WO2018045528A1 - 一种药芯焊条成型模块、制备装置及其制备方法 - Google Patents

一种药芯焊条成型模块、制备装置及其制备方法 Download PDF

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Publication number
WO2018045528A1
WO2018045528A1 PCT/CN2016/098418 CN2016098418W WO2018045528A1 WO 2018045528 A1 WO2018045528 A1 WO 2018045528A1 CN 2016098418 W CN2016098418 W CN 2016098418W WO 2018045528 A1 WO2018045528 A1 WO 2018045528A1
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Prior art keywords
alloy
flux
tube
core
cored electrode
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PCT/CN2016/098418
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English (en)
French (fr)
Inventor
李明茂
安占涛
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Jiangxi University of Science and Technology
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Jiangxi University of Science and Technology
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Priority to SG11201808655XA priority Critical patent/SG11201808655XA/en
Priority to CN201680000926.8A priority patent/CN108064194B/zh
Priority to PCT/CN2016/098418 priority patent/WO2018045528A1/zh
Publication of WO2018045528A1 publication Critical patent/WO2018045528A1/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/40—Making wire or rods for soldering or welding

Definitions

  • the invention relates to the technical field of welding rod molding, in particular to a welding rod preparation device and a welding rod preparation method.
  • Alloy electrodes such as copper and silver are commonly used brazing filler metals and are widely used in the welding between metal and metal. In the specific use of the electrode, it is often necessary to add a flux (flux) to assist the welding, in order to eliminate the oxidation of the metal and increase the fluidity of the molten metal to achieve a better welding effect.
  • a flux flux
  • solders such as tin alloys
  • the flux is often directly injected into the inside of the wire by split-compression extrusion, and then drawn into different specifications of the wire by stretching.
  • the split combination is only suitable for metals with low deformation resistance and good weldability.
  • the comparative document CN103551757B discloses an aluminum-silicon alloy seamless flux-cored wire for brazing, preparation and application, and the aluminum-silicon alloy is placed in an extrusion die to obtain a strip having a certain thickness, and then the strip is subjected to different pressures.
  • the roll is rolled into a hollow electrode with an O-shaped end face, and the core powder is wrapped in the electrode, and finally the cored electrode is placed in an annealing furnace for drawing to a specific size.
  • the above preparation method is complicated and cannot be continuously manufactured.
  • There is also a flux-cored wire in a steel electrode which is a slotted welding wire which is prepared by continuously wrapping a steel core with a steel strip, and then preparing the product by stretching and closing the mouth.
  • This method also needs to be used. More solder, and the metal layer of the electrode is thin (too thick to fold). In addition, there is a crease in the electrode, and the lubricant during stretching tends to remain in In the crease, it affects the performance of the electrode. Therefore, it is not currently used in alloy electrodes such as copper and silver.
  • the current method can only be made into a solid electrode.
  • additional flux is added and used together with the electrode.
  • there is a coated copper electrode which is coated with a layer of solder on the surface of the solid copper to ensure copper. Adhesion to the flux, a large amount of binder is added to the flux.
  • the coated copper welding rod has a good welding effect, but the production efficiency and the environmental cost are not ideal due to the cumbersome application process and the large amount of binder generating a large amount of flue gas during welding.
  • the technical problem to be solved by the present invention is to overcome the defects in the electrode prepared by using a metal material having a large deformation resistance in the prior art due to the use of an adhesive, resulting in a large amount of smoke generated during use, and formed by winding.
  • the crease problem provides a welding rod forming module and a welding rod preparation device and a welding rod preparation method.
  • the present invention provides a flux cored electrode forming module comprising:
  • a core comprising a core passage and a core injection passage, the core passage being in fluid communication with the core injection passage, the core injection passage being in fluid communication with the elongated housing for filling the flux The interior of the elongate housing.
  • the outer casing forming portion is a tubular outer casing forming portion
  • the elongated outer casing is an elongated alloy tube
  • the core passage and the core injection passage are both circular ducts.
  • the tubular outer casing forming portion includes: a cast pipe including a coaxially disposed outer tube and inner a tube having a molding cavity formed between the outer tube and the inner tube, wherein the outer tube is provided with an alloy inflow hole; a lead rod is disposed in the molding cavity and is movable in the molding cavity, The end of the lead rod is in contact with the alloy liquid phase, and after the alloy liquid is formed into an alloy tube, the alloy tube is taken out to the outside of the cast tube.
  • the outer tube includes: an alloy inflow portion, the alloy inflow portion is formed with the alloy inflow hole; an alloy tube forming portion, a protective sleeve is disposed outside the alloy tube forming portion, and a coolant is disposed in the protective sleeve Flows between the alloy tube forming portion.
  • the core injection tube includes: an inner tube shared with the cast tube; and an inner tube support connected to the inner tube, the inner tube support being screwed with the outer tube.
  • the invention also provides a flux core electrode preparation device, comprising:
  • An alloy casting furnace for melting metal alloys An alloy casting furnace for melting metal alloys
  • the cored electrode preparation apparatus further includes at least one flux cored electrode forming module.
  • the drug core channel is connected at one end to the inner tube support and at the other end to the drug can.
  • the alloy inflow portion of the outer tube is disposed inside the alloy casting furnace so that the molten alloy can flow in through the alloy inflow hole.
  • An air compressor is connected to the chemical tank for pressurizing the flux in the chemical tank.
  • a portion of the drug canister connected to the drug core channel is provided with a valve for controlling the drug core to enter the drug core channel.
  • the electrode preparation apparatus further includes an upper lead casting machine including two rollers disposed at a fixed distance, the lead being sandwiched between the two rollers.
  • the invention also provides a method for preparing a flux cored electrode by using a flux cored electrode preparation device, comprising the following steps:
  • the upper casting machine drives the lead rod to continuously pull the flux cored electrode to the outside of the casting tube;
  • the prepared flux cored electrode is wound or cut into a predetermined length as needed.
  • the present invention provides a flux cored electrode forming module comprising:
  • a core comprising a core passage and a core injection passage, the core passage being in fluid communication with the core injection passage, the core injection passage being in fluid communication with the elongated housing for filling the flux The interior of the elongated housing.
  • the device of the invention is suitable for a plurality of metals or alloys, and in the prior art, for a metal material having high deformation resistance, since it is difficult to complete injection molding by an extrusion device, the flux is often applied to the metal material. Outside. Even if a flux-cored wire is formed by wrapping a flux in a metal strip, the processing is complicated and cannot be continuously manufactured.
  • an elongated housing having a hollow shape is first formed in the molded portion of the outer casing, and then the flux is filled through the hollow portion of the casing through the core injection passage.
  • the flux is effectively filled into the inside of the casing, thereby preventing the prior art in that the flux is applied to the outer layer, bonded by the binder, and a large amount of smoke is generated during use.
  • the invention is also applicable to soft metal materials with less deformation resistance, such as aluminum silicon materials, tin alloys and the like.
  • the produced welding rod does not have a crease, thereby preventing the lubricating oil from entering the crease during the drawing of the welding rod in the later stage. In the absence of pollution to the electrode.
  • the present invention provides a flux cored electrode forming module, the tubular outer casing forming portion comprising: a cast pipe comprising a coaxially disposed outer tube and an inner tube, between the outer tube and the inner tube Forming a molding cavity, the outer tube is provided with an alloy inflow hole; a lead rod is disposed in the molding cavity and is movable in the molding cavity, and the end of the lead rod is in contact with the alloy liquid phase, when After the alloy liquid is formed into an alloy tube, the alloy tube is taken out to the outside of the cast tube.
  • the high temperature liquid alloy flows into the inside of the molding cavity through the alloy inflow hole on the outer tube, and is cooled to a solid state in the molding cavity, thereby forming an elongated casing.
  • the lead rod is in contact with the alloy liquid phase in the molding cavity. Since the temperature of the lead rod is low and the temperature of the alloy liquid is high, when the two are in contact, the alloy liquid will immediately solidify and stick to the end of the lead rod. At this point, the elongated shell can be continuously pulled out of the cast pipe by simply pulling the lead rod.
  • the present invention provides a flux cored electrode forming module, the outer tube comprising: an alloy inflow portion, the alloy inflow portion is formed with the alloy inflow hole; the alloy tube forming portion, the outer portion of the alloy tube forming portion is provided There is a protective sleeve through which the coolant flows between the protective sleeve and the alloy tube forming portion.
  • the alloy liquid enters the inner tube from the inflow hole of the alloy, and under the action of the pressure, the alloy liquid will continue to move forward, and at this time, it will flow into the forming portion of the alloy tube, and the coolant flows due to the outside of the molded portion of the alloy tube, so the alloy The liquid is rapidly cooled and solidified by the cold to form a solid elongated shell.
  • the present invention provides a flux cored electrode forming module, the core injection tube comprising: an inner tube shared with the casting tube; and an inner tube bearing connected to the inner tube, the inner tube A threaded connection is made between the support and the outer tube.
  • the inner tube is coaxially disposed with the inner tube through an inner tube support, and the inner tube support communicates with the inner tube, and the elongated housing is formed in the molding cavity between the outer tube and the inner tube, thereby passing
  • the inner tube bracket can accurately inject the drug core into the inside of the elongated housing.
  • the invention provides a flux core electrode preparation device, a flux core electrode preparation device, comprising:
  • a medicament tank containing a flux in the medicament tank; an alloy casting furnace for melting the metal alloy; and the flux core electrode preparation device further comprising at least one flux core electrode molding module.
  • the alloy casting furnace is in contact with the molded portion of the outer casing, and the molten liquid metal alloy in the alloy casting furnace flows into the molding cavity through the alloy inflow hole on the outer tube to form a solid elongated shell; the chemical tank contains the flux. Connected to the core, the flux is injected into the interior of the elongated casing through the core.
  • the present invention provides a flux cored electrode preparation apparatus having an air compressor connected thereto for pressurizing a flux in the chemical tank. Fill the empty space of this elongated shell with flux Heart.
  • the present invention provides a flux cored electrode preparation device, wherein a portion of the drug canister connected to the drug core channel is provided with a valve for controlling the drug core to enter the drug core channel.
  • the valve When the valve is opened, the flux in the canister will flow into the core channel, thereby starting the core injection process in the hollow of the elongated shell; when the hollow is filled with the core, the valve is closed to stop the injection of the core. .
  • the present invention provides a flux cored electrode preparing apparatus, the electrode strip preparing apparatus further comprising an upper lead casting machine, wherein the upper lead casting machine comprises two rollers disposed at a fixed distance, the lead rods being sandwiched between two Between the rollers.
  • the lead rod mainly plays the role of the formed welding rod to the outside of the flux cored electrode forming module, and the roller wheel gives a certain holding force to the lead rod, and drives the lead rod to take out the formed welding rod. Due to the presence of the upper casting machine, continuous production of the welding rod is enabled.
  • multiple sets of welding rods can be prepared simultaneously by combining multiple sets of flux cored electrode forming modules with the upper lead casting machine.
  • the present invention provides a method for preparing a flux cored electrode using a flux cored electrode preparation apparatus, comprising the steps of:
  • the upper casting machine drives the lead rod to continuously pull the flux cored electrode to the outside of the casting tube;
  • the preparation method of the flux cored electrode provided by the invention can realize the contact preparation of the flux cored electrode, and can have good manufacturing ability for different kinds of metal materials, especially metal materials with high self-deformation resistance, such as copper alloy.
  • the flux cored electrode of different specifications can be prepared by changing the size of the casting tube and the core tube.
  • FIG. 1 is a schematic structural view of the flux cored electrode provided by the present invention.
  • FIG. 2 is a schematic structural view of the flux cored electrode forming module provided by the present invention.
  • FIG. 3 is a schematic structural view of the preparation device of the flux cored electrode provided by the present invention.
  • connection In the description of the present invention, it should be noted that the terms “installation”, “connected”, and “connected” are to be understood broadly, and may be fixed or detachable, for example, unless otherwise explicitly defined and defined. Connected, or integrally connected; can be mechanical or electrical; can be directly connected, or indirectly connected through an intermediate medium, can be the internal communication of the two components.
  • Connected, or integrally connected can be mechanical or electrical; can be directly connected, or indirectly connected through an intermediate medium, can be the internal communication of the two components.
  • the specific meaning of the above terms in the present invention can be understood in a specific case by those skilled in the art.
  • the embodiment provides a flux cored electrode forming module, comprising:
  • a housing forming portion for forming a hollow elongated housing 1;
  • a core comprising a core channel 2 and a core injection channel 3, the core channel 2 being in fluid communication with a core injection channel 3, the core injection channel 3 being in fluid communication with the elongated housing 1 for
  • the flux 11 is filled inside the elongated casing 1.
  • the metal material is first formed into a hollow elongated casing 1 in the outer casing forming portion, and then the flux 11 is filled with the hollow of the casing through the core injection passage 3. unit.
  • the flux 11 is effectively filled into the interior of the casing, thereby preventing the prior art from the application of the flux 11 to the outer layer, bonding with an adhesive, and generating a large amount of smoke during use. defect.
  • the produced welding rod does not have a crease, thereby preventing the lubricating oil from entering the crease during the drawing of the welding rod in the later stage. In the absence of pollution to the electrode.
  • the outer casing forming portion is a tubular outer casing forming portion
  • the elongated outer casing 1 is an elongated alloy tube
  • the drug core passage 2 and the core injection passage 3 are both circular ducts.
  • the elongated casing 1 has a circular tubular shape.
  • the elongate casing 1 may have other shapes, such as a tubular body having a rectangular or elliptical cross section.
  • the tubular outer casing forming portion includes a cast tube 4 including an outer tube 41 and an inner tube 42 disposed coaxially, and a molding cavity 43 is formed between the outer tube 41 and the inner tube 42.
  • An alloy inflow hole 411 is defined in the outer tube 41; a lead rod 5 is disposed in the molding cavity 43 and can be disposed therein. The inside of the molding cavity 43 is moved, and the end of the lead rod 5 is in contact with the high temperature liquid alloy. After the high temperature liquid alloy is formed into a solid alloy tube, the solid alloy tube is taken out to the outside of the cast tube 4.
  • the inner tube 42 is designed to have a large proximal end, a small end, and a taper of 1-2°. Such a design facilitates rapid cooling and demolding of the high temperature liquid alloy inside the molding cavity 43, facilitating the extraction of the elongated casing 1 from the molding cavity 43.
  • the high temperature liquid alloy flows into the inside of the molding cavity 43 through the alloy inflow hole 411 on the outer tube 41, and is cooled to a solid state in the molding cavity 43, thereby forming the elongated casing 1.
  • the lead rod 5 is in contact with the high temperature liquid alloy in the molding cavity 43. Since the temperature of the lead rod 5 is low and the temperature of the high temperature liquid alloy is high, when the two are in contact, the high temperature liquid alloy is immediately bonded to the lead rod. At the end of the 5, the elongated housing 1 can be pulled out of the cast tube 4 by simply pulling the lead rod 5.
  • the outer tube 41 includes an alloy inflow portion 6 on which the alloy inflow hole 411 is formed, an alloy tube forming portion 7, and a protective sleeve 8 outside the alloy tube forming portion 7 for cooling
  • the liquid 17 flows between the protective sleeve 8 and the alloy tube forming portion 7.
  • the high-temperature liquid alloy enters the inside of the outer tube 41 from the alloy inflow hole 411. Under the action of the pressure, the high-temperature liquid alloy will continue to move forward, and at this time, the alloy tube forming portion 7 will flow into the outer portion of the alloy tube forming portion 7 The coolant 17 flows, so that the high temperature liquid alloy is rapidly cooled by the cold to form the solid elongated casing 1.
  • the cooling liquid 17 may be cooled by cooling water or may be cooled by oil.
  • the outer side of the protective sleeve 8 is wrapped with an insulating asbestos 15 and a graphite protective sleeve 16 is installed outside the insulating asbestos 15 for both. Play a role in insulation.
  • the core injection tube includes: an inner tube 42 shared with the cast tube 4; And an inner tube support 9 connected to the inner tube 42, the inner tube support 9 and the outer tube 41 being screwed.
  • the outer tube 41 is coaxially disposed with the inner tube 42 through the inner tube holder 9, and the inner tube holder 9 communicates with the inner tube 42, since the elongated housing 1 is formed in the outer tube 41 and the inner tube 42 In the intermediate molding chamber 43, therefore, the flux 11 can be accurately injected into the inside of the elongated casing 1 through the inner tube 42 bracket.
  • the inner tube 42 is formed with an external thread on the bracket, and the inner tube 41 is internally formed with an internal thread.
  • the embodiment provides a flux core electrode preparation device, comprising:
  • the chemical tank 10 contains a flux 11;
  • the flux cored electrode preparation apparatus further includes at least one flux cored electrode forming module.
  • the alloy casting furnace 12 is in contact with the outer casing forming portion, and the molten metal alloy melted in the alloy casting furnace 12 flows into the molding cavity 43 through the alloy inflow hole 411 on the outer tube 41 to form a solid elongated casing 1; the chemical tank 10 A flux 11 is placed therein, which is connected to the core, and the flux 11 is injected into the inside of the elongated casing 1 through the core.
  • the chemical tank 10 and the alloy casting furnace 12 are each provided with heating means for heating and maintaining the flux 11 and the alloy in a molten state.
  • a thermocouple is installed inside the chemical tank 10 and the alloy casting furnace 12 to monitor the temperature of the high temperature melt in real time.
  • the heating device may heat the electric resistance or may use other heating methods such as electromagnetic stirring.
  • one end of the core channel 2 is connected to the inner tube support 9, The other end is in communication with the medicament canister 10.
  • the entire flux cored electrode preparing device is immersed inside the alloy casting furnace 12, and the alloy inflow portion 6 of the outer tube 41 is surrounded by a high temperature liquid alloy melt, so that the molten alloy It can flow in through the alloy inflow hole 411.
  • a plurality of sets of flow holes may be simultaneously disposed under the chemical canister 10, and a plurality of the drug core channels 2 are connected to the flow holes, and each of the flux cored electrode forming modules may be prepared.
  • the root electrode is thus matched with a plurality of sets of flux cored electrode forming modules by a plurality of core channels 2, and a plurality of electrodes can be simultaneously prepared. Thereby achieving the connection of "one furnace and multiple lines".
  • the outer side of the core injection channel 3 is wrapped with a refractory material to prevent its oxidative burning at high temperatures.
  • An air compressor 13 is connected to the chemical tank 10 for pressurizing the flux 11 in the chemical tank 10.
  • the pressurization 11 in the chemical tank 10 is pressurized to fill the hollow portion of the elongated casing 1 with the flux 11.
  • the inside of the chemical tank 10 is further provided with a pressure gauge for detecting the pressure capability of the air compressor 13, so as to facilitate the control of the injection speed of the medicine core.
  • a portion of the drug canister 10 connected to the drug core channel 2 is provided with a valve 101 for controlling the drug core to enter the drug core channel 2.
  • the valve 101 When the valve 101 is opened, the flux 11 in the canister 10 will flow into the core channel 2, thereby starting the core injection process in the hollow of the elongated casing 1; when the hollow is filled with the flux 11, the valve is opened 101 is closed, stopping the injection of the flux 11.
  • the electrode preparation apparatus further includes an upper casting machine 14 including two roller wheels 141 disposed at a fixed distance, and the lead rods 5 are sandwiched between the two rollers. Between wheels 141.
  • the lead rod 5 mainly plays the role of the formed welding rod to the outside of the flux cored electrode forming module, and the roller wheel 141 gives a certain clamping force to the lead rod 5, and drives the lead rod 5 to carry the formed welding rod.
  • the embodiment provides a method for preparing a flux cored electrode by using a flux cored electrode preparation device, comprising the following steps:
  • the alloy inflow hole 6 on the alloy inflow hole 411 is connected to the alloy casting furnace 12, the high temperature liquid alloy into the molding cavity 43, the liquid alloy is cooled to form the elongated casing 1;
  • the upper casting machine 14 pulls the lead rod 5, the lead rod 5 leads the elongated shell 1 a distance;
  • the upper casting machine 14 drives the lead rod 5 to continuously pull the flux cored electrode to the outside of the casting tube 4;
  • the preparation method of the flux cored electrode provided by the invention can realize the continuous preparation of the flux cored electrode, and can have good manufacturing ability for different kinds of metal materials, especially metal materials with high self-deformation resistance, such as copper alloy.
  • the solid core can seal the liquid core in the pipe so that it does not eject from above the elongated casing 1.
  • the preparation method of the flux cored electrode is suitable for a wide range, and may be a soft material such as an aluminum silicon material or a tin alloy material, or a hard material such as a copper material.
  • the flux cored electrodes of different specifications can be prepared by changing the sizes of the casting tube 4 and the inner tube 42.
  • the inner tube 42 can control the inner diameter of the elongated casing 1, and the outer diameter of the casting tube 4 is used to control the outer diameter of the elongated casing 1.
  • each flux cored electrode forming module can be adjusted, and in the preparation device of the cored electrode, a plurality of sets of flux cored electrode forming modules can be arranged side by side, so that it can be prepared simultaneously under the premise of one heat. Roots of different sizes of flux cored electrodes.
  • the flux 11 may be made of rosin, the temperature is raised to 150 ° C, and the rosin is melted and kept warm. In the preparation process, it is necessary to cover a layer of charcoal or graphite scales above the alloy melt to protect the air and keep warm.
  • the prepared flux cored electrode is wound or cut into a predetermined length as needed.
  • the prepared flux-cored electrode is wound or wound to facilitate storage and transportation of the electrode.

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  • Mechanical Engineering (AREA)
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Abstract

一种药芯焊条成型模块、制备装置及其制备方法。当采用药芯焊条成型模块时，首先在外壳成型部中成型出具有空心的长形壳体（1），然后通过药芯注入通道（3）将焊药（11）注入壳体的空心部，从而解决了现有技术中焊药涂覆在合金管外层并通过粘结剂进行黏结，导致在使用过程中产生大量烟雾的问题。连续制备药芯焊条的方法所生产的药芯焊条不具有折缝，避免了后期对焊条进行拉拔过程中润滑油进入折缝中对焊条造成污染。

Description

一种药芯焊条成型模块、制备装置及其制备方法 技术领域
本发明涉及焊条成型技术领域，具体涉及一种焊条制备装置及焊条制备方法。
背景技术
铜、银等合金焊条是常用的硬钎料，广泛应用于金属与金属之间的焊接。在焊条的具体使用过程中，往往需要加入助焊剂(焊药)以辅助焊接，目的是消除金属的氧化，增加熔融金属流动性，以达到更好的焊接效果。
在锡合金等软钎料中，往往将焊药直接通过分流组合挤压法注入焊丝内部，然后通过拉伸将其拉制成不同规格的焊丝。但分流组合只适用于变形抗力低、焊合性能好的金属。
对比文件CN103551757B公开了一种钎焊用铝硅合金无缝药芯焊丝、制备及应用，将铝硅合金放入挤压模具中得到具有一定厚度的带材，然后将带材经过不同大小的压辊轧制合口成O形端面的空心焊条，同时将药芯粉料包裹在焊条中，最后将药芯焊条放在退火炉中进行拉拔至特定尺寸。但上述的制备方法复杂，且不能连续制造。在钢焊条中也有一种药芯焊丝，是一种有缝焊丝，它是通过钢带连续卷折包裹药芯，随后通过拉伸收口并制成规格而制备的，这种方法同样需要使用较多焊药，且焊条的金属层较薄(太厚无法卷折)。此外，焊条中具有折缝，拉伸时的润滑剂容易残留在 折缝中，影响焊条性能。因此，目前在铜、银等合金焊条中尚没有使用。
而对于自身变形抗力较高的金属材料，如铜材，难以采用上述方法制取药芯焊丝。目前的方法只能制成实心焊条，在焊接时另外添加焊药，与焊条一起使用；此外还有一种涂药铜焊条，是在实心铜材表面上涂覆一层焊药，为了保证铜材与焊药之间的粘着性，在焊药中添加了大量粘结剂。这种涂药铜焊条焊接效果较好，但由于涂药过程繁琐，且大量粘结剂在焊接时产生大量烟气，生产效率和环境成本很不理想。
为此，需要研发一种短流程的连续制造方法，将药芯填入连续长度的金属焊料中心，且没有药芯钢焊条这种卷折缝。
发明内容
因此，本发明要解决的技术问题在于克服现有技术中采用变形抗力较大的金属材料制备的焊条中由于使用粘结剂、导致使用时产生大量烟气的缺陷，以及通过卷折所形成的折缝问题，从而提供一种焊条成型模块及焊条制备装置以及焊条制备方法。
为此，本发明提供一种药芯焊条成型模块，包括：
外壳成型部，用以成型出具有空心的长形壳体；
模芯，包括药芯通道以及药芯注入通道，所述药芯通道与所述药芯注入通道流体连通，所述药芯注入通道与所述长形壳体流体连通，用以将焊药充满所述长形壳体的内部。
所述外壳成型部为管状外壳成型部，所述长形壳体为长形合金管，所述药芯通道和药芯注入通道均为圆形管道。
所述管状外壳成型部包括：铸管，所述铸管包括同轴设置的外管和内 管，所述外管和所述内管之间成型有成型腔，所述外管上开设有合金流入孔；引杆，设置在所述成型腔内并能够在所述成型腔内移动，所述引杆的端部与合金液相接触，当合金液成型为合金管后，将所述合金管引出至所述铸管外部。
所述外管包括：合金流入部，所述合金流入部上成型有所述合金流入孔；合金管成型部，所述合金管成型部外侧设有保护套管，冷却液在所述保护套管与所述合金管成型部之间流动。
所述药芯注入管包括：与所述铸管共用的内管；以及，与所述内管相连接的内管支座，所述内管支座与所述外管之间螺纹连接。
本发明同时提供一种药芯焊条制备装置，包括：
药剂罐，所述药剂罐内盛放有焊药；
合金铸造炉，用于熔化金属合金；
其特征在于，所述药芯焊条制备装置还包括至少一个药芯焊条成型模块。
所述药芯通道一端连接在所述内管支座上，另一端与所述药剂罐相连通。
所述外管的所述合金流入部设置在所述合金铸造炉内部，使得熔化的合金能通过所述合金流入孔流入。
所述药剂罐上连接有空气压缩机，用以对所述药剂罐内的焊药进行加压。
所述药剂罐与所述药芯通道相连接的部位设有阀门，用以控制药芯进入所述药芯通道内。
所述焊条制备装置还包括上引铸造机，所述上引铸造机包括间隔固定距离设置的两个辊轮，所述引杆夹设在两个所述辊轮之间。
本发明同时提供一种利用药芯焊条制备装置制备药芯焊条的方法，包括如下步骤：
a.将合金在所述合金铸造炉中熔化，保温；
b.关闭所述阀门，将所述药剂罐内的焊药熔化；
c.将所述合金流入部上的所述合金流入孔与所述合金铸造炉相连接，使高温液态合金进入所述成型腔中，液态合金冷却，形成长形壳体；
d.启动所述上引铸造机，所述上引铸造机拉动所述引杆，将所述长形壳体引出一段距离；
e.启动所述空气压缩机，使焊药进入所述药芯通道中，将焊药压入并填满所述长形壳体内部，并在所述长形壳体的上方冷却凝固，形成固态药芯；
f.所述上引铸造机带动引杆，将药芯焊条连续牵出至所述铸管外侧；
还包括如下步骤：
g.根据需要将制备的药芯焊条进行缠绕或切割成预定的长度。
本发明技术方案，具有如下优点：
1.本发明提供一种药芯焊条成型模块，包括：
外壳成型部，用以成型出具有空心的长形壳体；
模芯，包括药芯通道以及药芯注入通道，所述药芯通道与药芯注入通道流体连通，所述药芯注入通道与所述长形壳体流体连通，用以将焊药充满所述长形壳体的内部。
本发明的设备适用于多种金属或合金，而现有技术中，对于自身变形抗力较高的金属材料，由于很难通过挤压设备完成注药成型，所以往往将焊药涂抹在金属材料的外侧。即便采用将焊药包裹在金属带材中形成药芯焊丝，加工复杂，且不能连续制造。
当采用本发明提供的药芯焊条成型模块时，首先将在外壳成型部中成型出具有空心的长形壳体，然后通过药芯注入通道将焊药充满壳体的空心部。通过这样的制作方法，有效地将焊药充入了壳体内部，从而防止了现有技术中，焊药涂覆在外层、采用粘结剂进行黏结，在使用过程中产生大量烟雾的缺陷。同时，本发明还适用于自身变形抗力较小的软质金属材料，如铝硅材质、锡合金等。
同时，由于生产过程中并未采用现有技术中钢带连续卷折包裹药芯的制作方法，因此制作得到的焊条不具有折缝，从而防止后期对焊条进行拉拔过程中润滑油进入折缝中，对焊条造成污染的不足。
2.本发明提供一种药芯焊条成型模块，所述管状外壳成型部包括：铸管，所述铸管包括同轴设置的外管和内管，所述外管和所述内管之间成型有成型腔，所述外管上开设有合金流入孔；引杆，设置在所述成型腔内并能够在所述成型腔内移动，所述引杆的端部与合金液相接触，当合金液成型为合金管后，将所述合金管引出至所述铸管外部。
使用过程中，高温液态合金通过外管上的合金流入孔流入成型腔内部，并在成型腔中冷却为固态，从而形成长形壳体。
同时，引杆与成型腔中的合金液相接触，由于引杆温度较低，而合金液的温度较高，因此当二者接触时，合金液会立刻凝固并黏结在引杆的端 部，此时只需拉动引杆，便可以将长形壳体连续不断地从铸管中拉出。
3.本发明提供一种药芯焊条成型模块，所述外管包括：合金流入部，所述合金流入部上成型有所述合金流入孔；合金管成型部，所述合金管成型部外侧设有保护套管，冷却液在所述保护套管与所述合金管成型部之间流动。
合金液从所述合金流入孔中进入外管内部，在压力的作用下，合金液会继续向前运动，此时将流入合金管成型部，由于合金管成型部外侧有冷却液流动，因此合金液会受冷迅速冷却凝固，形成固态长形壳体。
4.本发明提供一种药芯焊条成型模块，所述药芯注入管包括：与所述铸管共用的内管；以及，与所述内管相连接的内管支座，所述内管支座与所述外管之间螺纹连接。
通过内管支座，将所述外管与所述内管同轴设置，内管支座与内管相连通，由于长形壳体形成在外管和内管之间的成型腔中，因此通过内管支架，可以将药芯精准地注入至长形壳体内部。
5.本发明提供一种药芯焊条制备装置，一种药芯焊条制备装置，包括：
药剂罐，所述药剂罐内盛放有焊药；合金铸造炉，用于熔化金属合金；所述药芯焊条制备装置还包括至少一个药芯焊条成型模块。
合金铸造炉与外壳成型部相接触，合金铸造炉内熔化的液态金属合金会通过外管上的合金流入孔流入成型腔中，形成固态的长形壳体；药剂罐内盛放有焊药，与模芯相连接，通过模芯将焊药注入长形壳体内部。
6.本发明提供一种药芯焊条制备装置，所述药剂罐上连接有空气压缩机，用以对所述药剂罐内的焊药进行加压。将焊药充满这个长形壳体的空 心处。
7.本发明提供一种药芯焊条制备装置，所述药剂罐与所述药芯通道相连接的部位设有阀门，用以控制药芯进入所述药芯通道内。
当阀门打开时，药剂罐内的焊药将流入药芯通道内，从而开始在长形壳体空心处的药芯注入过程；当空心处填满药芯后，将阀门关闭，停止药芯注入。
8.本发明提供一种药芯焊条制备装置，所述焊条制备装置还包括上引铸造机，所述上引铸造机包括间隔固定距离设置的两个辊轮，所述引杆夹设在两个所述辊轮之间。
引杆主要起将成型的焊条带出至药芯焊条成型模块外界的作用，而所述辊轮会给引杆一定的加持力，带动引杆进而将成型的焊条带出。由于所述上引铸造机的存在，使得能够对焊条进行连续生产。
同时，通过多组药芯焊条成型模块与上引铸造机相配合，可以同时制备多条焊条。
9.本发明提供一种利用药芯焊条制备装置制备药芯焊条的方法，包括如下步骤：
a.将合金在所述合金铸造炉中熔化，保温；
b.关闭所述阀门，将所述药剂罐内的焊药熔化；
c.将所述合金流入部上的所述合金流入孔与所述合金铸造炉相连接，使高温液态合金进入所述成型腔中，液态合金冷却，形成长形壳体；
d.启动所述上引铸造机，所述上引铸造机拉动所述引杆，将所述长形壳体引出一段距离；
e.打开所述阀门，启动所述空气压缩机，使焊药进入所述药芯通道中，将焊药压入并填满所述长形壳体内部，并在长形壳体的上方冷却凝固，形成固态药芯；
f.所述上引铸造机带动引杆，将药芯焊条连续牵出至所述铸管外侧；
通过本发明提供的药芯焊条制备方法，能够实现药芯焊条的联系制备，同时可以对不同种类的金属材料，尤其是自身变形抗力较高的金属材料，如铜合金具有良好的制作能力。
同时，采用本方法制备焊条时，通过改变铸管和药芯导管的尺寸可以制备不同规格的药芯焊条。
附图说明
为了更清楚地说明本发明具体实施方式或现有技术中的技术方案，下面将对具体实施方式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，下面描述中的附图是本发明的一些实施方式，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的附图。
图1为本发明提供的所述药芯焊条的结构示意图；
图2为本发明提供的所述药芯焊条成型模块的结构示意图；
图3为本发明提供的所述药芯焊条制备装置的结构示意图；
附图标记说明：
1-长形壳体；2-药芯通道；3-药芯注入通道；4-铸管；41-外管；411-合金流入孔；42-内管；43-成型腔；5-引杆；6-合金流入部；7-合金管成型部；8-保护套管；9-内管支座；10-药剂罐；101-阀门；11-焊药；12-合 金铸造炉；13-空气压缩机；14-上引铸造机；141-辊轮；15-保温石棉；16-石墨保护套；17-冷却液。
具体实施方式
下面将结合附图对本发明的技术方案进行清楚、完整地描述，显然，所描述的实施例是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
在本发明的描述中，需要说明的是，术语“中心”、“上”、“下”、“左”、“右”、“竖直”、“水平”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本发明和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本发明的限制。此外，术语“第一”、“第二”、“第三”仅用于描述目的，而不能理解为指示或暗示相对重要性。
在本发明的描述中，需要说明的是，除非另有明确的规定和限定，术语“安装”、“相连”、“连接”应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或一体地连接；可以是机械连接，也可以是电连接；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通。对于本领域的普通技术人员而言，可以具体情况理解上述术语在本发明中的具体含义。
此外，下面所描述的本发明不同实施方式中所涉及的技术特征只要彼此之间未构成冲突就可以相互结合。
实施例1
本实施例提供一种药芯焊条成型模块，包括：
外壳成型部，用以成型出具有空心的长形壳体1；
模芯，包括药芯通道2以及药芯注入通道3，所述药芯通道2与药芯注入通道3流体连通，所述药芯注入通道3与所述长形壳体1流体连通，用以将焊药11充满所述长形壳体1的内部。
现有技术中，对于自身变形抗力较高的金属材料，由于很难通过挤压设备拉拔成型，所以往往将焊药11涂抹在金属材料的外侧。
当采用本实施例提供的药芯焊条成型模块时，首先将金属材料在外壳成型部中成型出具有空心的长形壳体1，然后通过药芯注入通道3将焊药11充满壳体的空心部。通过这样的制作方法，有效地将焊药11充入了壳体内部，从而防止了现有技术中，焊药11涂覆在外层、采用粘结剂进行黏结，在使用过程中产生大量烟雾的缺陷。
同时，由于生产过程中并未采用现有技术中钢带连续卷折包裹药芯的制作方法，因此制作得到的焊条不具有折缝，从而防止后期对焊条进行拉拔过程中润滑油进入折缝中，对焊条造成污染的不足。
本实施例中，所述外壳成型部为管状外壳成型部，所述长形壳体1为长形合金管，所述药芯通道2和药芯注入通道3均为圆形管道。
本实施例中，所述长形壳体1为圆管状。作为变型，所述长形壳体1可以为其它形状，如剖面为矩形、椭圆形的管体。
所述管状外壳成型部包括：铸管4，所述铸管4包括同轴设置的外管41和内管42，所述外管41和所述内管42之间成型有成型腔43，所述外管41上开设有合金流入孔411；引杆5，设置在所述成型腔43内并能够在所 述成型腔43内移动，所述引杆5的端部与高温液态合金相接触，当高温液态合金成型为固态合金管后，将所述固态合金管引出至所述铸管4外部。
所述内管42的设计为近端大，末端小，锥度为1-2°。这样的设计便于高温液态合金在成型腔43内部迅速冷却并脱模，有利于将长形壳体1从成型腔43中引出。
使用过程中，高温液态合金通过外管41上的合金流入孔411流入成型腔43内部，并在成型腔43中冷却为固态，从而形成长形壳体1。
同时，引杆5与成型腔43中的高温液态合金相接触，由于引杆5温度较低，而高温液态合金的温度较高，因此当二者接触时，高温液态合金会立刻黏结在引杆5的端部，此时只需拉动引杆5，便可以将长形壳体1从铸管4中拉出。
所述外管41包括：合金流入部6，所述合金流入部6上成型有所述合金流入孔411；合金管成型部7，所述合金管成型部7外侧设有保护套管8，冷却液17在所述保护套管8与所述合金管成型部7之间流动。
高温液态合金从所述合金流入孔411中进入外管41内部，在压力的作用下，高温液态合金会继续向前运动，此时将流入合金管成型部7，由于合金管成型部7外侧有冷却液17流动，因此高温液态合金会受冷迅速冷却，形成固态长形壳体1。
具体地，所述冷却液17可以采用冷却水冷却，也可以采用油进行冷却，所述保护套管8外侧包裹有保温石棉15，在保温石棉15外侧安装有石墨保护套16，二者用以起到保温的作用。
本实施例中，所述药芯注入管包括：与所述铸管4共用的内管42；以 及，与所述内管42相连接的内管支座9，所述内管支座9与所述外管41之间螺纹连接。
通过内管支座9，将所述外管41与所述内管42同轴设置，内管支座9与内管42相连通，由于长形壳体1形成在外管41和内管42之间的成型腔43中，因此通过内管42支架，可以将焊药11精准地注入至长形壳体1内部。
具体地，所述内管42支架上成型有外螺纹，所述外管41内侧成型有内螺纹。
实施例2
本实施例提供一种药芯焊条制备装置，包括：
药剂罐10，所述药剂罐10内盛放有焊药11；
合金铸造炉12，用于熔化金属合金；
所述药芯焊条制备装置还包括至少一个药芯焊条成型模块。
合金铸造炉12与外壳成型部相接触，合金铸造炉12内熔化的液态金属合金会通过外管41上的合金流入孔411流入成型腔43中，形成固态的长形壳体1；药剂罐10内盛放有焊药11，与模芯相连接，通过模芯将焊药11注入长形壳体1内部。
具体地，所述药剂罐10与所述合金铸造炉12内均设有加热装置，用以将焊药11和合金加热并保持在熔体状态。所述药剂罐10和合金铸造炉12内部安装有热电偶，用以实时监测高温熔体的温度。该加热装置可以使电阻加热，也可以采用电磁搅拌等其它加热方式。
具体地，本实施例中，所述药芯通道2一端连接在所述内管支座9上， 另一端与所述药剂罐10相连通。
具体地，如图3所示，整个药芯焊条制备装置均浸入在所述合金铸造炉12内部，所述外管41的所述合金流入部6被高温液态合金熔体包围，使得熔化的合金能通过所述合金流入孔411流入。
本实施例中，可以在所述药剂罐10的下方同时设置多组流孔，多条所述药芯通道2连接在所述流孔上，由于每个药芯焊条成型模块均可以制备出一根焊条，因此通过多条药芯通道2与多组药芯焊条成型模块相配合，可以同时制备多根焊条。从而实现“一炉多线”的联系成型。
所述药芯注入通道3的外侧包裹有耐火材料，用以防止其在高温下的氧化烧损。
所述药剂罐10上连接有空气压缩机13，用以对所述药剂罐10内的焊药11进行加压。用以对所述药剂罐10内的焊药11进行加压，将焊药11充满这个长形壳体1的空心处。
所述药剂罐10内部还设有压力表，用以对空气压缩机13的加压能力进行检测，便于控制药芯的注入速度。
所述药剂罐10与所述药芯通道2相连接的部位设有阀门101，用以控制药芯进入所述药芯通道2内。当阀门101打开时，药剂罐10内的焊药11将流入药芯通道2内，从而开始在长形壳体1空心处的药芯注入过程；当空心处填满焊药11后，将阀门101关闭，停止焊药11注入。
本实施例中，所述焊条制备装置还包括上引铸造机14，所述上引铸造机14包括间隔固定距离设置的两个辊轮141，所述引杆5夹设在两个所述辊轮141之间。
引杆5主要起将成型的焊条带出至药芯焊条成型模块外界的作用，而所述辊轮141会给引杆5一定的夹持力，带动引杆5进而将成型的焊条带出。
实施例3
本实施例提供一种利用药芯焊条制备装置制备药芯焊条的方法，包括如下步骤：
a.将合金在所述合金铸造炉12中熔化，保温；
b.关闭所述阀门101，将所述药剂罐10内的焊药11熔化；
c.将所述合金流入部6上的所述合金流入孔411与所述合金铸造炉12相连接，使高温液态合金进入所述成型腔43中，液态合金冷却，形成长形壳体1；
d.启动所述上引铸造机14，所述上引铸造机14拉动所述引杆5，所述引杆5将所述长形壳体1引出一段距离；
e.打开所述阀门101，使焊药11进入所述药芯通道2中，启动所述空气压缩机13，将焊药11压入并填满所述长形壳体1内部，并在长形壳体1的上方冷却凝固，形成固态药芯；
f.所述上引铸造机14带动引杆5，将药芯焊条连续牵出至所述铸管4外侧；
通过本发明提供的药芯焊条制备方法，能够实现药芯焊条的连续制备，同时可以对不同种类的金属材料，尤其是自身变形抗力较高的金属材料，如铜合金具有良好的制作能力。固态药芯可密封管道内的液态药芯，使其不至于从长形壳体1的上方喷出。
本药芯焊条的制备方法适于范围较广，可以是铝硅材质、锡合金材质等柔软材质，也可以是铜材等硬性材质。
同时，采用本方法制备焊条时，通过改变铸管4和内管42的尺寸可以制备不同规格的药芯焊条。具体地，所述内管42能够控制所述长形壳体1的内径，所述铸管4的外径用以控制所述长形壳体1的外径。
由于可以对每个药芯焊条成型模块的尺寸进行调节，同时在药芯焊条的制备装置中，能够并排设置多组药芯焊条成型模块，因此可以实现在一炉次的前提下，同时制备多根不同尺寸的药芯焊条。
在步骤b当中，所述焊药11可以采用松香材质，将温度升高至150℃，将松香熔化并保温。在制备过程中，需要在合金熔体上方覆盖一层木炭或石墨鳞片，起到隔绝空气、保温的作用。
本实施例提供的所述焊条制备方法还包括如下步骤：
g.根据需要将制备的药芯焊条进行缠绕或切割成预定的长度。
对制备得到的药芯焊条缠绕打卷或切割，便于对焊条进行存放以及运输。
显然，上述实施例仅仅是为清楚地说明所作的举例，而并非对实施方式的限定。对于所属领域的普通技术人员来说，在上述说明的基础上还可以做出其它不同形式的变化或变动。这里无需也无法对所有的实施方式予以穷举。而由此所引伸出的显而易见的变化或变动仍处于本发明创造的保护范围之中。

Claims (12)

  1. 一种药芯焊条成型模块，其特征在于，包括：
    外壳成型部，用以成型出具有空心的长形壳体(1)；
    模芯，包括药芯通道(2)以及药芯注入通道(3)，所述药芯通道(2)与所述药芯注入通道(3)流体连通，所述药芯注入通道(3)与所述长形壳体(1)流体连通，用以将焊药(11)充满所述长形壳体(1)的内部。
  2. 根据权利要求1所述的药芯焊条成型模块，其特征在于，所述外壳成型部为管状外壳成型部，所述长形壳体(1)为长形合金管，所述药芯通道(2)和药芯注入通道(3)均为圆形管道。
  3. 根据权利要求2所述的药芯焊条成型模块，其特征在于，所述管状外壳成型部包括：
    铸管(4)，所述铸管包括同轴设置的外管(41)和内管(42)，所述外管(41)和所述内管(42)之间成型有成型腔(43)，所述外管(41)上开设有合金流入孔(411)；
    引杆(5)，设置在所述成型腔(43)内并能够在所述成型腔(43)内移动，所述引杆(5)的端部与合金液相接触，当合金液成型为合金管后，将所述合金管引出至所述铸管(4)外部。
  4. 根据权利要求3所述的药芯焊条成型模块，其特征在于，所述外管(41)包括：
    合金流入部(6)，所述合金流入部(6)上成型有所述合金流入孔(411)；
    合金管成型部(7)，所述合金管成型部(7)外侧设有保护套管(8)，冷却液在所述保护套管(8)与所述合金管成型部(7)之间流动。
  5. 根据权利要求3所述的药芯焊条成型模块，其特征在于，所述药芯注入管(3)包括：
    与所述铸管(4)共用的内管(42)；以及，
    与所述内管(42)相连接的内管支座(9)，所述内管支座(9)与所述外管(41)之间螺纹连接。
  6. 一种药芯焊条制备装置，包括：
    药剂罐(10)，所述药剂罐内盛放有焊药(11)；
    合金铸造炉(12)，用于熔化金属合金；
    其特征在于，所述药芯焊条制备装置还包括至少一个如权利要求1-5中任一项所述的药芯焊条成型模块。
  7. 如权利要求6所述的药芯焊条制备装置，其特征在于，
    所述药芯通道(2)一端连接在所述内管支座(9)上，另一端与所述药剂罐(10)相连通。
    所述外管(41)的所述合金流入部(6)设置在所述合金铸造炉(12)内部，使得熔化的合金能通过所述合金流入孔(411)流入。
  8. 根据权利要求6或7所述的药芯焊条制备装置，其特征在于，所述药剂罐上连接有空气压缩机(13)，用以对所述药剂罐(10)内的焊药(11)进行加压。
  9. 根据权利要求6或7所述的药芯焊条制备装置，其特征在于，所述药剂罐(10)与所述药芯通道(2)相连接的部位设有阀门(101)，用以控制药芯进入所述药芯通道(2)内。
  10. 根据权利要求6或7所述的药芯焊条制备装置，其特征在于，所述 焊条制备装置还包括上引铸造机(14)，所述上引铸造机(14)包括间隔固定距离设置的两个辊轮(141)，所述引杆(5)夹设在两个所述辊轮(141)之间。
  11. 一种利用权利要求6-10中任一项所述的药芯焊条制备装置制备药芯焊条的方法，包括如下步骤：
    a.将合金在所述合金铸造炉(12)中熔化，保温；
    b.关闭所述阀门(101)，将所述药剂罐(10)内的焊药熔化；
    c.将所述合金流入部(6)上的所述合金流入孔(411)与所述合金铸造炉(12)相连接，使高温液态合金进入所述成型腔(43)中，液态合金冷却，形成长形壳体(1)；
    d.启动所述上引铸造机(14)，所述上引铸造机(14)牵引所述引杆(5)，将所述长形壳体(1)引出一段距离；
    e.打开所述阀门(101)，启动所述空气压缩机(14)，使焊药(11)进入所述药芯通道(2)中，将焊药(11)压入并填满所述长形壳体(1)内部，并在所述长形壳体(1)的上方冷却凝固，形成固态药芯；
    f.所述上引铸造机(14)带动所述引杆(5)，将药芯焊条连续牵出至所述铸管(4)外侧。
  12. 如权利要求11所述的方法，其特征在于，还包括如下步骤：
    g.根据需要将制备的药芯焊条进行缠绕或切割成预定的长度。
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