CN100496770C - Resin membrane forming method and apparatus thereof - Google Patents

Abstract

The present invention relates toa resin film forming method and its equipment. It is characterized by that the resin is applied on the surface of metal workpiece, then said resin is heated and molten by using induction heating process, after having been cooled said resin is hardened so as to form resin film. Besides, said invention also provides the concrete steps of the above-mentioned induction heating process, so that one layer of thin resin film can meet the requirements of its durability and appearance quality.

Description

Resin molding formation method and device thereof

Technical field:

The present invention relates to regulation surface,, form the method and the relevant apparatus thereof of resin molding for reaching antirust or purpose such as adhesion at metal material.

Background technology:

In the past, for reaching purpose such as antirust forms resin molding on the surface of metal material method, for example open in patent documentation 1 (spy opens flat 10-160090 communique).This resin coating film method is: form the outstanding shape thing of resin powder at surface of steel plate, be dried, form resin powder gatherable layer, by eddy-current heating, with this gatherable layer heat fused, form molten film (resin molding) at surface of steel plate.

Yet in above-mentioned resin coating film method in the past, the resin powder gatherable layer because of forming at surface of steel plate utilizes eddy-current heating, and only 240 ℃ of left and right sides heat fused, cooling forms resin molding.Because resin is coated with thickness, produce pore etc. on its surface, make outward appearance not beautiful, and used resin often is limited to particular matters such as outstanding shape thing, therefore be easy to generate the too high problem of cost.

Particularly in above-mentioned resin coating film method in the past, when the metal surface forms the resin molding of relatively thinner micron unit thickness, only be heated to set point of temperature by normal temperature, the steam bubble that produces during heating remains in the gatherable layer (resin molding) and is difficult to outwards discharge fully, the surface of the resin molding that forms is easy to generate bubble or air gap etc., therefore, when requiring the existing durability of formed resin molding that the good surface appearance quality is arranged again, just be difficult to reach.

Summary of the invention:

Even the purpose of this invention is to provide a kind of very thin resin molding, also can satisfy resin molding formation method and device thereof that performance such as durability of products and presentation quality require.Mainly utilize eddy-current heating only 240 ℃ of left and right sides heat fused in the resin molding formation method of the existing metal material surface of solution, cooling forms resin molding, because resin is coated with thickness, at its surperficial pore etc. that produces, makes the not beautiful technical problem of outward appearance.

For solving the problems of the technologies described above, the present invention is achieved in that

A kind of resin molding formation method, be resin is coated in the metal works surface, make this resin heat fused by eddy-current heating, cool off after-hardening and form resin molding, it is characterized in that: in the eddy-current heating process, be heated to first heating-up temperature earlier, and after remaining on one the time that discharges with the corresponding default bubble that resin is produced in smearing of this heating-up temperature, be heated to second heating-up temperature higher again than above-mentioned first heating-up temperature.

Be heated to first temperature, and after one the time that has kept discharging, keeping default a period of time with the temperature lower again than the first heating-up temperature height ratio, second heating-up temperature with the corresponding default bubble that resin is produced in smearing of this heating-up temperature.

This resin membrane formation device, have with above-mentioned metal works resin be coated with wipe one's face the heater coil that is oppositely arranged and, the converter plant that high frequency electric is offered this heater coil reaches, control this converter plant by above-mentioned heater coil, can set a plurality of heating-up temperature heating resins in each stage and be coated with the control method of wiping one's face.

When first heating-up temperature remains on and this heating-up temperature after corresponding default a period of time, can set second heating-up temperature higher than above-mentioned first heating-up temperature.

This heater coil has with a plurality of resins of metal and is coated with the respectively corresponding a plurality of coil groups of wiping one's face, and this coil groups is connected in series.

Compared with prior art, technique effect of the present invention is:

When 1, being fixed by insulation board because of pair of conductors, roughly middle part from the relative direction of powered electrode, with relative direction roughly the direction of quadrature extend and to be provided with binding post, so can be to a pair of powered electrode, the for example good high frequency electric of balance between supply and demand, quenching product mass-energy raising of workpiece etc., the high accuracy of workpiece heating quality obtains stable the time, ledge disappears and to make compact conformation around powered electrode, can be complementary or the like with various production lines, therefore the versatility of device setting is improved.

2, at the output of power supply output transformer, owing to connected the safety coil that is in state in parallel with powered electrode, so around powered electrode, need not to be provided with the fork conductor, because safety coil, really prevented loose contact that the powered electrode workpiece is brought and so on influence simultaneously, the versatility that apparatus structure is simple more, device is provided with is further improved.

3, since the electrical characteristic value of safety coil to be set to when contacting with powered electrode with workpiece the electrical characteristic value between powered electrode corresponding, can prevent under the normal condition harmful effect when workpiece heated, even come in contact bad, harmful effect to workpiece also can be controlled at Min., can be enough fixed electric power heated parts.

4, because the cooling collar that disposes is provided with a plurality of spray-holes along the tooth peak portion of the tooth bar flank of tooth, sprayed cooling water between powered electrode, thereby the tooth peak portions of the flank of tooth etc. can cool off rapidly positively in high quality and quench along the tooth peak portion of the tooth bar flank of tooth.

Description of drawings:

Fig. 1 is the structural representation of resin membrane formation device of the present invention.

Fig. 2 is the exploded perspective view of heater coil shown in Figure 1 and workpiece.

Fig. 3 is the process chart of resin molding formation method of the present invention.

Fig. 4 is the time-temperature profile during the inventive method is implemented.

Among the figure:

1-------resin membrane formation device; The 2-------frequency changer circuit;

The 2a--2d-------branch road; 3a--3d-------FET;

The 8-------transformer; The 9-------output transformer;

The 10-------heater coil; The 10a--10c-------coil groups;

The 11-------differential transformer; 12-------detects transformer;

The 12a-------safety coil; The 12b-------output winding;

The 13-------control device; The 15-------workpiece;

The 15a-------chassis; The 15b-------protuberance;

The 16a--16c-------resin is coated with wipes one's face.

The specific embodiment:

Fig. 1-Fig. 4 is a kind of example that resin molding of the present invention forms method and apparatus.

In Fig. 1, resin membrane formation device 1 has the frequency changer circuit 2 of transistor type, on four branch road 2a--2d of this frequency changer circuit 2, is connected with four thyristor FET3a--3d etc. respectively.And, in each branch road 2a--2d of this frequency changer circuit 2, branch road 2a and branch road 2b series connection, branch road 2c and branch road 2d series connection.Simultaneously, because the tie point of branch road 2a and branch road 2c links to each other with dc source+end 4a, the tie point of branch road 2b and branch road 2d links to each other with dc source-end 4b, so constituted complete bridge circuit.Also have, between above-mentioned terminal 4a, 4b, connected electrolytic capacitor 5 and reached the resistance 6 of series connection and diode 7.

In addition, on the tie point of branch road 2a and branch road 2b, connect an end of the input coil of transformer 8, on the tie point of branch road 2c and branch road 2d, connected the other end of the input coil of above-mentioned transformer 8.Also have, the output of transformer 8 links to each other with the input of output transformer 9 (current transformer), and the output of this output transformer 9 is done detachable the connection by electrode holder etc. with heater coil 10.And above-mentioned transformer 8, output transformer 9 and frequency changer circuit 2 etc. have constituted converter plant of the present invention.

Also have, between the tie point of branch road 2a, branch road 2c and the drain electrode of the FET3a on the branch road 2a and the FET3c on the branch road 2c drain electrode between, the tie point of branch road 2b, branch road 2d with prop up

Between the source electrode of FET3b on the 2b of road and branch road 2d on the source electrode of FET3d between, designed the differential transformer 11 of each branch road 2a--2d electric current of balance respectively.

And, on the output winding of output transformer 9, connected the safety coil 12a as the input coil that detects transformer 12, this safety coil 12a and the output winding 12b of the detection transformer 12 that is connected with its do induction are connected with control device 13 as control device.The formation that detects transformer 12 is as follows: for example use copper round tube, copper coin, copper cash etc. safety coil 12a around cylindrical core, on the assigned position of this cylindrical core with electric wire etc. with a fixing turn coiled output winding 12b.

In addition, the induction coefficient of safety coil 12a (for example winding number of turns), corresponding with the induction coefficient (for example winding number of turns) of heater coil 10 of narration afterwards, be set at the smaller value of 1/2-1/10 scope.The inductance value of this safety coil 12a, as surpassing 1/2, the induction coefficient of safety coil 12a is excessive, brings harmful effect for the induction coefficient of heater coil 10, as less than 1/10, just can't measure the state of heater coil 10, and this value draws according to experimental result.Therefore, the safety coil 12a that detects transformer 12 is in parallel with heater coil 10, owing to the existence of safety coil 12a, when heater coil 10 short circuit appears, when abnormality such as opening circuit, this measured signal has been delivered to control device 13 from output winding 12b.

Above-mentioned control device 13, constitute by micro computer or relay, electromagnetic switch, program controller etc., its input side and the output winding 12b that detects transformer 12 etc. are connected, and its outlet side is connected with control FET3a--3d pass, the oscillator that closes, power circuit (not shown) etc.In addition, on branch road 2b, the 2d of frequency changer circuit 2, connect corresponding current detector 14 in case of necessity respectively.

Above-mentioned heater coil 10 as shown in Figure 2, be by one within it portion have the continuous circular copper pipe bending of cooling water path to form, three resins at workpiece 15 are coated with on the 16a--16c that wipes one's face, and three corresponding coil groups 10a--10c are arranged, and these coil groups 10a--10c is connected in series.That is to say, the structure of workpiece 15 is as follows: for example use copper coins (metal material) such as SUS, press certain external diameter in 15a centre of surface position, chassis, constituted the roughly discoid protuberance 15b of outstanding structure, by chassis 15a outer surface and protuberance 15b annulus part surperficial and the certain internal diameter outside the protuberance 15b on 15a surface, chassis, formed resin and be coated with the 16a--16c that wipes one's face.

And, it is corresponding that each coil groups 10a--10c of above-mentioned heater coil 10 and each resin of this workpiece 15 are coated with the 16a--16c that wipes one's face, turnover shown in arrow " Ren ", wherein to be coated with the 16b that wipes one's face, 16c corresponding for coil groups 10b and coil groups 10c and smooth resin, for example constitutes with shape arranged side by side 2 circles of reeling with circular copper pipe in the horizontal direction; It is corresponding that coil groups 10a and vertical resin are coated with the 16a that wipes one's face, and for example constitutes with shape arranged side by side 2 circles of reeling with circular copper pipe in vertical direction.

Also have, the outer surface of circular copper pipe has been applied in insulation processing 17 to prevent to be adjacent the short circuit between the circular copper pipe, and simultaneously, the outer surface of the copper pipe that 2 circles are reeled is side by side also reeled with insulating materials such as insulating tape 18.In addition, the two ends of the copper pipe of three coil groups 10a--10c that reel to form are by above-mentioned electrode holder or do not have the output winding of illustrated connection copper coin etc. and output transformer 9, for example detachable connection.

Below, the resin membrane formation device 1 that constitutes according to aforesaid way and by the shape of workpiece shown in Figure 2 15 in conjunction with process chart 3, the formation method of the resin molding of workpiece 15 is illustrated by an example.As shown in Figure 3, at first, settle workpiece 15 (K101) in the drawings not on the production line operation platform of the resin membrane formation device 1 of expression, the resin of regulation is smeared (K102) respectively be coated with on the 16a--16c that wipes one's face at each resin of workpiece 15 by smearing robot.Used resin has antirust, anti-edible or plays effects such as bonding, is coated with wipe one's face desired quality, performance etc. according to each resin of workpiece 15 and uses corresponding resin.

Each resin that resin is coated in workpiece 15 is coated with after the 16a--16c that wipes one's face goes up, and in the surface of workpiece 15 side, shown in Fig. 2 arrow " Ren ", for example heater coil 10 is made as (K103) shape that advances.Under this state, by the control signal of control device 13, start frequency changer circuit 2 first electric current offered heater coil 10, each resin be coated with the 16a--16c that wipes one's face with first heating-up temperature (by Fig. 4, T1=100 ℃) heating, implement the heating (K104) of phase I.When heating in this phase I, frequency changer circuit 2 will move in the following manner.

Promptly, control signal by control device 13, above-mentioned oscillator action reaches, the FET3a--3d open and close of frequency changer circuit 2, be attached on the input side of transformer 8 with the high frequency electric of oscillator corresponding frequencies, this high frequency electric is converted to big electric current as first current value by the output transformer 9 that is connected transformer 8 outlet sides, and this first current value offers heater coil 10 by electrode holder with the high frequency electric form.And, when high frequency electric one flows to heater coil 10, be coated with the 16a--16c that wipes one's face at each resin; just because of the sensed heating of Vortex stream with the corresponding workpiece 15 of each coil groups 10a--10c of this heater coil 10, by this eddy-current heating, each resin is coated with the 16a--16c that wipes one's face and is heated to first heating-up temperature.

So, implemented for first heating period, stop the action of frequency changer circuit 2 again by control device 13, the electric current that flows to heater coil 10 is cut off, make this state keep certain hour, promptly workpiece 15 is placed the regular hour (K105) by frequency changer circuit 2.As shown in Figure 4, heat since moment t0, be heated to 100 ℃ at moment t1, owing to be placed certain hour, so each resin of heated workpiece 15 is coated with the temperature of the 16a--16c that wipes one's face roughly since 100 ℃ of times that rise to naturally about 150 ℃, be exactly maintained time (tb=t2-t1), by first heating period and placement, the bubble that produces in the first heating period resin is smeared discharges.Also have, get (for example) 3-15 minutes better as tb standing time among the operation K105, the time ta from moment t0 to moment t1 gets 30-90 seconds for well.

And, after first heating period standing time tb after t2 finishes constantly, make the frequency changer circuit action again by control device 13, second current value is offered heater coil 10, each resin of workpiece 15 be coated with the 16a--16c that wipes one's face with second heating-up temperature (for example by Fig. 4, T3=300 ℃) heating, implement second heating period (K106).In this second heating period, only provide difference to the current value of heater coil, other action of frequency changer circuit 2 is identical with first heating period, and the control signal by control device 13 makes frequency changer circuit 2 stop action when having reached the moment point of second heating-up temperature.

Second heating period finished, i.e. moment t4 in Fig. 4, and the action that reaches the second heating-up temperature T3, frequency changer circuit 2 when heating-up temperature stops, and constantly to moment t5, the stipulated time (K107) for workpiece is placed, workpiece 15 is cooled off naturally from this.Then, for example remove heater coil 10 (K108), afterwards workpiece 15 is taken out (K109) from operating desk.In the tc standing time of above-mentioned operation K107 (t5-t3), as shown in Figure 4, the heating temperature that makes each resin be coated with the 16a--16c that wipes one's face is in the temperature T 2 (the occasion T2=200 of Fig. 4 ℃) lower than the first heating-up temperature T1 height ratio, the second heating-up temperature T3, passed through for second heating period, resin has obtained the necessary time of good sclerosis, the occasion of Fig. 4 for example is set at, more than tc=5 minute.

And, since the workpiece 15 that takes out from production line by place naturally (or forcing cooling) wait cool off after, be coated in each resin and be coated with hardening of resin on the 16a--16c that wipes one's face, each resin of workpiece 15 is coated with the performance improvement of the 16a--16c that wipes one's face, and the resin molding of excellent appearance quality forms.Also have, an example in the process chart as shown in Figure 3 for example, when operation K107 places beginning, can be removed heater coil 10 etc., can do suitable change.

And, when operation K104 and operation K106 heating, utilize following method that the abnormal current of frequency changer circuit 2 is monitored by above-mentioned control device 13.Promptly, when high frequency electric is offered heater coil 10, the electric current that flows into electrode holder (outlet side of output transformer 9) also flow into the safety coil 12a that detects transformer 12, by detecting transformer 12, detect and flow into heater coil 10 corresponding predetermined electric current values, be input to control device 13 after measuring.

And control device 13 is being compared by a reference value that stores in advance in current value that detects transformer 12 detections and input and the control device 13 holder (not shown)s.For example, owing to the short circuit that self causes of heater coil 10, open circuit, or owing to the loose contact of heater coil and electrode holder causes when detecting current anomaly, for example surpass a reference value (or less than a reference value), whether heater coil 10 is judged unusually, then oscillator is sent stop signal immediately, make the oscillator failure of oscillations.Thus, can prevent the damage of the FET3a--3d that causes by abnormal current.

This shows, in the resin membrane formation device 1 of above-mentioned example, by control device 13 control frequency changer circuits 2, be coated with two heating periods of first heating-up temperature and second heating-up temperature of the 16a--16c that wipes one's face by each resin of heater coil 10 setting workpiece 15.Each resin of workpiece 15 is coated with wipes one's face 16a--16c when eddy-current heating, residual bubble wherein, really can get rid of in first heating period, thereby obtain not having the excellent appearance quality of air gap etc., after the exhaust simultaneously, heating period by second heating-up temperature higher, the performances such as durability of resin molding are greatly improved than delivery temperature.

Also have, according to experiment, forming thin resin film thickness is occasion about 40 microns, the various performances such as adaptability of its adhesion strength, tension force, hot strength, environment are compared the raising that several times and even tens of times are all arranged with original method, simultaneously, the excellent appearance quality of generation such as no air gap also obtains confirming.

And, heater coil 10, have with workpiece 15 each resin and be coated with the corresponding respectively a plurality of coil groups 10a--10c of 16a--16c that wipe one's face, because this coil groups 10a--10c is connected in series, so it is corresponding to make each coil groups 10a--10c and each resin be coated with the 16a--16c that wipes one's face really, and can produce uniform eddy-current heating, be coated with on the 16a--16c that wipes one's face at each resin of workpiece 15 and can form high-precision resin molding simply.Particularly, as heater coil 10, owing to curve the regulation shape with a circular copper pipe, and again by reeling, make the coil groups 10a--10c of formation be coated with the 16a--16c that wipes one's face and become the almost parallel shape with each resin of workpiece 15, therefore, by each coil groups 10a--10c, each resin is coated with wipe one's face 16a--16c eddy-current heating more equably, the product mass-energy of resin molding becomes better.

In addition, the control section of control device 13, the frequency changer circuit 2 that an adjustable transistor type of current value is arranged, simultaneously, owing to used dismountable heater coil 10, so each resin of workpiece 15 is coated with the 16a--16c that wipes one's face coat resin after, it all can be finished by robot automatically from being heated to operations such as taking-up, the resin molding formation operation of workpiece 15 is raised the efficiency, aspect the resin that uses, can use general resin, can be with forming high-quality resin molding at a low price, this device is applicable to various workpiece.

In addition, owing to used the frequency changer circuit 2 of the transistor type of being furnished with safety coil 12, because heater coil self reason or loose contact, for example heater coil 10 is if be in off-state, the terminals of output transformer 9 still are in the state that links to each other with safety coil 12, so terminals put on the abnormal load (overload) of frequency changer circuit 2 when disconnecting fully, as long as safety coil 12 induction parts, just can alleviate, can prevent that frequency changer circuit 2 from damaging.

Particularly, the induction coefficient of the safety coil 12a of the detection transformer 12 in parallel with heater coil 10, be set to performance to heater coil 10 and do not produce smaller value bad influence, in the prescribed limit, therefore, its effect is only can accurately detect heater coil unusual.Particularly, when heater coil is detachable structure, is short-circuited easily, opens circuit, therefore can prevent the damage of expensive FET3a--3d really, simultaneously, by position that detection transformer 12 is installed on easy care or the form of using easy care, can reach the purpose that maintenance cost is reduced.

In addition, when heater coil is in normal connection status, the induction coefficient of safety coil 12a is set at the scope that the heating properties of heater coil 10 is not had bad influence, therefore, when obtaining the sufficient efficiency of heating surface, owing on frequency changer circuit 2, designed differential transformer 11, flow into the current value energy uniform distribution of frequency changer circuit 2 each branch road 2a--2d, utilize design at branch road 2b, current detector 14 on the 2d also can be measured abnormal current, can make frequency changer circuit 2 stop action, thereby obtain to prevent abnormal current, the good frequency changer circuit 2 of extremely safe (resin membrane formation device) again.

Also have, in above-mentioned example, three coil groups 10a--10c in the heater coil 10 are designed to the series connection form, but the present invention is not limited thereto, the form that is coated with the 16a--16c that wipes one's face with the resin of workpiece 15 is corresponding, for example also can design the coil groups more than two or four, each coil groups also can be connected in parallel.In addition, in the frequency changer circuit 2 of above-mentioned example, FET3a--3d as thyristor, but can for example be used various thyristors such as general transistor, thyristor, IGBT.Have, in above-mentioned example, the form of workpiece 15, heater coil 10 etc. also is an example, even can the uses such as metal works of the different shape of energy eddy-current heating again.

The present invention is not limited to the resin molding formation aspect of metal works predetermined surface, for example, can be used in the regulation surface that other materials such as metal, plastics, timber, stone material is adhered to metal by resin equally.

Claims (3)

1, a kind of resin membrane formation device, it is characterized in that: this resin membrane formation device, have with the metal works resin be coated with wipe one's face the heater coil that is oppositely arranged and, the converter plant that high frequency electric is offered this heater coil reaches, control this converter plant by above-mentioned heater coil, can set a plurality of heating-up temperature heating resins in each stage and be coated with the control method of wiping one's face;

This resin membrane formation device has the frequency changer circuit of transistor type, on four branch road 2a--2d of this frequency changer circuit, is connected with four thyristor FET3a--3d etc. respectively; In each branch road 2a--2d of this frequency changer circuit, branch road 2a and branch road 2b series connection, branch road 2c and branch road 2d series connection; Because the tie point of branch road 2a and branch road 2c links to each other with dc source+end 4a, the tie point of branch road 2b and branch road 2d links to each other with dc source-end 4b, so constituted complete bridge circuit; Between above-mentioned terminal 4a, 4b, connected electrolytic capacitor and reached the resistance of series connection and diode;

On the tie point of branch road 2a and branch road 2b, connected an end of the input coil of transformer, on the tie point of branch road 2c and branch road 2d, connected the other end of the input coil of above-mentioned transformer; The output of transformer links to each other with the input of output transformer, and the output of this output transformer is done detachable the connection by electrode holder etc. with heater coil; And the converter plant that above-mentioned transformer, output transformer and frequency changer circuit etc. have constituted;

Between the drain electrode of FET3a on the tie point of branch road 2a, branch road 2c and the branch road 2a and branch road 2c on FET3c drain electrode between, between the source electrode of FET3b on the tie point of branch road 2b, branch road 2d and the branch road 2b and branch road 2d on the source electrode of FET3d between, designed the differential transformer of each branch road 2a--2d electric current of balance respectively;

On the output winding of output transformer, connected safety coil 12a as the input coil that detects transformer, this safety coil 12a and the output winding 12b of the detection transformer that is connected with its do induction are connected with control device as control device.

2, resin membrane formation device according to claim 1 is characterized in that: when first heating-up temperature remains on and this heating-up temperature after corresponding default a period of time, can set second heating-up temperature higher than above-mentioned first heating-up temperature.

3, resin membrane formation device according to claim 1 and 2 is characterized in that: this heater coil, and have with a plurality of resins of metal and be coated with the respectively corresponding a plurality of coil groups of wiping one's face, this coil groups is connected in series.

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