EP2371467A1 - Verfahren zur herstellung von induktoren für induktionsheizung unter verwendung von mikroschmelztechniken - Google Patents

Verfahren zur herstellung von induktoren für induktionsheizung unter verwendung von mikroschmelztechniken Download PDF

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Publication number
EP2371467A1
EP2371467A1 EP08879272A EP08879272A EP2371467A1 EP 2371467 A1 EP2371467 A1 EP 2371467A1 EP 08879272 A EP08879272 A EP 08879272A EP 08879272 A EP08879272 A EP 08879272A EP 2371467 A1 EP2371467 A1 EP 2371467A1
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EP
European Patent Office
Prior art keywords
inductor
microfusion
induction heating
techniques
mould
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP08879272A
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English (en)
French (fr)
Other versions
EP2371467A4 (de
Inventor
Pedro MORATALLA MARTÍNEZ
Miguel Mezquida Gisbert
José JORDÁN MARTÍNEZ
Enrique DEDE GARCÍA-SANTAMARÍA
Manuel DURÁN SÁNCHEZ
Vicente ESTEVE GÓMEZ
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
GH Electrotermia SA
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GH Electrotermia SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by GH Electrotermia SA filed Critical GH Electrotermia SA
Publication of EP2371467A1 publication Critical patent/EP2371467A1/de
Publication of EP2371467A4 publication Critical patent/EP2371467A4/de
Withdrawn legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C5/00—Alloys based on noble metals
    • C22C5/06—Alloys based on silver
    • C22C5/08—Alloys based on silver with copper as the next major constituent

Definitions

  • the present invention refers to a method for manufacturing inductors for induction heating using MICROFUSION techniques.
  • This manufacturing system four major improvements over current manufacturing systems are achieved.
  • the first of these improvements is the use of a data storage system for storing physical and mechanical characteristics of the inductor, thus allowing the exact reproduction of new inductors, which optimizes the processes of replacing inductors for processes wherein hundreds of thousands of pieces are manufactured.
  • the second of the improvements is the use of a suitable highly conductive metal alloy, in order to minimize losses in the inductor and thereby increase the half-life thereof, being able to duplicate with respect to the inductors made with pure copper and silver solders.
  • the third of the improvements is the use of planes in three dimensions for optimizing the inductors and lowering the points of higher current density by changing the geometric characteristics thereof, by means of minor modifications to the planes increasing the durability of the inductors is creased, by removing the hot spots thereof.
  • the fourth of the improvements is the internal design of the inductor, through which the cooling thereof flows, being able to increase the flow rate with respect to those made with copper tube, or increase the thickness of the inductor wall where appropriate.
  • the manual manufacturing of the inductors has generated other kind of problems, such as can be errors in the solders, slightly different dimensions, partial blockage inside the inductor, etc. All of these errors due to manual production have been attempted to be solved through automation in the procedure for manufacturing the inductors. All the automation attempts in the manufacturing of inductors have been made by means of machine tools developed for precisely machining the pieces. These machine tools are designed to basically work on hard materials such as carbon steel.
  • the problem of automation in the manufacturing of inductors is basically the use of current technology for machining solid pieces of copper. The system used basically consisted of, from a large piece of copper, machining the exterior of the inductor removing all the excess of copper.
  • a MICROFUSION method for obtaining jewelry pieces has been used from some time. This method consists of filling a mould with a noble material for making these pieces of jewelry. For making the moulds, a wax original mold usually made by hand is usually used. The materials used in jewelry pieces usually are gold, silver, etc. The functionality of the pieces made by MICROFUSION is only ornamental, and should have no power requirement.
  • the present invention consists of implementing a number of steps result of which is obtaining a given inductor for induction heating.
  • the first step, element 1 in Figure 1 consists in generating one or more two-dimensional planes, with the external physical characteristics of the heating inductor. This step takes into account which will be the part that will be in the vicinity of the piece to be treated. This initial design will be determined by, previous experiences, simulations carried out with proper tools for such purpose, etc.
  • the second step, element 2 in Figure 1 consists in generating a plane in three dimensions, which meets the characteristics determined by the initial planes.
  • This plane in three dimensions has both the face and the exterior of the inductor, and the inside thereof, through which the cooling water of inductor will flow. In this plane will be drawn, both the electrical connections (1) of the inductor, and the connections for the cooling water (2).
  • the plane in three dimensions must contain all the information on inductor model, since over this plane both cooling and electrical improvements will be made, such as the possible future modifications to be carried out In new versions of the inductor.
  • the generation of this plane has to be done on a data storage medium that stores information on the inductor for producing replicas besides having the ability to communicate with a printer for printing wax layers.
  • the first space is determined by the internal parts (4) of the inductor (through which the cooling flows), the second of the spaces is formed by the body (5) of the inductor (the tube walls), the third space is formed by the external part of the inductor (corresponding to the areas wherein no operation has to be done).
  • the first of the spaces can be sustained it is necessary to use areas that communicate it to the third of the spaces. These communication areas have to be in places through which high current density does not flow, since they can produce unwanted interfaces. Sprues or stalks needs to be designed so as being used for filling of the alloys, as well as for coating the first of the spaces.
  • the third step consists of the deposition of thin layers of wax that are formed one above the other the three-dimensional model defined in the second step.
  • two waxes with different melting temperature are used for the formation of wax layers.
  • the wax, melting temperature of which is the lowest (8) is used for forming the first of the spaces defined in the second step (the hollow interior of the inductor through which the cooling water flows).
  • the wax, melting point of which is the highest (9) is used to form the body of the inductor.
  • This third step has to be done with specific machines for the deposition of wax layers.
  • the mechanical characteristics of the wax must be such as to allow a three-dimensional model completely rigid. In the case of small sized inductors it is necessary to define in the second step connection parts of the weakest areas. These connection areas will be eliminated in the final machining process of the inductor.
  • the fourth step, element 4 in Figure 1 aims to fill the body of the inductor with optimum alloy for use in induction heating.
  • This step is divided into two main parts.
  • the first part undergoes the model obtained in the third step to a temperature slightly above the melting temperature of the wax of the first of the spaces (the wax with the lowest melting temperature).
  • Once the wax is liquid is evacuated by gravity and the space that contained thereof (first space) is filled with a high-flow ceramic coating, so that all voids of this space are filled.
  • the piece is put in an oven at a controlled temperature and humidity in order to produce the drying of the ceramic coating.
  • the second part of this fourth step is to introduce the three-dimensional model of the third step in a mould dimensions of which are between 0.1 mm and 500 mm, preferably between 1 mm and 50 mm and more preferably between 20 mm and 30 mm larger than the dimensions of the inductor.
  • the mould containing the inductor and inside of which there is also a ceramic coating is filled with ceramic coating. It is important to make connections so-called blast nozzles (3) that allow the ceramic coating of the outer mould remains attached to the ceramic coating of the internal part (the first part of the fourth step). To properly forge this second coating is also necessary to control its temperature and humidity in the oven. After forging the ceramic coating the oven temperature is increased until exceeding the melting temperature of the wax with the highest melting point.
  • the wax that occupied the second space in a liquid state is extracted in a vacuum oven, leaving hollow whole the body of the inductor.
  • This final mould is introduced into a Microfusion oven with centrifugal motion and filled with the suitable alloy that enables a high conductivity and prevents the pores.
  • the filler alloy consists of any highly conductive element or combination of elements result of which has high conductivity, preferably a combination of 75% silver and 25% copper, with a variation of these ratios to a maximum of 10% and preferably to a maximum of 5%.
  • the fifth step, element 5 in Figure 1 is to break the ceramic mould and extracting the inductor from inside.
  • To eliminate the mould of third space mechanical methods by breaking the ceramic coating, are used.
  • To eliminate the mould of the first space (inside the inductor) pickling chemical agents that remove the coating are used.
  • the method for manufacturing inductors of the present invention which comprises the previous steps, allows the repetition of steps for obtaining copies of the same inductor, element 6 in Figure 1 , or introducing improvements in the inductor, element 7 in Figure 1 ,
  • the layer printer After generating the plane in three dimensions, the layer printer reproduces the model layers in three dimensions by depositing thin layers of wax with at least two types of waxes with different melting temperatures, Figure 4 . These layers define the first, second and third spaces that corresponds to the internal (4), body (5) and external (6) spaces of the inductor, respectively.
  • the wax (8) with the lowest melting point is used, whereas for performing the second space of the inductor the wax (9) with the highest melting temperature is used.
  • the first space of the inductor is emptied by subjecting the inductor to a temperature above the melting temperature of the wax with the lowest melting temperature (8) and below the melting temperature of the wax with the highest melting temperature (9), after which the wax with the lowest temperature is evacuated by gravity.
  • the first space of inductor is filled with a high-flow ceramic coating, wherein the drying process is carried out by introducing thereof in an oven under controlled temperature and humidity.
  • the inductor is introduced in a mould composed of two parts (11, 12), Figure 5 , in order to facilitate the introduction of the inductor in the mould, and an upper hole (10) to facilitate the entry of both the coatings and alloy.
  • Said mould having dimensions 25 mm higher than the external dimensions of the inductor.
  • the mould containing the inductor with a high flow coating is filled, after which it is introduced in an oven under controlled temperature and humidity for drying the ceramic coating.
  • the oven temperature is Increased to above the melting point of the wax with the highest (9) melting temperature and making up the body of the inductor, and then the wax is extracted in a vacuum oven, such that the second space of the inductor is emptied.
  • the mould is filled with a high-conductivity alloy of 75% silver and 25% copper by introducing thereof into a Microfusion oven with centrifugal motion making up the body of the inductor. Said alloy is allowed to dry.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • General Induction Heating (AREA)
EP08879272.6A 2008-12-30 2008-12-30 Verfahren zur herstellung von induktoren für induktionsheizung unter verwendung von mikroschmelztechniken Withdrawn EP2371467A4 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/ES2008/000814 WO2010076346A1 (es) 2008-12-30 2008-12-30 Método de fabricación de inductores de calentamiento por inducción mediante técnicas de microfusión

Publications (2)

Publication Number Publication Date
EP2371467A1 true EP2371467A1 (de) 2011-10-05
EP2371467A4 EP2371467A4 (de) 2017-08-02

Family

ID=42309859

Family Applications (1)

Application Number Title Priority Date Filing Date
EP08879272.6A Withdrawn EP2371467A4 (de) 2008-12-30 2008-12-30 Verfahren zur herstellung von induktoren für induktionsheizung unter verwendung von mikroschmelztechniken

Country Status (2)

Country Link
EP (1) EP2371467A4 (de)
WO (1) WO2010076346A1 (de)

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NO854531L (no) * 1984-11-19 1986-05-20 Aluminum Co Of America Varmefast induktorblokk for kanalinduksjonsovn og fremgangsmaate til fremstilling av samme.
US5121329A (en) * 1989-10-30 1992-06-09 Stratasys, Inc. Apparatus and method for creating three-dimensional objects
US5518060A (en) * 1994-01-25 1996-05-21 Brunswick Corporation Method of producing polymeric patterns for use in evaporable foam casting
JPH10321361A (ja) * 1997-05-19 1998-12-04 Kokusai Electric Co Ltd 高周波誘導加熱コイル、半導体製造装置、および高周波誘導加熱コイルの製造方法
JP3875359B2 (ja) * 1997-06-30 2007-01-31 本田技研工業株式会社 高周波誘導加熱コイルの製造方法
JP2001279320A (ja) * 2000-03-28 2001-10-10 High Frequency Heattreat Co Ltd 誘導加熱コイル及び高周波焼入方法
JP4860981B2 (ja) * 2005-10-20 2012-01-25 本田技研工業株式会社 誘導加熱コイルおよびその製造方法、並びに高周波加熱装置
JP4854454B2 (ja) * 2006-10-02 2012-01-18 株式会社三社電機製作所 誘導加熱コイル及び誘導加熱コイルの製造方法

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO2010076346A1 *

Also Published As

Publication number Publication date
WO2010076346A1 (es) 2010-07-08
EP2371467A4 (de) 2017-08-02

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