Cast copper heater and preparation method thereof

Abstract

The invention provides a cast copper heater and a preparation method thereof.The cast copper heater comprises two arc-shaped heating pieces arranged oppositely, each arc-shaped heating piece comprises a heating body, a cast copper body, a heat preservation layer and a binding post assembly, the heating bodies are embedded in the cast copper bodies, and the heating bodies extend in a spiral or S shape; the heat preservation layer wraps the outer side of the cast copper body; a heat insulation layer is arranged between the cast copper body and the heat preservation layer; the binding post assembly penetrates through the heat preservation layer and the cast copper body and is connected with the heating body. The cast copper heater adopts a split structure, is convenient to mount and dismount, and can be suitable for heating scenes of more products; the heating body in the cast copper body extends in a spiral or S shape, so that the heating area can be increased, and the heating efficiency can be improved; the heat insulation layer and the heat preservation layer are arranged outside the cast copper body, heat dissipation can be avoided, and heating efficiency is guaranteed.

Description

Technical Field

[0001] The invention relates to the technical field of heaters, and in particular to a cast copper heater and a preparation method thereof. Background Art

[0002] The cast copper heater uses a tubular electric heating element as the heating element, which is bent into shape, and then centrifugally cast into various shapes using high-quality metal alloy materials as the outer shell in the mold, including round, flat, right-angle, air-cooled, water-cooled and other special shapes. Currently, most cast copper heaters are monolithic structures, which are not very suitable, and the disassembly and assembly process is relatively cumbersome. In addition, the cast copper material in the current cast copper heater is exposed, which easily leads to heat dissipation and low heating efficiency. Summary of the invention

[0003] The purpose of the present invention is to solve the shortcomings existing in the prior art and to propose a cast copper heater and a preparation method thereof, so as to improve the thermal conductivity and heat preservation performance of the cast copper heater, improve the applicability, and enhance the disassembly and assembly efficiency.

[0004] To achieve the above object, the present invention adopts the following technical solutions: According to a first aspect of the present invention, a cast copper heater is provided, comprising two relatively arranged arc-shaped heating elements, each arc-shaped heating element comprising a heating body, a cast copper body, a thermal insulation layer and a terminal assembly, wherein the heating body is embedded in the interior of the cast copper body, and the heating body extends in a spiral or S shape; the thermal insulation layer is wrapped around the outside of the cast copper body; the terminal assembly passes through the thermal insulation layer and the cast copper body and is connected to the heating body.

[0005] Preferably, the terminal assembly includes a positive terminal, a negative terminal and a ground terminal; the arc-shaped heating element also includes a sealed terminal box, which is arranged on the outside of the insulation layer, and the terminal assembly is located inside the sealed terminal box.

[0006] Preferably, a thermocouple is further provided in the sealed junction box, and a detection end of the thermocouple passes through the insulation layer and then penetrates into the interior of the cast copper body.

[0007] Preferably, the cast copper heater also includes an instrument box, in which a control module, an input module and an output module are provided, the input module and the output module are electrically connected to the control module respectively; the control module is also electrically connected to the thermocouple, and the output module is also electrically connected to the terminal assembly; the input module is used for the user to input the heating temperature and heating time, and the control module is used to control the voltage output by the output module to the heating body.

[0008] Preferably, positioning grooves are respectively provided on both axial sides of the cast copper body, the cross-sectional shape of the thermal insulation layer is U-shaped, and the two axial sides of the thermal insulation layer are respectively located in the positioning grooves.

[0009] Preferably, a heat insulating layer is provided between the cast copper body and the heat insulating layer, and the heat insulating layer is made of fireproof heat insulating cotton.

[0010] Preferably, the ends of the two arc-shaped heating elements are respectively provided with clamping holes, and the clamping hole on each arc-shaped heating element passes through the thermal insulation layer, the heat insulation layer and the cast copper body; the ends of the two arc-shaped heating elements are connected by clamping bolts, and the clamping bolts pass through the clamping holes on the two arc-shaped heating elements in turn, and a gap of 3.0mm to 8.0mm is left between the end faces of the two arc-shaped heating elements.

[0011] Preferably, the weight fraction of each component in the heating body is: C: 0.01%~0.05%, Si: 0.50%~2.20%, S: ≤0.003%, P: ≤0.02%, Cr: 16.5%~22.8%, Al: 0.2%~0.8%, Ti: 0.01%~0.05%, Zr: 0.15%~0.22%, rare earth elements: 0.01%~0.20%, and the balance is Ni; wherein the rare earth elements include La, Ce, and Y, and the weight ratio of La:Ce:Y is 1:(0.5~1.5):(0.6~1.8).

[0012] Preferably, the weight fraction of each component in the cast copper body is: Al: 0.8%-2.5%, Mg: 0.8%-2.5%, Mn: 1.2%-2.2%, Si: 0.2%-1.0%, Fe: 0.6%-1.2%, Co: 0.1%-0.5%, Zr: 0.15%-0.20%, Ti: 0.15%-0.20, and the balance is Cu; wherein the weight ratio of Co:Zr:Ti is 1:(0.8-2.5):(0.8-3.0).

[0013] According to a second aspect of the present invention, a method for preparing a cast copper heater is provided, the method for preparing the cast copper heater comprising the following steps: Step S1: bending the heating body into a desired spiral shape or S shape and fixing it into a casting mold; Step S2: using a centrifugal casting process to obtain an arc-shaped copper casting body, so that the heating body is embedded in the copper casting body; and positioning grooves are processed on both axial sides of the copper casting body; Step S3: coating the outside of the cast copper body with a heat insulation layer; Step S4: wrapping a heat-insulating layer outside the heat-insulating layer to form an arc-shaped heating element; Step S5: Use a clamping bolt to connect the two arc-shaped heating elements, and reserve a gap of 3.0 mm to 8.0 mm between the end surfaces of the two arc-shaped heating elements.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: the cast copper heater of the present invention comprises two relatively arranged arc-shaped heating bodies, which are convenient to install and disassemble, and can be applied to heating scenarios of more products; the heating body inside the cast copper body is extended in a spiral or S shape, which can increase the heating area and improve the heating efficiency; an insulation layer is arranged on the outside of the cast copper body, which can avoid heat dissipation and ensure heating efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 Schematic diagram of the three-dimensional structure of the cast copper heater according to some embodiments of the present invention.

[0016] Figure 2 Schematic diagram of the disassembled structure of the cast copper heater according to some embodiments of the present invention.

[0017] Figure 3 Schematic diagram of the structure of the cast copper body in some embodiments of the present invention.

[0018] Figure 4 Schematic diagram of the cross-sectional structure of the cast copper heater according to some embodiments of the present invention.

[0019] Figure 5 Schematic diagram of electrical connection of cast copper heaters according to some embodiments of the present invention.

[0020] In the figure, 10-heating body, 20-cast copper body, 21-positioning groove, 22-pressing hole, 23-pressing bolt, 30-insulating layer, 40-insulating layer, 50-terminal assembly, 51-positive terminal, 52-negative terminal, 53-ground terminal, 60-sealed terminal box, 70-thermocouple, 80-instrument box, 81-control module, 82-input module, 83-output module. DETAILED DESCRIPTION

[0021] In order to make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the embodiment of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiment of the present invention. Obviously, the described embodiment is a part of the embodiment of the present invention, not all of the embodiments. Based on the described embodiment of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work belong to the scope of protection of the present invention. It can be understood that some technical means of the various embodiments described herein can be replaced or combined with each other without conflict.

[0022] In the description of the present invention, if there are terms such as "first", "second", etc., they are only used to distinguish the objects described, and do not have any order or technical meaning. Therefore, the objects defined as "first", "second", etc. may explicitly or implicitly include one or more of the objects. In addition, "one" or "a" and similar words do not indicate a quantity limitation, but indicate the existence of at least one, and "multiple" means not less than two.

[0023] In the description of the present specification, reference to "one embodiment" or "some embodiments" etc. means that one or more embodiments of the present invention include a specific feature, structure or characteristic described in conjunction with the embodiment. Therefore, the phrases "in one embodiment", "in some embodiments", "in some other embodiments", "in some other embodiments", etc. appearing in different places in this specification do not necessarily refer to the same embodiment, but mean "one or more but not all embodiments", unless otherwise specifically emphasized in other ways.

[0024] According to a first aspect of the present invention, there is provided a cast copper heater. Figures 1 to 4 In some embodiments, the cast copper heater includes two arc-shaped heating elements arranged opposite to each other, and the two arc-shaped heating elements are assembled to form a ring-shaped cast copper heater. Each arc-shaped heating element includes a heating body 10, a cast copper body 20, a heat preservation layer 40 and a terminal assembly 50. The heating body 10 is embedded in the cast copper body 20, and the heating body 10 extends in a spiral or S shape. The heat preservation layer 40 is wrapped around the outer side of the cast copper body 20; the terminal assembly 50 passes through the heat preservation layer 40 and the cast copper body 20 and is connected to the heating body 10.

[0025] In application, the product to be heated is placed between two arc-shaped heating elements, and the power supply is passed into the heating body 10 through the terminal assembly 50. The heating body 10 generates heat after being energized, and the heat is transferred inward to the product through the cast copper body 20. The insulation layer 40 on the outside of the cast copper body 20 can play a role in insulation and prevent heat from dissipating to the outside.

[0026] The cast copper heater of the present invention adopts a split structure, which is convenient for installation and disassembly, and can be applied to heating scenarios of more products; the heating body 10 inside the cast copper body 20 adopts a spiral or S-shaped extension, which can increase the heating area and improve the heating efficiency; an insulation layer 40 is arranged on the outside of the cast copper body 20, which can avoid heat dissipation and ensure heating efficiency.

[0027] It should be noted that the sizes of the heating body 10, the cast copper body 20, and the insulation layer 40 can be reasonably set according to actual needs. For example, in some embodiments, the inner diameter of the cast copper body 20 is 265 mm, the outer diameter of the insulation layer 40 is 360 mm, and the thickness of the insulation layer 40 is 2 mm to 10 mm.

[0028] Reference Figure 3 In some embodiments, the terminal assembly 50 includes a positive terminal 51, a negative terminal 52 and a ground terminal 53, wherein the positive terminal 51 is used to connect the positive pole of the power supply, the negative terminal 52 is used to connect the negative pole of the power supply, and the ground terminal 53 is used for grounding to ensure safety in use. The arc heating element also includes a sealed junction box 60, which is arranged on the outside of the insulation layer 40, and the terminal assembly 50 is inside the sealed junction box 60. The sealed junction box 60 can be made of high temperature resistant insulating material, which is used to protect the terminal assembly 50 to ensure safety in use.

[0029] Furthermore, a thermocouple 70 is also provided in the sealed junction box 60, and the detection end of the thermocouple 70 penetrates through the insulation layer 40 and then penetrates into the interior of the cast copper body 20. The thermocouple 70 can be a thermocouple product in the prior art, which is used to detect and feedback the temperature of the cast copper body 20, so as to accurately control the heating body 10.

[0030] Reference Figure 5 In some embodiments, the cast copper heater further comprises an instrument box 80, in which a control module 81, an input module 82 and an output module 83 are provided, and the input module 82 and the output module 83 are electrically connected to the control module 81 respectively. The control module 81 is also electrically connected to the thermocouple 70, and the output module 83 is also electrically connected to the terminal assembly 50. Among them, the input module 82 is used for the user to input the heating temperature and heating time, the thermocouple 70 is used to detect the temperature of the cast copper body 20 and feed it back to the control module 81, and the control module 81 can be used to control the voltage output by the output module 83 to the heating body 10 according to the set heating temperature and the detected heating temperature; the control module 81 can also control the working time of the output module 83 according to the set heating time. It should be noted that the two arc-shaped heating elements are electrically connected to the instrument box 80 respectively, and the instrument box 80 can control the working state of the two arc-shaped heating elements respectively, which can meet the heating requirements of different products and improve applicability.

[0031] Reference Figure 2 and Figure 4 The axial sides of the cast copper body 20 are respectively provided with positioning grooves 21, and the cross-sectional shape of the insulation layer 40 is U-shaped, and the axial sides of the insulation layer 40 are respectively located in the positioning grooves 21. In this way, not only the installation accuracy of the cast copper heater can be ensured, but also the insulation layer 40 can be used to wrap the three sides of the cast copper body 20, so as to achieve a better insulation effect.

[0032] Furthermore, a heat insulating layer 30 is provided between the copper casting body 20 and the heat insulating layer 40, and the heat insulating layer 30 is made of fireproof heat insulating cotton. The heat insulating layer 30 can play a good heat insulating role, prevent the heat in the copper casting body 20 from dissipating outward, and further improve the heating efficiency.

[0033] Reference Figure 1 and Figure 2 , the ends of the two arc-shaped heating elements are respectively provided with clamping holes 22, and the clamping holes 22 on each arc-shaped heating element are set through the thermal insulation layer 40, the heat insulation layer 30 and the cast copper body 20. The ends of the two arc-shaped heating elements are connected by clamping bolts 23, and the clamping bolts 23 pass through the clamping holes 22 on the two arc-shaped heating elements in turn, and a gap of 3.0mm to 8.0mm is left between the end faces of the two arc-shaped heating elements. The reserved gap can provide a buffer space to prevent thermal expansion and contraction from affecting the overall effect of the cast copper heater. It should be noted that the number of clamping holes 22 can be reasonably set according to actual needs.

[0034] In some embodiments, the heating body 10 is made of nickel-chromium electric heating alloy material, and the weight fractions of the components in the heating body 10 are: C: 0.01% to 0.05%, Si: 0.50% to 2.20%, S: ≤0.003%, P: ≤0.02%, Cr: 16.5% to 22.8%, Al: 0.2% to 0.8%, Ti: 0.01% to 0.05%, Zr: 0.15% to 0.22%, rare earth elements: 0.01% to 0.20%, and the balance is Ni; wherein the rare earth elements include La, Ce, and Y, and the weight ratio of La:Ce:Y is 1: (0.5 to 1.5): (0.6 to 1.8). The reasonable proportion of each element can improve the organizational structure of the alloy, enhance its physical properties, and enhance the electrothermal conversion efficiency after power-on.

[0035] After testing, the resistivity of the heating body 10 using the above-mentioned component ratio is greater than 1.14μΩ·mm 2 / m, and it has excellent anti-oxidation and high temperature resistance.

[0036] Furthermore, the weight fraction of each component in the heating body 10 is: C: 0.01%~0.03%, Si: 1.20%~1.80%, S: ≤0.003%, P: ≤0.01%, Cr: 19.6%~22.8%, Al: 0.5%~0.8%, Ti: 0.01%~0.05%, Zr: 0.15%~0.22%, rare earth elements: 0.01%~0.20%, and the remainder is Ni; wherein the rare earth elements include La, Ce, and Y, and the weight ratio of La:Ce:Y is 1:(0.8~1.2):(1.0~1.8).

[0037] In some embodiments, the cast copper body 20 is made of a copper alloy material with high thermal conductivity, and the weight fractions of the components in the cast copper body 20 are: Al: 0.8% to 2.5%, Mg: 0.8% to 2.5%, Mn: 1.2% to 2.2%, Si: 0.2% to 1.0%, Fe: 0.6% to 1.2%, Co: 0.1% to 0.5%, Zr: 0.15% to 0.20%, Ti: 0.15% to 0.20, and the balance is Cu; wherein the weight ratio of Co: Zr: Ti is 1: (0.8 to 2.5): (0.8 to 3.0). The reasonable proportion of each element can improve the comprehensive performance of the cast copper body and improve its thermal conductivity.

[0038] Furthermore, the weight fractions of the components in the cast copper body 20 are: Al: 1.8%-2.5%, Mg: 1.5%-2.5%, Mn: 1.2%-2.2%, Si: 0.5%-1.0%, Fe: 0.6%-1.0%, Co: 0.1%-0.3%, Zr: 0.15%-0.20%, Ti: 0.15%-0.20, and the remainder is Cu; wherein the weight ratio of Co:Zr:Ti is 1:(1.2-1.8):(1.5-2.0).

[0039] According to a second aspect of the present invention, a method for preparing a cast copper heater is provided. The method for preparing the cast copper heater comprises the following steps: Step S1: bending the heating body 10 into a desired spiral shape or S shape, and fixing it into a casting mold; Step S2: a centrifugal casting process is used to produce an arc-shaped copper casting body 20, so that the heating body 10 is embedded in the copper casting body 20; and positioning grooves 21 are processed on both axial sides of the copper casting body 20; Step S3: Covering the outer portion of the cast copper body 20 with a heat insulation layer 30; Step S4: Covering the heat-insulating layer 40 on the outside of the heat-insulating layer 30 to form an arc-shaped heating element; Step S5: Use the clamping bolts 23 to connect the two arc-shaped heating elements, and reserve a gap of 3.0 mm to 8.0 mm between the end surfaces of the two arc-shaped heating elements.

[0040] The cast copper heater of the present invention adopts a split structure, which is convenient for installation and disassembly, and can be applied to heating scenarios of more products; the heating body inside the cast copper body is extended in a spiral or S shape, which can increase the heating area and improve the heating efficiency; the heat insulation layer and the thermal insulation layer are arranged outside the cast copper body, which can avoid heat dissipation and ensure the heating efficiency. In addition, the present invention optimizes the component ratio of the heating body, improves its electric heat conversion efficiency; optimizes the component ratio of the cast copper body, and improves its thermal conductivity.

[0041] The present invention has been described by the above-mentioned relevant embodiments, however, the above-mentioned embodiments are only examples for implementing the present invention. It must be pointed out that the disclosed embodiments do not limit the scope of the present invention. On the contrary, changes and modifications made without departing from the spirit and scope of the present invention are all within the scope of patent protection of the present invention.

Claims

1. A cast copper heater, characterized in that: The cast copper heater comprises two arc-shaped heating elements arranged opposite to each other, each arc-shaped heating element comprises a heating body, a cast copper body, a thermal insulation layer and a terminal assembly, the heating body is embedded in the interior of the cast copper body, and the heating body extends in a spiral or S shape; the thermal insulation layer is wrapped around the outside of the cast copper body; the terminal assembly passes through the thermal insulation layer, the cast copper body and is connected to the heating body.

2. The cast copper heater according to claim 1, characterized in that: The terminal assembly includes a positive terminal, a negative terminal and a ground terminal; the arc-shaped heating element also includes a sealed terminal box, which is arranged on the outside of the insulation layer, and the terminal assembly is located inside the sealed terminal box.

3. The cast copper heater according to claim 2, characterized in that: A thermocouple is also arranged in the sealed junction box, and the detection end of the thermocouple passes through the insulation layer and then penetrates into the interior of the cast copper body.

4. The cast copper heater according to claim 3, characterized in that: The cast copper heater also includes an instrument box, which is provided with a control module, an input module and an output module, wherein the input module and the output module are electrically connected to the control module respectively; the control module is also electrically connected to the thermocouple, and the output module is also electrically connected to the terminal assembly; the input module is used for the user to input the heating temperature and heating time, and the control module is used to control the voltage output by the output module to the heating body.

5. The cast copper heater according to claim 1, characterized in that: Positioning grooves are respectively arranged on two axial sides of the cast copper body. The cross-sectional shape of the thermal insulation layer is U-shaped. The two axial sides of the thermal insulation layer are respectively located in the positioning grooves.

6. The cast copper heater according to claim 1, characterized in that: A heat insulating layer is also provided between the cast copper body and the heat insulating layer, and the heat insulating layer is made of fireproof heat insulating cotton.

7. The cast copper heater according to claim 6, characterized in that: The ends of the two arc-shaped heating elements are respectively provided with clamping holes, and the clamping hole on each arc-shaped heating element passes through the thermal insulation layer, the heat insulation layer and the cast copper body; the ends of the two arc-shaped heating elements are connected by clamping bolts, and the clamping bolts pass through the clamping holes on the two arc-shaped heating elements in turn, and a gap of 3.0mm to 8.0mm is left between the end faces of the two arc-shaped heating elements.

8. The cast copper heater according to claim 1, characterized in that: The weight fractions of the components in the heating body are: C: 0.01%-0.05%, Si: 0.50%-2.20%, S: ≤0.003%, P: ≤0.02%, Cr: 16.5%-22.8%, Al: 0.2%-0.8%, Ti: 0.01%-0.05%, Zr: 0.15%-0.22%, rare earth elements: 0.01%-0.20%, and the balance is Ni; wherein the rare earth elements include La, Ce, and Y, and the weight ratio of La:Ce:Y is 1:(0.5-1.5):(0.6-1.8).

9. The cast copper heater according to claim 1, characterized in that: The weight fractions of the components in the cast copper body are: Al: 0.8%-2.5%, Mg: 0.8%-2.5%, Mn: 1.2%-2.2%, Si: 0.2%-1.0%, Fe: 0.6%-1.2%, Co: 0.1%-0.5%, Zr: 0.15%-0.20%, Ti: 0.15%-0.20, and the balance is Cu; wherein the weight ratio of Co:Zr:Ti is 1:(0.8-2.5):(0.8-3.0).

10. A method for preparing a cast copper heater according to any one of claims 1 to 9, characterized in that: The preparation method of the cast copper heater comprises the following steps: Step S1: bending the heating body into a desired spiral shape or S shape and fixing it into a casting mold; Step S2: using a centrifugal casting process to obtain an arc-shaped copper casting body, so that the heating body is embedded in the copper casting body; and positioning grooves are processed on both axial sides of the copper casting body; Step S3: coating the outside of the cast copper body with a heat insulation layer; Step S4: wrapping a heat-insulating layer outside the heat-insulating layer to form an arc-shaped heating element; Step S5: Use a clamping bolt to connect the two arc-shaped heating elements, and reserve a gap of 3.0 mm to 8.0 mm between the end surfaces of the two arc-shaped heating elements.

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