This application is based upon and claims the benefit of the priority of Japanese patent application No. 2008-206261 filed on Aug. 8, 2008, the disclosure of which is incorporated herein in its entirety by reference thereto.
The present invention relates to a heating device and a heating method.
A thin and high-strengthened material is used for parts of an automobile, for example, for satisfying both safety and economic purposes. A hot pressing (die quenching or hot forming) method, in which a heated steel plate is pressed by press-dies of low temperature and quenched, is known for a purpose of obtaining such a material. The method is practiced as follows. A steel plate is heated to the austenitizing temperature or more and then rapidly cooled by press-dies to quench the steel plate at the same time of its shape forming.
As a heating method for the hot pressing method, a method is known such as an electric (conduction) heating method or a method using a block heater, which can heat a material rapidly, as well as a furnace heating method. Patent Document 1 discloses a technique using a near infrared radiation heater as a heating furnace for hot pressing of parts of an automobile. Patent Documents 2 and 3 disclose a technique using infrared radiation for supplementary heating in a very small area of an electronic circuit part.
Patent Document 4 discloses a heating furnace for a work inside of which is divided into regions and each region can be heated at different temperature.
The entire disclosures of the above Patent Documents 1 to 4 are incorporated herein by reference thereto. The analysis on the related art is set forth below by the present invention.
On the other hand, there is a problem that a steel plate made by the hot pressing method becomes difficult to process than a steel plate before quenching because the steel plate made by the hot pressing method has a higher strength than that before quenching. As a result, needs for partial heat processing, by which a material is partially quenched or partially non-quenched, are increasing even for a hot pressing method for a purpose of optimizing property of product and processing steps. In that case, a portion to be partially heated should be partitioned in any desired shapes and in very small area according to a demand.
However, conventional furnaces or an electric heating cannot fulfill the needs, nor the heating furnace disclosed in Patent Document 1. As for partitioning of the furnace as described in Patent Document 4, it is difficult to partition in any desired shapes, and a gradual temperature-changing portion between a high temperature portion and a low temperature portion will become wide.
A near infrared radiation heating method is an alternative for rapid heating. The infrared radiation heating can set desired heating temperature of an infrared radiation lamp, and therefore it can heat a material to be heated partially and may change heating temperature partially.
However, according to knowledge of the present inventors, when heating a material partially by infrared radiation heaters, multiple heaters have to be arranged in a specified pattern and heating temperature of each heater has to be controlled separately. Even in that case, only linear partial heating was possible and it was difficult to control a position of a boundary of temperature definitely. In addition, a gradual temperature-changing portion between a high temperature portion and a low temperature portion was very wide and it was not possible to make the gradual temperature-changing portion as narrow as practical.
It is an object of the present invention to provide a heating device and a heating method which are able to quickly and accurately partition each region of a material to be heated and heat up each of the region to a required temperature, and a shape and required temperature of each region is different from each other. In addition, a gradual temperature-changing portion between the regions, that is, a portion that has a temperature gradient, can be made as small as practical by the device or method.
The object can be achieved by a heating device and a heating method that can heat a material to be heated by applying an electromagnetic wave to the material, wherein a plate member(s) which shields, absorbs and/or reflects the applied electromagnetic wave and has a predetermined pattern contour can be placed, at least partially, close to the material to be heated.
Steel materials such as a steel bar and a steel plate (steel sheet or steel product formed three-dimensionally) are typically selected as a material to be heated and non-iron materials, alloys, composite materials and the like are also included. Infrared radiation, microwave, laser and the like can be used as an electromagnetic wave for heating. Particularly, near infrared radiation can heat various kinds of metals rapidly. An insulator such as ceramics, asbestos and the like, reflecting mirror such as a gold-plating reflecting mirror and the like or reflecting materials may be used as a material to shield, absorb and/or reflect such electromagnetic radiations.
Another aspect of the present invention is a plate member(s) having predetermined patterned contour and used for any one of the heating device above explained, which shields, absorbs and/or reflect the electromagnetic wave for heating.
According to the present invention, it is possible to quickly and accurately partition each region of a material to be heated and heat up each of the region separately to a required temperature for each region, and a shape and required temperature of each of the region is different from each other, and a gradual temperature-changing portion between the regions, that is, a portion that has a temperature gradient, can be made as small as practical.
As for the explanation of symbols, please refer to the end of description.
Preferably, a plurality of generators of the electromagnetic radiation are arranged in the heating device of the present invention and a heating capacity of each of the generators can be controlled. By combining with a plate member such as a heat shielding plate, any region for high temperature heating portion or low temperature heating portion can be set.
Preferably, the generators of the electromagnetic radiation are arranged two- or three-dimensionally around the material to be heated and accordingly the plate member is placed two- or three-dimensionally between the generators and the material to be heated. A three-dimensional material to be heated can be also heated by the structure.
The generators may be near infrared generators and the plate member is made of material(s) which shield, absorb and/or reflect the irradiated near infrared radiation.
The plate member may be made of at least one of ceramics, fiber materials that can shield the irradiated radiation or a composite material thereof, and a reflecting mirror.
Preferably, the plate member is made of at least one component formed two- or three-dimensionally in conformity with a shape of a desired heating area of the material to be heated.
The material to be heated may be a steel plate or a steel plate product shaped three dimensionally. Particularly, a steel plate for parts of an automobile is preferably used.
The heating device may further include at least one radiation generator that is different from the generator of the electromagnetic wave.
The plate member may be supported by a stay bar and placed without contacting with a surface of the material to be heated. Or the plate member may be placed in contact with a surface of the material to be heated.
The generators may be one of middle-infrared generators, far-infrared generators, microwave generators and laser beam generators, and the plate member is made of material(s) which shield, absorb and/or reflect the irradiated electromagnetic radiation.
The whole of a steel material to be heated may be heated at a temperature lower than the austenitizing temperature and at the same time a predetermined area is heated at a temperature higher than the austenitizing temperature. It is possible, by the method, to shorten the heating time for the high temperature heating portion and also to increase shape retentivity of the product.
The present invention will be explained in detail with reference to drawings and exemplary examples. Before explaining the present invention, knowledge obtained by the inventors of the present invention will be explained for clarifying features of the present invention.
As shown in
In the vicinity of the temperature boundary 22a, the high temperature infrared ray 2a′ is shielded by the heat shielding plate 10 and therefore it does not interfere with the low temperature heating portion 23. Thus, the temperature boundary 22a can be positioned accurately and the gradual temperature-changing portion around the temperature boundary 22a can be made small enough. The fact that the temperature boundary 22a can be set in any shape means that a high-strengthened portion and a low-strengthened portion of a hot-formed product can be positioned freely according to functional requirements of the product, and it is advantageous for optimizing product performance and increasing of freedom of product design.
In this example, a portion where strength is given by a hot pressing is heated at high temperature up to the austenitizing temperature or more (approximately 800 degrees C. or more is preferable) and other portion is heated at the temperature lower than the austenitizing temperature by heating including from below. This contributes to shortening the heating time of the high temperature heating portion and to increasing shape retentivity of the material, that is, a spring back of the material to be heated after forming becomes small.
Thanks to the shielding plate, as shown in
A high temperature heating portion 21 (where no local heat shielding plate 10 is provided) is heated to a high preset temperature by a high temperature infrared ray 2a radiated from the infrared lamps 1 disposed above for high temperature heating. In addition, the heating time is shortened because the bottom side of the high temperature heating portion 21 is also heated by the low temperature infrared ray 2b radiated from the near infrared lamps 1 disposed below. The high temperature infrared ray 2a′ is shielded along the shape of the local heat shielding plate 10, and therefore no interference to the low temperature heating portion 23 occurs and it becomes possible to position the boundary from the high temperature heating portion 21 accurately and to make the gradual temperature-changing portion around the boundary small. A shape of the low temperature heating portion 23 can be changed as desired by changing the shape of the local heat shielding plate 10 as desired.
A low temperature heating portion 23 around the high temperature heating portion 21 is not heated to a high preset temperature because a high temperature infrared ray 2a′ from the above is shielded by the heat shielding plate 10 but heated to a low preset temperature by a low temperature infrared ray 2b radiated from the near infrared lamps 1 disposed below. Other portion is heated to a low preset temperature by low temperature infrared rays 2b from both above and below.
The high temperature infrared ray 2a′ is shielded along the shape of the heat shielding plate 10, and therefore no interference to the low temperature heating portion 23 occurs and it becomes possible to position the boundary from the high temperature heating portion 21 accurately and to make the gradual temperature-changing portion around the boundary small. A shape of the high temperature heating portion 21 can be changed as desired by changing the shape of the cut out portion of the heat shielding plate 10 as desired.
Although a sheet plate is used as a material to be heated in examples above explained, a three dimensional material to be heated may be used according to the present invention. That is, a pre-formed product, which is formed in three dimensions to some degree by cold forming or hot forming, can be heated further using the heating device of the present invention. In this case, radiation (electromagnetic wave) generators such as infrared lamps are arranged in three dimensions around a material to be heated and heat shielding plate(s) are arranged in three dimensions between the material to be heated and the electromagnetic wave generators.
A material that can shield infrared rays and difficult to heat such as a ceramics plate or asbestos plate is preferably used as a heat shielding plate. A cooling device may be provided with the heat shielding plate as necessary. A plate a surface of which has a mirror structure such as a gold-reflector for reflecting infrared rays may be also available. In addition, some members of different materials can be combined for making a heat shielding plate.
In examples above explained, a portion other than a high temperature heating portion is heated by infrared radiation at low temperature to increase heating efficiency and to improve shape retentivity after forming. However, only a high temperature heating portion may be heated. Any electromagnetic wave generator other than infrared radiation and a heat shielding plate for shielding the electromagnetic wave may be combined for the present invention. In addition, other heating means may be combined with an electromagnetic wave generator.
The heat shielding plate 10 has a replaceable structure. Thus different heating patterns can be applied by changing the heat shielding plate 10 without changing the near infrared lamps themselves. The heating machine is very versatile because various kinds of materials that can be heated by infrared rays can be heated. In addition, it has a high operability because there is no need for rearrangement of the infrared lamps and it can eliminate the conventional rearrangement works.
It should be noted that other objects, features and aspects of the present invention will become apparent in the entire disclosure and that modifications may be done without departing the gist and scope of the present invention as disclosed herein and claimed as appended herewith.
Also it should be noted that any combination of the disclosed and/or claimed elements, matters and/or items may fall under the modifications aforementioned.
Number | Date | Country | Kind |
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2008-206261 | Aug 2008 | JP | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP2009/064008 | 8/7/2009 | WO | 00 | 2/7/2011 |
Publishing Document | Publishing Date | Country | Kind |
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WO2010/016566 | 2/11/2010 | WO | A |
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Number | Date | Country | |
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20110132897 A1 | Jun 2011 | US |