A stacked inductor for inductive brazing

Abstract

This invention discloses a stacking inductor for induction brazing, comprising a hollow copper tube, a fiberglass sleeve, a PTFE insulating sheet, and an inductor base. The hollow copper tube is the core component, fixed end-to-end to the base and wound in the middle to form a ring-shaped heating port with three inner and two outer sections, used to transmit high-frequency current and create a uniform magnetic field. The fiberglass sleeve and PTFE insulating sheet provide electrical insulation and high-temperature resistance. The symmetrical structure of the base ensures stability. This invention achieves rapid workpiece heating through electromagnetic induction, offering advantages such as fast heating, high precision, energy saving, environmental friendliness, and safety and reliability. It is suitable for precision welding processes in the refrigeration industry and related manufacturing fields.

Description

Technical Field

[0001] This utility model relates to the technical field of high-frequency welding equipment, and in particular to a stacking inductor for induction brazing. Background Technology

[0002] In the refrigeration industry and related manufacturing sectors, welding processes play a crucial role in product quality and production efficiency. Traditional brazing, especially techniques using oxy-acetylene flame welding, has long been widely used for connecting components such as distributors and single-pipe fittings. However, this traditional process has several drawbacks. The wide heating range and large heat-affected zone of the flame can easily lead to overheating and deformation of the base material, negatively impacting the weld quality. Furthermore, at high temperatures, the workpiece surface is prone to oxidation, potentially leaving corrosive impurities that further affect the durability and reliability of the welded area. Traditional brazing processes have low energy conversion efficiency, resulting in high long-term operating costs. They also rely on manual operation, making it difficult to guarantee temperature uniformity and leading to unstable weld quality. More seriously, open-flame operations carry the risk of combustion and explosion, and the exhaust gases produced not only threaten human health but also pollute the environment. Therefore, developing an efficient, safe, and environmentally friendly welding technology has become an urgent technical challenge. Meanwhile, while existing high-frequency induction brazing technology overcomes some of the shortcomings of traditional processes to a certain extent, it typically requires an additional magnetic conductor to constrain the magnetic field in order to achieve high-quality welding. This increases the complexity and cost of the equipment, limiting its widespread application. Therefore, designing an induction brazing device that can achieve efficient and high-precision welding without the need for an additional magnetic conductor has become an important research direction in the current technological field. Utility Model Content

[0003] The purpose of this invention is to provide a stacking sensor for induction brazing, so as to overcome the shortcomings of the prior art.

[0004] To achieve the above objectives, this utility model provides the following technical solution: A stacked inductor for induction brazing includes a hollow copper tube fitted with a fiberglass sleeve, reinforcing ribs, a PTFE insulating sheet, and an inductor base, wherein: The hollow copper tube is the core component of the sensor, with its two ends fixedly connected to the sensor base. A ring-shaped heating port is wound around its center; the winding method involves two radial layers, with the outer ring having two turns and the inner ring having three turns. Furthermore, the hollow copper tube is used to transmit current, creating a high-frequency magnetic field at the heating port to achieve rapid heating of the workpiece to be welded. In addition, the encased fiberglass sleeve provides excellent electrical insulation, allowing current to flow effectively throughout the hollow copper tube.

[0005] Specifically, the sensor base has a symmetrical structure for mounting and securing the coaxial transformer and hollow copper tube. The sensor base not only provides stable support but also ensures the stability of the sensor during operation through its symmetrical design, guaranteeing the stability of the magnetic field distribution during welding.

[0006] Furthermore, the PTFE insulating sheet is fixedly disposed in the gap between the hollow copper tube and the sensor base to isolate the two ends of the hollow copper tube and prevent direct conduction. The PTFE insulating sheet ensures normal current flow within the sensor while avoiding safety hazards caused by short circuits, preventing short circuits and electrical sparks. The PTFE material is chosen based on its excellent insulation properties and high-temperature resistance, meeting the stringent requirements of high-frequency welding environments.

[0007] In particular, induction welding generates high temperatures. In this invention, the hollow copper tube is fitted with a fiberglass sleeve, which provides good insulation. The finished inductor can also circulate internal cooling water, increasing its service life.

[0008] The working principle of this invention is as follows: When the coaxial transformer is started, the hollow copper tube delivers current in one direction, and a uniform magnetic field with the same direction is formed at the heating port. Based on the "eddy current effect" of electromagnetic induction, the workpiece to be welded, placed in the center of the heating port, will rapidly heat up under the action of the magnetic field, thereby achieving efficient and high-quality welding.

[0009] Compared with the prior art, the beneficial effects of this utility model are as follows: 1. Fast heating speed: Utilizing direct electromagnetic induction heating, the temperature rise rate can reach the second level, making it 3-5 times more efficient than traditional flame brazing. This improved heating speed is attributed to the radial winding method of the hollow copper tube and the centralized transmission design of high-frequency current.

[0010] 2. High welding precision: Narrow heat-affected zone and small deformation, suitable for welding precision workpieces. The improved welding precision stems from the uniformity of the high-frequency magnetic field distribution at the heating port and the optimized design of the number of turns in the hollow copper tube.

[0011] 3. Energy saving and environmental protection: High electrical energy conversion efficiency, with energy consumption costs only 1 / 3 of those of flame brazing; no open flame, no exhaust gas emissions, and workshop pollution reduced by 90%. The realization of the energy saving and environmental protection effects depends on the high-efficiency energy transmission characteristics of the hollow copper tube and the design of the cooling system.

[0012] 4. High safety: No open flame is required, eliminating the risk of combustion and explosion, and avoiding the harm to human health and the environment caused by combustion exhaust gases. This enhanced safety is attributed to the application of PTFE insulation sheets and the stable support design of the sensor base.

[0013] 5. Easy integration: It can be linked with robots to achieve automated mass production and adapt to the needs of modern production. This easy integration feature stems from the compact overall structure of the sensor and the standardized interface design.

[0014] In summary, this invention, through its unique structural design and material selection, solves many problems inherent in traditional brazing processes, including slow heating, large heat-affected zone, high energy consumption, and numerous safety hazards. The specific implementation of the technical solution includes a radially wound structure of hollow copper tubes, an electrical isolation design using PTFE insulation sheets, and optimized symmetrical structure of the sensor base. This invention has broad application prospects, particularly suitable for precision welding processes in the refrigeration industry and related manufacturing fields. Attached Figure Description

[0015] Figure 1 This is the front view of the present utility model; Figure 2 This is a three-dimensional structural diagram of the present invention; Figure 3 This is a side view of the present invention.

[0016] Attached image annotations: 1. Hollow copper tube; 2. PTFE insulation sheet; 3. Sensor base; 4. Heating port. Detailed Implementation

[0017] This invention provides a stacking inductor for induction brazing, whose structural design and material selection have been optimized to achieve efficient and high-quality welding results. The specific embodiments of this invention are described in detail below with reference to the accompanying drawings.

[0018] like Figures 1 to 3 As shown, the core component of this invention is a hollow copper tube 1, whose two ends are fixedly connected to the sensor base 3, and a ring-shaped heating port 4 is wound in the middle. The radial winding of the hollow copper tube 1 adopts a three-inner-two-outer-turns distribution, that is, the inner circle has three turns and the outer circle has two turns. This unique winding method, verified by experiments and theoretical calculations, ensures that the strength and uniformity of the high-frequency magnetic field reach the optimal state. The hollow copper tube 1 is made of high-purity copper, which has excellent electrical and thermal conductivity, effectively reducing resistance loss and improving energy transmission efficiency. In addition, the hollow part of the hollow copper tube 1 is designed to carry the circulating flow of cooling water or other cooling media. The cooling media is introduced through an external pumping system and forms a stable flow path inside the hollow copper tube 1, thereby quickly removing the heat generated during the operation of the sensor and effectively extending the service life of the sensor.

[0019] The hollow copper tube 1 is externally fitted with a fiberglass sleeve, which is woven from high-strength fiberglass and possesses excellent electrical insulation and high-temperature resistance. The thickness and density of the fiberglass sleeve are precisely calculated to meet the electrical insulation requirements of high-frequency welding environments while also ensuring good heat dissipation. The fiberglass sleeve fits tightly against the outer surface of the hollow copper tube 1 to prevent insulation failure due to loosening or displacement. The hollow copper tube 1 and the fiberglass sleeve are fixed together with a special adhesive to ensure a stable connection during long-term use.

[0020] The PTFE insulating sheet 2 is fixedly installed in the gap between the hollow copper tube 1 and the sensor base 3 to isolate the two ends of the hollow copper tube 1 and prevent direct conductivity. The PTFE insulating sheet 2 is made of polytetrafluoroethylene (PTFE), a material with excellent electrical insulation and high-temperature resistance, capable of withstanding the high-temperature environment generated during high-frequency welding. The shape and size of the PTFE insulating sheet 2 match the connection points of the hollow copper tube 1 and the sensor base 3, ensuring a tight fit and stability after installation. The PTFE insulating sheet 2 is fixed to the connection point by mechanical compression, and its surface undergoes special treatment to enhance wear resistance.

[0021] The sensor base 3 features a symmetrical design to support and secure the hollow copper tube 1. Made of high-strength aluminum alloy, the sensor base 3 undergoes precision machining and surface treatment, resulting in excellent mechanical strength and corrosion resistance. The design of the sensor base 3 was optimized through computer-aided engineering analysis to ensure its overall stability and uniform magnetic field distribution during operation. The symmetrical structure of the sensor base 3 not only enhances the sensor's shock resistance but also reduces welding quality issues caused by uneven magnetic field distribution. Mounting holes are provided at the bottom of the sensor base 3 for easy connection and fixing to external equipment.

[0022] Heating port 4 is located in the middle of the hollow copper tube 1 and has a ring-shaped structure with a radial winding distribution of three turns inside and two turns outside. The design of heating port 4 was verified through precise electromagnetic field simulation and experiments to ensure that the concentration and uniformity of the high-frequency magnetic field are optimal. When the coaxial transformer is started, the hollow copper tube 1 delivers a high-frequency current in one direction, forming a uniform high-frequency magnetic field with the same direction at heating port 4. Based on the eddy current effect of electromagnetic induction, the workpiece to be welded, placed in the center of heating port 4, will rapidly heat up under the action of the magnetic field, thereby achieving efficient and high-quality welding.

[0023] The working principle of the present utility model is as follows: When the coaxial transformer starts, high-frequency current enters the hollow copper tube 1 from the power input terminal and flows in a single direction inside the hollow copper tube 1. Due to the radial winding structure of the hollow copper tube 1, a uniform high-frequency magnetic field with the same direction is generated at the heating port 4. The workpiece to be welded placed in the center of the heating port 4 is affected by the high-frequency magnetic field, and an eddy current effect is generated inside, thereby rapidly heating up. The heating rate of the workpiece to be welded can reach the level of seconds, which is significantly higher than the efficiency of traditional flame brazing. During this process, the glass fiber sleeve and the tetrafluoroethylene insulating sheet 2 respectively play the roles of electrical insulation and safety isolation, ensuring that the high-frequency current only flows inside the hollow copper tube 1 and avoiding the occurrence of electric leakage or short circuit phenomena. At the same time, the cooling medium inside the hollow copper tube 1 circulates continuously, quickly taking away the heat generated during the operation of the inductor and maintaining the normal working temperature of the inductor.

[0024] The technical effects of the present utility model are mainly reflected in the following aspects: S1 Fast heating speed. By directly heating using electromagnetic induction, the heating rate can reach the level of seconds, and the efficiency is 3 - 5 times higher than that of traditional flame brazing. This effect benefits from the radial winding method of the hollow copper tube 1 and the concentrated transmission design of the high-frequency current, enabling the energy of the high-frequency magnetic field to act concentratedly on the local area of the workpiece to be welded, significantly shortening the heating time. S2 High welding precision, narrow heat-affected zone, and small deformation amount, suitable for welding precision workpieces. This effect stems from the uniformity of the high-frequency magnetic field distribution at the heating port 4 and the optimized turn number design of the hollow copper tube 1, making the heating process of the workpiece to be welded more controllable and avoiding deformation problems caused by heat stress concentration. S3 Energy-saving and environmentally friendly, with high electric energy conversion efficiency, and the energy consumption cost is only 1 / 3 of that of flame brazing; there is no open flame and no waste gas emission, reducing the workshop pollution by 90%. This effect depends on the high-efficiency energy transmission characteristics of the hollow copper tube 1 and the design of the cooling system, reducing energy loss and environmental pollution. S4 High safety, without the use of open flame, eliminating the risk of combustion and explosion, and at the same time avoiding the harm of combustion waste gas to human health and the environment. This effect benefits from the application of the tetrafluoroethylene insulating sheet 2 and the stable support design of the inductor base 3, ensuring the reliable operation of the inductor in a high-temperature environment. S5 Easy to integrate, can be linked with robots to achieve automated mass production, meeting the needs of modern production. This effect comes from the overall compact structure of the inductor and the standardization of the interface design, facilitating seamless docking with other equipment.

[0025] Specific applications of this invention include welding processes for components such as distributors and single-pass pipes in the refrigeration industry and related manufacturing fields. For example, in the production of refrigeration equipment, the welding quality of distributors and single-pass pipes directly affects the performance and reliability of the product. Using the stacked inductor of this invention, high-quality welding can be completed in a short time, significantly improving production efficiency and product quality. Furthermore, this invention can also be applied to automotive parts, aerospace components, and other industrial fields requiring precision welding, demonstrating broad application prospects.

[0026] In summary, this invention, through its unique structural design and material selection, solves many problems inherent in traditional brazing processes, including slow heating, large heat-affected zone, high energy consumption, and numerous safety hazards. The specific implementation of the technical solution includes the radial winding structure of the hollow copper tube 1, the electrical isolation design of the PTFE insulating sheet 2, and the optimized symmetrical structure of the sensor base 3. This invention has broad application prospects, especially suitable for precision welding processes in the refrigeration industry and related manufacturing fields.

Claims

1. A stacked inductor for induction brazing, characterized in that, It includes: a hollow copper tube fitted with a fiberglass sleeve, the two ends of which are fixedly connected to the sensor base, and a ring-shaped heating port is formed in the middle; a reinforcing rib; and a sensor base for supporting and fixing the hollow copper tube; the heating port of the hollow copper tube is radially wound into an inner and outer two-layer structure, wherein the inner ring has three turns and the outer ring has two turns.

2. The stacked sensor according to claim 1, characterized in that, The fiberglass sleeve is fitted over the hollow copper tube and has good electrical insulation properties, ensuring that current can flow effectively within the hollow copper tube.

3. The stacked sensor according to claim 1, characterized in that, The sensor also includes a PTFE insulating sheet, which is fixedly disposed in the gap between the hollow copper tube and the sensor base to isolate the two ends of the hollow copper tube and prevent direct conduction.

4. The stacked sensor according to claim 3, characterized in that, The PTFE insulating sheet is made of polytetrafluoroethylene, which has excellent electrical insulation properties and good high-temperature resistance.

5. The stacked sensor according to claim 1, characterized in that, The sensor base has a symmetrical structure to ensure the overall stability and magnetic field distribution stability of the sensor during operation.

6. The stacked sensor according to claim 1, characterized in that, The hollow copper tube is used to transmit high-frequency current and form a uniform high-frequency magnetic field with consistent direction at the heating port.

7. The stacked sensor according to claim 1, characterized in that, The hollow interior of the hollow copper tube is used to carry the circulating flow of cooling water or other cooling media for effective cooling.

8. The stacked sensor according to claim 1, characterized in that, The high-frequency magnetic field generated by the heating port causes the workpiece to be welded, which is placed in the center of the heating port, to heat up rapidly through electromagnetic induction.

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