JP2015009260A - Method for manufacturing tubular member cast plate - Google Patents

Abstract

The present invention provides a method for producing a high-performance tubular member cast plate that has high production efficiency and can keep production costs low. A method for producing a tubular member cast plate, comprising: a step of preparing a mold having a concave internal space and a tubular member; and the mold and the tubular member prepared in the step of preparing. A step of heating at least the tubular member to a predetermined temperature by a heating means, and arranging the heated tubular member so as to cross from one end to the other end of the inner space of the mold, A step of injecting a molten metal having a melting point lower than the melting point of the tubular member into the inner space of the mold in which the tubular member heated in the disposing step is disposed; and the melting injected in the injecting step A step of rapidly cooling the metal with a cooling means provided around the mold, and a step of taking out the tubular member cast plate in which the tubular member is cast from the mold after the cooling step; At least. [Selection] Figure 3

Description

  The present invention relates to a method for producing a cast plate having a tubular member provided therein, and more particularly to a method for producing a tubular member cast plate used as a water-cooled cooling plate for a solar battery cell.

  The power generation method using solar cells is regarded as a favorite of solar energy use, and the market size is rapidly expanding. However, the power generation cost is still higher than the power generation method using other fossil fuels, and further power generation cost reduction is required.

Moreover, the utilization efficiency of solar energy by the solar cell is about 20% or less in the current method, and development of a method for effectively using the solar cell is awaited.
Although most of solar cell modules that are commercially available have less than 20% solar energy use efficiency, solar water heaters have achieved energy use efficiency exceeding 50%.

  However, with the current solar water heater, the convenience of the hot water obtained is poor, and its spread has been stagnant. There is a concentrating solar cell as a system that can simultaneously generate power and hot water using a solar cell module, but since a commercially available device is small in scale and expensive in terms of unit price of power generation, it has not been fully spread. However, a concentrating solar cell is expected to be most advantageous for highly efficient use of solar energy.

By the way, there are some problems to be solved in full-scale diffusion of concentrating solar cells, and one of them is “establishment of a cheap and highly efficient cooling plate manufacturing method”.
In the concentrating solar cell, the temperature of the solar battery cell is heated to several hundred degrees or more, but the energy conversion efficiency of the solar battery cell decreases as the temperature rises, so it has to be cooled to about room temperature as much as possible. Must not.

  If an inexpensive and highly heat conductive aluminum material can be applied to the cooling of solar cells as a water cooling structure, the most inexpensive and highly efficient cooling is possible. Moreover, the hot water obtained by water-cooling an aluminum plate can be effectively used for various uses such as agriculture and snow melting. Therefore, with such a configuration, it is expected that a highly efficient solar energy utilization device will be put into practical use and spread in earnest.

  As a method for producing a water-cooled aluminum plate, there are a method of providing a water hole in an aluminum plate by machining, a method of providing a groove by a machining method, and embedding a tubular member, and all of them are expensive.

  On the other hand, although the casting method is the most advantageous in terms of cost, the pipe molding plate is not easy to manufacture by the ordinary sand casting method, so the vacuum sealing molding process (V-process casting). It is necessary to produce by a method called “law”.

  In this V-process casting method, as shown in FIG. 5 (a), the sand molds 100 and 102 are first formed, and then, as shown in FIG. 5 (b), the sand molds 100 and 102 are respectively formed into sheets. It is covered with the member 104, and the sand molds 100 and 102 are evacuated and decompressed to improve the strength and thermal conductivity of the sand mold. Then, as shown in FIG. 5C, after the tubular member 106 is disposed in the sand molds 100 and 102 covered with the sheet member 104, the sand molds 100 and 102 are closed, and the structure shown in FIG. As shown in FIG. 6 (b), the molten metal 108 is poured into the sand molds 100 and 102, and after the molten metal 108 is cooled and solidified, the decompression is released and the sand mold is returned to the atmospheric pressure. The molds 100 and 102 are separated to obtain the tubular member cast plate 110.

  Since such a V-process casting method can be made into a precise sand mold, a fine casting surface can be obtained as compared with a normal sand mold casting method, and a casting that requires higher precision is required. It is preferably used.

  However, since such a V-process casting method has poor production efficiency and high production costs, there is a real need for an inexpensive and high-performance method for producing a tubular member casting plate. .

  In view of such a current situation, an object of the present invention is to provide a method for producing a high-performance tubular member cast plate that has high production efficiency and can keep production costs low.

  The conventional sand mold casting method makes it difficult to manufacture a tubular member casting plate, and there are various theories as to why it can be managed by the V-process casting method. The main reason is the contact between the tubular member and the molten metal. The theory that it is caused by the length of time is prominent.

  In other words, in the normal sand mold casting method, the injected molten metal is rapidly cooled when it comes into contact with the sand mold and solidifies in the contact area. However, since the thermal conductivity of the sand mold is low, it takes a considerable amount of time to completely solidify the molten metal. is there.

  The specific solidification time varies depending on the scale, shape, etc., and cannot be determined unconditionally. However, the V-process casting method makes it possible to produce a tubular member casting plate. The sand casting process demonstrates that considerable time is required for complete solidification.

  That is, in the V-process casting method, since the sand mold is evacuated, most of the air intervening between the sand is removed. As a result, the thermal conductivity of the entire sand mold is higher in each stage than the sand mold containing air in the normal sand mold casting method.

As a result, the cooling rate of the molten metal is increased, and as a result, the time for the material of the tubular member to melt by fusion with the molten metal is shortened, and the tubular member cast plate can be manufactured safely.
Furthermore, since the tubular member is suddenly heated at the moment when high-temperature molten metal is injected during casting, it is difficult to produce an accurate and precise tubular member casting plate because of deformation due to thermal expansion. Are known.

Accordingly, in order to manufacture a tubular member cast plate in which a tubular member is cast, means for solving the following technical problem is required.
1) Means for cooling the molten metal as quickly as possible to shorten the reaction time with the material of the tubular member and to prevent the tubular member material from melting into the molten metal.

2) Means for suppressing deformation of the material of the tubular member due to rapid thermal expansion.
It is obvious that the temperature of the material of the tubular member may be preheated to be equal to the temperature of the molten metal in order to prevent the molten material from contacting the tubular member and deforming due to rapid thermal expansion. is there.

However, if the temperature of the tubular member is heated to a high temperature, the probability of fusion due to contact with the molten metal increases, and as it is, a hole is opened in the tubular member due to reaction with the molten metal. In order to suppress the thermal expansion of the tubular member during the pouring of the molten metal, the temperature of the material of the tubular member needs to be heated to the same level as that of the molten metal. It can be seen that there is a need for a method that can shorten the fusion time.
Furthermore, means for suppressing the tubular member from being softened at high temperature and deformed by its own weight is also effective for producing a high-precision product.

The present invention was invented in order to achieve the problems and objects in the prior art as described above,
The method for producing the tubular member cast plate of the present invention comprises:
Preparing a mold having a concave internal space and a tubular member;
Of the mold and the tubular member prepared in the preparing step, at least the tubular member is heated to a predetermined temperature by a heating means, and the heated tubular member is removed from one end of the inner space of the mold. A step of bridging and arranging so as to cross each end;
Injecting a molten metal having a melting point lower than the melting point of the tubular member into the internal space of the mold in which the tubular member heated in the arranging step is disposed;
A step of rapidly cooling the molten metal injected in the step of injecting by a cooling means provided around the mold;
After the cooling step, taking out the tubular member cast plate in which the tubular member is cast from the mold, and
It is characterized by having at least.

Moreover, the manufacturing method of the tubular member casting plate of the present invention includes:
In the arranging step,
The mold and the tubular member are heated to a predetermined temperature by the heating means, and the tubular member is arranged so as to bridge from one end to the other end of the internal space of the mold. And

Furthermore, the manufacturing method of the tubular member casting plate of the present invention includes:
In the arranging step,
After bridging the tubular member so as to exceed the other end of the inner space of the mold, the mold provided with the tubular member is heated to a predetermined temperature by the heating means. And

With such a manufacturing method, the mold can be reused as it is, so that the production efficiency is good and the production cost can be reduced as a result.
Furthermore, since the molten metal injected into the inner space of the mold is rapidly cooled by the cooling means, the tubular member can be prevented from being deformed by the molten metal, and the tubular member cast plate is manufactured with high accuracy. can do.
Note that only the tubular member may be heated to a predetermined temperature, placed in an unheated mold, poured with molten metal, and similarly cooled rapidly to produce a product.

Moreover, the manufacturing method of the tubular member casting plate of the present invention includes:
The mold is made of carbon and is subjected to an oxidation resistance treatment.

  Thus, if it is made of carbon, it has a high thermal conductivity, is easy to machine, and is suitable for a mold because it is resistant to thermal shock. Carbon molds may oxidize at around 600 ° C. in air. Therefore, if the mold surface is subjected to oxidation resistance treatment, oxidation can be prevented, and repeated molds can be used. Production costs can be reduced.

Moreover, the manufacturing method of the tubular member casting plate of the present invention includes:
The tubular member is made of copper.
Thus, if it is a copper tubular member, since heat conductivity is high, it is suitable for the tubular member for the purpose of cooling.

Moreover, the manufacturing method of the tubular member casting plate of the present invention includes:
The molten metal injected into the inner space of the mold in the injecting step is a molten aluminum.
As described above, when the molten metal is a molten aluminum, it has a high thermal conductivity and is easily available. Therefore, it is suitable for cooling solar cells, and the production cost can be reduced.

Moreover, the manufacturing method of the tubular member casting plate of the present invention includes:
The heating means is an electric furnace.
Thus, if it is an electric furnace, a tubular member and a casting_mold | template can be reliably heated to predetermined temperature.

Moreover, the manufacturing method of the tubular member casting plate of the present invention includes:
The cooling means is an air cooling system.
Thus, if it is an air cooling system, it can cool rapidly and solidify a molten metal, maintaining a safe working environment, before a tubular member melts and breaks after pouring a molten metal.

Moreover, the manufacturing method of the tubular member casting plate of the present invention includes:
The tubular member cast plate is a water-cooled cooling plate of a solar battery cell.
Thus, if it is a water-cooled cooling plate of a photovoltaic cell, the production cost of a photovoltaic cell can be held down and a high-performance photovoltaic cell can be provided at low cost.

Moreover, the manufacturing method of the tubular member casting plate of the present invention includes:
The tubular member is formed by inserting a rod-like member having heat resistance and mechanical strength into the tube.
If it does in this way, it can control effectively that a tubular member deforms by softening under high temperature.

  ADVANTAGE OF THE INVENTION According to this invention, since a casting_mold | template can be reused repeatedly and production efficiency is good, it is possible to provide a production method of a high-performance tubular member casting plate that is good in production efficiency and can keep production costs low. it can.

FIG. 1 is a schematic view of a tubular member cast plate obtained by the production method of the present invention. FIG. 2 is a process diagram for explaining the manufacturing process of the tubular member casting plate of the present invention. FIG. 3 is a process diagram for explaining the manufacturing process of the tubular member casting plate of the present invention. FIG. 4 is a conceptual diagram of the manufacturing site of the tubular member cast plate of the present invention. FIG. 5 is a process diagram for explaining a conventional process for producing a tubular member cast plate by the V-process casting method. FIG. 6 is a process diagram for explaining a conventional process for producing a tubular member cast plate by the V-process casting method.

Hereinafter, embodiments (examples) of the present invention will be described in more detail with reference to the drawings.
The present invention relates to a method for producing a cast plate in which a tubular member is provided, and particularly relates to a method for producing a tubular member cast plate suitable for use as a water-cooled cooling plate of a solar battery cell.

<Tubular member casting plate 70>
First, as shown in FIG. 1, the tubular member cast plate 70 manufactured by the manufacturing method of the present invention is formed by providing the tubular members 20, 20 inside the cast plate 32.

Such a tubular member casting plate 70 is used as a water-cooled cooling plate attached to the surface of a solar battery cell (not shown) used in, for example, a solar power generation device. The solar cells are brought into contact with each other in a planar shape, and water is allowed to flow through the tubular member 20 to efficiently dissipate the heat of the solar cells that have reached a high temperature.
In the method for manufacturing a tubular member casting plate according to the present invention, the tubular member casting plate 70 is manufactured as follows, and the manufacturing method is characterized.

<Method for Manufacturing Tubular Member Casting Plate 70>
First, as shown to Fig.2 (a), the casting_mold | template 10 which has the internal space 12 with a concave cross section, and the tubular member 20 (two in this embodiment) are prepared. The mold 10 is provided with a notch portion 14 in advance, and the notch portion 14 is notched in accordance with the tubular member 20. The position of the notch 14 is set so that the tubular member 20 is positioned in the vicinity of the middle from the lower end to the upper end of the internal space 12 of the mold 10.

  The material of the mold 10 is preferably a material having high thermal shock resistance that can suppress reaction with the molten metal 30 described later, has high thermal conductivity, and is resistant to repeated rapid heating and rapid cooling. For example, carbon is used. Can do.

  Note that such carbon may react with air near 700 ° C. to deteriorate the surface. For this reason, the mold 10 made of carbon is immersed in a reaction solution in which silicon oxide and zirconium oxide fine powder are mixed in a calcium phosphate solution, and is baked at 500 ° C. to improve the oxidation resistance of the surface. By applying, it can be used stably in air at a high temperature of 800 ° C. In the case of the carbon mold 10, the thickness of the mold 10 is preferably about 10 mm from the viewpoint of resistance to repeated use or cooling efficiency.

  On the other hand, the material of the tubular member 20 may be any material having a high thermal conductivity, and for example, copper is suitable. The tubular member 20 is commercially available in various specifications, and is preferably selected as appropriate in accordance with the relationship with the molten metal 30.

  The length of the tubular member 20 is a length exceeding the other end of the inner space 12 of the mold 10, and when the tubular member 20 is disposed in the notch portion 14 of the mold 10 as described later, The tubular member 20 is set so as to be bridged between the one and the other notches 14 and 14.

The tubular member 20 can be used as it is, but it may be formed by inserting a rod-like member having heat resistance and mechanical strength into the tube.
By doing in this way, it can suppress effectively that a tubular member deforms by softening under high temperature. As a material of the rod-shaped member, for example, ceramic is suitable.

  Next, as shown in FIG. 2B, after the tubular member 20 is disposed in the notch portion 14 of the mold 10, the upper end of the notch portion 14 is filled as shown in FIG. The leakage prevention pieces 16 are inserted into the notches 14 respectively. As a result, the tubular member 20 is fitted into the mold 10. The leakage prevention piece 16 is preferably made of the same material as that of the mold 10, but may not be the same as long as it has a higher melting point than the molten metal 30 described later.

Note that a carbon cloth may be disposed between the notch portion 14 of the mold 10 and the tubular member 20 so that the gap between the notch portion 14 and the tubular member 20 is securely sealed.
The mold 10 in this state is now placed in the heating means 40 as shown in FIG. 4 and heated to a predetermined temperature. Although it does not specifically limit as the heating means 40 here, For example, an electric furnace can be used.

  In order to prevent the tubular member 20 from being thermally expanded and deformed at the time of molten metal injection, it is preferable that the temperature to be heated is maintained to be as close as possible to the temperature of the molten metal.

After the heating is completed, the mold 10 is taken out from the heating means 40, and the molten metal 30 is quickly poured into the internal space 12 of the mold 10 as shown in FIG.
The material of the molten metal 30 may be any material that has a melting point lower than that of the tubular member 20 and a high thermal conductivity. For example, a molten aluminum is preferable.

  Then, as shown in FIG. 4 immediately, the mold 10 into which the molten metal 30 has been poured is rapidly cooled by the upper and lower cooling means 50 and 52 to solidify the molten metal 30. As the cooling means 50 and 52, an air cooling system is particularly preferable from the viewpoint of safety.

In FIG. 4, reference numeral 60 denotes an operation panel for the heating means 40 and the cooling means 50 and 52. The amount of air blown by the cooling means 50 and 52 varies depending on the size of the mold 10, but if the mold 10 is, for example, about 1500 mm wide × 500 mm deep × 300 mm high, it is about 2 to 10 m ³ / min Is preferred.

By rapidly cooling, the melting point drop due to the reaction between the molten metal and the tubular member can be suppressed as much as possible.
After the molten metal 30 is solidified and the cast plate 32 is formed, the leakage prevention piece 16 is removed from the mold 10 and the cast plate 32 is removed from the mold 10 as shown in FIG.

Thereby, the tubular member casting plate 70 as shown in FIG. 1 is obtained.
Since the mold 10 and the leakage preventing piece 16 used in the manufacturing method of the present invention can be reused in the manufacturing process shown in FIGS. 2 (a) to 3 (b), the conventional V-process casting method is used. Thus, it is not necessary to perform mold separation every time, and the production efficiency is good and the production cost can be kept low.

  As mentioned above, although preferable embodiment of this invention was described, the manufacturing method of the tubular member casting plate of this invention is not limited to this, For example, the number of the tubular members 20 is limited to two like this embodiment. In addition, the position of the tubular member 20 may be arranged not on the center of the layer thickness of the cast-in plate 32 but on one side.

  Furthermore, in the above-described embodiment, the tubular member 20 is first disposed on the mold 10 and then heated by the heating means 40. However, the present invention is not limited to this. And is placed in the mold 10 that is not heated, or the mold 10 and the tubular member 20 are separately heated by the heating means 40, and then the tubular member heated to the heated mold 10 is heated. 20 may be arranged, and various modifications can be made without departing from the object of the present invention.

DESCRIPTION OF SYMBOLS 10 ... Mold 12 ... Internal space 14 ... Notch part 16 ... Leakage prevention piece 20 ... Tubular member 30 ... Molten metal 32 ... Cast-in board 40 ... Heating means DESCRIPTION OF SYMBOLS 50 ... Cooling means 52 ... Cooling means 60 ... Operation panel 70 ... Tubular member casting plate 100 ... Sand mold 102 ... Sand mold 104 ... Sheet member 106 ... Tubular member 108 ..Molten metal 110 ... Tubular member cast plate

Claims (10)

A method of manufacturing a tubular member cast plate,
Preparing a mold having a concave internal space and a tubular member;
Of the mold and the tubular member prepared in the preparing step, at least the tubular member is heated to a predetermined temperature by a heating means, and the heated tubular member is removed from one end of the inner space of the mold. A step of bridging and arranging so as to cross each end;
Injecting a molten metal having a melting point lower than the melting point of the tubular member into the internal space of the mold in which the tubular member heated in the arranging step is disposed;
A step of rapidly cooling the molten metal injected in the step of injecting by a cooling means provided around the mold;
After the cooling step, taking out the tubular member cast plate in which the tubular member is cast from the mold, and
The manufacturing method of the tubular member casting plate characterized by having at least. In the arranging step,
The mold and the tubular member are heated to a predetermined temperature by the heating means, and the tubular member is arranged so as to bridge from one end to the other end of the internal space of the mold. The manufacturing method of the tubular member casting plate of Claim 1. In the arranging step,
After bridging the tubular member so as to exceed the other end of the inner space of the mold, the mold provided with the tubular member is heated to a predetermined temperature by the heating means. The manufacturing method of the tubular member casting plate of Claim 1.   The method of manufacturing a tubular member cast plate according to any one of claims 1 to 3, wherein the mold is made of carbon and subjected to an oxidation resistance treatment.   The method for manufacturing a tubular member casting plate according to any one of claims 1 to 4, wherein the tubular member is made of copper.   The method for manufacturing a tubular member cast plate according to any one of claims 1 to 5, wherein the molten metal injected into the inner space of the mold in the injecting step is a molten aluminum.   The said heating means is an electric furnace, The manufacturing method of the tubular member casting plate in any one of Claims 1-6 characterized by the above-mentioned.   The said cooling means is an air cooling system, The manufacturing method of the tubular member casting plate in any one of Claims 1-7 characterized by the above-mentioned.   The method for manufacturing a tubular member casting plate according to any one of claims 1 to 8, wherein the tubular member casting plate is a water-cooled cooling plate of a solar battery cell.   The method for manufacturing a tubular member casting plate according to any one of claims 1 to 9, wherein the tubular member is formed by inserting a rod-shaped member having heat resistance and mechanical strength into the tube.

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