Heater with high electric energy conversion efficiency

Abstract

The utility model discloses a heater with high electric energy conversion efficiency. The heater comprises an electric heating wire assembly, an end high-temperature-resistant heat insulation arc block and a high-temperature heat insulation layer. The heating device has the advantages that each spiral heating wire is exposed in the heating cavity with the ceramic tube as a sleeving carrier, heat in the middles of the spiral heating wires circulates into the heating cavity through a hole channel in the ceramic tube capable of conducting heat, and the structural form that the heating wires are installed and fixed through a traditional groove placing structure is changed; hindering of the installation structure to heat radiation is avoided, the electric energy conversion efficiency is greatly improved, and energy conservation and environmental protection are achieved; the light high-temperature heat insulation layer with low heat specific volume is adopted, so that the heat storage is low, the cooling rate is improved, and more products can be produced in unit time; a high-temperature thermal protection group cooling structure can be formed at the inlet and outlet port of the heater, so that low-temperature air in an external space is prevented from entering a workpiece heating cavity, and the stability of the temperature in the workpiece heating cavity is ensured; the high-temperature-resistant strength of the installation supporting structure is enhanced, burning loss is not prone to occurring, and the service life of the furnace body is long

Description

Technical Field

[0001] The utility model relates to the field of heaters, in particular to a heater with high electric energy conversion efficiency. Background Art

[0002] Traditional diffusion filament furnaces have the following drawbacks: 1. The heating filaments are embedded in insulating refractory materials, resulting in low radiative heat transfer efficiency. Most of the heat is transferred to the refractory materials through heat conduction, resulting in high heat storage in the refractory materials. This wastes more electricity for heat storage in the furnace, resulting in low utilization of the heat generated by the electricity and high energy consumption. 2. External low-temperature air easily enters the heating chamber through the workpiece inlet and outlet ports at both ends of the furnace, causing significant temperature fluctuations and failing to effectively maintain temperature stability within the heating chamber. 3. Mainstream furnace manufacturers on the market choose to overload the heating filaments for long periods of time, resulting in generally lower-than-expected furnace lifespans. 4. High temperatures can easily exacerbate damage to the intercrystalline connection structure within the corresponding insulating refractory materials, resulting in poor durability. Therefore, a heater with high electrical energy conversion efficiency is proposed to address the above issues. Utility Model Content

[0003] The purpose of the present invention is to provide a heater with high electric energy conversion efficiency in order to solve the above problems.

[0004] The utility model achieves the above-mentioned purpose through the following technical solutions: a heater with high electric energy conversion efficiency, comprising an electric heating wire assembly, a molded sheet metal back plate, a front molded sheet metal cover, a middle molded sheet metal cover, a rear molded sheet metal cover, a high-temperature resistant heat-insulating arc block at the end, a power wiring module and a high-temperature heat-insulating layer, the front molded sheet metal cover and the rear molded sheet metal cover connected at the front and rear ends of the middle molded sheet metal cover form a tubular metal shell with the molded sheet metal back plate, and the tubular metal shell is fixedly connected to the corresponding distributed splicing ring keels through distributed keel positioning connectors, the high-temperature heat-insulating layer is wrapped on the distributed splicing ring keels, and positioning holes are distributed on the annular surface of the splicing ring keels;

[0005] The electric heating wire assembly specifically includes a workpiece heating section and a high-temperature heat protection section located at the front and rear ends of the workpiece heating section. Each group of first spiral heating wires located in the workpiece heating section is annularly distributed between two spliced ​​ring keels of one group. Each group of second spiral heating wires located in the high-temperature heat protection section is annularly distributed between two spliced ​​ring keels of another group. Each of the first spiral heating wires and each of the second spiral heating wires are respectively sleeved on a first ceramic tube and a second ceramic tube.

[0006] The spliced ​​ring keel is composed of eight segmented ceramic blocks connected end to end in sequence, and each segmented ceramic block is provided with positioning holes. The first spiral heating wire and the second spiral heating wire are both close to the inner wall of the high-temperature insulation layer.

[0007] Preferably, the diameter of the first spiral heating wire and the diameter of the second spiral heating wire are calculated by a wire diameter calculation formula to be 2.5 mm and 3 mm respectively.

[0008] Preferably, nine positioning holes are provided on the segmented ceramic block located within the high-temperature heat protection section, and eight positioning holes are provided on the segmented ceramic block located within the workpiece heating section.

[0009] Preferably, the distribution density of the second spiral heating wires at the high-temperature thermal protection section is greater than the distribution density of the first spiral heating wires at the workpiece heating section, each group of second spiral heating wires is divided into four equal parts, and the eighteen second spiral heating wires in each part are electrically connected in series end to end, and each group of first spiral heating wires is divided into four equal parts, and the sixteen first spiral heating wires in each part are electrically connected in series end to end.

[0010] Preferably, both end ports of the tubular metal shell are sealed with end high-temperature resistant insulation arc blocks, and at least three equal parts of the end high-temperature resistant insulation arc blocks are connected end to end to form a ring structure, and an expansion joint is formed between each two adjacent end high-temperature resistant insulation arc blocks, and the end high-temperature resistant insulation arc blocks are polycrystalline mullite and aluminum silicate refractory materials.

[0011] Preferably, both ends of the middle molded sheet metal cover are fixedly connected to the end of the front molded sheet metal cover and the end of the rear molded sheet metal cover respectively through semi-annular connecting pieces.

[0012] Preferably, the surface of the middle molded sheet metal cover, the surface of the front molded sheet metal cover and the surface of the rear molded sheet metal cover are respectively provided with corresponding power wiring modules and thermocouple fixing modules.

[0013] Preferably, the keel positioning connector includes a U-shaped ceramic block and a high-strength double-headed screw. The U-shaped ceramic block has a built-in spliced ​​ring keel part, and the screw hole located in the middle of the surface of the U-shaped ceramic block is threadedly fixed to one end of the double-headed screw, and the other end of the double-headed screw is fixedly connected to the corresponding part of the tubular metal shell.

[0014] Preferably, the ring keel is not limited to being made of ceramic, but can also be made of silicon carbide and high-temperature alloy steel.

[0015] The beneficial effects of the utility model are:

[0016] 1. The workpiece is heated by using 64 groups of electric heating wire heating structures, and each spiral electric heating wire is exposed in the heating chamber with a ceramic tube as a set carrier. At the same time, the heat in the middle of the spiral electric heating wire is circulated into the heating chamber by the internal channel of the heat-conducting ceramic tube, and a lightweight high-temperature thermal insulation layer with low thermal capacity is used. The structural form of the fixed heating wire installed in the traditional slot structure is changed, which avoids the obstruction of the installation structure to heat radiation, greatly improves the power conversion efficiency, saves energy and is environmentally friendly, and at the same time the cooling rate is increased, and more products can be produced per unit time; when the inlet and outlet ports of the heater are heated in a state higher than the heating temperature of the workpiece by combining the 72 groups of electric heating wire heating structures, it is conducive to forming a high-temperature heat protection group cooling structure, effectively preventing low-temperature air from the external space from entering the workpiece heating chamber, and ensuring the stability of the temperature inside the workpiece heating chamber;

[0017] Second, the use of a structural support method that is not limited to a group of four segmented ceramic blocks connected end to end to form a ring keel, combined with the positioning holes set on the segmented ceramic blocks, enhances the high temperature resistance of the installation support structure and is not easy to burn;

[0018] 3. The diameters of the two heating wires are calculated to be 2.5mm and 3mm respectively using the wire diameter calculation formula, so as to obtain heating wires that meet the heating surface load. This solves the problem that the furnace life is generally lower than expected due to the heating wire being overloaded for a long time, thereby extending the furnace life. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0020] Figure 1 It is a three-dimensional diagram of the overall structure of the utility model;

[0021] Figure 2 It is a partial exploded view of the overall structure of the utility model;

[0022] Figure 3 This is a schematic diagram of the structure of the electric heating wire assembly of the utility model;

[0023] Figure 4 This is a schematic diagram of the high-temperature thermal protection section connection structure of the utility model;

[0024] Figure 5 This is a schematic diagram of the connection structure of the workpiece heating section of the utility model;

[0025] Figure 6It is a partial enlarged view of the overall internal structure of the utility model;

[0026] Figure 7 This is another composition form of the ring keel of the utility model;

[0027] Figure 8 for Figure 2 Enlarged view of point A in the middle.

[0028] In the figure: 1. Electric heating wire assembly; 110. Spliced ​​ring keel; 111. Segmented ceramic block; 112. Positioning hole; 120. Workpiece heating section; 121. First ceramic tube; 122. First spiral heating wire; 123. First ceramic gear ring frame; 130. High-temperature thermal protection section; 131. Second ceramic tube; 132. Second spiral heating wire; 140. Keel positioning connector; 2. Molded sheet metal back plate; 210. Semi-annular connector; 3. Front molded sheet metal cover; 4. Middle molded sheet metal cover; 5. Rear molded sheet metal cover; 6. High-temperature resistant insulation arc block at the end; 610. Expansion joint; 7. Power connection module; 8. High-temperature insulation layer; 9. Thermocouple fixing module. DETAILED DESCRIPTION

[0029] In order to make the purpose, features, and advantages of the present invention more obvious and easy to understand, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described below are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0030] The technical solution of the present invention will be further described below with reference to the accompanying drawings and through specific implementation methods.

[0031] In the description of the present invention, it should be understood that the terms "upper", "lower", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0032] See also Figure 1-8As shown, a heater with high electric energy conversion efficiency includes an electric heating wire assembly 1, a molded sheet metal back plate 2, a front molded sheet metal cover 3, a middle molded sheet metal cover 4, a rear molded sheet metal cover 5, an end high-temperature resistant heat-insulating arc block 6, a power connection module 7 and a high-temperature heat-insulating layer 8, the front molded sheet metal cover 3 and the rear molded sheet metal cover 5 connected at the front and rear ends of the middle molded sheet metal cover 4 form a tubular metal shell with the molded sheet metal back plate 2, and the tubular metal shell is fixedly connected to the corresponding distributed splicing ring keels 110 through distributed keel positioning connectors 140, and positioning holes 112 are distributed on the annular surface of the splicing ring keel 110, and the splicing ring keel 110 is composed of eight segmented ceramic blocks 111 connected end to end in sequence, and each of the segmented ceramic blocks 111 is distributed with a positioning hole 112;

[0033] Combine Figure 4 and Figure 5 As shown, the structural support method of the segmented ceramic blocks 111 connected end to end to form a spliced ​​ring keel 110 is not limited to a group of eight, and combined with the positioning holes 112 set on the segmented ceramic blocks 111, the high temperature resistance of the installation support structure is enhanced, and it is not easy to burn, and the replacement and assembly are convenient and efficient.

[0034] like Figure 4 and Figure 5 As shown, the electric heating wire assembly 1 specifically includes a workpiece heating section 120 and a high-temperature heat protection section 130 located at the front and rear ends of the workpiece heating section 120, each group of first spiral heating wires 122 located in the workpiece heating section 120 is annularly distributed between the two splicing ring keels 110 of one group, and each group of second spiral heating wires 132 located in the high-temperature heat protection section 130 is annularly distributed between the two splicing ring keels 110 of the other group, each of the first spiral heating wires 122 and each of the second spiral heating wires 132 are respectively sleeved on the first ceramic tube 121 and the second ceramic tube 131, and the first spiral heating wire 122 and the second spiral heating wire 132 are close to each other between the inner wall of the high-temperature thermal insulation layer 8, nine positioning holes 112 are provided on the segmented ceramic block 111 located within the range of the high-temperature heat protection section 130, and eight positioning holes 112 are provided on the segmented ceramic block 111 located within the range of the workpiece heating section 120, and the high-temperature thermal insulation layer 8 is wrapped on the distributed splicing ring keels 110;

[0035] By installing the first ceramic tubes 121 each containing the first spiral heating wire 122 on the positioning holes 112 on the four groups of segmented ceramic blocks 111, a ring-shaped sixty-four heating wire heating structure is formed. In combination with the second ceramic tubes 131 each containing the second spiral heating wire 132 being installed on the positioning holes 112 on the corresponding four groups of segmented ceramic blocks 111, a ring-shaped seventy-two heating wire heating structure is formed.

[0036] Sixty-four groups of heating wire heating structures are used to heat the workpiece, and each spiral heating wire is exposed in the heating chamber with a ceramic tube as a sheath carrier. At the same time, the heat in the middle of the spiral heating wire is circulated to the heating chamber through the internal channel of the heat-conducting ceramic tube, and combined with a lightweight high-temperature insulation layer 8 with low thermal capacity, the structural form of the traditional slot structure for installing and fixing the heating wire is changed, which avoids the obstruction of the installation structure to heat radiation, greatly improves the high-energy conversion efficiency, and saves energy and is environmentally friendly; when the inlet and outlet ports of the heater are heated in combination with seventy-two groups of heating wire heating structures to a state higher than the heating temperature of the workpiece, it is conducive to forming a high-temperature heat protection group cooling structure, which effectively prevents low-temperature air from the external space from entering the workpiece heating chamber, and ensures the stability of the temperature inside the workpiece heating chamber.

[0037] The diameters of the first spiral heating wire 122 and the second spiral heating wire 132 are calculated to be 2.5 mm and 3 mm respectively through the wire diameter calculation formula, so as to obtain heating wires that meet the heating surface load, solve the problem that the life of the furnace body is generally lower than expected due to the heating wire being overloaded for a long time, and extend the life of the furnace body.

[0038] Combine Figure 4 and Figure 5 As shown, the distribution density of the second spiral heating wires 132 at the high-temperature heat protection section 130 is greater than the distribution density of the first spiral heating wires 122 at the workpiece heating section 120, each group of second spiral heating wires 132 is divided into four equal parts, and the eighteen second spiral heating wires 132 in each equal part are electrically connected in series end to end, and each group of first spiral heating wires 122 is divided into four equal parts, and the sixteen first spiral heating wires 122 in each equal part are electrically connected in series end to end.

[0039] As 2 and Figure 8 As shown, both end ports of the tubular metal shell are sealed with end high-temperature resistant heat-insulating arc blocks 6, and at least three equal parts of the end high-temperature resistant heat-insulating arc blocks 6 are connected end to end to form a ring structure, and an expansion joint 610 is formed between each two adjacent end high-temperature resistant heat-insulating arc blocks 6. The end high-temperature resistant heat-insulating arc blocks 6 are made of polycrystalline mullite and aluminum silicate refractory materials. The expansion joint 610 can cope with the influence of thermal expansion and contraction on the end high-temperature resistant heat-insulating arc blocks 6, and has a long service life.

[0040] like Figure 1 and Figure 2 As shown, both ends of the middle molded sheet metal cover 4 are fixedly connected to the ends of the front molded sheet metal cover 3 and the ends of the rear molded sheet metal cover 5 through semi-annular connecting parts 210, and the surfaces of the middle molded sheet metal cover 4, the front molded sheet metal cover 3 and the rear molded sheet metal cover 5 are respectively provided with corresponding power wiring modules 7 and thermocouple fixing modules 9.

[0041] Combine Figure 4 、 Figure 5 and Figure 6 As shown, the keel positioning connector 140 includes a U-shaped ceramic block and a high-strength double-headed screw. The U-shaped ceramic block is clamped with a portion of the spliced ​​ring keel 110, and the screw hole located in the middle of the surface of the U-shaped ceramic block is threadedly fixed to one end of the double-headed screw, and the other end of the double-headed screw is fixedly connected to the corresponding part of the tubular metal shell, playing a role in positioning connection.

[0042] The ring keel 110 is not limited to being made of ceramic, but may also be made of silicon carbide and high-temperature alloy steel.

[0043] Working Principle: The structural support method of the ring keel 110 is formed by connecting the segmented ceramic blocks 111 end to end, which is not limited to a group of four. In combination with the positioning holes 112 provided on the segmented ceramic blocks 111, the high-temperature resistance of the installation support structure is enhanced, and it is not easy to burn. Replacement and assembly are convenient and efficient.

[0044] By installing the first ceramic tubes 121 each containing the first spiral heating wire 122 on the positioning holes 112 on the four groups of segmented ceramic blocks 111, a ring-shaped sixty-four heating wire heating structure is formed. In combination with the second ceramic tubes 131 each containing the second spiral heating wire 132 being installed on the positioning holes 112 on the corresponding four groups of segmented ceramic blocks 111, a ring-shaped seventy-two heating wire heating structure is formed.

[0045] Sixty-four groups of electric heating wire heating structures are used to heat the workpiece, and each spiral heating wire is exposed in the heating chamber with a ceramic tube as a sheath carrier. At the same time, the heat in the middle of the spiral heating wire is circulated to the heating chamber by the internal channel of the heat-conducting ceramic tube, and a lightweight high-temperature thermal insulation layer 8 with low thermal capacity is used. The structural form of the traditional slot-type structure for installing and fixing the heating wire is changed, thereby avoiding the obstruction of the installation structure to heat radiation, greatly improving the high-energy conversion efficiency, and saving energy and being environmentally friendly. When the inlet and outlet ports of the heater are heated in a state higher than the heating temperature of the workpiece by combining the seventy-two groups of electric heating wire heating structures, it is conducive to forming a high-temperature heat protection group cooling structure, effectively preventing low-temperature air from the external space from entering the workpiece heating chamber, and ensuring the stability of the temperature inside the workpiece heating chamber.

[0046] The diameters of the first spiral heating wire 122 and the second spiral heating wire 132 are calculated to be 2.5 mm and 3 mm respectively through the wire diameter calculation formula, so as to obtain heating wires that meet the heating surface load, solve the problem that the life of the furnace body is generally lower than expected due to the heating wire being overloaded for a long time, and extend the life of the furnace body.

[0047] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the present invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the present invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the present invention is defined by the appended claims, not the foregoing description, and it is intended that all variations within the meaning and scope of the appended claims be encompassed within the present invention. Any reference sign in a claim should not be construed as limiting the claim to which it relates.

[0048] As described above, the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A heater with high power conversion efficiency, characterized by: The invention comprises an electric heating wire assembly (1), a molded sheet metal back plate (2), a front molded sheet metal cover (3), a middle molded sheet metal cover (4), a rear molded sheet metal cover (5), an end high-temperature resistant heat-insulating arc block (6), a power connection module (7) and a high-temperature heat-insulating layer (8), wherein the front molded sheet metal cover (3) and the rear molded sheet metal cover (5) connected at the front and rear ends of the middle molded sheet metal cover (4) form a tubular metal shell with the molded sheet metal back plate (2), and the tubular metal shell is fixedly connected to the corresponding distributed splicing ring keels (110) through the distributed keel positioning connectors (140), the high-temperature heat-insulating layer (8) is wrapped on the distributed splicing ring keels (110), and positioning holes (112) are distributed on the annular surface of the splicing ring keels (110); The electric heating wire assembly (1) specifically includes a workpiece heating section (120) and a high-temperature heat protection section (130) located at the front and rear ends of the workpiece heating section (120); each group of first spiral heating wires (122) located in the workpiece heating section (120) is annularly distributed between two spliced ​​ring keels (110) of one group; each group of second spiral heating wires (132) located in the high-temperature heat protection section (130) is annularly distributed between two spliced ​​ring keels (110) of another group; each of the first spiral heating wires (122) and each of the second spiral heating wires (132) are respectively sleeved on the first ceramic tube (121) and the second ceramic tube (131); The spliced ​​ring keel (110) is formed by connecting eight segmented ceramic blocks (111) end to end in sequence, and each segmented ceramic block (111) is provided with a positioning hole (112), and the first spiral heating wire (122) and the second spiral heating wire (132) are both close to the inner wall of the high-temperature insulation layer (8).

2. The heater with high power conversion efficiency according to claim 1, characterized in that: The diameter size of the first spiral heating wire (122) and the diameter size of the second spiral heating wire (132) are calculated by a wire diameter calculation formula to be 2.5 mm and 3 mm respectively.

3. The heater with high power conversion efficiency according to claim 1, characterized in that: Nine positioning holes (112) are provided on the segmented ceramic block (111) within the high-temperature heat protection section (130), and eight positioning holes (112) are provided on the segmented ceramic block (111) within the workpiece heating section (120).

4. The heater with high power conversion efficiency according to claim 1, characterized in that: The distribution density of the second spiral heating wires (132) at the high-temperature heat protection section (130) is greater than the distribution density of the first spiral heating wires (122) at the workpiece heating section (120), each group of second spiral heating wires (132) is divided into four equal parts, and the eighteen second spiral heating wires (132) in each equal part are electrically connected in series end to end, and each group of first spiral heating wires (122) is divided into four equal parts, and the sixteen first spiral heating wires (122) in each equal part are electrically connected in series end to end.

5. The heater with high power conversion efficiency according to claim 1, characterized in that: Both end ports of the tubular metal shell are sealed with end high-temperature resistant heat-insulating arc blocks (6), and at least three equal parts of the end high-temperature resistant heat-insulating arc blocks (6) are connected end to end to form a ring structure, and an expansion joint (610) is formed between each two adjacent end high-temperature resistant heat-insulating arc blocks (6). The end high-temperature resistant heat-insulating arc blocks (6) are made of polycrystalline mullite and aluminum silicate refractory materials.

6. The heater with high power conversion efficiency according to claim 1, characterized in that: Both ends of the middle formed sheet metal cover (4) are fixedly connected to the end of the front formed sheet metal cover (3) and the end of the rear formed sheet metal cover (5) respectively through a semi-annular connecting piece (210).

7. The heater with high power conversion efficiency according to claim 1, characterized in that: The surface of the middle formed sheet metal cover (4), the surface of the front formed sheet metal cover (3), and the surface of the rear formed sheet metal cover (5) are respectively provided with corresponding power connection modules (7) and thermocouple fixing modules (9).

8. The heater with high power conversion efficiency according to claim 1, characterized in that: The keel positioning connector (140) comprises a U-shaped ceramic block and a high-strength double-headed screw, wherein the U-shaped ceramic block has a built-in ring keel (110) portion, and a screw hole located in the middle of the surface of the U-shaped ceramic block and one end of the double-headed screw are threadedly fixed to each other, and the other end of the double-headed screw is fixedly connected to the corresponding part of the tubular metal shell.

9. The heater with high power conversion efficiency according to claim 1, characterized in that: The material of the spliced ​​ring keel (110) is selected from ceramics, silicon carbide or high-temperature alloy steel.

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