WO2017035896A1 - 感应加热装置及其制作方法 - Google Patents

感应加热装置及其制作方法 Download PDF

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Publication number
WO2017035896A1
WO2017035896A1 PCT/CN2015/091318 CN2015091318W WO2017035896A1 WO 2017035896 A1 WO2017035896 A1 WO 2017035896A1 CN 2015091318 W CN2015091318 W CN 2015091318W WO 2017035896 A1 WO2017035896 A1 WO 2017035896A1
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Prior art keywords
heating coil
receiving body
bottom wall
heating
induction heating
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PCT/CN2015/091318
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English (en)
French (fr)
Inventor
孙侥鲜
刘秀强
王长明
谢守德
徐丹
Original Assignee
东莞劲胜精密组件股份有限公司
东莞华程金属科技有限公司
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Application filed by 东莞劲胜精密组件股份有限公司, 东莞华程金属科技有限公司 filed Critical 东莞劲胜精密组件股份有限公司
Publication of WO2017035896A1 publication Critical patent/WO2017035896A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/02—Induction heating
    • H05B6/36—Coil arrangements

Definitions

  • the invention relates to an induction heating device and a manufacturing method thereof.
  • the heating coil of the ordinary electrical product is generally a 2D coil, and the heating of the 2D coil generally heats the bottom of the inner pot, and the heat is transmitted from the bottom of the container to the upper portion through contact conduction, so that the temperature of the pot is slow and the heat is not uniform.
  • An induction heating device comprising:
  • the heating coil is distributed in a plurality of turns, and the two ends of the heating coil are respectively formed with contacts;
  • the receiving body formed on the surface of the heating coil, the receiving body comprising a bottom wall and a side wall surrounding the bottom wall, the heating coil being attached to the bottom wall and the side wall of the receiving body;
  • a cover layer is injection-molded on the receiving body, and the heating coil is wrapped between the receiving body and the covering layer, and the two contacts are exposed outside the receiving body to form a positive and negative electrode.
  • a method for manufacturing an induction heating device includes the following steps:
  • the heating coil is distributed in a plurality of turns, and the heating coil is respectively formed with contacts at both ends;
  • the receiving body integrally formed on a surface of the heating coil, the receiving body comprising a bottom wall and a side wall surrounding the bottom wall, the heating coil being attached to the bottom wall and the side wall;
  • the heating coil is attached to the bottom wall and the side wall of the receiving body, the area thereof can be relatively designed relatively, and the surrounding heating of the pan placed on the receiving body can be realized, thereby improving the heating effect and allowing the receiving.
  • the pot on the body heats up quickly and the heating effect is more uniform.
  • FIG. 1 is a perspective view of a heating coil of an embodiment
  • Figure 2 is a perspective view of the heating coil of Figure 1 after injection molding
  • Figure 3 is a perspective view of an induction heating device of an embodiment
  • Figure 4 is a partial enlarged view of the contact and the empty slot of the induction heating device shown in Figure 3;
  • Fig. 5 is a flow chart showing the steps of a method of fabricating an induction heating device according to an embodiment.
  • an induction heating device 100 (see FIG. 3 ) of an embodiment includes a heating coil 1 , a receiving body 2 , and a cover layer 3 .
  • the overall contour of the heating coil 1 is in the shape of a pot and is distributed in a plurality of turns.
  • the receiving body 2 is injection molded on the surface of the heating coil 1, and includes a bottom wall and a side wall surrounding the bottom wall.
  • the heating coil 1 is attached to the bottom wall and the side wall of the housing 2.
  • the cover layer 3 is injection molded on the container 2, and the heating coil 1 is wrapped between the cover layer 3 and the container 2.
  • the heating coil 1 includes two contacts 6 at its both ends, and the contacts 6 are exposed from the cover layer 3 to form positive and negative electrodes.
  • the container 2 is injection molded on the outer surface of the heating coil 1.
  • the housing 2 can be injection molded on the inner surface of the heating coil 1.
  • the cover layer 3 leaves an empty slot 7 at the position of the contact 6 to expose the contact 6 in the recess 7.
  • the edge of the housing 2 is also integrally formed with a positioning buckle 4.
  • the positioning buckles 4 are plural and are evenly spaced along the circumference of the housing 2 for positioning the housing 2 at a place such as a cooktop.
  • the heating coil 1 When the heating coil 1 is powered on by the contact 6, a surrounding magnetic field can be formed.
  • the metal pot When heating, the metal pot is placed in the receiving body 2, and the alternating magnetic field lines in the close magnetic field pass through the magnetic of the nearby metal pot.
  • Metal (iron, cobalt, nickel) materials will drive the microcrystalline structure of the metal, resulting in a myriad of small eddy currents, so that the microstructure of the metal material itself rubs against each other and heats itself, thus achieving the purpose of non-contact heating of the metal material.
  • the induction heating device 100 is heated by electromagnetic induction, and the heating coil 1 itself does not generate heat due to the magnetic field, and the heating ability and efficiency are high.
  • the heating coil 1 is disposed on the bottom wall and the side wall of the housing 2, the area of the heating coil 1 can be designed to be larger, and wraparound heating can be realized, thereby improving the heating effect, so that the housing is placed in the housing 2
  • the induction heating device 100 is small in size, saves space, and has a light overall weight.
  • the induction heating device 100 has a uniform magnetic field distribution, a large effective induction area, uniform heating, high heating efficiency, and stable product performance.
  • the pot-shaped heating coil 1 is integrally formed with the injection molding material to form the induction heating device 100, which can be used for products such as intelligent heating pots. In addition to the traditional bottom heating, it can realize the wraparound heating of the entire inner tank, that is, the metal pot, and obtain a very uniform The overall heating effect, the heating area is increased by 50% compared with the ordinary coil, the temperature rises rapidly and the heating is uniform.
  • the power of the induction heating device of the present invention can easily reach about 1500 watts and is high in efficiency compared to the heat limit of several hundred watts of the heat resistance of the limited coil of the conventional coil.
  • the heating coil 1 of the present invention can also be used for purposes such as conducting electricity, receiving signals from an antenna, and the like.
  • the heating coil 1 Since the overall injection molding of the heating coil 1 is not exposed, only the two contacts 6 are exposed, so that the heating coil 1 is well protected, especially corrosion-resistant, and can be reliably waterproofed, which can greatly extend the service life of the product.
  • the heating coil 1 is integrally molded and wrapped, and the problem that a short circuit may occur between the wires of the coil after the product is used for a long time. It is also advantageous to obtain a higher quality factor by heating the coil 1, thereby significantly reducing the loss and increasing the inductance of the coil.
  • Induction heating device 100 can be widely used in various electrical fields, such as smart home appliances, including smart pots, smart refrigerators, smart TVs, etc., providing dustproof, scratch-resistant and anti-corrosion for future multi-functional consumer electronics induction heating devices. Excellent solutions such as anti-drop, shockproof and anti-oxidation.
  • a method for manufacturing an induction heating device includes the following steps:
  • step S101 the heating coil 1 is formed by processing with a metal material, and the heating coil 1 is distributed around the plurality of turns, and the heating coil 1 is respectively formed with the contacts 6 at both ends.
  • the pot-shaped heating coil 1 is stamped and formed according to the shape required by the product, and the contacts 6 are respectively formed at both ends of the heating coil 1.
  • the heating coil 1 is made of a metal material having good electrical conductivity, small electrical resistivity and fast heat dissipation, such as silver, brass, phosphor bronze, beryllium copper, and the like.
  • the heating coil 1 is formed by stamping, including cutting, stretching, punching, and the like.
  • the heating coil 1 can be stamped and formed from a single piece of metal material. Each turn of the heating coil 1 may be circular (as shown in FIG. 1-2), square or polygonal, or several shapes in parallel.
  • the length and width of the heating coil 1 may be set as needed, and may be 160 mm or more, and the width of the heating coil 1 and the coil pitch may be set as needed.
  • the heating coil 1 has a width of 1.5 to 6 mm and a line width of 0.5 to 3 mm to obtain a large inductance value and good inductance.
  • the heating coil 1 can be nickel plated before being stamped.
  • the two contacts 6 are formed at positions near the head and the tail of the heating coil 1. It is also possible to weld the two metal contacts 6 at corresponding positions of the heating coil 1.
  • the two contacts 6 are pretreated, such as nickel plated or gold plated. Nickel plating can prevent the surface of the product from chemically reacting with oxygen or chlorine in the air or water, which can keep the appearance clean and bright and prolong the service life. It is gold-plated and has good chemical stability.
  • the heating coil 1 can be processed by CNC, laser engraving and/or engraving, laser cutting, etc. after stamping the whole piece of metal, and the width and coil spacing of the heating coil 1 can be very flexible and convenient. Process and adjust according to actual needs.
  • the housing 2 is integrally molded on the surface of the heating coil 1.
  • the housing 2 includes a bottom wall and a side wall surrounding the bottom wall, and the heating coil 1 is attached to the bottom wall and the side wall.
  • the heating coil 1 is placed in an injection mold, and the container 2 is integrally molded on the outer surface of the heating coil 1.
  • the material of the container 2 can be any plastic or ceramic material.
  • the plastic is, for example, PC, ABS, PC+ABS, PC+20%GF, and the like.
  • the heating coil 1 has a thickness of 1.0 to 3.0 mm.
  • the nozzle temperature is 270-300 ° C
  • the mold temperature is 60-100 ° C
  • the injection pressure is 50-80 MPa
  • a plurality of positioning buckles 4 can be integrally formed on the edge of the container 2.
  • the plurality of positioning buckles 4 are evenly spaced along the circumference of the housing 2 for positioning the housing 2 at a place such as a cooktop.
  • Step S103 performing overmolding on the container 2 to form the cover layer 3, so that the heating coil 1 is wrapped between the container 2 and the cover layer 3, and the two contacts 6 are exposed outside the container 2 to form positive and negative. pole.
  • the heating coil 1 and the container 2 are placed together in a mold to perform overmolding of the plastic to form a cover layer 3 on the inner surface of the heating coil 1.
  • the cover layer 3 covers the inner surface of the heating coil 1.
  • the injection molding material used in the step S102 and the step S103 may be a plastic material or a ceramic material suitable for injection molding.
  • the step of exposing the two contacts 6 of the heating coil 1 is specifically: the cover layer 3 leaves an empty slot 7 at the position of the contact 6 to expose the contact 6 to the empty slot 7 in.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • General Induction Heating (AREA)
  • Cookers (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

一种感应加热装置(100)，包括加热线圈(1)、收容体(2)及覆盖层(3)。加热线圈(1)呈多圈环绕分布，加热线圈(1)两端分别形成有触头(6)。收容体(2)注塑形成于加热线圈(1)的表面，收容体(2)包括底壁及环绕所述底壁的侧壁。加热线圈(1)贴合于收容体(2)的底壁与侧壁上。覆盖层(3)注塑形成于收容体(2)上，并将加热线圈(1)包覆于收容体(2)与覆盖层(3)之间，两个触头(6)露出于收容体(2)外以形成正负极。

Description

感应加热装置及其制作方法
【技术领域】
本发明涉及一种感应加热装置及其制作方法。
【背景技术】
电器产品在我们的生活中应用越来越广泛，人们对生活品质的提高，促进了电器产品的发展。普通电器产品的加热用线圈一般为2D线圈，而2D线圈加热一般是加热内锅底部，通过接触传导使热量从收容体底部传导到上部，这样使得锅体升温慢，且受热不均匀。
【发明内容】
有鉴于此，有必要提供一种升温快且受热均匀的感应加热装置及其制作方法。
一种感应加热装置，包括：
加热线圈，呈多圈环绕分布，所述加热线圈两端分别形成有触头；
收容体，注塑形成于所述加热线圈的表面，所述收容体包括底壁及环绕所述底壁的侧壁，所述加热线圈贴合于所述收容体的底壁与侧壁上；以及
覆盖层，注塑形成于所述收容体上，并将所述加热线圈包覆于所述收容体与所述覆盖层之间，所述两个触头露出于所述收容体外以形成正负极。
一种感应加热装置的制作方法，包括以下步骤：
采用金属材料加工形成加热线圈，所述加热线圈呈多圈环绕分布，所述加热线圈于两端分别形成有触头；
于所述加热线圈的表面一体注塑形成收容体，所述收容体包括底壁及环绕所述底壁的侧壁，所述加热线圈贴合于所述底壁与所述侧壁上；以及
于所述收容体上进行二次注塑形成覆盖层，以将所述加热线圈包覆于所述收容体与所述覆盖层之间，所述两个触头露出于所述收容体外以形成正负极。
由于加热线圈贴合于收容体的底壁与侧壁上，使得其面积可以相对设计得更大，且可实现对放置于收容体上的锅的环绕式加热，进而可以提高加热效果，使得收容体上的锅升温快且加热效果更为均匀。
【附图说明】
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他实施例的附图。
图1为一实施例的加热线圈的立体示意图；
图2为图1所述的加热线圈注塑后的立体示意图；
图3为一实施例的感应加热装置的立体示意图；
图4为图3所示的感应加热装置的触头及空槽的局部放大图；以及
图5为一实施例的感应加热装置的制作方法的步骤流程图。
【具体实施方式】
为了便于理解本发明，下面将参照相关附图对本发明进行更全面的描述。附图中给出了本发明的较佳实施例。但是，本发明可以以许多不同的形式来实现，并不限于本文所描述的实施例。相反地，提供这些实施例的目的是使对本发明的公开内容的理解更加透彻全面。
请参阅图1至图4，一实施例的感应加热装置100(见图3)包括：加热线圈1、收容体2以及覆盖层3。加热线圈1的整体轮廓为锅状，且呈多圈环绕分布，收容体2注塑形成于加热线圈1的表面，其包括底壁及环绕所述底壁的侧壁。加热线圈1贴合于收容体2的底壁与侧壁上。覆盖层3注塑形成于收容体2上，并将加热线圈1包覆于覆盖层3与收容体2之间。加热线圈1包括处于其两端的两个触头6，触头6从覆盖层3中露出以形成正负极。
由于加热线圈1整体轮廓为锅状，且呈多圈环绕分布，因此其并非在同一平面上环绕，因而可称之为3D加热线圈。在本实施例中，收容体2注塑形成于加热线圈1的外表面上。在其他实施例中，收容体2可注塑形成于加热线圈1的内表面上。在本实施例中，覆盖层3于触头6的位置留出空槽7，以使触头6暴露于空槽7中。收容体2的边缘还一体形成有定位扣4。定位扣4为多个且沿收容体2的周缘均匀间隔分布，用于将收容体2定位于灶台等地方。
当加热线圈1通过触头6接通电源后，即可形成一个环绕的磁场，加热时，将金属锅放置于收容体2内，当近距磁场内的交变磁力线通过附近的金属锅的磁性金属(铁、钴、镍)材料时，会驱动金属的微晶结构，产生无数的小涡流，使金属材料微结构本身互相摩擦从而自行发热，从而达到非接触加热金属材料的目的。感应加热装置100通过电磁感应加热，加热线圈1本身并不因磁场而发热，加热能力和效率都很高。
由于加热线圈1贴合设置于收容体2的底壁与侧壁上，因而加热线圈1的面积可以设计得更大，且可实现环绕式加热，进而可以提高加热效果，使得放置在收容体2上的锅升温快且加热效果更为均匀。同时感应加热装置100体积小，节省了空间，整体重量轻。
上述感应加热装置100的磁场分布均匀，有效感应作用面积大，加热均匀，加热效率高，产品性能稳定。锅状的加热线圈1与注塑材料一体成型制成感应加热装置100，可用于智能加热锅等产品，除了传统的底部加热，能实现对整个内胆即金属锅的环绕式加热，获得非常均匀地整体加热效果，加热面积对比普通线圈增加达50%，升温迅速且加热均匀。相比传统线圈的受限电阻盘热安全的几百瓦功率上限，本发明的感应加热装置的功率可以轻松达到1500瓦左右，而且效率高。
除了用作感应加热线圈之外，本发明的加热线圈1还可用于导电、天线接收信号等用途。
由于加热线圈1的整体注塑不外露，只露出两个触头6，因此对加热线圈1起到很好的保护作用，尤其耐腐蚀，且非常能够可靠地防水，能够大大延长产品使用寿命。将加热线圈1整体注塑包裹住，还能避免产品用久之后线圈的线路之间可能黏在一起而发生短路的问题。还有利于加热线圈1获得更高的品质因数，从而显著降低损耗、提高线圈的电感值。
感应加热装置100可广泛应用在各种电器领域，如智能家居电器，包括智能锅、智能冰箱、智能电视等，为未来的多功能消费电子的感应加热装置提供了防尘、防刮、防腐蚀、防摔、防震、抗氧化等优异的解决方案。
请一并参阅图5，一实施例的感应加热装置的制作方法，包括以下步骤：
步骤S101、采用金属材料加工形成加热线圈1，加热线圈1呈多圈环绕分布，加热线圈1于两端分别形成有触头6。
请参阅图1，首先，根据产品需要的形状冲压成型锅状的加热线圈1，加热线圈1的两端分别形成有触头6。加热线圈1选用导电性能好，电阻率小，散热快的金属材质，如银、黄铜、磷铜、铍铜等制成。加热线圈1采用冲压方式，包括开料、拉伸、冲切等方式形成。加热线圈1可以是整块金属材料冲压成型的。加热线圈1的每圈可以为圆形（如图1-2所示）、方形或多边形，或几个形状并联等。另外，加热线圈1的长、宽可根据需要设定，可以均为160毫米以上，且加热线圈1的宽度与线圈间距可根据需要设定。
在一实施例中，加热线圈1的宽为1.5-6毫米，线宽为0.5-3毫米，以获得较大的电感值和好的感应性。在一实施例中，加热线圈1冲压成型前可对金属材料做镀镍处理。两个触头6形成于在加热线圈1接近头、尾的位置。也可以在加热线圈1相应位置焊接上两金属触头6。两触头6做预处理，如镀镍或镀金。做镀镍处理，可防止产品表面在与空气中或水中氧或氯发生化学反应，可使外观保持洁净亮丽，延长使用寿命。做镀金处理，化学稳定性好。
可以理解，在步骤S101中，还可于冲压整块金属后采用CNC、镭雕和/或精雕、激光切割等工艺加工出加热线圈1，加热线圈1的宽度与线圈间距可以非常灵活方便地根据实际需要加工和调整。
步骤S102、于加热线圈1的表面一体注塑形成收容体2，收容体2包括底壁及环绕所述底壁的侧壁，加热线圈1贴合于底壁与侧壁上。请参阅图2，具体地，将加热线圈1置入注塑模具内，并于加热线圈1的外表面上一体注塑成型收容体2。收容体2的材质可为任一种塑胶或陶瓷材质。塑胶例如为PC、ABS、PC+ABS、PC+20%GF等。加热线圈1的厚度为1.0-3.0毫米。注塑时，喷嘴温度为270-300℃，模具温度为60-100℃，注射压力为50～80MPa，可于收容体2的边缘一体成型出多个定位扣4。多个定位扣4沿收容体2的周缘均匀间隔地分布，用于将收容体2定位于灶台等地方。
步骤S103、于收容体2上进行二次注塑形成覆盖层3，以将加热线圈1包覆于收容体2与覆盖层3之间，两个触头6露出于收容体2外以形成正负极。请参阅图3，具体地，将加热线圈1及收容体2一并置入模具内进行二次注塑塑胶，以于加热线圈1的内表面形成覆盖层3。覆盖层3覆盖加热线圈1的内表面。
步骤S102和步骤S103中所用的注塑材料可以为塑胶材料，也可以为适于注塑的陶瓷材料。在一实施例中，步骤S103中，露出加热线圈1的两个触头6的步骤具体为：覆盖层3于触头6的位置留出空槽7，以使触头6暴露于空槽7中。
以上所述实施例仅表达了本发明的几种实施方式，其描述较为具体和详细，但并不能因此而理解为对本发明专利范围的限制。应当指出的是，对于本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干变形和改进，这些都属于本发明的保护范围。因此，本发明专利的保护范围应以所附权利要求为准。

Claims (12)

  1. 一种感应加热装置，其特征在于，包括：
    加热线圈，呈多圈环绕分布，所述加热线圈两端分别形成有触头；
    收容体，注塑形成于所述加热线圈的表面，所述收容体包括底壁及环绕所述底壁的侧壁，所述加热线圈贴合于所述收容体的底壁与侧壁上；以及
    覆盖层，注塑形成于所述收容体上，并将所述加热线圈包覆于所述收容体与所述覆盖层之间，所述两个触头露出于所述收容体外以形成正负极。
  2. 如权利要求1所述的感应加热装置，其特征在于，所述加热线圈的每一圈为圆形、方形或多边形。
  3. 如权利要求1所述的感应加热装置，其特征在于，所述加热线圈的材料为银、黄铜、磷铜或铍铜。
  4. 如权利要求1所述的感应加热装置，其特征在于，所述收容体为塑胶或陶瓷材料注塑制成。
  5. 如权利要求1所述的感应加热装置，其特征在于，所述收容体的边缘一体成型有多个定位扣，所述多个定位扣沿所述收容体的周缘均匀间隔分布，以定位所述收容体。
  6. 如权利要求1所述的感应加热装置，其特征在于，所述收容体注塑形成于所述加热线圈的外表面上。
  7. 如权利要求1所述的感应加热装置，其特征在于，所述收容体于所述触头的位置形成有空槽，所述触头露出于所述空槽中。
  8. 一种感应加热装置的制作方法，包括以下步骤：
    采用金属材料加工形成加热线圈，所述加热线圈呈多圈环绕分布，所述加热线圈于两端分别形成有触头；
    于所述加热线圈的表面一体注塑形成收容体，所述收容体包括底壁及环绕所述底壁的侧壁，所述加热线圈贴合于所述底壁与所述侧壁上；以及
    于所述收容体上进行二次注塑形成覆盖层，以将所述加热线圈包覆于所述收容体与所述覆盖层之间，所述两个触头露出于所述收容体外以形成正负极。
  9. 如权利要求8所述的方法，其特征在于，所述收容体注塑形成于所述加热线圈的外表面，所述覆盖层覆盖所述加热线圈的内表面。
  10. 如权利要求8所述的方法，其特征在于，所述加热线圈是由银、黄铜、磷铜或铍铜冲压形成的。
  11. 如权利要求8所述的方法，其特征在于，所述收容体及所述覆盖层为塑胶或陶瓷材料注塑制成。
  12. 如权利要求8所述的方法，其特征在于，注塑所述覆盖层时，于所述触头的位置留出空槽，所述触头露出于所述空槽内。
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