Method for manufacturing cloisonne electric ceramic stove

Abstract

The invention relates to the technical field of electric ceramic furnace manufacturing, and particularly discloses a method for manufacturing a cloisonne electric ceramic furnace, which comprises the following steps: S1, preparing a metal matrix: selecting a copper alloy plate, and carrying out punch forming on the copper alloy plate to form a furnace body base and a panel required by the electric ceramic furnace; s2, pattern design is carried out, cloisonne pattern design is carried out on the surface of the metal matrix, concave line subareas are formed through carving, and then the concave line subareas are filled with filigree; s3, glaze filling; through the steps of metal matrix preparation and pattern design, high-precision structure forming and artistic expression are achieved, a high-purity red copper plate is selected, precision stamping is adopted, a laser engraving process is combined, a precise carrier structure is provided for glaze filling, heat distribution is more uniform through the high-purity copper matrix and the precision forming process, and the glaze filling quality is improved. The problem of glaze cracking caused by local overheating of a traditional electric ceramic furnace is solved, the stability of a line partition formed through laser engraving is high, it is ensured that the pattern boundary is clear after glaze filling, and the burr problem of a traditional etching process is avoided.

Description

Technical Field

[0001] The present invention belongs to the technical field of electro-ceramic stove manufacturing, and particularly relates to a method for manufacturing a cloisonné electro-ceramic stove. Background Art

[0002] As a modern kitchen appliance, the electro-ceramic stove has been widely welcomed in the market due to its characteristics such as uniform heating, no open flame, safety and environmental protection. With the continuous improvement of consumers' requirements for the quality of life, the design of the electro-ceramic stove has gradually developed from simple functionality to the combination of functionality and artistry. As a traditional craft with a long history, cloisonné has become an important inspiration source for the artistic design of electro-ceramic stoves with its exquisite patterns and unique glaze effects.

[0003] However, the existing methods for manufacturing cloisonné electro-ceramic stoves still have some deficiencies, mainly reflected in the problem of glaze cracking. During the manufacturing process of traditional electro-ceramic stoves, due to the limitations of the purity of the metal matrix material and the forming process, the heat distribution is often uneven, and local overheating occurs frequently. Especially when filling the glaze and performing high-temperature firing, this problem of uneven heat distribution is particularly prominent, which is likely to cause glaze cracking, seriously affecting the aesthetics and durability of the product. In addition, some lead-based glaze materials are used in part of the cloisonné process, which poses a health hazard and has a certain impact on health. Moreover, the firing process has high energy consumption and high defect rate, restricting the large-scale production and market promotion of cloisonné electro-ceramic stoves. Therefore, it is necessary for workers to improve it. Summary of the Invention

[0004] The purpose of the present invention is to provide a method for manufacturing a cloisonné electro-ceramic stove to solve the problems raised in the above background art.

[0005] To achieve the above purpose, the present invention provides the following technical solutions:

[0006] A method for manufacturing a cloisonné electro-ceramic stove includes the following steps:

[0007] S1. Preparation of the metal matrix: Select copper or copper alloy plates and stamp them into the furnace body base and panel required for the electro-ceramic stove.

[0008] S2. Pattern design: Conduct cloisonné pattern design on the surface of the metal matrix, form sunken texture partitions through engraving or etching, and then fill the sunken texture partitions with wire inlay.

[0009] S3. Glaze filling: Fill the pre-prepared enamel glaze into the sunken textures according to the designed partitions, ensuring that the glaze thickness is 0.2 - 0.5 mm higher than the surface of the matrix.

[0010] S4. High-temperature firing: Conduct multiple firings under the condition of 800 - 900 °C to make the glaze melt and solidify, and fill the shrinkage gaps after each firing.

[0011] S5. Surface polishing: Polish the fired surface to make the glaze surface and metal substrate smooth and transitional;

[0012] S6. Functional component assembly: Install the electric ceramic stove heating module, temperature control device and insulation layer in the base to ensure that the panel and heating element fit tightly;

[0013] S7. Coating protection: Coat the exposed metal parts with an anti-oxidation layer and conduct a final cleaning inspection.

[0014] Preferably, in step S3, the enamel glaze is prepared by mixing quartz, feldspar, borax and metal oxide colorant in a mass ratio of 3:2:1:0.5.

[0015] Preferably, in step S4, the firing times are 3 to 5 times, and after each firing, the same color glaze is used for local filling.

[0016] Preferably, in step S6, the heating module is a nickel-chromium alloy heating wire coil, and its surface is covered with a microcrystalline glass insulation layer.

[0017] Preferably, in step S1, the edge of the panel is provided with a decorative metal edging made by cloisonné craft, and the edging is connected to the panel by brazing.

[0018] Preferably, in step S1, the panel surface has a cloisonné glaze pattern, and the glaze surface has a temperature resistance of not less than 300°C.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] (1) Through the steps of metal matrix preparation and pattern design, high-precision structural forming and artistic expression are achieved. High-purity copper plates are selected and precision stamping is adopted, combined with laser engraving technology to provide a precise carrier structure for glaze filling. The high-purity copper matrix and precision forming process make the heat distribution more uniform, solving the problem of glaze cracking caused by local overheating of traditional electric ceramic furnaces. The texture partition formed by laser engraving has high stability, ensuring clear pattern boundaries after glaze filling, avoiding the burr problem of traditional etching process.

[0021] (2) Through the glaze formula and step-by-step firing procedures, a double breakthrough in environmental protection and process efficiency is achieved. Lead-free glaze is used and step-by-step temperature control firing is used to optimize the glaze melting and substrate bonding performance. The lead-free formula is RoHS-certified, which solves the health risks of traditional lead-based glazes. Step-by-step firing reduces the total number of firings from 6 to 8 times to 4 times, and the glaze layer shrinkage rate is stabilized at 12±0.5%, significantly reducing energy consumption and defect rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 The figure is a flow chart of the method of the present invention. Detailed implementation manners

[0023] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0024] Embodiment 1:

[0025] Please refer to Figure 1 As shown, a method for manufacturing a cloisonné electric ceramic stove includes the following steps:

[0026] S1. Preparation of the metal matrix: Select a copper sheet with a thickness of 1.2 mm, and stamp it into the furnace body base and panel of the electric ceramic stove. A hemming and welding area is reserved at the edge of the panel, and a decorative metal hemming is made of copper alloy. The hemming is connected to the panel by silver brazing to ensure firm bonding and not affect the subsequent enamel process.

[0027] S2. Pattern design: Use a laser engraving process to form a traditional cloisonné twining lotus pattern on the surface of the metal matrix. The engraving depth is 0.3 mm, and the width of the pattern partition is 1.5 - 2 mm to ensure the structural stability during glaze filling. Then, fill the recessed pattern partitions with wire inlay.

[0028] S3. Glaze filling: Fill the pre-prepared enamel glaze (by mass ratio: 30 parts of quartz, 20 parts of feldspar, 10 parts of borax, 5 parts of cobalt oxide colorant) into the recessed patterns zone by zone with a special glaze spatula, and control the thickness of the glaze layer to be 0.4 mm, which is higher than the surface of the matrix to avoid depression after firing.

[0029] S4. High-temperature firing: Conduct step-by-step firing in a controllable atmosphere furnace:

[0030] The first firing: Keep the temperature at 850 °C for 5 minutes, check the glaze surface after natural cooling, and refill the same-color glaze in the shrinkage area;

[0031] Repeat the process of refilling and firing 3 times, and finally complete the last firing at 880 °C to ensure that the glaze surface is completely vitrified.

[0032] S5. Surface polishing: Use a diamond grinding head with 400 - 1000 meshes to perform step-by-step polishing on the glaze surface until the glaze surface is flush with the metal matrix and presents a mirror-like luster.

[0033] S6. Assembly of functional components: Install a nickel-chromium alloy heating wire coil (power 1000 - 2000 W) in the base, and its surface is covered with a 4-mm-thick microcrystalline glass heat insulation layer;

[0034] Integrated PID temperature control module, the temperature measurement probe is in close contact with the bottom surface of the panel, and the temperature control accuracy is ±5°C.

[0035] S7. Coating protection: Gold plating treatment (thickness 2μm) is carried out on the metal edging and non-glazed areas, and ultrasonic cleaning is used to remove surface impurities.

[0036] Product characteristics obtained: The enamel pattern on the cloisonné electric ceramic stove panel finally obtained has bright colors. The glaze surface has no cracking or discoloration after 300°C constant temperature test. The heating module can heat up to 200°C within 30 seconds, combining artistry and practicality.

[0037] Material selection: T2 red copper plate (purity ≥99.9%) is selected, with a thickness of 1.2 ± 0.05mm (after 10 stamping forming tests, the matrix deformation rate at this thickness is <0.3%).

[0038] Stamping parameters: Use a 200T hydraulic press, the die temperature is 120°C, the stamping speed is 5mm / s, and the flatness error of the base after forming is ≤0.1mm / m 2 (Detected by a three-dimensional measuring instrument).

[0039] Edge welding: The copper alloy edge (CuZn37) and the matrix are brazed with BAg-1 silver solder (melting point 780°C), and the tensile strength after brazing is ≥210MPa (tested by a universal material testing machine).

[0040] Formula verification:

[0041]

[0042]

[0043] Fired glaze performance:

[0044] Microhardness (HV): 580 ± 20 (load 50g, pressure holding for 15s)

[0045] Coefficient of thermal expansion: 7.2×10 -6 / °C (in the range of 20 - 300°C, measured by a thermal dilatometer).

[0046] Firing curve:

[0047] Stage Temperature (°C) Heating rate (°C / min) Holding time (min) Purpose Pre-firing 300 5 10 Removing organic matter Initial firing 850 8 5 Initial melting of glaze Post-firing 880 10 3 Complete vitrification

[0048] Shrinkage rate control:

[0049] After 5 firings, the volume shrinkage rate of the glaze layer is stable at 12 ± 0.5% (measured by a three-dimensional profilometer), and the amount of glaze replenishment each time is 15% - 18% of the initial glaze amount.

[0050] Functional test data

[0051] Thermal performance:

[0052] Test items Test conditions Results Temperature resistance of glaze surface Constant temperature at 300°C for 240 h No cracks, color difference ΔE < 1.5 (colorimeter) Heating efficiency 220V / 1500W, from room temperature to 200°C 28 ± 1.5 s (monitored by infrared thermal imager) Temperature uniformity Heating area with a diameter of 12 cm Temperature difference between the center and the edge ≤ 8°C

[0053] Mechanical strength:

[0054]

[0055]

[0056] Example 2:

[0057] Please refer to Figure 1 as shown in the figure, a method for making a cloisonné electric ceramic stove includes the following steps:

[0058] Preparation of the metal matrix: Select a T2 copper sheet with a thickness of 1.8 mm (the measured thermal expansion coefficient is 19.2×10-6 / ℃), and precision stamp it into a circular matrix with a diameter of 28 cm. Use a numerical control engraving machine to process a "twining peony" pattern groove with a depth of 0.3 mm, a groove width of 0.8 mm, and a groove spacing of 1.2 mm on the surface of the matrix. The edge of the matrix is hydraulically bent to form a 2-cm-high enclosure, and the bending part is processed with an R1.5 fillet.

[0059] Functional wire embedding integration: Use a hollow oxygen-free copper wire with a wall thickness of 0.12 mm and an inner diameter of 0.4 mm (purity 99.95%), and form it into the design pattern by an automatic wire bending machine. Implant a PT1000 platinum resistance sensor with a diameter of 0.1 mm (response time 0.8 seconds) inside the copper wire, and connect the sensor lead wire to the Bluetooth 5.0 module (transmission distance 12 meters) at the bottom of the matrix with a silver-plated copper wire (diameter 0.08 mm). Fix the wire embedding in the groove with a silver-copper solder (Ag72Cu28, melting point 635℃), and the solder joint spacing is 4 cm.

[0060] Gradient glaze preparation

[0061] Bottom glaze: Borosilicate glass matrix (SiO2 62 wt%, B2O3 18 wt%, Al2O3 5 wt%) + 5 wt% nano-zirconia (particle size 40 nm) + 2 wt% cerium oxide, and the measured thermal expansion coefficient after ball milling and mixing is 9.6×10 -6 / ℃.

[0062] Surface glaze: The same matrix + 10 wt% nano-zirconia + 0.8 wt% cobalt oxide, thermal expansion coefficient 7.4×10 -6 / ℃. The fineness of the glaze is controlled at D50 = 15 μm.

[0063] Layered glaze application process

[0064] Carried out using a precision glaze dotting machine:

[0065] Underlying glazing: Pressure 0.2 MPa, glaze layer thickness 0.18 mm, covering all the roots of the wire inlays.

[0066] Pre-drying: Hot air circulation drying at 125 °C for 12 minutes.

[0067] Surface glazing: Using atomized spraying, glaze layer thickness 0.12 mm.

[0068] Sintering: Heating to 800 °C at a rate of 10 °C / min in a nitrogen-protected atmosphere furnace and holding for 4 minutes.

[0069] Fabrication of the bionic heating layer

[0070] Heating wire: Cr20Ni80 alloy wire (diameter 0.25 mm), arranged in a regular hexagon with a side length of 4 mm.

[0071] PTC element: In the central area, BaTiO3-based ceramic with a Curie temperature of 705 °C (resistivity temperature coefficient 12% / °C) is used, and in the edge area, the same type of material with a Curie temperature of 395 °C is used.

[0072] Power distribution: Density in the central area is 14 turns / cm 2 (Power density 13.5 W / cm 2 ) and in the edge area is 9 turns / cm 2 (Power density 9 W / cm 2 ).

[0073] Integrated assembly: Use Al2O3 ceramic glue with a heat resistance of 1200 °C to bond the heating layer and the matrix.

[0074] Temperature zone control: Set the central area at 700 ± 5 °C and the edge area at 400 ± 5 °C, and achieve precise temperature control through the PID algorithm (Kp = 2.8, Ki = 0.15, Kd = 0.3).

[0075] Product performance testing

[0076] Thermal cycle test: After 100 cycles in the range of 25 °C to 700 °C, there are no visible cracks on the glaze surface (detected by a 50-fold microscope), and the shear strength retention rate at the connection between the wire inlays and the matrix is 98%.

[0077] Temperature control test: The steady-state temperature in the central area is 698 ± 3 °C, and the steady-state temperature in the edge area is 402 ± 4 °C.

[0078] Temperature uniformity: The temperature difference between any two points ≤ 8 °C.

[0079] Wireless transmission performance: Transmission success rate at a distance of 10 m is 99.7%, and the temperature data update frequency is 1 Hz.

[0080] Energy efficiency test: Thermal efficiency is 82% (15% higher than traditional electric ceramic stoves), and it takes 3 minutes and 50 seconds to boil 1L of water.

[0081] Example 3:

[0082] Please refer to Figure 1 as shown, comparison of metal matrix preparation processes

[0083]

[0084]

[0085] Advantages: High-purity copper matrix + precision stamping significantly improve thermal conductivity uniformity (measured temperature difference reduced by 40%); The edge-wrapping structure enhances mechanical strength and avoids glaze edge cracking.

[0086] Comparison of enamel glaze formula and performance:

[0087]

[0088] Advantages: Environmentally friendly and non-toxic, passing the RoHS certification;

[0089] Better thermal matching, porosity < 0.5% after firing (traditional process ≥ 2%).

[0090] Comparison of firing processes:

[0091] Comparison items Example 1 Traditional cloisonné process Firing times 4 times (step temperature control at 850 - 880°C) 6 - 8 times (single temperature 800°C) Glaze shrinkage rate 12 ± 0.5% (controllable glaze replenishment) 18 - 20% (multiple glaze replenishments required) Energy consumption Total energy consumption 8.5 kW·h per piece Total energy consumption 12.3 kW·h per piece

[0092] Advantages: Reduce the number of firings, production efficiency increased by 30%;

[0093] Precise temperature control reduces the glaze defect rate (defect rate in the example < 3% vs 15% in the traditional process).

[0094] Comparison of functional component performance:

[0095]

[0096]

[0097] Advantages: Combination of artistry and functionality, glaze heat resistance reaches industrial grade standards;

[0098] Heating efficiency increased by 38%, significant energy-saving effect.

[0099] Comprehensive performance test comparison:

[0100]

[0101] Example 1 is significantly superior to the prior art in the following aspects through material optimization (high-purity copper matrix + lead-free glaze), process innovation (step firing + precise temperature control), and structural design (integrated edging and wire embedding):

[0102] Artistry: Improved color stability (ΔE < 1.5) and durability of the glaze surface;

[0103] Safety: Completely lead-free, meeting international environmental protection standards;

[0104] Functionality: Core indicators such as heating efficiency and temperature control accuracy reach the leading level in the industry.

[0105] Data support: All comparative tests are carried out in accordance with the standards of GB / T 23148-2022 and IEC 60335-1, with repeatability.

[0106] The standard parts used in the present invention can all be purchased from the market. The special-shaped parts can be customized according to the description in the specification and the drawings. The specific connection methods of each part all adopt conventional means such as bolts, rivets, and welding that are mature in the prior art. The machines, parts, and equipment all adopt conventional models in the prior art. Coupled with the circuit connection adopting the conventional connection method in the prior art, details are not described herein. The content not described in detail in this specification belongs to the prior art well-known to those skilled in the art.

[0107] In the description of the present invention, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of such features. The meaning of "a plurality" is two or more, unless otherwise specifically defined.

[0108] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed", etc. should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or integrated; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the internal communication of two components or the interaction relationship between two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0109] In the present invention, unless otherwise clearly specified or limited, the first feature being "on" or "under" the second feature may mean that the first and second features are in direct contact, or the first and second features are indirectly in contact through an intermediate medium. Moreover, the first feature being "above", "over" and "on top of" the second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the horizontal height of the first feature is higher than that of the second feature. The first feature being "under", "below" and "beneath" the second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the horizontal height of the first feature is lower than that of the second feature.

[0110] In the description of this specification, the description with reference to terms such as "an embodiment", "some embodiments", "exemplifications", "specific exemplifications" or "some exemplifications" etc. means that the specific features, structures, materials or characteristics described in connection with the embodiment or exemplification are included in at least one embodiment or exemplification of the present invention. In this specification, the schematic representations of the above terms do not have to be directed to the same embodiment or exemplification. Moreover, the specific features, structures, materials or characteristics described can be combined in a suitable manner in any one or more embodiments or exemplifications. In addition, without contradiction, those skilled in the art can combine and combine the different embodiments or exemplifications described in this specification and the features of different embodiments or exemplifications.

[0111] In the attached drawings of the disclosed embodiments of the present invention, only the structures related to the disclosed embodiments are involved. Other structures can refer to the general design. Without conflict, the same embodiment and different embodiments of the present invention can be combined with each other.

[0112] Although the present invention has been described in detail with reference to the foregoing embodiments, for those skilled in the art, they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements on some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A method for making a cloisonné electric ceramic furnace, characterized in that: The following steps are involved: S1. Preparation of metal substrate: copper alloy plates are selected and stamped into the furnace base and panel required for the electric ceramic stove; S2. Pattern design: Design cloisonné patterns on the surface of the metal substrate, form concave pattern partitions by engraving, and then fill the concave pattern partitions with filigree; S3, glaze filling: fill the pre-mixed enamel glaze into the concave lines according to the designed partitions, ensuring that the glaze thickness is 0.2-0.5mm higher than the substrate surface; S4, high temperature firing: multiple firings are carried out at 800-900℃ to melt and solidify the glaze, and the shrinkage gaps are filled after each firing; S5. Surface polishing: Polish the fired surface to make the glaze surface and metal substrate smooth and transitional; S6. Functional component assembly: Install the electric ceramic stove heating module, temperature control device and insulation layer in the base to ensure that the panel and heating element fit tightly; S7. Coating protection: Coat the exposed metal parts with an anti-oxidation layer and conduct a final cleaning inspection.

2. The method for making a cloisonné electric ceramic furnace according to claim 1, characterized in that: In step S3, the enamel glaze is prepared by mixing quartz, feldspar, borax and metal oxide colorant in a mass ratio of 3:2:1:0.

5.

3. The method for making a cloisonné electric ceramic furnace according to claim 1, characterized in that: In step S4, the firing times are 3 to 5 times, and after each firing, the same color glaze is used for local filling.

4. The method for making a cloisonné electric ceramic furnace according to claim 1, characterized in that: In step S6, the heating module is a nickel-chromium alloy heating wire coil, and its surface is covered with a microcrystalline glass insulation layer.

5. The method for making a cloisonné electric ceramic furnace according to claim 1, characterized in that: In step S1, a decorative metal edging made by cloisonné craft is provided on the edge of the panel, and the edging is connected to the panel by brazing.

6. The method for making a cloisonné electric ceramic furnace according to claim 1, characterized in that: In step S1, a cloisonné glaze pattern is formed on the surface of the panel, and the glaze surface has a temperature resistance of not less than 300°C.

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