Field
[0001] The present invention relates to a pipe embedded structure in which a pipe is embedded
in a metal member, the pipe circulating a temperature adjustment medium, such as a
cooling gas or cooling water, and a method of manufacturing the pipe embedded structure.
Background
[0002] Structures (hereinafter, referred to as pipe embedded structures) in which a pipe,
which circulates a fluid is embedded in a metal member are used in various uses, such
as a process of manufacturing products including semiconductors, liquid crystal display
devices, and optical disks. For example, a pipe embedded structure in which a heating
medium (coolant) is circulated in the pipe is used as a temperature adjustment device
(cold plate, or the like) that adjusts (cools or heats) the temperature of a substrate
(for example, see Patent Literature 1). Further, a pipe embedded structure in which
a gas containing a predetermined constituent is circulated in a passage is sometimes
used as a shower plate that supplies the gas to a substrate.
[0003] Such pipe embedded structures are conventionally manufactured such that the pipe
that circulates a fluid, and the metal member in which a recessed portion having a
shape corresponding to the pipe is formed by drilling or the like are separately made,
and the pipe is fitted into the recessed portion in the metal member.
[0004] Further, in recent years, a technology of embedding a pipe in a metal member by a
so-called cold spray method has been proposed, the cold spray method being to spray
metal powder on a base material while maintaining a solid phase state of the metal
powder, and to deposit the metal on the base material, thereby to form a structure
(for example, see Patent Literature 2).
Citation List
Patent Literature
[0005]
Patent Literature 1: Japanese Laid-open Patent Publication No. 2009-13497
Patent Literature 2: Japanese Laid-open Patent Publication No. 2011-238705
Summary
Technical Problem
[0006] In the pipe embedded structures, if a gap exists between the pipe and the metal member,
the thermal resistance becomes large, and the thermal conductivity and the thermal
uniformity between the fluid circulated in the pipe and the metal member are deteriorated.
Further, a foreign body may enter the gap therebetween, or the pipe may be shaky in
the recessed portion due to the gap. However, it is difficult to bond them adhering
to each other by only the method of simply fitting the pipe in the recessed portion,
which is provided in the metal member, so as not to cause the gap between an inner
wall of the recessed portion and an external wall of the pipe.
[0007] On this point, with the cold spray method, a dense metal coating film can be deposited
around the pipe. Therefore, a structure having excellent thermal conductivity can
be made. However, even in this case, adhesive properties of the metal coating film
to the pipe may be deteriorated because a local gap is caused around the pipe, depending
on a condition, such as the shape of the pipe or an angle at which the metal powder
is sprayed on the pipe and the base material.
[0008] The present invention has been made in view of the foregoing, and an objective is
to provide a pipe embedded structure with improved adhesive properties between a pipe
that forms a passage and a metal member, and a method of manufacturing the pipe embedded
structure. Solution to Problem
[0009] To solve the above-described problem and achieve the object, a pipe embedded structure
according to the present invention includes: a pipe made of a metal or an alloy, and
having a periphery forming a circular shape in a transverse section; a base material
made of a metal or an alloy, including a recessed portion having an inner wall on
which a part of the periphery abuts and in which the pipe is fitted; and a deposited
layer formed by accelerating powder formed of a metal or an alloy together with a
gas in a state where the pipe is fitted into the recessed portion, and spraying and
depositing the powder on surfaces of the pipe and the base material while maintaining
a solid phase state of the powder, wherein a ratio h/R of a protruding amount h by
which the pipe protrudes from the surface of the base material and a curvature R of
the periphery is not smaller than 0.3 and not greater than 0.7.
[0010] In the above-described pipe embedded structure, in the transverse section of the
pipe, a clearance of the recessed portion and the pipe is not smaller than 0 mm and
not greater than 0.05 mm.
[0011] In the above-described pipe embedded structure, the pipe is formed of stainless steel,
a copper alloy, a nickel alloy, tantalum, niobium, titanium, aluminum, or an aluminum
alloy.
[0012] In the above-described pipe embedded structure, the base material is formed of copper,
a copper alloy, aluminum, or an aluminum alloy.
[0013] In the above-described pipe embedded structure, the powder is formed of copper or
aluminum.
[0014] A method of manufacturing a pipe embedded structure according to the present invention
includes: a base material forming step of forming, in a base material made of a metal
or an alloy, a recessed portion having an inner wall on which a part of a periphery
of a pipe abuts, the pipe being made of a metal or an alloy and having the periphery
forming a circular shape in a transverse section; and a deposited layer forming step
of forming a deposited layer by fitting the pipe into the recessed portion, accelerating
powder formed of a metal or an alloy together with a gas, and spraying and depositing
the powder on surfaces of the pipe and the base material while maintaining a solid
phase state of the powder, wherein the base material forming step causes a ratio h/R
of a protruding amount h by which the pipe protrudes from the surface of the base
material and a curvature R of the periphery to be not smaller than 0.3 and not greater
than 0.7.
[0015] In the above-described method of manufacturing a pipe embedded structure, the base
material forming step causes a clearance of a width of the recessed portion in the
transverse section of the pipe and an outer diameter of the pipe to be not smaller
than 0 mm and not greater than 0.05 mm.
Advantageous Effects of Invention
[0016] According to the present invention, the recessed portion having the ratio h/R not
smaller than 0.3 and not greater than 0.7 is formed on the base material, the ratio
h/R being a ratio of the protruding amount h of the pipe that forms a passage from
the base material, and the curvature R of the periphery of the pipe, the pipe is fitted
into the recessed portion, and the deposited layer is formed on the surfaces of the
pipe and the base material by a so-called cold spray method. Therefore, a dense deposited
layer can be formed around the pipe that protrudes from the base material, and the
adhesive properties between the pipe and the metal member can be improved.
Brief Description of Drawings
[0017]
FIG. 1 is a cross sectional view illustrating a structure of a pipe embedded structure
according to an embodiment of the present invention.
FIG. 2 is a flowchart illustrating a method of manufacturing the pipe embedded structure
illustrated in FIG. 1.
FIG. 3A is a schematic diagram for describing process S1 illustrated in FIG. 2.
FIG. 3B is a schematic diagram for describing process S2 illustrated in FIG. 2.
FIG. 3C is a schematic diagram for describing process S3 illustrated in FIG. 2.
FIG. 4 is a schematic diagram illustrating an overview of a cold spray device.
FIG. 5 is a SEM image illustrating a deposited layer in a first example.
FIG. 6 is a SEM image illustrating a deposited layer in a second example.
FIG. 7A is a SEM image illustrating a deposited layer in a first comparative example.
FIG. 7B is a schematic diagram illustrating a positional relationship between a pipe
and a base material in the first comparative example.
FIG. 8A is a SEM image illustrating a deposited layer in a second comparative example.
FIG. 8B is a schematic diagram illustrating a positional relationship between a pipe
and a base material in the second comparative example.
FIG. 9 is an optical photograph illustrating a deposited layer in a third example.
FIG. 10 is an optical photograph illustrating a deposited layer in a fourth example.
FIG. 11 is an optical photograph illustrating a deposited layer in a third comparative
example.
Description of Embodiments
[0018] Hereinafter, embodiments for implementing the present invention will be described
in detail with reference to the drawings. Note that the present invention is not limited
by the following embodiments. Further, the drawings referred in the following description
merely schematically illustrate the shape, the size, and the positional relationship
to the extent that the content of the present invention can be understood. That is,
the present invention is not limited only by the shape, the size, and the positional
relationship exemplarily illustrated in the drawings.
(Embodiment)
[0019] FIG. 1 is a cross sectional view illustrating a structure of a pipe embedded structure
according to an embodiment of the present invention. As illustrated in FIG. 1, a pipe
embedded structure 1 according to the present embodiment includes: a pipe 10 made
of a metal or an alloy and having a periphery that forms a circular shape in a transverse
section; a base material 11 made of a metal or an alloy, including a recessed portion
11a to which the pipe is fitted; and a deposited layer 12 made of a metal or an alloy
and formed on the pipe 10 and the base material 11. Such a pipe embedded structure
1 circulates a desired fluid (a liquid or a gas) in the pipe 10, and is used as a
temperature adjustment device (for example, a cold plate), a fluid supply device (for
example, a shower plate), or the like.
[0020] The pipe 10 is a pipe having a tube shaped cross section with an outer diameter ϕ
and a curvature R of the periphery. Note that the thickness of the pipe 10 is appropriately
determined according to the use or the material.
[0021] The shape of the pipe 10 in a length direction (a direction into which the fluid
is circulated) is not especially limited, and the planar shape of the pipe 10 as viewed
from above of the pipe embedded structure 1 can be various shapes, such as a linear
shape, a spiral shape or a meandering shape.
[0022] The material of the pipe 10 is selected according to the fluid to be circulated in
the pipe 10 or the use of the pipe embedded structure 1. For example, when a liquid
or a gas having corrosion properties is circulated, a metal or an alloy having corrosion
resistance, such as stainless steel, a copper alloy, a nickel alloy, tantalum, niobium,
or titanium, is used. Further, when city water or sea water is circulated as cooling
water, a material having favorable thermal conductivity, such as stainless steel,
of the above-described materials, is used. Meanwhile, when process cooling water (PCW),
an organic solvent, an inert gas, or the like is circulated, the corrosion resistance
is not essential, and aluminum or an aluminum alloy having excellent thermal conductivity
can be used.
[0023] The base material 11 is a bulk material formed of a metal or a metal alloy having
favorable thermal conductivity, such as copper, a copper alloy, aluminum, or an aluminum
alloy. The recessed portion 11a is formed such that an upper surface 11b of the base
material 11 is drilled in a groove manner. Note that the planar shape of the recessed
portion 11a on the upper surface 11b corresponds to the planar shape of the pipe 10.
[0024] The recessed portion 11a has an inner wall on which a part of the periphery of the
pipe 10 abuts. The transverse section shape of the inner wall of the recessed portion
11a is an arc shape along the periphery of the pipe 10. The depth d of the recessed
portion 11a is defined such that a ratio h/R of a height (hereinafter, referred to
as protruding amount) h by which the pipe 10 protrudes from the upper surface 11b,
and the curvature R of the periphery of the pipe 10 becomes not smaller than 0.3 and
not greater than 0.7. Further, the width of the recessed portion 11a has a maximum
value w (w ≅ ϕ) at a height corresponding to the curvature R, based on a deepest portion
of the recessed portion 11a, and the recessed portion 11a opens from the height to
an upper portion while maintaining the maximum value w. Further, a clearance w - ϕ
of the recessed portion 11a and the pipe 10 falls within a range from 0 to 0.05 mm,
both inclusive.
[0025] The deposited layer 12 is formed by a so-called cold spray method. Here, the cold
spray method is a coating film forming method, which accelerates powder made of a
metal or an alloy together with a gas, and sprays the powder with the gas on a surface
of a base (the pipe 10 and the base material 11 in the present embodiment) while maintaining
a solid phase state of the powder, thereby to deposit the powder. The deposited layer
12 formed by the cold spray method does not have phase transformation, and oxidization
is suppressed. Therefore, the deposited layer 12 has high thermal conductivity. Further,
when the powder collides with the base or the coating film deposited on the base before,
plastic deformation is caused between the powder and the base, and anchor effect can
be obtained. In addition, oxide coating films of both sides are destroyed and metallic
bond by newly formed surfaces is caused. Therefore, the adhesive strength of the powder
with the base becomes strong, and a coating film with suppressed thermal resistance
can be formed.
[0026] Such a deposited layer 12 is formed of a metal or an alloy having favorable thermal
conductivity, such as copper or aluminum.
[0027] Next, a method of manufacturing the pipe embedded structure 1 will be described.
FIG. 2 is a flowchart illustrating a method of manufacturing the pipe embedded structure
1. Further, FIGS. 3A to 3C are schematic diagrams for describing the method of manufacturing
the pipe embedded structure 1.
[0028] First, in process S1, the groove-shaped recessed portion 11a is formed on a surface
of a bulk material 13 made of a metal or an alloy by drilling, and the base material
11 is made, as illustrated in FIG. 3A.
[0029] Next, in process S2, the pipe 10 is fitted into the recessed portion 11a, as illustrated
in FIG. 3B.
[0030] Further, in process S3, the deposited layer 12 is formed on the surfaces of the pipe
10 and the base material 11 by the cold spray method, as illustrated in FIG. 3C.
[0031] FIG. 4 is a schematic diagram illustrating an overview of a cold spray device used
in process S3. As illustrated in FIG. 4, a cold spray device 20 includes a gas heater
21, a powder supply device 22, a gas nozzle 24, and valves 25 and 26. The gas heater
21 heats a compressed gas. The powder supply device 22 houses powder (hereinafter,
may be simply referred to as powder) 28 of the material of the deposited layer 12,
and supplies the powder 28 to a spray gun 23. The gas nozzle 24 jets the heated compressed
gas and the powder 28 supplied thereto to a base 27. The valves 25 and 26 respectively
adjust supply amounts of the compressed gas to the gas heater 21 and to the powder
supply device 22.
[0032] As the compressed gas, helium, nitrogen, oxygen, or the like is used. The compressed
gas supplied to the gas heater 21 is 50°C or more, for example, and is heated to a
temperature in a range lower than a melting point of the powder 28, and is then supplied
to the spray gun 23. The heating temperature of the compressed gas is favorably 300
to 900°C. Meanwhile, the compressed gas supplied to the powder supply device 22 supplies
the powder 28 in the powder supply device 22 to the spray gun 23 such that the amount
of the powder 28 becomes a predetermined discharge amount.
[0033] The heated compressed gas is caused to form ultrasonic flow (about 340 m/s or more)
by the gas nozzle 24 having a widening shape from an inlet toward an outlet. The gas
pressure of the compressed gas at this time is favorably about 1 to 5 MPa. By adjusting
the pressure of the compressed gas to the range, the adhesive strength of the powder
(coating film) with respect to the base 27 can be improved. More favorably, the processing
is performed at a pressure of about 2 to 4 MPa. The powder 28 supplied to the spray
gun 23 is accelerated by being put into the ultrasonic flow of the compressed gas,
collides with the base 27 at a high speed while remaining in the solid phase state,
and is deposited on the base 27. Note that the cold spray device is not limited to
the cold spray device 20 illustrated in FIG. 4 as long as the device can cause the
powder 28 to collide with the base 27 while maintaining the solid phase state of the
powder 28, and form a coating film.
[0034] In such a cold spray device 20, as the base 27, the base material 11 obtained such
that the pipe 10 is fitted into the recessed portion 11a is arranged, and the coating
film is formed on the surfaces of the pipe 10 and the base material 11. At this time,
the powder 28 enters regions 14 between vicinities of upper ends of the recessed portion
11a and the pipe 10, and forms the coating film.
[0035] As described above, by forming the deposited layer 12 to have a desired thickness,
the pipe embedded structure 1 illustrated in FIG. 1 is completed. Note that, as illustrated
in FIG. 3C, a part of the pipe 10 rises more than the upper surface 11b of the base
material, and thus the deposited layer 12 has a shape rising on an upper portion of
the pipe 10. Therefore, the deposited layer 12 is formed thicker, and then an unnecessary
portion is removed by cutting or the like, so that the surface of the deposited layer
12 may be flattened.
[0036] Next, the relationship between the transverse section of the pipe 10 and the recessed
portion 11a provided in the base material 11 will be described.
[0037] In the cold spray method, typically, the powder 28, which is jetted through the gas
nozzle 24 into one direction, is caused to collide with the base 27, and the coating
film is formed. Therefore, the coating film cannot be formed on a shaded portion with
respect to the jetting direction of the powder 28. Further, formation of the coating
film becomes more difficult as a forming surface of the coating film becomes closer
to parallel to the jetting direction of the powder 28. Therefore, the inventors of
the present application have diligently performed experiments in order to obtain conditions
for forming a dense and uniform deposited layer 12 at side portions of the pipe 10,
that is, in the vicinities of interfaces between the pipe 10 and the base material
11 when the deposited layer 12 is formed by the cold spray method.
[0038] As a result, the inventors of the present application have found out that, when manufacturing
the pipe embedded structure 1 in which the pipe 10 having a periphery that forms a
circular shape in a transverse section is embedded, the inventors can form the dense
and uniform deposited layer 12 adhering to the pipe 10 and the base material 11 by
providing the recessed portion 11a that satisfies following conditions (1) and (2)
to the base material 11.
- (1) The radio h/R of the protruding amount h by which the pipe 10 protrudes from the
surface of the base material 11, and the curvature R of the periphery of the pipe
10 is caused to be from 0.3 to 0.7, both inclusive.
- (2) The clearance Δ of the recessed portion 11a and the pipe 10 is caused to be from
0 to 0.05 mm, both inclusive.
[0039] According to the present embodiment, the recessed portion defined by the above-described
conditions is formed in the base material, the pipe is fitted into the recessed portion,
and the deposited layer is formed by the cold spray method, whereby the dense and
uniform deposited layer adhering to the pipe and the base material can be formed around
the pipe. Therefore, when the pipe embedded structure having the adhesive properties
improved as described above is used as a temperature adjustment device or a shower
plate, temperature adjustment efficiency can be improved by the favorable thermal
conductivity and thermal uniformity. Note that, in this case, it is favorable to use
the deposited layer 12 side as a thermal conduction surface.
[Example]
[0040] Hereinafter, examples and comparative examples will be described with reference to
FIGS. 5 to 11.
[0041] First, first and second examples and first and second comparative examples will be
described. FIGS. 5, 6, 7A, and 8A are SEM images of the pipe 10, the base material
11, and the deposited layer 12 imaged from a direction perpendicular to the transverse
section of the pipe 10, when forming the deposited layer 12 while changing the ratio
h/R. Note that, in FIGS. 5, 6, 7A, and 8A, an interface between a side surface and
an upper surface of the base material 11 is illustrated by a single-dotted chain line.
Further, a part of an outer diameter of the pipe 10 is supplemented by a broken line.
FIGS. 7B and 8B are schematic diagrams illustrating the positional relationship between
the pipe 10 and the base material 11 in the first and second comparative examples.
[0042] Samples were made with following materials and conditions in the first and second
examples and the first and second comparative examples.
[0043] The base material: a copper alloy plate having 40 mm x 40 mm and the thickness of
10 mm
[0044] The pipe: a copper alloy having the outer diameter ϕ = 6 mm and the curvature R of
the periphery = 3 mm
[0045] The material of the deposited layer: copper powder having an average particle diameter
of 26.18 µm
[0046] The clearance of the recessed portion provided in the base material and the pipe:
Δ = 0 mm
(First Example)
[0047] The ratio h/R was 0.67. As a result, the dense and uniform deposited layer 12 having
a sufficient thickness at the side portions of the pipe 10 was able to be formed,
as illustrated in FIG. 5.
(Second Example)
[0048] The ratio h/R was 0.33. As a result, the dense and uniform deposited layer 12 having
a sufficient thickness at the side portions of the pipe 10 was able to be formed,
as illustrated in FIG. 6.
(First Comparative Example)
[0049] The ratio h/R was 1 (the protruding amount h = the curvature R), that is, the recessed
portion 11a having a depth corresponding to half of the outer diameter ϕ of the pipe
10 was formed in the base material 11, and just half of the pipe 10 was housed in
the recessed portion 11a. In this case, as illustrated in FIG. 7B, end portions of
the side portions of the pipe 10 that protrudes from the upper surface 11b of the
base material 11 were nearly parallel to the jetting direction of the powder, and
the powder was not able to adhere to the portions. Therefore, as illustrated in FIG.
7A, the deposited layer 12 was not able to be formed on the side portions of the pipe
10, and cracking was caused between the deposited layer 12 formed on the pipe 10 and
the deposited layer 12 formed on the base material 11.
(Second Comparative Example)
[0050] The ratio h/R was 0 (the protruding amount h = 0), that is, the recessed portion
11a having a depth corresponding to the outer diameter ϕ of the pipe 10 was formed
in the base material 11, and the entire pipe 10 was housed in the recessed portion
11a. In this case, as illustrated in FIG. 8B, a deep gap was caused between the inner
wall of the recessed portion 11a and the pipe 10, and the powder was not able to be
sufficiently filled. Therefore, as illustrated in FIG. 8A, a sufficient deposited
layer 12 was not be able to be formed on the side portions of the pipe 10, and cracking
was caused between the deposited layer 12 formed on the pipe 10 and the deposited
layer 12 formed on the base material 11.
[0051] Next, third and fourth examples and a third comparative example will be described.
FIGS. 9 to 11 are optical photographs illustrating the deposited layer 12 when the
clearance Δ of the recessed portion 11a and the pipe 10 was changed. These optical
photographs are polished surfaces of the deposited layer 12 imaged from an upper surface
side. The polished surfaces were obtained such that the deposited layer 12 was sufficiently
(from an upper end surface of the pipe 10 to the height exceeding 1 mm) formed on
the pipe 10, the deposited layer 12 was then cut at the height of 1 mm from the upper
end surface of the pipe 10 by milling, and the deposited layer 12 was further polished.
[0052] In the third and fourth examples and the third comparative example, samples were
made with following materials and conditions.
[0053] The base material: the copper alloy plate having 40 mm x 40 mm and the thickness
of 10 mm
[0054] The pipe: a copper alloy having the outer diameter ϕ = 6 mm and the curvature R of
the periphery = 3 mm
[0055] The material of the deposited layer: copper powder having an average particle diameter
of 26.18 µm
[0056] The ratio h/R = 0.5
(Third Example)
[0057] The clearance Δ was 0 mm. As a result, a dense and uniform deposited layer 12 smoothly
continuous with a region on the pipe 10 and a region on the base material 11 was able
to be formed, as illustrated in FIG. 9.
(Fourth Example)
[0058] The clearance Δ was 0.05 mm. As a result, a dense and uniform deposited layer 12
smoothly continuous with a region on the pipe 10 and a region on the base material
11 was able to be formed, although interface lines of surfaces were observed between
the region on the pipe 10 and the region on the base material 11, as illustrated in
FIG. 10.
(Third Comparative Example)
[0059] The clearance Δ was 0.10 mm. In this case, cracking was observed between a region
on the pipe 10 and a region on the base material 11, as illustrated in FIG. 11. Reference
Signs List
[0060]
- 1
- Pipe embedded structure
- 10
- Pipe
- 11
- Base material
- 11a
- Recessed portion
- 11b
- Upper surface
- 12
- Deposited layer
- 13
- Bulk material
- 14
- Regions
- 20
- Cold spray device
- 21
- Gas heater
- 22
- Powder supply device
- 23
- Spray gun
- 24
- Gas nozzle
- 25
- and 26 Valve
- 27
- Base
- 28
- Powder
1. A pipe embedded structure comprising:
a pipe made of a metal or an alloy, and having a periphery forming a circular shape
in a transverse section;
a base material made of a metal or an alloy, comprising a recessed portion having
an inner wall on which a part of the periphery abuts and in which the pipe is fitted;
and
a deposited layer formed by accelerating powder formed of a metal or an alloy together
with a gas in a state where the pipe is fitted into the recessed portion, and spraying
and depositing the powder on surfaces of the pipe and the base material while maintaining
a solid phase state of the powder, wherein
a ratio h/R of a protruding amount h by which the pipe protrudes from the surface
of the base material and a curvature R of the periphery is not smaller than 0.3 and
not greater than 0.7.
2. The pipe embedded structure according to claim 1, wherein, in the transverse section
of the pipe, a clearance of the recessed portion and the pipe is not smaller than
0 mm and not greater than 0.05 mm.
3. The pipe embedded structure according to claim 1 or 2, wherein the pipe is formed
of stainless steel, a copper alloy, a nickel alloy, tantalum, niobium, titanium, aluminum,
or an aluminum alloy.
4. The pipe embedded structure according to any one of claims 1 to 3, wherein the base
material is formed of copper, a copper alloy, aluminum, or an aluminum alloy.
5. The pipe embedded structure according to claim 4, wherein the powder is formed of
copper or aluminum.
6. A method of manufacturing a pipe embedded structure, the method comprising:
a base material forming step of forming, in a base material made of a metal or an
alloy, a recessed portion having an inner wall on which a part of a periphery of a
pipe abuts, the pipe being made of a metal or an alloy and having the periphery forming
a circular shape in a transverse section; and
a deposited layer forming step of forming a deposited layer by fitting the pipe into
the recessed portion, accelerating powder formed of a metal or an alloy together with
a gas, and spraying and depositing the powder on surfaces of the pipe and the base
material while maintaining a solid phase state of the powder, wherein
the base material forming step causes a ratio h/R of a protruding amount h by which
the pipe protrudes from the surface of the base material and a curvature R of the
periphery to be not smaller than 0.3 and not greater than 0.7.
7. The method of manufacturing a pipe embedded structure according to claim 6, wherein
the base material forming step causes a clearance of a width of the recessed portion
in the transverse section of the pipe and an outer diameter of the pipe to be not
smaller than 0 mm and not greater than 0.05 mm.