A contactless high-frequency electromagnetic welding system

Abstract

The utility model provides a kind of non-contact high-frequency electromagnetic welding system, it is related to electromagnetic welding technical field, include electromagnetic welding assembly and support component, electromagnetic welding assembly includes at least by inductive coil and shielded magnetic strip constitute welding area, inductive coil is linearly arranged, shielded magnetic strip is set to the bottom and / or outer periphery of inductive coil;Support component is set in the opposite side of welding area, to support workpiece to be welded;The inductive coil of the scheme has discarded traditional spiral disc or dense S type arrangement mode, but linearly arranged, inductive coil is linearly arranged mode, on the one hand can meet linear weld path or the welding demand of micro welding spot, on the other hand can concentrate energy in target area, improve energy effective utilization, also can avoid excessive heating to base material, solve the existing deficiency.

Description

Technical Field

[0001] This utility model relates to the field of electromagnetic welding technology, specifically a non-contact high-frequency electromagnetic welding system. Background Technology

[0002] Electromagnetic welding technology is widely used in the fabrication of semiconductor devices, photovoltaic cells, and precision electronic components due to its advantages such as non-contact operation, fast heating speed, and ease of control. The core of this electromagnetic welding technology lies in using an induction coil to pass high-frequency alternating current to generate an alternating magnetic field, which in turn induces eddy currents in the welding material or base material placed in the magnetic field to achieve resistance heating, and finally completes the connection of materials.

[0003] Currently, in order to obtain a large-area uniform magnetic field, traditional electromagnetic welding equipment typically uses spiral winding or dense S-shaped arrangement of electromagnetic induction coils. However, this traditional planar heating mode has revealed many defects in actual industrial production: (1) Because the alternating magnetic field covers the entire coil projection area, the heating area is much larger than the actual required solder joint or weld. Especially for precision process components made of polymer materials, ceramics or fragile wafers (such as the encapsulation layer of photovoltaic panels and the insulating substrate of semiconductor devices), this indiscriminate thermal radiation is very likely to cause overheating and decomposition, resulting in irreversible carbonization, yellowing or performance degradation, which seriously reduces the yield and long-term reliability of the product.

[0004] (2) Large-area heating also means that a lot of energy is consumed in non-target areas, which is essentially a huge waste of energy, resulting in high energy consumption, which is contrary to the current industrial trend of green manufacturing and energy conservation and emission reduction.

[0005] (3) Traditional planar heating methods are difficult to achieve precise processing of straight weld paths or micro weld points.

[0006] Based on the above analysis, this solution designs a novel non-contact high-frequency electromagnetic welding system that can fundamentally overcome the drawbacks of large-area heating and achieve precise and controllable energy distribution in space. Utility Model Content

[0007] The purpose of this invention is to provide a non-contact high-frequency electromagnetic welding system to address at least one deficiency in the prior art.

[0008] To achieve the above objectives, this utility model provides the following technical solution: A non-contact high-frequency electromagnetic welding system includes an electromagnetic welding assembly and a support assembly. The electromagnetic welding assembly includes a welding area consisting of at least an induction coil and a shielding magnetic strip. The induction coil is arranged linearly, and the shielding magnetic strip is disposed at the bottom and / or the outer periphery of the induction coil. The support assembly is disposed on the opposite side of the welding area to support the workpiece to be welded. The workpiece to be welded can be induced to generate heat and melt or reach a plastic state under the action of the alternating electromagnetic field generated by the induction coil to achieve welding.

[0009] As a preferred embodiment of this application, the support component is a vacuum seal, which includes a first half-shell, a second half-shell, and a vacuum line. The first half-shell and the second half-shell are sealably joined together to form a sealed cavity between them. At the same time, at least one of the first half-shell and the second half-shell is provided with an air extraction hole connected to the vacuum line.

[0010] As a preferred embodiment of this application, both the first half-shell and the second half-shell are provided with air extraction holes, and airflow grooves communicating with the air extraction holes are respectively provided on the inner walls of the first half-shell and the second half-shell.

[0011] As a preferred embodiment of this application, at least one of the first half-shell and the second half-shell is provided with a positioning groove on its inner side. The positioning groove can limit the workpiece to be welded to ensure that the welding point is located in the sealed cavity corresponding to the welding area.

[0012] As a preferred embodiment of this application, a pressure plate is provided at the opening position of the first half shell and the second half shell, and the positioning groove is a countersunk groove provided on the pressure plate.

[0013] As a preferred embodiment of this application, the electromagnetic welding assembly includes a protective housing and a top cover, wherein the induction coil and the shielding magnetic strip are disposed within the protective housing, and a welding area is formed on the top cover.

[0014] As a preferred embodiment of this application, the specific structure of the linear arrangement of the induction coil includes: the induction coil is a series of straight rollers bent from copper wire and arranged in parallel, the effective working area of ​​the multiple straight rollers being elongated; or, the induction coil is composed of multiple independent straight roller copper wires arranged in parallel, the multiple straight roller copper wires being connected in parallel to each other.

[0015] As a preferred embodiment of this application, the support component is suspended 10-30mm directly above the electromagnetic welding component via a support frame.

[0016] Compared with the prior art, the beneficial effects of this utility model are: This solution designs a non-contact high-frequency electromagnetic welding system, which includes an electromagnetic welding component and a support component. The support component is positioned above the electromagnetic welding component to fix the workpiece to be welded. The induction coils in the electromagnetic welding component abandon the traditional spiral or dense S-shaped arrangement and instead adopt a linear arrangement. This linear arrangement of the induction coils can meet the welding requirements of straight weld paths or micro weld points, and can concentrate energy in the target area, improving energy efficiency and avoiding overheating of the base material. In addition, the support component of this solution is preferably designed as a vacuum seal, that is, welding the base material in a vacuum environment. Compared with the conventional environment, this can effectively avoid oxidation and contamination of the base material and welding materials at high temperatures, significantly reduce defects such as porosity in the weld, and thus greatly improve the density and reliability of the weld, meeting the urgent needs of modern precision manufacturing for micro-damage, low-energy consumption, and high-precision welding. Attached Figure Description

[0017] Figure 1 This is a cross-sectional structural diagram of the non-contact high-frequency electromagnetic welding system provided by this utility model.

[0018] Figure 2 Provided by this utility model Figure 1 A magnified view of a portion of point B in the middle.

[0019] Figure 3 Provided by this utility model Figure 1 A magnified view of a portion of point C.

[0020] Figure 4 This is a schematic diagram of the layout structure of the induction coil provided by this utility model.

[0021] Figure 5 A top view of the internal structure of the first or second half-shell provided by this utility model.

[0022] Figure 6 Provided by this utility model Figure 5 A magnified view of a portion of point A in the middle.

[0023] Figure 7 This is a schematic diagram of the structure in which the base material provided by this utility model is arranged in a crisscross pattern on the first or second half-shell to achieve a warp and weft connection process.

[0024] Figure 8 A front view structural diagram showing the sealing connection between the first half-shell and the second half-shell provided by this utility model.

[0025] Figure Labels

[0026] 10 is the electromagnetic welding assembly 10; 11 is the protective shell; 12 is the induction coil; 13 is the shielding magnetic strip; 14 is the top cover; 15 is the coil support block; 20 is the support component; 21 is the first half-shell; 22 is the second half-shell; 23 is the air extraction hole; 24 is the airflow groove; 25 is the sealing gasket; 26 is the workpiece to be welded; 27 is the pressure plate; 28 is the positioning groove. Detailed Implementation

[0027] The present invention will be further described in detail below with reference to specific embodiments and accompanying drawings. It should be emphasized that the following description is merely exemplary and not intended to limit the scope and application of the present invention.

[0028] This embodiment provides a contactless high-frequency electromagnetic welding system, which includes an electromagnetic welding assembly 10 and a support assembly 20, such as... Figure 1 As shown, the electromagnetic welding assembly 10 includes a welding area composed of an induction coil 12 and a shielding magnetic strip 13. In this embodiment, the welding area is preferably located at the upper end of the electromagnetic welding assembly 10. The induction coil 12 is arranged linearly. As the name suggests, the effective working section of the induction coil 12 is long and narrow. It can be seen that this embodiment abandons the traditional method of spiral coiling or dense S-shaped arrangement of the induction coil 12, and instead adopts a linear arrangement. After the induction coil 12 is energized, it will generate a strip-shaped alternating electromagnetic field. This strip-shaped induced magnetic field can meet the welding requirements of straight weld paths or micro weld points, and can concentrate energy in the target area, improving the effective utilization of energy while avoiding excessive heating of the base material. The shielding magnetic strip 13 is set at the bottom and outer periphery of the induction coil 12 to adjust the emission direction of the alternating electromagnetic field toward the welding area, avoid magnetic field diffusion, and improve the effective utilization rate of the electromagnetic field. In this embodiment, the shielding magnetic strip 13 is preferably a soft magnetic ferrite strip. The support assembly 20 is set at the bottom and outer periphery of the induction coil 12. On the opposite side of the welding area, since the welding area is located at the upper end of the electromagnetic welding assembly 10, in this embodiment, the support assembly 20 is suspended above the electromagnetic welding assembly 10 by a bracket. In this embodiment, the bracket is preferably a braking mechanism in an existing non-contact electromagnetic welding system. It can be understood that in this embodiment, the distance between the support assembly 20 and the electromagnetic welding assembly 10 can be flexibly adjusted by the braking mechanism according to actual needs. Preferably, the support assembly 20 is suspended 10-30mm above the electromagnetic welding assembly 10. The support assembly 20 is used to support the workpiece 26 to be welded. The workpiece 26 to be welded is only the base material, or the workpiece 26 to be welded is both the base material and the welding material. As is known in the art, when it is only the base material, the base material is induced to generate heat under the action of the alternating electromagnetic field of the induction coil 12 and reaches a plastic state to achieve welding. When it includes both the base material and the welding material, since the melting point of the welding material is usually lower than that of the base material, the welding material can be induced to generate heat and melt under the action of the alternating electromagnetic field of the induction coil 12 to weld the base material.

[0029] In this embodiment, the specific structure of the linear arrangement of the induction coil 12 includes: Induction coil 12 is composed of multiple straight rollers bent from copper wire in a continuous and parallel manner. The effective working area of ​​these multiple straight rollers is elongated, such as... Figure 4 As shown, in this structure, the induction coil 12 is formed by bending a copper wire. The beginning and end of the induction coil 12 are the positive and negative poles, respectively. It can be understood that in this structure, the distance between two adjacent straight rollers is fixed, and the required distance needs to be determined before bending.

[0030] Alternatively, the electromagnetic induction coil 12 is composed of multiple independent straight roller copper wires arranged in parallel, with the multiple straight roller copper wires connected in parallel to each other (shown in the figure). In this structure, the induction coil 12 is composed of multiple independent straight roller copper wires, and each straight roller copper wire can be energized individually or simultaneously. In addition, in this structure, the distance between two adjacent straight roller copper wires can be flexibly adjusted as needed to improve adaptability.

[0031] The above are two preferred arrangements of the copper wire in the electromagnetic induction coil 12 in this embodiment. Under the guidance of this embodiment, other feasible and reasonable structures are also within the protection scope of this embodiment, ensuring that a strip alternating magnetic field can be provided.

[0032] In a preferred embodiment, the electromagnetic welding assembly 10 includes a protective housing 11 and a top cover 14, the top cover 14 sealing the protective housing 11; an induction coil 12 and a shielding magnetic strip 13 are disposed within the protective housing 11, and a welding area is formed on the top cover 14, such as... Figure 2 As shown; in this embodiment, the induction coil 12 is preferably fixed inside the protective shell 11 by the coil support block 15, and the shielding magnetic strip 13 is fixed to the inner wall of the protective shell 11 by means of adhesive or snap-fit ​​and is located at the bottom and around the induction coil 12, as shown. Figure 4 As shown; in this embodiment, the protective shell 11 is preferably made of a high-strength material such as aluminum alloy, stainless steel or carbon steel, and the top cover 14 is made of an insulating material such as glass fiber epoxy resin, ceramic or engineering plastic that is easily penetrated by magnetic fields, so as to ensure that the alternating magnetic field can penetrate the top cover 14 and the support component 20 to act on the induction coil 12.

[0033] As a preferred embodiment, the support component 20 is a vacuum seal, which includes a first half-shell 21, a second half-shell 22, and a vacuum line. The first half-shell 21 and the second half-shell 22 are sealably joined together to form a sealed cavity. It is understood that, if necessary, a sealing gasket 25 can be added between the first half-shell 21 and the second half-shell 22. Simultaneously, at least one of the first half-shell 21 and the second half-shell 22 is provided with an air extraction port 23 connected to the vacuum line. Figure 8 As shown.

[0034] Specifically, the first half-shell 21 and the second half-shell 22 are symmetrical in structure, both being half-shells with internal cavities. The second half-shell 22 is preferably a bottom shell, and the workpiece 26 to be welded (welding material and base material) can be placed inside the second half-shell 22. It is understood that the internal cavity size of the second half-shell 22 should meet the placement requirements of the workpiece 26 to be welded. After the workpiece 26 to be welded is placed, the first half-shell 21 can be closed on the second half-shell 22 to form a sealed cavity. A vacuum line is then used to evacuate the sealed cavity, so that the welding of the workpiece 26 to be welded is completed in a vacuum environment. Compared with the conventional environment, placing the electromagnetic welding process in a vacuum environment can effectively avoid oxidation and contamination of the workpiece 26 to be welded at high temperatures, and can significantly reduce defects such as porosity in the weld, thereby greatly improving the density and reliability of the weld. It is understood that the vacuum line should include a negative pressure pump and a gas supply line.

[0035] In a preferred embodiment, both the first half-shell 21 and the second half-shell 22 are provided with air extraction holes 23, and the inner walls of the first half-shell 21 and the second half-shell 22 are respectively provided with airflow grooves 24 communicating with the air extraction holes 23. In this embodiment, the airflow grooves 24 preferably include multiple interconnected grooves, such as... Figure 5 As shown, the airflow channel 24 provides a flow path for the gas in the sealed cavity, eliminating the vacuum dead zone and thus achieving rapid and efficient vacuuming.

[0036] As a preferred embodiment, at least one of the first half-shell 21 and the second half-shell 22 is provided with a positioning groove 28 on its inner side. The positioning groove 28 can limit the workpiece 26 (base material and / or welding material) to be welded to ensure that the welding point of the base material and the welding material are located in the sealed cavity corresponding to the welding area and are accurately aligned. In this embodiment, the positioning groove 28 is preferably used to position the base material to ensure that its welding point is located in the sealed cavity corresponding to the welding area. When in use, the base material can be inserted into the positioning groove 28. It can be understood that the specific structure of the positioning groove 28 can be determined according to the shape and size of the base material to be welded, i.e., the workpiece. This embodiment does not make specific limitations.

[0037] like Figure 5-6 The diagram shown is a schematic diagram of a body structure with a positioning groove 28 provided in this embodiment. The positioning groove 28 is preferably a plurality of rectangular grooves, which are adapted to fit the rod-shaped workpiece 26 (base material) to be welded. In use, the rod-shaped workpiece 26 (base material) to be welded can be snapped into the rectangular groove.

[0038] like Figure 7The diagram shows a schematic of the structure for achieving mesh-like spot welding by arranging multiple rod-shaped workpieces 26 to be welded in a crisscross pattern, as provided in this embodiment. Specifically, multiple rod-shaped workpieces 26 are first placed into the corresponding positioning slots 28 of the second half-shell 22 to achieve a crisscross arrangement. After the arrangement is completed, the first half-shell 21 is closed and vacuumed. Then, the electromagnetic welding assembly 10 is activated. The welding surface of the electromagnetic welding assembly 10 will generate a high-level linear electromagnetic field. This electromagnetic field penetrates the first half-shell 21 and the protective shell 11 and simultaneously induces eddy currents and generates high temperatures at the intersections of all the rod-shaped workpieces 26. The welding material or base material at all intersections melts instantly or reaches a plastic state to achieve welding. After cooling, a solid weld point is formed, completing the "crisscrossing" of the entire mesh surface in one go. It can be seen that the welding system in this embodiment can not only achieve linear welding but also perform multi-point welding simultaneously, providing a new approach for efficient and rapid spot welding.

[0039] As a preferred embodiment, a pressure plate 27 is provided at the opening position of the first half-shell 21 and the second half-shell 22, and the positioning groove 28 is a countersunk groove provided on the pressure plate 27. In this embodiment, the pressure plate 27 can be a mesh panel adapted to the size of the opening end of the half-shell, or it can be a "U"-shaped plate only provided at the opening position of the half-shell. After the first half-shell 21 and the second half-shell 22 are connected, the pressure plate 27 located at the opening of the first half-shell 21 and the second half-shell 22 can be connected and form a positioning cavity at the positioning groove 28 position. By using the pressure plate 27 in conjunction with the positioning groove 28, the stability of the workpiece 26 to be welded in the sealed cavity can be improved, and displacement can be avoided.

[0040] The specific operating principle of this embodiment includes: First, place the workpiece 26 to be welded in the positioning groove 28 of the second half shell 22, and close the first half shell 21 to position the workpiece 26 to be welded. At the same time, a sealed cavity is formed between the first half shell 21 and the second half shell 22. Then, start the vacuum line to create a vacuum environment in the sealed cavity. Finally, start the electromagnetic welding assembly 10 and use the linear electromagnetic field generated by the induction coil 12 to perform linear or spot welding on the workpiece 26 to be welded.

[0041] As can be seen, the induction coil 12 in the electromagnetic welding assembly 10 of this embodiment abandons the traditional spiral or dense S-shaped arrangement and adopts a linear arrangement. The linear arrangement of the induction coil 12 can meet the welding requirements of straight weld paths or micro welds, and can concentrate energy in the target area, improving energy utilization efficiency while avoiding excessive heating of the base material. In addition, the support assembly 20 of this embodiment is preferably designed as a vacuum seal, that is, welding the base material in a vacuum environment. Compared with the conventional environment, it can effectively avoid oxidation and contamination of the base material and welding material at high temperatures, significantly reduce defects such as porosity in the weld, and thus greatly improve the density and reliability of the weld, meeting the urgent needs of modern precision manufacturing industry for micro-damage, low energy consumption and high-precision welding.

[0042] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A non-contact high-frequency electromagnetic welding system, characterized in that, The device includes an electromagnetic welding assembly and a support assembly. The electromagnetic welding assembly includes a welding area consisting of at least an induction coil and a shielding magnetic strip. The induction coil is arranged linearly, and the shielding magnetic strip is disposed at the bottom and / or the outer periphery of the induction coil. The support assembly is disposed on the opposite side of the welding area to support the workpiece to be welded. The workpiece to be welded can be induced to generate heat and melt or reach a plastic state under the action of the alternating electromagnetic field generated by the induction coil to achieve welding.

2. The non-contact high-frequency electromagnetic welding system according to claim 1, characterized in that, The support assembly is a vacuum seal, which includes a first half-shell, a second half-shell, and a vacuum line. The first half-shell and the second half-shell are sealably joined together to form a sealed cavity between them. At the same time, at least one of the first half-shell and the second half-shell is provided with an air extraction hole connected to the vacuum line.

3. The non-contact high-frequency electromagnetic welding system according to claim 2, characterized in that, Both the first half-shell and the second half-shell are provided with air extraction holes, and airflow grooves communicating with the air extraction holes are respectively provided on the inner walls of the first half-shell and the second half-shell.

4. The non-contact high-frequency electromagnetic welding system according to claim 2, characterized in that, The inner side of at least one of the first half-shell and the second half-shell is provided with a positioning groove, which can limit the workpiece to be welded to ensure that the welding point is located in the sealed cavity corresponding to the welding area.

5. The non-contact high-frequency electromagnetic welding system according to claim 4, characterized in that, The openings of the first and second half-shells are provided with pressure plates, and the positioning groove is a countersunk groove provided on the pressure plate.

6. The non-contact high-frequency electromagnetic welding system according to claim 1, characterized in that, The electromagnetic welding assembly includes a protective housing and a top cover. The induction coil and shielding magnetic strip are disposed inside the protective housing and form a welding area on the top cover.

7. The non-contact high-frequency electromagnetic welding system according to claim 1, characterized in that, The specific structure of the linear arrangement of the induction coil includes: the induction coil is a series of straight rollers bent from copper wire and arranged in parallel, with the effective working area of ​​the multiple straight rollers being elongated; or, the induction coil is composed of multiple independent straight roller copper wires arranged in parallel, with the multiple straight roller copper wires connected in parallel to each other.

8. The non-contact high-frequency electromagnetic welding system according to claim 1, characterized in that, The support assembly is suspended 10-30mm directly above the electromagnetic welding assembly via a support frame.

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