CN102752889A - 用于多孔材料致密化的装置 - Google Patents
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- H05B6/00—Heating by electric, magnetic or electromagnetic fields
- H05B6/02—Induction heating
- H05B6/10—Induction heating apparatus, other than furnaces, for specific applications
- H05B6/105—Induction heating apparatus, other than furnaces, for specific applications using a susceptor
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Abstract
本发明涉及一种用于多孔材料致密化的装置。感应加热装置,特别是使用液体沉积前驱体,以对多孔制品进行致密化。该感应加热装置使用感应线圈,所述感应线圈由机械加工的或者铣削的平整金属板制成,例如铜板,而不用将构件(特别是中空构件)弯曲为线圈形状。与传统弯曲技术比较,根据本发明的感应线圈能够更加准确并且更加一致地进行制造。
Description
本申请是申请号为200780029426.8,申请日为2007年8月7日,发明名称为“用于多孔材料致密化的装置”的中国专利申请的分案申请。
在先申请
本申请要求2007年8月7日提交的美国临时申请第60/821,596号的优先权的权益,其全部内容合并于此作为参考。
技术领域
本发明涉及对具有理想高生产率的多孔制品进行致密化,特别是但不必只是关于例如飞行器制动器的摩擦制动制品领域中的多孔制品。
背景技术
在摩擦材料的领域,通常公知的是使用多孔材料基质以制造摩擦构件,例如摩擦制动盘。
这种摩擦构件的制造通常以多孔预制件的构造作为开始。例如,在很多摩擦制动器应用中使用环状预制件。能够使用若干不同的已知方法构造环状预制件。例如,碳纤维织物层能够缝合在一起,环状预制件能够从堆叠材料中切割下来。氧化聚丙烯腈(“PAN”)纤维或沥青基纤维是在这类应用中使用的起始纤维的普通例子。随后,在致密化之前,这些纤维可以在高温处理步骤中碳化。
此后,多孔预制件被致密化。致密化的通常公知的方法使用在多孔预制件中沉积的材料的液体前驱体,以对预制件进行致密化。这种致密化在本领域中有时称为“膜状沸腾(film boiling)”。
通常,膜状沸腾致密化包括将多孔预制件浸入液态碳氢化合物,从而使得液体基本上完全渗透预制件的孔隙和空隙。此后,浸入的预制件被感应地加热至高于液态碳氢化合物的分解温度的温度(典型地为1000℃或者更高,典型地高至大约1400℃)。更加特别地,邻近感应地加热的预制件结构的液态碳氢化合物在预制件多孔结构中分离为不同的气相物类(species)。这些气相物类的进一步热分解导致在多孔材料的开放区域中在内表面上形成热解碳(pyrolitic carbon)。
用于致密化的液体前驱体的使用例如在美国专利第4472454、5389152、5397595、5733611、5547717、5981002以及6726962号中讨论。这些文件的各个文件以及每个文件都全部合并于此作为参考。
发明内容
本发明提出一种感应加热组件,包括:支撑框架;至少一对螺旋感应加热线圈,所述至少一对螺旋感应加热线圈安装在支撑框架上并且在通常平行的方向上彼此对准,该对感应加热线圈以线圈分离距离彼此隔开;以及电源,所述电源电连接至该对感应加热线圈;其中每个螺旋感应加热线圈由机械加工的或者铣削的平整金属板制成,机械加工或铣削限定螺旋感应加热线圈的螺旋形式。
所述至少一对螺旋感应加热线圈的每个螺旋感应加热线圈具有水冷却管,所述水冷却管沿着螺旋感应加热线圈的螺旋形式在螺旋方向上延伸。
每个水冷却管硬焊至各个螺旋感应加热线圈。
每个感应加热线圈在感应加热线圈的相邻线匝之间具有至多大约0.75英寸的间隙。
每个感应加热线圈具有大约25英寸的外径。
每个感应加热线圈具有大约3英寸的内径。
支撑框架由G-10玻璃材料制成。
每个加热感应线圈具有一个或多个螺栓头,所述螺栓头布置为提供用于在支撑框架上安装加热感应线圈的装置。
用于安装加热感应线圈的装置对于调节所述至少一对感应加热线圈之间的空间来说是能够调节的。
支撑框架在工件的边界处的各个加热感应线圈之间具有用于支撑通过所述至少一对加热感应线圈加热的工件的一个或多个支架。
附图说明
参考这里所附的附图,本发明将可以得到更加清楚的理解,其中:
图1是液体致密化装置的剖视示意侧视图;
图2是通常与图1中所示相对应的液体致密化装置的剖视示意俯视图;
图3是多孔制品的示意横截面视图,所述多孔制品相对于传统感应线圈安装以感应地加热该制品;
图4是多孔制品的示意横截面视图,所述多孔制品相对于根据本发明的感应线圈安装,以感应地加热该制品;
图5是如图4中所示的感应线圈的一部分的特写横截面视图;
图6是图4中所示的布置的放大的局部视图;
图7是图示用于在本发明的装置中安装多孔制品的布置的示意侧视图;
图8是用于多个多孔制品的液体致密化的例示性装置的示意性立体图;
图9是用于多个多孔制品的液体致密化的例示性装置的示意性横截面视图;以及
图10-12是致密化的多孔预制件的X光图像,用于图示感应加热线圈的结构对于致密化的影响。
具体实施方式
根据本发明的典型致密化设备包括一个或多个反应器室(reactorchamber)以及相应的感应加热线圈,设置所述反应器室的尺寸并将其构造为在其中支持一个或多个预制件构件,同时基本上浸入选择的液体前驱体。例如,反应器室能够合适地由铝制成。其它合适的材料是非磁性的,非限制性地包括玻璃、不锈钢、陶瓷或其组合。根据进行致密化的预制件的尺寸提供专用内总线和线圈。预制件直径的典型例子在从大约10”到大约25”的范围内,厚度在从15mm到50mm的范围内。特别普通的例子包括15”以及20”直径的预制件。
一个或多个反应室的每个都具有与待处理的每个预制件相对应的感应加热线圈。感应线圈和被处理的预制件优选地使用化学上不反应以及热稳定的支架相对于彼此安装到位,所述支架例如由能够承受液态碳氢化合物环境的非导电玻璃复合材料(例如在本领域中公知的“G-10”)制成。
感应加热线圈优选地为水冷却扁平螺旋线圈,并且通常由铜金属制成。出于这个原因,需要提供专用于感应线圈的水冷却系统的热交换器,以下将进一步具体讨论。在使用中,被致密化的预制件(或磨损的制动器)通过直接与感应线圈耦合而加热。
图1和2是通常根据本发明的线圈/反应器室100的侧视和俯视示意图。对于可选择地可打开的顶盖150,提供一个或多个预制件160的加载和卸载所需的例如锁定机构。
每个反应器室100(与所提供的一样多)与普通前驱体供给线路180和到达冷凝器和热氧化剂的普通排放线路140连接。通过计算机控制系统,每个反应器室100能够被充满、排空以及监测。来自致密化过程的排放蒸汽被冷凝并反馈至反应器,而然后残余流出气体优选地被引至传统热氧化剂(未示出)并且燃烧。
为了使得预制件达到其全密度(full density),需要预制件的中心最初被加热至高于前驱体液体的热解温度。随着致密化的进行,由于通过感应加热产生的加热轮廓(heating profile),致密化从预制件的中心部分径向向外移动。在一个例子中,电源的频率设置为(考虑预制件的材料特征)提供大致接近预制件的中心的趋肤深度。随着预制件的中心致密化,响应于由致密化引起的预制件的电特征中的变化,电源的频率增加。
现在在下文中讨论目前预期的发明的特定特征,其在适当的地方与膜状沸腾致密化的传统方面有区别。
在一个预期例子中,在各个反应室中的感应线圈与相应的电源相联。适合于这种应用的市场上可获得的电源的例子是Model No.LSP14-400/30 Lepel感应式电源。
来自电源的能量通过具有外部水冷却网络的(根据给定致密化设备的物理布置)定制的铜总线汇流条传递至感应线圈。
例如,Lepel电源具有远程PID循环控制能力,并且能够通过计算机控制终端进行监测和控制。通过已知方法的致密化过程的功率密度、电压控制、电流控制、频率控制以及/或者温度控制也处于预期布置的范围内。
合适的液体前驱体通过前驱体存储罐供给至一个或多个反应室。系统包括传统流体传递系统,用于管理新的(以及旧的)前驱体液体(未示出)的输送。燃料传递系统可以包括一个或多个远程存储罐,用于存储新的液体前驱体供给并且可能用于临时存储旧的前驱体液体。也能够提供用于新的前驱体液体的相对较小的本地存储罐。
根据本发明使用的前驱体液体的一个例子是环己烷(C6H12)。然而,根据前驱体液体的选择,严格地作为例子而不是限制,相应的沉积材料可以是任意以下材料:碳、碳化硅、氮化硅、碳化碳-硅或者氮化碳-硅。为了在预制件中沉积碳,例如,能够使用诸如环己烷、正己烷、苯、甲苯或其组合的碳氢化合物。能够使用甲基三氯硅烷、二甲基二氯硅烷、以及甲基二氯硅烷、三正甲基氨基硅烷或者其它有机硅烷混合物以沉积碳化硅和氮化硅。
此外,能够选择前驱体液体以共同沉积(co-deposit)材料。例如,通过使用三正甲基氨基或其它硅烷化合物,能够沉积碳化硅和氮化硅的混合物。同样,诸如碳化碳-硅以及氮化碳-硅的共同沉积的材料能够与适当选择的前驱体的混合物一起生产。根据所需的基体,在基体致密化中在致密化或者共同沉积的早期阶段中,能够生产碳化硅或氮化硅界面涂层。
优选地,提供充分的液体前驱体以基本上使得被致密化的预制件以及与其相联的感应加热线圈浸入。如前面所述,膜状沸腾过程产生气体物类,其最终导致在预制件多孔结构的内表面上形成热解碳。优选地,为了过程中可能的再循环,前驱体蒸汽被尽可能地收集并冷凝。仍然残留的流出气体优选地被传送至已知配置的热氧化剂,以将流出气体中的残余碳氢化合物烧掉。
在膜状沸腾致密化过程中使用的感应线圈130的结构对于获得具有合适机械特征(包括摩擦特征)的致密化的预制件来说非常重要。
例如如图3中所示,使用由中空铜管(方的或者圆的)构造的传统扁平线圈会导致与螺旋感应线圈的结构相对应的不需要的“螺旋”致密化(有时候称为“镜像效应”)。已经确定的是,传统铜管相对地难于形成(即,弯曲)为扁平线圈,特别是对于保持线圈相邻线匝之间的一致间隙来说。而且,保持线圈各线匝之间的一致(并且相对较小)间隙的愿望使得关于适当地弯曲铜管以提供紧密线匝的制造和结构问题变得不可避免。
图3的传统感应线圈和图4的线圈之间的特别差别在于以下事实:图3中所示的现有感应加热线圈200由弯曲为需要的线圈形式的方形或者圆形中空铜管230制成。铜管具有如下两个功能:传递用于感应加热的能量(通过铜金属)以及通过入口端口250和出口端口260传送冷却水。例如,图3的线圈200具有标称3/4”的间隙以及18”的内径(ID)范围和8.5”的外径(OD)范围。出于图示的目的,图3显示了放置在氧化铝支架220的内侧并且由G-10支架270支撑的碳化预制件240。
相反,图4显示了根据本发明的感应加热线圈300的例子,其由例如1/4”实心铜板制成,所述铜板被铣削或者以其它方式机械加工为需要的线圈形式330,而不用转动或者弯曲为如同图3中线圈的形状。优选地,使用高精度机械加工操作以通过铜板形成线圈,诸如,例如,CNC铣削以及类似操作。中空金属(例如,铜)水冷却管335硬焊在机械加工的铜线圈330的外(即,与面对使用中的预制件的侧面相对)侧面上。只要它能够承受期望的温度环境,硬焊组合物可以是适合于对铜进行硬焊的任何商业上可获得的组合物。
因为目前预期的感应线圈使用机械加工的平整铜板,与弯曲铜管比较,其能够以更高的精度(特别关于线圈的线匝之间的间隙)生产。此外,机械加工的铜板并不像弯曲的铜管一样承受应力和应变变形。
根据本发明的线圈的相邻线匝之间的间隙基本上一致,并且在大约4mm至大约8mm之间。
此外,已经观察到的是,在一些情况下,传统铜管变得膨胀并且至少易于破裂(以类似血管动脉瘤的方式)(如果实际上不发生破裂)。试验性地认为,传统铜管感应线圈对于冷却水来说会变得过热,以致于不能适当地驱散热量。设想的是,这会使得传统铜管内的冷却水的汽化在其中具有不可接受的压力增加。相信这种压力会导致膨胀管变形以及管破裂的增大的风险。
考虑到在致密化的过程中线圈浸入液态碳氢化合物前驱体,在致密化过程中铜管会破裂的可能性不能忽视。如果冷却水在致密化的过程中离开线圈(例如,由于管故障),水会突然变为蒸汽,其会提供氧的来源。因为在致密化的过程中液态碳氢化合物典型地已经高于其自燃温度,引入氧的来源会出现爆炸的严重风险。
同样,由铜管制成的现有的感应线圈(例如图3中所示)在径向内外边界受到螺旋致密化特征和较弱致密化的不利影响,下面在图10和11中能够看出。
“螺旋致密化”是技术上承认的术语,其通常指的是非均匀致密化,特别地特征在于通常圆周的“条纹”区域,在所述“条纹”区域中致密化与邻近区域明显不同。这个问题明显地涉及线圈设计中的不完美,特别是关于线圈的相邻线匝之间的间隙距离。将会认识到,如果不认真监测线圈结构,线圈各线匝之间的间隙可能会导致邻近预制件的不充分加热。接着这就导致较差的致密化。此外,扁平线圈距离通常处于固定位置,其并不允许为了深度穿透而进行任何调节。
图10和11中所示的预制件是在膜状沸腾致密化过程中以传统铜管感应线圈形成的。在两幅图像中,密度偏差的较大的、在圆周上延伸的区域是明显的。特别地,可以注意到密度非常小的区域(对应于两个预制件的大约“10点”位置处的白色区域)。此外,如前面所述,例如在预制件的径向向外边界,能够看到较差的致密化。例如,参见沿着每个X光扫描的大约底部一半的白色区域。
图12是类似类型的X光扫描,其图示了使用感应线圈致密化的预制件的致密化,所述感应线圈由机械加工的铜板制成并且具有硬焊至其上的冷却水管,如前面参考图4所述。相对于图12,图10和11之间需要注意的重要特征是在图12中没有明显或突出的圆周延伸的斑点及类似物(不像在图10和11中),其表示致密化水平中的较大偏差以及更特别地表示不需要的低致密化区域。
在下文中,图5是根据本发明的感应线圈的一段的横截面视图。冷却水管400硬焊至用作感应加热线圈的机械加工的铜线圈402的外(相对于被致密化的预制件)侧面。诸如螺栓轴401的安装卡具可以固定至冷却水管400的外部,以将线圈安装至反应室内的支架。
如上面所述,根据本发明的反应室包括至少一个如这里所述的感应加热线圈,以感应加热邻近其安装的预制件。在典型布置中,提供成对的线圈,被处理的预制件安装在它们之间。
在本领域中公知的是,在致密化之前预制件通常是软的并且是易弯的。因此,在预制件致密化之前,需要以一种方式相对于感应加热线圈支持预制件,以减小弯曲以及其它形式的翘曲或变形。
在一种布置中,可以使用支撑构件以将预制件支持到位。例如,参见图6和7。在上述例子中,预制件通过一个或多个支架530支持到位,所述支架530例如安装在安装感应线圈的相同支架上。例如,支架可以是不反应的石英玻璃或氧化铝圆柱,其具有形成于其中的尺寸合适且适当对准的凹口。如图6和7中双方向径向延伸的箭头所示,能够调节一些支架或者所有支架的径向(相对于预制件)位置,以例如适应预制件相对于加热线圈的插入,或者以适应不同直径的预制件。
能够通过螺栓轴520(对应于图5中所见的螺栓轴401)的旋入或旋出调节线圈和预制件之间的距离,以在最初致密化的过程中提供有效的加热。感应线圈和预制件之间的这种间距的控制在感应加热的过程中能够有助于控制预制件中的电流集中,从而一方面避免“镜像效应”或“螺旋”致密化,并且通过并不使得线圈距离预制件太远而增加产能(power yield)。
在下文中,图8是根据本发明的反应室700的立体图,三个预制件(以及相联的感应加热线圈)加载于其中。该图示严格地作为例子以图示多个多孔部分的致密化,具有其它数量预制件的其它加载布置也是可能的。
总的来说,多部分致密化显示了在至少三部分致密化配置中生产碳盘的另一方法。在该布置中,液体前驱体通过端口710供给至反应室700。来自电源的能量通过具有外部水冷却网络的适当布置的(根据给定致密化设备的物理布置)铜总线汇流条760传递至感应线圈730。
如上面所述,在致密化的过程中,多孔部分固定并位于扁平线圈730的中心。例如,Lepel电源具有远程PID循环控制能力,并且能够通过计算机控制终端进行监测和控制。通过已知方法的致密化过程的功率密度、电压控制、电流控制以及/或者温度控制也处于预期布置的范围内。
液体前驱体通过本地前驱体存储罐供给至一个或多个反应室700。优选地,提供充分的液体前驱体以基本上使得被致密化的一个或多个预制件以及与其相联的感应加热线圈浸入。膜状沸腾过程产生气体物类,其部分导致在预制件多孔结构的内表面上形成热解碳。为了过程中可能的再循环,前驱体蒸汽通过排放线路720释放并且排出至外冷凝器(未示出)。仍然残留的流出气体优选地被传送至热氧化剂(未示出)。
在线圈/反应器室700的这个例子中,多孔预制件的加载和卸载例如需要对前反应器盖板750以及相应的外总线连接760进行螺栓连接和拆除螺栓。每个反应器室700(与所提供的一样多)与普通前驱体供给线路和到达冷凝器和热氧化剂的普通排放线路720连接。通过计算机控制系统,每个反应器室能够被充满、排空以及监测。来自致密化过程的排放蒸汽被冷凝并反馈至反应器,而然后残余流出气体被引至热氧化剂并且燃烧。
图9图示了用于多个多孔部分的液体致密化的另一布置。该图示显示了密封反应室800内的多个多孔部分870的致密化。由多个多孔部分870和其间的石墨板860组成的加载堆被预先装配。加载堆放置在陶瓷或电绝缘架890上,在加载和卸载操作的过程中移除炉盖805。来自电源的能量通过能量端口880传递至多区线圈810、820和830。通过对于致密化过程的功率密度、电压控制、电流控制、频率控制以及/或者温度控制,单个PID区域控制成为可能。
多孔部分870的加热通过使用例如多区感应线圈810、820和830完成,所述多区感应线圈直接耦合至石墨板860。环状石墨板860具有与环状多孔部分类似的ID和OD尺寸,环状石墨板的厚度在5mm至25mm的范围内。
在这种情况下,致密化前锋(fronts)从与石墨板860接触的受热的预制件表面开始。液体前驱体供给至反应器室800,液体能够通过端口895被充满以及排空。液面指示器840在充满、排空以及致密化的过程中指示前驱体流体的液面。提供充分的液体前驱体以基本上使得反应器室空腔806内的加载堆浸入。在致密化的过程中,液体前驱体的连续供应也是可能的。
如前面所述,致密化过程产生气体物类,蒸汽从端口850释放并且出于可能的再循环的目的引至冷凝器。未被收集的流出气体被传送至热氧化剂,以将残余的碳氢化合物烧掉。
在加热线圈的影响下,认为相对于相应的线圈安装预制件可能是有用的,从而使得预制件能够在致密化的过程中绕其中心旋转。例如,在给定预制件的中心能够提供安装组件,其能够适当地连接至位于各个反应室之外的驱动设备。根据目前预期,预制件的旋转速率可以为每分钟从大约一到大约五转。
根据预期的系统,为线圈和/或总线提供不粘的电绝缘涂层会是有用的,例如环氧树脂或聚四氟乙烯,以防止电加载故障或者由预制件和线圈和/或总线之间的无意接触引起的短路。
虽然已经根据认为是本发明的最有用的实施方式对本发明进行了描述,但应特别注意到,这仅仅是作为例子,在所附权利要求的范围内,其适当的修改和变化都是可能的。
Claims (10)
1.一种感应加热组件,包括:
支撑框架;
至少一对螺旋感应加热线圈,所述至少一对螺旋感应加热线圈安装在支撑框架上并且在通常平行的方向上彼此对准,该对感应加热线圈以线圈分离距离彼此隔开;以及
电源,所述电源电连接至该对感应加热线圈;
其中每个螺旋感应加热线圈由机械加工的或者铣削的平整金属板制成,机械加工或铣削限定螺旋感应加热线圈的螺旋形式。
2.根据权利要求1所述的感应加热组件,其中所述至少一对螺旋感应加热线圈的每个螺旋感应加热线圈具有水冷却管,所述水冷却管沿着螺旋感应加热线圈的螺旋形式在螺旋方向上延伸。
3.根据权利要求2所述的感应加热组件,其中每个水冷却管硬焊至各个螺旋感应加热线圈。
4.根据权利要求1所述的感应加热组件,其中每个感应加热线圈在感应加热线圈的相邻线匝之间具有至多大约0.75英寸的间隙。
5.根据权利要求1所述的感应加热组件,其中每个感应加热线圈具有大约25英寸的外径。
6.根据权利要求1所述的感应加热组件,其中每个感应加热线圈具有大约3英寸的内径。
7.根据权利要求1所述的感应加热组件,其中支撑框架由G-10玻璃材料制成。
8.根据权利要求1所述的感应加热组件,其中每个加热感应线圈具有一个或多个螺栓头,所述螺栓头布置为提供用于在支撑框架上安装加热感应线圈的装置。
9.根据权利要求8所述的感应加热组件,其中用于安装加热感应线圈的装置对于调节所述至少一对感应加热线圈之间的空间来说是能够调节的。
10.根据权利要求1所述的感应加热组件,其中支撑框架在工件的边界处的各个加热感应线圈之间具有用于支撑通过所述至少一对加热感应线圈加热的工件的一个或多个支架。
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