Copper casting heater and method of manufacturing the same

Abstract

The application provides a cast copper heater and a preparation method thereof. The cast copper heater comprises two oppositely arranged arc-shaped heating members. Each arc-shaped heating member comprises a heating body, a cast copper body, a heat preservation layer and a terminal post assembly. The heating body is embedded in the inside of the cast copper body and extends in a spiral or S shape. The heat preservation layer is wrapped on the outside of the cast copper body. A heat insulation layer is arranged between the cast copper body and the heat preservation layer. The terminal post assembly penetrates through the heat preservation layer, the cast copper body and is connected with the heating body. The cast copper heater adopts a split structure, is convenient to install and disassemble, and can be applied to more heating scenes of products. The heating body in the inside of the cast copper body extends in a spiral or S shape, can increase the heating area and improve the heating efficiency. The heat insulation layer and the heat preservation layer are arranged on the outside of the cast copper body, can avoid heat dissipation and ensure the heating efficiency.

Description

Technical Field

[0001] This invention relates to the field of heater technology, and in particular to a cast copper heater and its preparation method. Background Technology

[0002] Cast copper heaters use tubular heating elements as the heating body, which are bent and shaped, then centrifugally cast into various shapes using a high-quality metal alloy shell. These shapes include round, flat, right-angled, air-cooled, water-cooled, and other irregular shapes. Currently, most cast copper heaters are of integral structure, which limits their applicability and makes assembly and disassembly cumbersome. Furthermore, the exposed cast copper material in current heaters easily leads to heat dissipation and low heating efficiency. Summary of the Invention

[0003] The purpose of this invention is to address the shortcomings of existing technologies by proposing a cast copper heater and its preparation method, thereby improving the thermal conductivity and insulation performance of the cast copper heater, enhancing its applicability, and increasing its assembly and disassembly efficiency.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] According to a first aspect of the present invention, a cast copper heater is provided, the cast copper heater comprising two opposing arc-shaped heating elements, each arc-shaped heating element comprising a heating element, a cast copper body, a heat insulation layer and a terminal assembly, the heating element being embedded inside the cast copper body and extending in a spiral or S-shape; the heat insulation layer being wrapped around the outside of the cast copper body; the terminal assembly passing through the heat insulation layer and the cast copper body and being connected to the heating element.

[0006] Preferably, the terminal assembly includes a positive terminal, a negative terminal, and a ground terminal; the arc-shaped heating element further includes a sealed junction box, which is located on the outside of the insulation layer, and the terminal assembly is located inside the sealed junction box.

[0007] Preferably, the sealed junction box is further provided with a thermocouple, the detection end of which passes through the insulation layer and then enters the interior of the cast copper body.

[0008] Preferably, the cast copper heater further includes an instrument box, which contains a control module, an input module, and an output module. The input module and the output module are electrically connected to the control module. 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 users to input heating temperature and heating time, and the control module is used to control the voltage output by the output module to the heating element.

[0009] Preferably, the cast copper body has positioning grooves on both axial sides, the insulation layer has a U-shaped cross-section, and the insulation layer has both axial sides located in the positioning grooves.

[0010] Preferably, a heat insulation layer is provided between the cast copper body and the heat insulation layer, and the heat insulation layer is made of fireproof heat insulation cotton.

[0011] Preferably, the ends of the two arc-shaped heating elements are respectively provided with clamping holes, and the clamping holes on each arc-shaped heating element are provided through the heat 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 sequence, and a gap of 3.0mm to 8.0mm is left between the end faces of the two arc-shaped heating elements.

[0012] Preferably, the weight fractions of each component in the heating element are as follows: 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).

[0013] Preferably, the weight fractions of each component in the cast copper body are as follows: 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%, with the balance being Cu; wherein the weight ratio of Co:Zr:Ti is 1:(0.8–2.5):(0.8–3.0).

[0014] According to a second aspect of the present invention, a method for preparing a cast copper heater is provided, the method comprising the following steps:

[0015] Step S1: Bend the heating element into the desired spiral or S-shape and fix it into the casting mold;

[0016] Step S2: An arc-shaped cast bronze body is produced by centrifugal casting process, so that the heating element is embedded in the cast bronze body; and positioning grooves are machined on both sides of the cast bronze body along the axial direction.

[0017] Step S3: Cover the outside of the cast bronze body with a heat insulation layer;

[0018] Step S4: Cover the outside of the insulation layer with a heat insulation layer to form an arc-shaped heating element;

[0019] Step S5: Connect the two arc-shaped heating elements using clamping bolts, and leave a gap of 3.0mm to 8.0mm between the end faces of the two arc-shaped heating elements.

[0020] Compared with the prior art, the beneficial effects of the present invention are as follows: The cast copper heater of the present invention includes two oppositely arranged arc-shaped heating elements, which are more convenient to install and disassemble, and can be applied to more product heating scenarios; the heating elements inside the cast copper body are extended in a spiral or S-shape, which can increase the heating area and improve the heating efficiency; the heat insulation layer is set on the outside of the cast copper body, which can avoid heat dissipation and ensure heating efficiency. Attached Figure Description

[0021] Figure 1 This is a three-dimensional structural schematic diagram of a cast copper heater according to some embodiments of the present invention.

[0022] Figure 2 This is a schematic diagram of the disassembled structure of a cast copper heater according to some embodiments of the present invention.

[0023] Figure 3 This is a schematic diagram of the structure of the cast bronze body in some embodiments of the present invention.

[0024] Figure 4 This is a cross-sectional structural diagram of a cast copper heater according to some embodiments of the present invention.

[0025] Figure 5 This is a schematic diagram of the electrical connections of a cast copper heater according to some embodiments of the present invention.

[0026] In the diagram, 10-heating element, 20-cast copper body, 21-positioning groove, 22-clamping hole, 23-clamping bolt, 30-insulation layer, 40-thermal insulation layer, 50-terminal assembly, 51-positive terminal, 52-negative terminal, 53-ground terminal, 60-sealed junction box, 70-thermocouple, 80-instrument box, 81-control module, 82-input module, 83-output module. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the described embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. It is understood that, without conflict, some technical means of the various embodiments described herein can be substituted for or combined with each other.

[0028] In the description of this invention, the terms "first," "second," etc., are used only to distinguish the described objects and have no sequential or technical meaning. Therefore, objects specified with "first," "second," etc., may explicitly or implicitly include one or more of those objects. Furthermore, the words "one" or "a" do not indicate a quantity limitation, but rather indicate the presence of at least one, while "multiple" indicates at least two.

[0029] In the description of this invention, references to "one embodiment" or "some embodiments" mean that one or more embodiments of the invention include a particular feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "one embodiment," "some embodiments," "other embodiments," "and other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized.

[0030] According to a first aspect of the present invention, a cast copper heater is provided. (Refer to...) Figures 1 to 4 In some embodiments, the cast copper heater includes two opposing arc-shaped heating elements, which are joined together to form a ring-shaped cast copper heater. Each arc-shaped heating element includes a heating element 10, a cast copper body 20, an insulation layer 40, and a terminal assembly 50. The heating element 10 is embedded inside the cast copper body 20 and extends in a spiral or S-shape. The insulation layer 40 wraps around the outside of the cast copper body 20; the terminal assembly 50 passes through the insulation layer 40 and the cast copper body 20 and is connected to the heating element 10.

[0031] In the application, the product to be heated is placed between two arc-shaped heating elements. The power supply is supplied to the heating element 10 through the terminal assembly 50. After the heating element 10 is powered on, it generates heat. The heat is transferred 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 heat preservation role and prevent heat from dissipating to the outside.

[0032] 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 element 10 inside the cast copper body 20 extends in a spiral or S-shape, which can increase the heating area and improve the heating efficiency; the heat insulation layer 40 is provided on the outside of the cast copper body 20 to avoid heat dissipation and ensure heating efficiency.

[0033] It should be noted that the dimensions of the heating element 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 265mm, the outer diameter of the insulation layer 40 is 360mm, and the thickness of the insulation layer 40 is 2mm to 10mm.

[0034] Reference Figure 3 In some embodiments, the terminal assembly 50 includes a positive terminal 51, a negative terminal 52, and a ground terminal 53. The positive terminal 51 is connected to the positive terminal of the power supply, the negative terminal 52 is connected to the negative terminal, and the ground terminal 53 is used for grounding to ensure safety. The arc-shaped heating element also includes a sealed junction box 60, which is located outside the insulation layer 40, with the terminal assembly 50 inside. The sealed junction box 60 can be made of a high-temperature resistant insulating material to protect the terminal assembly 50 and ensure safety.

[0035] Furthermore, a thermocouple 70 is also provided inside the sealed junction box 60. The detection end of the thermocouple 70 passes through the insulation layer 40 and then enters the interior of the cast copper body 20. The thermocouple 70 can be a thermocouple product of the prior art, which is used to detect and provide feedback on the temperature of the cast copper body 20, so as to facilitate precise control of the heating element 10.

[0036] Reference Figure 5 In some embodiments, the cast copper heater further includes an instrument box 80, which contains a control module 81, an input module 82, and an output module 83. The input module 82 and the output module 83 are electrically connected to the control module 81. The control module 81 is also electrically connected to a thermocouple 70, and the output module 83 is also electrically connected to a terminal assembly 50. The input module 82 is used for user input of 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. The control module 81 can 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, and the instrument box 80 can control the working status of the two arc-shaped heating elements separately, which can meet the heating needs of different products and improve applicability.

[0037] Reference Figure 2 and Figure 4 The cast copper body 20 has positioning grooves 21 on both axial sides, and the insulation layer 40 has a U-shaped cross-section, with both axial sides of the insulation layer 40 located within the positioning grooves 21. This not only ensures the installation accuracy of the cast copper heater but also allows the insulation layer 40 to cover three sides of the cast copper body 20, providing better insulation.

[0038] Furthermore, a heat insulation layer 30 is provided between the cast bronze body 20 and the insulation layer 40. The heat insulation layer 30 is made of fireproof and heat-insulating cotton. The heat insulation layer 30 can play a good role in heat insulation, preventing heat in the cast bronze body 20 from dissipating outward and further improving heating efficiency.

[0039] Reference Figure 1 and Figure 2 Each of the two arc-shaped heating elements has a corresponding clamping hole 22 at its end. The clamping hole 22 on each arc-shaped heating element penetrates the 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, which pass sequentially through the clamping holes 22 on the two arc-shaped heating elements. A gap of 3.0mm to 8.0mm is left between the end faces of the two arc-shaped heating elements. This gap provides buffer space to prevent thermal expansion and contraction from affecting the overall performance of the cast copper heater. It should be noted that the number of clamping holes 22 can be reasonably set according to actual needs.

[0040] In some embodiments, the heating element 10 is made of a nickel-chromium electrothermal alloy. The weight fractions of each component in the heating element 10 are as follows: 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). The reasonable proportion of each element can improve the microstructure of the alloy, enhance its physical properties, and improve the electrothermal conversion efficiency after energization.

[0041] Testing revealed that the resistivity of the heating element 10, using the above-mentioned component ratio, is greater than 1.14 μΩ·mm. 2 / m, and it has excellent antioxidant and high temperature resistance properties.

[0042] Further, the weight fractions of each component in the heating element 10 are as follows: 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 balance 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).

[0043] In some embodiments, the cast copper body 20 is made of a copper alloy material with high thermal conductivity. The weight fractions of each component in the cast copper body 20 are as follows: 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%, with the balance being Cu; wherein the weight ratio of Co:Zr:Ti is 1:(0.8–2.5):(0.8–3.0). The reasonable proportion of each element can improve the overall performance of the cast copper body and enhance its thermal conductivity.

[0044] Furthermore, the weight fractions of each component in the cast copper body 20 are as follows: 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%, with the balance being Cu; wherein the weight ratio of Co:Zr:Ti is 1:(1.2–1.8):(1.5–2.0).

[0045] 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 includes the following steps:

[0046] Step S1: Bend the heating element 10 into the desired spiral or S-shape and fix it into the casting mold;

[0047] Step S2: An arc-shaped cast bronze body 20 is obtained by centrifugal casting process, so that the heating element 10 is embedded in the cast bronze body 20; and positioning grooves 21 are machined on both sides of the axial direction of the cast bronze body 20.

[0048] Step S3: Cover the outside of the cast bronze body 20 with a heat insulation layer 30;

[0049] Step S4: Cover the outside of the insulation layer 30 with the heat insulation layer 40 to form an arc-shaped heating element;

[0050] Step S5: Connect the two arc-shaped heating elements using clamping bolts 23, with a gap of 3.0mm to 8.0mm reserved between the end faces of the two arc-shaped heating elements.

[0051] The cast copper heater of this invention adopts a split structure, which is convenient for installation and disassembly and can be applied to heating scenarios for more products. The heating element inside the cast copper body extends in a spiral or S-shape, which can increase the heating area and improve heating efficiency. The heat insulation layer and heat preservation layer are set on the outside of the cast copper body to avoid heat dissipation and ensure heating efficiency. In addition, this invention optimizes the component ratio of the heating element, thereby improving its electrothermal conversion efficiency; and optimizes the component ratio of the cast copper body, thereby improving its thermal conductivity.

[0052] The present invention has been described in the above-described embodiments; however, these embodiments are merely examples for implementing the present invention. It must be noted that the disclosed embodiments do not limit the scope of the present invention. Conversely, any modifications and refinements made without departing from the spirit and scope of the present invention are within the scope of patent protection of the present invention.

Claims

1. A cast copper heater, characterized in that: The cast copper heater includes two oppositely arranged arc-shaped heating elements. Each arc-shaped heating element includes a heating element, a cast copper body, a heat insulation layer, and a terminal assembly. The heating element is embedded inside the cast copper body and extends in a spiral or S-shape. The heat insulation layer wraps around the outside of the cast copper body. The terminal assembly passes through the heat insulation layer and the cast copper body and is connected to the heating element. The weight fractions of each component in the heating element are as follows: 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%, with the balance being 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); the resistivity of the heating element is greater than 1.14 μΩ·mm. 2 / m; The weight fractions of each component in the cast copper body are as follows: 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%, with the balance being Cu; wherein the weight ratio of Co:Zr:Ti is 1:(0.8–2.5):(0.8–3.0).

2. The cast copper heater as described in 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 junction box, which is located on the outside of the insulation layer, and the terminal assembly is located inside the sealed junction box.

3. The cast copper heater as described in claim 2, characterized in that: The sealed junction box is also equipped with a thermocouple, the detection end of which passes through the insulation layer and then enters the interior of the cast copper body.

4. The cast copper heater as described in claim 3, characterized in that: The cast copper heater also includes an instrument box, which contains a control module, an input module, and an output module. The input module and the output module are electrically connected to the control module. 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 users to input heating temperature and heating time, and the control module is used to control the voltage output by the output module to the heating element.

5. The cast copper heater as described in claim 1, characterized in that: The cast bronze body has positioning grooves on both sides of its axial direction, and the heat insulation layer has a U-shaped cross-section, with both sides of the heat insulation layer located in the positioning grooves.

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

7. The cast copper heater as described in claim 6, characterized in that: The ends of the two arc-shaped heating elements are respectively provided with clamping holes, and the clamping holes on each arc-shaped heating element are provided through the heat 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 sequence, and a gap of 3.0mm to 8.0mm is left between the end faces of the two arc-shaped heating elements.

8. A method for preparing a cast copper heater as described in any one of claims 1-7, characterized in that: The method for preparing the cast copper heater includes the following steps: Step S1: Bend the heating element into the desired spiral or S-shape and fix it into the casting mold; Step S2: An arc-shaped cast bronze body is produced by centrifugal casting process, so that the heating element is embedded in the cast bronze body; and positioning grooves are machined on both sides of the cast bronze body along the axial direction. Step S3: Cover the outside of the cast bronze body with a heat insulation layer; Step S4: Cover the outside of the insulation layer with a heat insulation layer to form an arc-shaped heating element; Step S5: Connect the two arc-shaped heating elements using clamping bolts, and leave a gap of 3.0mm to 8.0mm between the end faces of the two arc-shaped heating elements.

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