuum valve 11;

[0042] Vacuum chamber 13 is connected to vacuum hose 10 via vacuum valve 11. The other end of vacuum hose 10 is connected to vacuum oil pump 8, forming a vacuuming passage. Vacuum gauge 9 is installed at vacuum valve 11 to monitor the vacuum level in the chamber in real time. All connections use standard KF connectors and sealing rings to ensure the airtightness of the system. Vacuuming and pressure holding functions can be achieved by controlling the opening and closing of vacuum valve 11. Vacuum oil pump 8 serves as the vacuum source, providing a vacuum environment for the entire system.

[0043] An observation window 12 is provided at the top of the vacuum chamber 13;

[0044] The working principle of this invention is as follows: Before vacuum impregnation, the operator can set the required precise temperature through the control panel 5, and the temperature controller will automatically start heating and maintain a constant temperature. The entire heating process is carried out in a sealed vacuum environment, which ensures temperature stability and avoids the influence of sample oxidation or other environmental factors.

[0045] Figure 2 This is a structural diagram of an embodiment;

[0046] Example:

[0047] A vacuum impregnation apparatus with heating function, the specific structure and technical parameters of which are as follows:

[0048] 1. Overall structural dimensions

[0049] - Vacuum impregnation apparatus dimensions: Length 80cm × Width 60cm × Height 50cm;

[0050] - Effective working area dimensions: 50cm (length) × 40cm (width) × 30cm (height);

[0051] - Base thickness: 5cm;

[0052] - Total equipment weight: Approximately 45kg;

[0053] 2. Base heating system 2

[0054] - Heat dissipation plate 6: Made of 6061 aerospace aluminum material, 8mm thick;

[0055] - Heating element: 240V / 2000W silicone heating film, divided into 4 heating zones;

[0056] - Temperature sensor 3: PT100 platinum resistance temperature sensor 3, accuracy ±0.1℃;

[0057] - Heating temperature range: room temperature ~ 200℃;

[0058] - Temperature uniformity: ±2℃ (at an operating temperature of 100℃);

[0059] 3. Temperature controller 4

[0060] - Controller model: Uses Japanese Fuji PXF4 series temperature controller

[0061] - Control accuracy: ±0.5℃

[0062] - PID parameters:

[0063] * Proportional band (P): Self-tuning;

[0064] * Integration time (I): 120 seconds;

[0065] * Differential time (D): 30 seconds;

[0066] - Display resolution: 0.1℃;

[0067] - Sampling period: 500ms;

[0068] 4. Vacuum System 1

[0069] - Vacuum pump: Leybold D16C vacuum pump (Germany);

[0070] * Pumping rate: 16 m³ / h;

[0071] * Ultimate vacuum: 2×10 - ³ mbar;

[0072] * Power: 0.55kW;

[0073] - Vacuum piping: 304 stainless steel corrugated pipe, DN25;

[0074] - Vacuum Gauge 9: Digital vacuum gauge, measuring range 1×10 - ³~10¹³ mbar;

[0075] - Sealing ring: Fluororubber O-ring, temperature resistant to 200℃;

[0076] 5. Thermal insulation design

[0077] - Thermal insulation material: Aerogel felt is used;

[0078] * Thermal conductivity: ≤0.02W / (m·K);

[0079] * Thickness: 10mm;

[0080] * Operating temperature range: -50~200℃

[0081] - Maximum surface temperature of the casing: ≤45℃ (under ambient temperature of 25℃);

[0082] 6. Safety protection devices

[0083] - Over-temperature protection:

[0084] * Level 1 protection: Software controlled, with a set upper temperature limit;

[0085] * Secondary protection: Independent hardware over-temperature protector, fixed power-off point 220℃;

[0086] - Vacuum protection:

[0087] * Abnormal vacuum level alarm;

[0088] * Evacuation timeout protection;

[0089] - Electrical protection:

[0090] * Residual current device (RCD): 30mA / 0.1s

[0091] Overcurrent protection: 10A circuit breaker

[0092] 7. Work Process

[0093] (1) Power-on preheating:

[0094] - Connect the power supply and initiate the system self-test;

[0095] - Set the target temperature (e.g., 120℃);

[0096] - Preheating time is approximately 15-20 minutes;

[0097] (2) Sample placement:

[0098] - Check the condition of the sealing ring (the sealing ring is a rubber ring installed between the sealing cover on the top of the vacuum chamber 13 and the chamber body to ensure the airtightness of the vacuum chamber 13. It is usually made of high temperature and oil resistant fluororubber or silicone rubber to prevent air leakage during the vacuuming process).

[0099] - Place the sample to be impregnated in the center of the heating platform;

[0100] - Inject impregnation liquid (according to process requirements)

[0101] (3) Vacuuming process:

[0102] - Close vacuum chamber 13;

[0103] - Turn on the vacuum pump;

[0104] - Evacuate to the set vacuum level (e.g., 1×10⁻⁶) - ² mbar);

[0105] - The holding time is set according to the process requirements;

[0106] (4) Constant temperature immersion:

[0107] - The system automatically maintains the set temperature;

[0108] - Monitor the immersion status through the observation window;

[0109] - Record process parameters such as temperature and vacuum level;

[0110] (5) Processing complete:

[0111] - Turn off heating system 2;

[0112] - Slowly introduce air to atmospheric pressure;

[0113] - Take out the sample;

[0114] 8. Usage Effect

[0115] The vacuum impregnation apparatus of this embodiment has achieved good results in practical applications:

[0116] - Temperature control accuracy reaches ±0.5℃;

[0117] - Temperature uniformity in the working area is better than ±2℃;

[0118] - Vacuum level can reach 2×10 - ³ mbar;

[0119] - The sample is well-impregnated and free of air bubbles;

[0120] - Good repeatability and high batch consistency;

[0121] 9. Maintenance and upkeep

[0122] - Check the vacuum pump oil level and quality monthly;

[0123] - Inspect the integrity of the seals quarterly;

[0124] - Temperature sensor 3, calibrated every six months;

[0125] - Clean the heating platform and observation window regularly.

[0126] In traditional epoxy resin curing processes, samples need to be continuously impregnated at room temperature (25℃) for 8-10 hours, which not only consumes a significant amount of valuable laboratory and production line time but also increases labor and equipment costs. Our innovative vacuum impregnation machine, through integrated heating, precisely controls the curing time to just 2 hours at 45℃, a time reduction of up to 75% compared to traditional processes. For example, a medium-sized materials laboratory processing 10-20 samples per day, where each sample previously required 8-10 hours to cure, now only needs 2 hours, theoretically increasing daily sample processing capacity by 300-400%. This means:

[0127] It can save 6-8 hours of valuable laboratory time every day;

[0128] It can save approximately 1,500-2,000 hours of research and production time annually;

[0129] Significantly reduces labor costs; a laboratory can save approximately 50,000 to 80,000 yuan in labor costs annually.

[0130] Significantly improves equipment utilization; the annual utilization rate of a single piece of equipment can be increased by 50%-70%.

[0131] More importantly, this time compression does not come at the expense of material properties. Under curing conditions of 45°C, the mechanical properties, heat resistance, and chemical stability of epoxy resin are basically the same as those under room temperature curing conditions, a fact that has been repeatedly verified through numerous experiments.

[0132] 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 or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A vacuum impregnation apparatus with heating function, characterized in that: include: Vacuum system, heating system, temperature sensor and temperature controller; The heating system and temperature sensor are located inside the vacuum system; The heating system includes a heat-conducting plate embedded in the bottom of the vacuum system base; Heating modules are distributed inside the heat-conducting plate; One end of the temperature sensor is connected to the heat-conducting plate; The other end of the temperature sensor is connected to the temperature controller.

2. A vacuum impregnation apparatus with heating function according to claim 1, characterized in that: The heating module uses an electric heating wire or a PTC heating element.

3. A vacuum impregnation apparatus with heating function according to claim 1, characterized in that: The temperature controller uses a PID control module.

4. A vacuum impregnation apparatus with heating function according to claim 1, characterized in that: The base is provided with a heat insulation layer on its outer layer.

5. A vacuum impregnation apparatus with heating function according to claim 1, characterized in that: The upper surface of the heat-conducting plate is provided with heating points arranged in a matrix.

6. A vacuum impregnation apparatus with heating function according to claim 3, characterized in that: It also includes a control panel, which is connected to the PID control module.

7. A vacuum impregnation apparatus with heating function according to claim 3, characterized in that: The PID control module uses a Fuji PXF4 series temperature controller.

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