US20070181564A1 - Bonding of Materials with Induction Heating - Google Patents
Bonding of Materials with Induction Heating Download PDFInfo
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- US20070181564A1 US20070181564A1 US11/735,098 US73509807A US2007181564A1 US 20070181564 A1 US20070181564 A1 US 20070181564A1 US 73509807 A US73509807 A US 73509807A US 2007181564 A1 US2007181564 A1 US 2007181564A1
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- United States
- Prior art keywords
- induction heating
- heating plate
- induction
- frame
- electrically conductive
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- Abandoned
Links
- 230000006698 induction Effects 0.000 title claims abstract description 147
- 238000010438 heat treatment Methods 0.000 title claims abstract description 103
- 239000000463 material Substances 0.000 title claims abstract description 48
- 238000000034 method Methods 0.000 claims abstract description 20
- 239000007788 liquid Substances 0.000 claims abstract description 10
- 238000003825 pressing Methods 0.000 claims abstract description 5
- 239000003779 heat-resistant material Substances 0.000 claims description 10
- 238000007373 indentation Methods 0.000 claims description 9
- 238000010791 quenching Methods 0.000 claims description 8
- 238000001816 cooling Methods 0.000 claims description 4
- 239000012530 fluid Substances 0.000 claims description 3
- 230000000171 quenching effect Effects 0.000 claims description 3
- 239000004020 conductor Substances 0.000 abstract description 6
- 239000011344 liquid material Substances 0.000 abstract description 2
- 239000002184 metal Substances 0.000 description 56
- 229910052751 metal Inorganic materials 0.000 description 56
- 239000010953 base metal Substances 0.000 description 13
- 239000000203 mixture Substances 0.000 description 12
- 229910000831 Steel Inorganic materials 0.000 description 4
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- 239000010959 steel Substances 0.000 description 4
- 229910000838 Al alloy Inorganic materials 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000956 alloy Substances 0.000 description 3
- 239000000919 ceramic Substances 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- 229910000906 Bronze Inorganic materials 0.000 description 2
- 229910000881 Cu alloy Inorganic materials 0.000 description 2
- 239000010974 bronze Substances 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 238000010924 continuous production Methods 0.000 description 2
- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 238000005304 joining Methods 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 238000003801 milling Methods 0.000 description 2
- 238000010923 batch production Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
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- 229910052802 copper Inorganic materials 0.000 description 1
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Images
Classifications
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B6/00—Heating by electric, magnetic or electromagnetic fields
- H05B6/02—Induction heating
- H05B6/10—Induction heating apparatus, other than furnaces, for specific applications
- H05B6/105—Induction heating apparatus, other than furnaces, for specific applications using a susceptor
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
- F16C33/02—Parts of sliding-contact bearings
- F16C33/04—Brasses; Bushes; Linings
- F16C33/06—Sliding surface mainly made of metal
- F16C33/14—Special methods of manufacture; Running-in
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C2223/00—Surface treatments; Hardening; Coating
- F16C2223/30—Coating surfaces
- F16C2223/32—Coating surfaces by attaching pre-existing layers, e.g. resin sheets or foils by adhesion to a substrate; Laminating
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31678—Of metal
Definitions
- the present invention relates to the use of magnetic induction heating of a material to bond multiple materials together.
- a slide bearing may be formed from a bonded composition that consists of a metal backing plate and a bearing surface material that is bonded to the plate.
- the bearing surface material may be a metal composition such as a copper or an aluminum alloy.
- Slide bearings are linear or rotary in form. Linear slide bearings are in sheet form, whereas rotary slide bearings are in cylindrical or half-cylindrical form. Half-cylindrical slide bearings are used in pairs for applications such as journal bearings in internal combustion engines.
- One method of producing slide bearings involves a continuous process line wherein the feedstock for the metal backing plate is a continuous roll of sheet steel.
- the continuous roll of sheet steel is fed through heat treating furnaces and further conditioned before the bearing surface material is applied to it. Raised edge lips are formed on the longitudinal edges of the continuous sheet and the bearing surface material, in a liquid form, such as a molten copper or aluminum alloy, is poured onto the sheet.
- the molten alloy solidifies and is bonded to the sheet, and can be quench treated. Subsequent milling controls the thickness of the bearing surface material.
- the sheet is cut into desired sizes for slide bearing applications. For rotary slide bearings, the cut pieces are further formed into a cylindrical shape.
- the present invention is an apparatus for, and method of, producing a bonded product.
- An electrically conductive sheet is placed between a first induction heating plate, and the combination of a frame and a second induction heating plate disposed within the frame, and inductively heated.
- the second induction heating plate is moved away from the electrically conductive sheet.
- a liquid bonding composition such as a molten metal, is poured into the open interior space of the frame over the top of the electrically conductive sheet wherein it solidifies and bonds to the electrically conductive sheet to produce a bonded product.
- the electrically conductive sheet may be placed in an indentation in the first induction heating plate which also serves to contain the liquid bonding composition.
- the present invention is an apparatus for, and method of, continuously producing a bonded product by pressing together a continuous electrically conductive sheet and a continuous bonding material sheet, and advancing the pressed together sheets through an induction coil to heat the electrically conductive sheet and bond the bonding material sheet to the electrically conductive sheet.
- two continuous bonding material sheets are disposed between two electrically conductive sheets, pressed together and advanced through an induction coil to heat the two electrically conductive sheets and bond each of the bonding material sheets to its adjacent electrically conductive sheet.
- FIG. 1 is an isometric view of one example of an apparatus of the present invention for bonding materials with induction heating.
- FIG. 2 is an isometric view illustrating one example of an arrangement of induction coils for the apparatus shown in FIG. 1 .
- FIG. 3 is a front elevational view of the apparatus shown in FIG. 1 .
- FIG. 4 is a side elevational view of the apparatus shown in FIG. 1 .
- FIG. 5 is a top view of the apparatus shown in FIG. 1 , further illustrating the arrangement of induction coils shown in FIG. 2 .
- FIG. 6 is a side elevational view of another example of an apparatus of the present invention for bonding materials with induction heating.
- FIG. 7 is a side elevational view of another example of an apparatus of the present invention for bonding materials with induction heating.
- FIGS. 8 ( a ), 8 ( b ) and 8 ( c ) illustrate another example of the present invention for bonding materials with induction heating.
- Apparatus 10 includes first induction heating plate 12 , frame 14 and second induction heating plate 16 .
- First and second induction heating plates 12 and 16 , and frame 14 are formed from a heat resistant, non-electrically conductive material, such as a ceramic composition.
- First plate induction coil 18 is disposed in first induction heating plate 12 ; frame induction coil 20 is disposed in frame 14 ; and second plate induction coil 22 is disposed in second induction heating plate 16 .
- a castable material such as a ceramic composition
- the coils may be embedded in the heating plates and frame during the casting process.
- the induction coils are arranged to form a transverse induction coil assembly for inductively heating an electrically conductive sheet 90 placed between the first induction heating plate, and the combination of the frame and second induction heating plate when the second induction heating plate is inserted into the frame. While the sheet is generally referred to as a metal sheet, any electrically conductive material may be used.
- the particular arrangement of coils shown in the figures illustrates one non-limiting example of transverse flux coil arrangements that can be used in the present invention.
- the illustrated induction coils may be fluid (liquid or gas) cooled by circulation of a cooling fluid, such as water, through hollow induction coils or separate cooling coils in the heating plates and frame. In some examples of the invention, an induction coil may not be necessary in frame 14 .
- Metal sheet 90 is placed upon the top surface of first induction heating plate 12 .
- the dimensions of metal sheet 90 are such that when frame 14 is placed over the top surface of first induction heating plate 12 , the perimeter of the metal sheet will extend beyond the interior open space in frame 14 to establish a metal sheet contact surface around the metal sheet's perimeter that is sandwiched between the top surface of the first induction heating plate 12 and the bottom surface of frame 14 .
- first induction heating plate 12 With metal sheet 90 positioned on the surface of first induction heating plate 12 , as described above, frame 14 and second induction heating plate 16 are placed over the top surface of the first induction heating plate 12 and the metal sheet.
- the interior open space in frame 14 is sized to allow the fitting of second induction heating plate 16 so that the bottom surface of the second induction heating plate 16 makes contact with metal sheet 90 .
- suitable ac current is supplied from one or more power sources to first plate induction coil 18 , frame induction coil 20 , and second plate induction coil 22 .
- the magnetic field created by ac current flow in the first plate induction coil 18 inductively penetrates and heats into the facing side of metal sheet 90
- the magnetic fields created by ac current flow in the frame induction coil and second plate induction coil inductively penetrate and heat into the opposing side of the metal sheet.
- the orthogonal orientation of the first plate induction coil to the combination of the frame and second plate induction coils provides a crisscross induction heating pattern that enhances uniform heat penetration of the sheet. Pressing the metal sheet between the first and second induction heating plates prevents surface distortion of the sheet as it is heated.
- second induction heating plate 16 When metal sheet 90 has been inductively heated to a desired temperature, second induction heating plate 16 is raised at least a sufficient distance to allow pouring of a molten metal composition, such as a copper or aluminum alloy, onto the top surface of the heated metal sheet.
- the temperature of the metal sheet may be sensed by one or more sensors, such as contact thermocouples embedded in the first and/or second induction heating plates to determine when the sheet has been heated to the desired temperature. For example, if the metal sheet is steel, it is heated to approximately 2,100° F. for casting of a molten alloy, such as bronze, onto its surface. While the term “molten metal” or “molten alloy” is used, any liquid material capable of bonding with the heated electrically conductive sheet may be used.
- Frame 14 remains in place to hold the metal sheet flat and to provide a dam for the molten metal composition.
- the molten metal may be ported through one or more openings in frame 14 , or poured, into the interior open space in frame 14 which was previously occupied by the second induction heating plate. After pouring a quantity of molten metal over the top surface of the metal sheet, the metal will bond with the sheet as it cools.
- the metal can be quenched by injecting a quench fluid or gas into the interior open space in the frame over the top surface of the cooled molten metal.
- the quench material may be ported through one or more openings in frame 14 , or poured, into the interior open space in frame 14 .
- the now solidified molten metal is bonded to the metal sheet to form a bonded metal product, and frame 14 can be removed from over the top surface of first induction heating plate 12 .
- the interior surface wall of frame 14 may be skewed towards its outer wall in the region where the molten metal is poured to facilitate removal of the frame. Additionally the same region of the wall may be specially treated with a coating that will inhibit bonding of the molten metal to the wall of the frame.
- a typical range of thickness of the metal sheet is approximately 3.5 to 19 mm, and a typical range of thickness of the cast metal on the metal sheet is approximately 2.5 to 5.0 mm.
- Further working of the product can include milling for thickness control of the product. If the product is used as slide bearings, the product is appropriately cut to the desired dimensions. For rotary slide bearings, the cut product is then worked to a cylindrical shaped.
- the top surface of first induction heating plate 12 is indented for an area approximately equal to the surface area of the bottom surface of second induction heating plate 16 .
- the second induction heating plate can be moved towards the metal sheet to apply sufficient pressure on the heated sheet to force it into the indentation in the first induction heating plate.
- the frame does not generally provide a dam for the molten metal composition that is poured over the top of the sheet since the raised edges of the indented metal sheet and/or the walls of the indentation will serve as a dam for the molten metal composition.
- the frame serves as a means for holding the metal sheet in place during induction heating and molten metal pour after the sheet is pressed into the indentation in the first induction heating plate.
- solenoidal induction coil 21 is disposed in inductor assembly 23 .
- Metal sheet 90 is inserted into indentation 25 in first heat resistant plate 13 .
- Second heat resistant plate 17 is placed over the first ceramic plate and the enclosed metal sheet is inserted into inductor assembly 23 as shown in FIG. 8 ( b ) wherein it is inductively heated by a magnetic field established when as current flows through coil 21 .
- the enclosed metal sheet is removed from the inductor assembly, and the second heat resistant plate is removed, as shown in FIG. 8 ( c ), so that the molten metal can be poured over the metal sheet in the indentation.
- a continuous supply of base metal sheet 92 is provided from base metal sheet supply roll 30 and a continuous supply of bond material sheet 94 is provided from bond material sheet supply roll 32 .
- Steel is a suitable, but non-limiting, composition of the base metal sheet
- bronze is a suitable, but non-limiting, composition of the bond material sheet.
- Suitable joining and conveying means, such as rollers 36 press metal sheet 92 and bond material sheet 94 together and advance it through one or more induction coils 38 wherein the magnetic field established by an ac current flow through the coils inductively heats and bonds the bond material sheet to the base metal sheet.
- the one or more induction coils may be of any suitable configuration, including transverse flux or longitudinal flux coils, or a combination thereof. Since the induced current flows in the bond material sheet and returns through the base metal sheet, the required frequency of the ac current in the one or more induction coils is lower than that required for the previous examples of the invention.
- the bonded sheets may be quenched with a suitable quench medium supplied through quench apparatus 40 after the bonded sheets exit from the one or more induction coils.
- the bonded sheets can be accumulated, for example, on bonded sheets product roll 42 for bulk shipment to finishing facilities that produce, for example, slide bearings from the product roll.
- the bonded sheets may be cut into one or more bonded products by applying suitable cutting means, such as cutting shear 41 , which is schematically shown in FIG. 6 and FIG. 7 , to the bonded sheet.
- suitable cutting means such as cutting shear 41 , which is schematically shown in FIG. 6 and FIG. 7 .
- FIG. 7 illustrates an alternative to the arrangement in FIG. 6 .
- two bond material sheets 94 a and 94 b are provided from bond material sheet supply rolls 32 a and 32 b , respectively, and are disposed between two base metal sheets 92 a and 92 b , which are provided from base metal sheet supply rolls 30 a and 30 b .
- Suitable joining and conveying means such as rollers 36 press metal sheets 92 a and 92 b together with the two bond material sheets 94 a and 94 b between them, and advance the pressed sheets through one or more induction coils 38 wherein the magnetic field established by an ac current flow through the coils inductively heats and bonds each of the two bond material sheets to the base metal sheet making contact with it.
- the melt temperature of the bond material sheet is lower than the melt temperature of the base metal sheet.
- the required heated temperature of the base metal sheet may be sufficient to overheat the bond material sheet.
- the arrangement shown in FIG. 7 minimizes heating of the bond material sheets since induced currents flow only through the two opposing base metal sheets.
- bonded sheets comprising base metal sheet 92 a and bond material sheet 94 a is accumulated on bonded sheets product roll 42 a and bonded sheets comprising base metal sheet 92 b and bond material sheet 94 b is accumulated on bonded sheets product roll 42 b .
- a sheet of heat resistant material can be inserted between adjacent facing sides of bond material sheets 94 a and 94 b prior to induction heating to keep the two bond metal sheets from sticking together. The sheet of heat resistant material is removed subsequent to the step of induction heating.
Abstract
An apparatus and process are provided for bonding of materials by induction heating of an electrically conductive material upon which a second material is bonded. The electrically conductive material is induction heated between a first induction heating plate, and the combination of a frame and a second induction heating plate that is disposed within the frame. The second induction heating plate is removed from the surface of the electrically conductive sheet, while the frame continues to hold the electrically conductive sheet flat, and the second material, in liquid form, is poured into the interior opening of the frame in which the second induction heating plate was originally placed. The liquid material solidifies and bonds to the electrically conductive sheet to produce a bonded product. A continuous sheet of an electrically conductive material may be bonded to a continuous sheet of a second material by pressing them together and moving the pressed together materials through an induction coil to inductively heat the electrically conductive material and bond it with the second material.
Description
- This is a divisional application of application Ser. No. 10/615,150, filed Jul. 8, 2003, which claims the benefit of U.S. Provisional Application No. 60/394,515, filed Jul. 9, 2002, both of which are hereby incorporated herein by reference in their entireties.
- The present invention relates to the use of magnetic induction heating of a material to bond multiple materials together.
- Bonded materials are used in many applications. For example, a slide bearing may be formed from a bonded composition that consists of a metal backing plate and a bearing surface material that is bonded to the plate. The bearing surface material may be a metal composition such as a copper or an aluminum alloy. Slide bearings are linear or rotary in form. Linear slide bearings are in sheet form, whereas rotary slide bearings are in cylindrical or half-cylindrical form. Half-cylindrical slide bearings are used in pairs for applications such as journal bearings in internal combustion engines.
- One method of producing slide bearings involves a continuous process line wherein the feedstock for the metal backing plate is a continuous roll of sheet steel. The continuous roll of sheet steel is fed through heat treating furnaces and further conditioned before the bearing surface material is applied to it. Raised edge lips are formed on the longitudinal edges of the continuous sheet and the bearing surface material, in a liquid form, such as a molten copper or aluminum alloy, is poured onto the sheet. The molten alloy solidifies and is bonded to the sheet, and can be quench treated. Subsequent milling controls the thickness of the bearing surface material. The sheet is cut into desired sizes for slide bearing applications. For rotary slide bearings, the cut pieces are further formed into a cylindrical shape. Economically, the process must operate as an uninterrupted line process, since stopping the line and restarting the line involves a substantial effort in repeatedly bringing the line's furnaces to operating temperature. Therefore there exists the need for a method of bonding metals in a batch process for applications such as slide bearings or in a continuous process without liquid or molten form of bearing material.
- In one aspect, the present invention is an apparatus for, and method of, producing a bonded product. An electrically conductive sheet is placed between a first induction heating plate, and the combination of a frame and a second induction heating plate disposed within the frame, and inductively heated. The second induction heating plate is moved away from the electrically conductive sheet. A liquid bonding composition, such as a molten metal, is poured into the open interior space of the frame over the top of the electrically conductive sheet wherein it solidifies and bonds to the electrically conductive sheet to produce a bonded product. Optionally the electrically conductive sheet may be placed in an indentation in the first induction heating plate which also serves to contain the liquid bonding composition.
- In another aspect, the present invention is an apparatus for, and method of, continuously producing a bonded product by pressing together a continuous electrically conductive sheet and a continuous bonding material sheet, and advancing the pressed together sheets through an induction coil to heat the electrically conductive sheet and bond the bonding material sheet to the electrically conductive sheet. Alternatively two continuous bonding material sheets are disposed between two electrically conductive sheets, pressed together and advanced through an induction coil to heat the two electrically conductive sheets and bond each of the bonding material sheets to its adjacent electrically conductive sheet.
- These and other aspects of the invention are set forth in this specification and the appended claims.
- The figures, in conjunction with the specification and claims, illustrate one or more non-limiting modes of practicing the invention. The invention is not limited to the illustrated layout and content of the figures in the drawings.
-
FIG. 1 is an isometric view of one example of an apparatus of the present invention for bonding materials with induction heating. -
FIG. 2 is an isometric view illustrating one example of an arrangement of induction coils for the apparatus shown inFIG. 1 . -
FIG. 3 is a front elevational view of the apparatus shown inFIG. 1 . -
FIG. 4 is a side elevational view of the apparatus shown inFIG. 1 . -
FIG. 5 is a top view of the apparatus shown inFIG. 1 , further illustrating the arrangement of induction coils shown inFIG. 2 . -
FIG. 6 is a side elevational view of another example of an apparatus of the present invention for bonding materials with induction heating. -
FIG. 7 is a side elevational view of another example of an apparatus of the present invention for bonding materials with induction heating. - FIGS. 8(a), 8(b) and 8(c) illustrate another example of the present invention for bonding materials with induction heating.
- Referring now to the drawings, wherein like numerals indicate like elements, there is shown in
FIG. 1 throughFIG. 5 , one example ofapparatus 10 of the present invention for bonding of materials with induction heating.Apparatus 10 includes firstinduction heating plate 12,frame 14 and secondinduction heating plate 16. First and secondinduction heating plates frame 14, are formed from a heat resistant, non-electrically conductive material, such as a ceramic composition. Firstplate induction coil 18 is disposed in firstinduction heating plate 12;frame induction coil 20 is disposed inframe 14; and secondplate induction coil 22 is disposed in secondinduction heating plate 16. When a castable material, such as a ceramic composition, is used for the heating plates and frames, the coils may be embedded in the heating plates and frame during the casting process. - The induction coils are arranged to form a transverse induction coil assembly for inductively heating an electrically
conductive sheet 90 placed between the first induction heating plate, and the combination of the frame and second induction heating plate when the second induction heating plate is inserted into the frame. While the sheet is generally referred to as a metal sheet, any electrically conductive material may be used. The particular arrangement of coils shown in the figures illustrates one non-limiting example of transverse flux coil arrangements that can be used in the present invention. The illustrated induction coils may be fluid (liquid or gas) cooled by circulation of a cooling fluid, such as water, through hollow induction coils or separate cooling coils in the heating plates and frame. In some examples of the invention, an induction coil may not be necessary inframe 14. -
Metal sheet 90 is placed upon the top surface of firstinduction heating plate 12. The dimensions ofmetal sheet 90 are such that whenframe 14 is placed over the top surface of firstinduction heating plate 12, the perimeter of the metal sheet will extend beyond the interior open space inframe 14 to establish a metal sheet contact surface around the metal sheet's perimeter that is sandwiched between the top surface of the firstinduction heating plate 12 and the bottom surface offrame 14. - With
metal sheet 90 positioned on the surface of firstinduction heating plate 12, as described above,frame 14 and secondinduction heating plate 16 are placed over the top surface of the firstinduction heating plate 12 and the metal sheet. The interior open space inframe 14 is sized to allow the fitting of secondinduction heating plate 16 so that the bottom surface of the secondinduction heating plate 16 makes contact withmetal sheet 90. With the frame and second induction heating plate placed overmetal sheet 90, suitable ac current is supplied from one or more power sources to firstplate induction coil 18,frame induction coil 20, and secondplate induction coil 22. The magnetic field created by ac current flow in the firstplate induction coil 18 inductively penetrates and heats into the facing side ofmetal sheet 90, whereas the magnetic fields created by ac current flow in the frame induction coil and second plate induction coil inductively penetrate and heat into the opposing side of the metal sheet. As best illustrated inFIG. 5 , the orthogonal orientation of the first plate induction coil to the combination of the frame and second plate induction coils provides a crisscross induction heating pattern that enhances uniform heat penetration of the sheet. Pressing the metal sheet between the first and second induction heating plates prevents surface distortion of the sheet as it is heated. - When
metal sheet 90 has been inductively heated to a desired temperature, secondinduction heating plate 16 is raised at least a sufficient distance to allow pouring of a molten metal composition, such as a copper or aluminum alloy, onto the top surface of the heated metal sheet. The temperature of the metal sheet may be sensed by one or more sensors, such as contact thermocouples embedded in the first and/or second induction heating plates to determine when the sheet has been heated to the desired temperature. For example, if the metal sheet is steel, it is heated to approximately 2,100° F. for casting of a molten alloy, such as bronze, onto its surface. While the term “molten metal” or “molten alloy” is used, any liquid material capable of bonding with the heated electrically conductive sheet may be used.Frame 14 remains in place to hold the metal sheet flat and to provide a dam for the molten metal composition. The molten metal may be ported through one or more openings inframe 14, or poured, into the interior open space inframe 14 which was previously occupied by the second induction heating plate. After pouring a quantity of molten metal over the top surface of the metal sheet, the metal will bond with the sheet as it cools. Alternatively, the metal can be quenched by injecting a quench fluid or gas into the interior open space in the frame over the top surface of the cooled molten metal. The quench material may be ported through one or more openings inframe 14, or poured, into the interior open space inframe 14. The now solidified molten metal is bonded to the metal sheet to form a bonded metal product, andframe 14 can be removed from over the top surface of firstinduction heating plate 12. The interior surface wall offrame 14 may be skewed towards its outer wall in the region where the molten metal is poured to facilitate removal of the frame. Additionally the same region of the wall may be specially treated with a coating that will inhibit bonding of the molten metal to the wall of the frame. By way of example, and not limitation, a typical range of thickness of the metal sheet is approximately 3.5 to 19 mm, and a typical range of thickness of the cast metal on the metal sheet is approximately 2.5 to 5.0 mm. Further working of the product can include milling for thickness control of the product. If the product is used as slide bearings, the product is appropriately cut to the desired dimensions. For rotary slide bearings, the cut product is then worked to a cylindrical shaped. - In an alternative embodiment of the invention, the top surface of first
induction heating plate 12, rather than being flat, is indented for an area approximately equal to the surface area of the bottom surface of secondinduction heating plate 16. In this arrangement, aftermetal sheet 90 has been heated, the second induction heating plate can be moved towards the metal sheet to apply sufficient pressure on the heated sheet to force it into the indentation in the first induction heating plate. In this example, the frame does not generally provide a dam for the molten metal composition that is poured over the top of the sheet since the raised edges of the indented metal sheet and/or the walls of the indentation will serve as a dam for the molten metal composition. In this example of the invention, the frame serves as a means for holding the metal sheet in place during induction heating and molten metal pour after the sheet is pressed into the indentation in the first induction heating plate. - In other examples of the invention longitudinal flux coils, such as solenoidal coils, may be utilized. For example, as illustrated in
FIG. 8 (a),solenoidal induction coil 21 is disposed ininductor assembly 23.Metal sheet 90 is inserted intoindentation 25 in first heatresistant plate 13. Second heatresistant plate 17 is placed over the first ceramic plate and the enclosed metal sheet is inserted intoinductor assembly 23 as shown inFIG. 8 (b) wherein it is inductively heated by a magnetic field established when as current flows throughcoil 21. After the metal sheet reaches the desired temperature, the enclosed metal sheet is removed from the inductor assembly, and the second heat resistant plate is removed, as shown inFIG. 8 (c), so that the molten metal can be poured over the metal sheet in the indentation. - In another example of
apparatus 11 of the present invention for bonding of materials with induction heating, as illustrated inFIG. 6 , a continuous supply ofbase metal sheet 92 is provided from base metalsheet supply roll 30 and a continuous supply ofbond material sheet 94 is provided from bond materialsheet supply roll 32. Steel is a suitable, but non-limiting, composition of the base metal sheet, and bronze is a suitable, but non-limiting, composition of the bond material sheet. Suitable joining and conveying means, such asrollers 36press metal sheet 92 andbond material sheet 94 together and advance it through one or more induction coils 38 wherein the magnetic field established by an ac current flow through the coils inductively heats and bonds the bond material sheet to the base metal sheet. The one or more induction coils may be of any suitable configuration, including transverse flux or longitudinal flux coils, or a combination thereof. Since the induced current flows in the bond material sheet and returns through the base metal sheet, the required frequency of the ac current in the one or more induction coils is lower than that required for the previous examples of the invention. Optionally the bonded sheets may be quenched with a suitable quench medium supplied through quenchapparatus 40 after the bonded sheets exit from the one or more induction coils. The bonded sheets can be accumulated, for example, on bondedsheets product roll 42 for bulk shipment to finishing facilities that produce, for example, slide bearings from the product roll. - Optionally the bonded sheets may be cut into one or more bonded products by applying suitable cutting means, such as cutting
shear 41, which is schematically shown inFIG. 6 andFIG. 7 , to the bonded sheet. -
FIG. 7 illustrates an alternative to the arrangement inFIG. 6 . In the example of the invention shown inFIG. 7 , twobond material sheets 94 a and 94 b are provided from bond material sheet supply rolls 32 a and 32 b, respectively, and are disposed between twobase metal sheets 92 a and 92 b, which are provided from base metal sheet supply rolls 30 a and 30 b. Suitable joining and conveying means, such asrollers 36press metal sheets 92 a and 92 b together with the twobond material sheets 94 a and 94 b between them, and advance the pressed sheets through one or more induction coils 38 wherein the magnetic field established by an ac current flow through the coils inductively heats and bonds each of the two bond material sheets to the base metal sheet making contact with it. Generally the melt temperature of the bond material sheet is lower than the melt temperature of the base metal sheet. In some arrangements the required heated temperature of the base metal sheet may be sufficient to overheat the bond material sheet. The arrangement shown inFIG. 7 minimizes heating of the bond material sheets since induced currents flow only through the two opposing base metal sheets. Consequently the required frequency of the ac current in the one or more induction coils is lower than that required for the previous example of the invention inFIG. 6 . After optional quenching, bonded sheets comprising base metal sheet 92 a and bond material sheet 94 a is accumulated on bondedsheets product roll 42 a and bonded sheets comprisingbase metal sheet 92 b andbond material sheet 94 b is accumulated on bondedsheets product roll 42 b. Optionally a sheet of heat resistant material can be inserted between adjacent facing sides ofbond material sheets 94 a and 94 b prior to induction heating to keep the two bond metal sheets from sticking together. The sheet of heat resistant material is removed subsequent to the step of induction heating. - The foregoing examples do not limit the scope of the disclosed invention. The scope of the disclosed invention is further set forth in the appended claims.
Claims (20)
1. An electric induction bonding apparatus comprising:
a first induction heating plate having a surface for placement of an electrically conductive sheet, the first induction heating plate comprising one or more first induction coils disposed within a heat resistant material;
a second induction heating plate selectively locatable over the surface of the first induction heating plate, the second induction heating plate comprising one or more second induction coils disposed within a heat resistant material;
a frame disposed around the second induction heating plate, the frame selectively locatable over the surface of the first induction heating plate to form a dam over the surface of the first induction heating plate; and
at least one or more ac power supplies connected to the one or more first and second induction coils.
2. The electric induction bonding apparatus of claim 1 wherein the frame further comprises one or more third induction heating coils disposed within a heat resistant material.
3. The electric induction bonding apparatus of claim 1 further comprising one or more fluid cooling passages in at least the first or second induction heating plate.
4. The electric induction bonding apparatus of claim 1 wherein the one or more first induction coils are orthogonally oriented to the one or more second induction heating coils.
5. The electric induction bonding apparatus of claim 1 wherein the first or second induction heating plates further comprises one or more temperature sensing devices disposed in the heat resistant material.
6. A method of producing a bonded product by electric induction heating, the method comprising the steps of:
placing an electrically conductive sheet between a first induction heating plate and a second induction heating plate disposed within a separable frame;
supplying ac current to one or more induction heating coils in the first and second induction heating plates to establish magnetic fields that couple with the electrically conductive sheet to inductively heat the sheet;
separating the first induction heating plate and the frame from the second induction heating plate; and
pouring a liquid bonding material into the volume bounded by the frame and a surface of the electrically conductive sheet.
7. The method of claim 6 further comprising the step of quenching the liquid bonding material on the electrically conductive sheet.
8. The method of claim 6 further comprising the step of cooling at least the first induction heating plate, the second induction heating plate, or the frame.
9. The method of claim 6 further comprising the step of sensing the temperature of the first or second induction heating plate prior to the step of separating the first induction heating plate and the frame from the second induction heating plate.
10. The method of claim 6 further comprising the step of supplying ac current to one or more induction coils in the frame.
11. An electric induction bonding apparatus comprising:
a first induction heating plate having an indented surface area for placement of an electrically conductive sheet, the first induction heating plate comprising one or more first induction coils disposed within a heat resistant material;
a second induction heating plate having a surface area substantially the same as the indented surface area of the first induction heating plate, the surface area of the second induction heating plate selectively locatable over the indented surface area of the first induction heating plate, the second induction heating plate comprising one or more second induction coils disposed within a heat resistant material;
a frame disposed around the second induction heating plate, the frame selectively locatable over the surface of the first induction heating plate; and
at least one or more ac power supplies connected to the one or more first and second induction coils.
12. The electric induction bonding apparatus of claim 11 wherein the frame further comprises one or more third induction heating coils disposed within a heat resistant material.
13. The electric induction bonding apparatus of claim 11 wherein the one or more first induction coils are orthogonally oriented to the one or more second induction coils.
14. The electric induction bonding apparatus of claim 11 wherein the first or second induction heating plates further comprises one or more temperature sensing devices disposed in the heat resistant material.
15. A method of producing a bonded product by electric induction heating, the method comprising the steps of:
placing an electrically conductive sheet between a first induction heating plate and a second induction heating plate disposed within a separable frame;
supplying ac current to one or more induction heating coils in the first and second induction heating plates to establish magnetic fields that couple with the electrically conductive sheet to inductively heat the sheet;
pressing the electrically conductive sheet into an indentation in the first induction heating plate with the second induction heating plate;
moving the second induction heating plate away from the electrically conductive sheet; and
pouring a liquid bonding material into the indentation over the electrically conductive sheet.
16. The method of claim 15 further comprising the step of quenching the liquid bonding material over the electrically conductive sheet.
17. The method of claim 15 further comprising the step of supplying ac current to one or more induction coils in the frame.
18. The method of claim 15 further comprising the step of cooling at least the first induction heating plate, the second induction heating plate, or the frame.
19. The method of claim 15 further comprising the step of sensing the temperature of the first or second induction heating plate prior to the step of pressing the electrically conductive sheet into the indentation in the first induction heating plate with the second induction heating plate.
20. The method of claim 15 further comprising the step of sensing the temperature of the first or second induction heating plate prior to the step of moving the second induction heating plate away from the electrically conductive sheet.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/735,098 US20070181564A1 (en) | 2002-07-09 | 2007-04-13 | Bonding of Materials with Induction Heating |
US12/537,113 US20090291320A1 (en) | 2002-07-09 | 2009-08-06 | Bonding of Materials with Induction Heating |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US39451502P | 2002-07-09 | 2002-07-09 | |
US10/615,150 US7205516B2 (en) | 2002-07-09 | 2003-07-08 | Bonding of materials with induction heating |
US11/735,098 US20070181564A1 (en) | 2002-07-09 | 2007-04-13 | Bonding of Materials with Induction Heating |
Related Parent Applications (1)
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US10/615,150 Division US7205516B2 (en) | 2002-07-09 | 2003-07-08 | Bonding of materials with induction heating |
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US12/537,113 Division US20090291320A1 (en) | 2002-07-09 | 2009-08-06 | Bonding of Materials with Induction Heating |
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US10/615,150 Expired - Fee Related US7205516B2 (en) | 2002-07-09 | 2003-07-08 | Bonding of materials with induction heating |
US11/735,098 Abandoned US20070181564A1 (en) | 2002-07-09 | 2007-04-13 | Bonding of Materials with Induction Heating |
US12/537,113 Abandoned US20090291320A1 (en) | 2002-07-09 | 2009-08-06 | Bonding of Materials with Induction Heating |
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US10/615,150 Expired - Fee Related US7205516B2 (en) | 2002-07-09 | 2003-07-08 | Bonding of materials with induction heating |
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US12/537,113 Abandoned US20090291320A1 (en) | 2002-07-09 | 2009-08-06 | Bonding of Materials with Induction Heating |
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US (3) | US7205516B2 (en) |
AU (1) | AU2003256459A1 (en) |
WO (1) | WO2004006274A2 (en) |
Cited By (1)
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---|---|---|---|---|
US20090324456A1 (en) * | 2002-02-11 | 2009-12-31 | Mcwhorter Edward Milton | Linear allignment chamber for carbon dioxide large volume disposal |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
AU2007204999A1 (en) * | 2006-01-09 | 2007-07-19 | Inductotherm Corp. | Electromagnetically shielded induction heating apparatus |
WO2011029274A1 (en) * | 2009-09-11 | 2011-03-17 | Suzhou Red Maple Wind Blade Mould Co., Ltd. | Wind blade mould including a heating system |
DE102011053672B4 (en) * | 2011-09-16 | 2017-08-10 | Benteler Automobiltechnik Gmbh | Method and arrangement for heating a metal plate |
TW201414559A (en) * | 2012-10-08 | 2014-04-16 | Power Mate Technology Co Ltd | Welding method for metal housing and plate body |
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- 2003-07-08 WO PCT/US2003/021296 patent/WO2004006274A2/en not_active Application Discontinuation
- 2003-07-08 US US10/615,150 patent/US7205516B2/en not_active Expired - Fee Related
- 2003-07-08 AU AU2003256459A patent/AU2003256459A1/en not_active Abandoned
-
2007
- 2007-04-13 US US11/735,098 patent/US20070181564A1/en not_active Abandoned
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2009
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US5483043A (en) * | 1993-11-29 | 1996-01-09 | General Electric Company | Induction heating of polymer matrix composites in a mold press |
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US7205516B2 (en) | 2007-04-17 |
WO2004006274A3 (en) | 2004-03-25 |
WO2004006274A2 (en) | 2004-01-15 |
AU2003256459A1 (en) | 2004-01-23 |
AU2003256459A8 (en) | 2004-01-23 |
US20090291320A1 (en) | 2009-11-26 |
US20040007568A1 (en) | 2004-01-15 |
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Owner name: INDUCTOTHERM CORP., NEW JERSEY Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:FISHMAN, OLEG S.;CAO, MIKE MAOCHANG;REEL/FRAME:020146/0695 Effective date: 20071121 |
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