This application is based upon and claims the benefit of the priority of Japanese patent application No. 2008-014434 filed on Jan. 25, 2008, the disclosure of which is incorporated herein in its entirety by reference thereto.
The present invention relates to a heating equipment and a heating method for heating a plate material to be heated, and particularly the invention relates to a heating equipment and a heating method for heating a material to be heated by directly contacting a plurality of heating elements with the material to be heated.
A hot press-forming is a public technique to press a heated steel material in a hot state for forming automobile parts and the like. In addition, when quenching the material with a low-temperature press die(s) at the same time of the press-forming, it is possible to form a part that have excellent characteristics such as a high tensile strength and the like.
For heating a material, it is a common method to heat a material in a heating equipment such as a heating furnace, and the like; however, it will take approximately 3 to 5 minutes to heat a material up to 900 degrees C. in a heating furnace, for example, and the time is rather longer than a time required for a pressing step. It causes decrease in production efficiency because useless waiting time is necessary at the pressing step. Thus there is a demand to provide a method that can heat a material more rapidly.
One of methods for heating a material rapidly is a block heating method. This is a method to heat a steel plate material 21 to be heated, as shown in
The entire disclosures of the above Patent Documents 1 and 2 are incorporated herein by reference thereto. The analysis on the related art is set forth below by the present invention.
When heating a material up to 900 degrees C. or more using a block heating equipment, a cost of the equipment becomes very high because a material for the block is limited to that having a high melting point. Therefore, when heating a large part, it needs a large number of blocks and resulting in a high-cost heating equipment.
The block heating is a method to heat a steel plate by contacting a metal block, which is heated by heaters internally embedded, with the steel plate. A material for a block is limited to that causes small thermal deformation or distortion even when the block is heated up to high temperature so as to assure a tight contact of the block with a steel plate. In addition, the block should be in tight contact with embedded heaters so as to ensure heating of the block itself and therefore, it is necessary to machine and assemble the block and heaters with high accuracy and materials of less thermal deformation or distortion are required again for this point of view.
Since materials suitable for a block are limited due to its requirement for long time usage in high temperatures, it causes a high cost. In addition, such materials are generally difficult to machine, resulting in a high machining cost and fabrication cost. When heating a large part such as a structural part of an automobile, a large equipment is necessary and thus a cost for such an equipment becomes very high due to reasons above mentioned. On the other hand, such an equipment consumes much electric power since heaters should be switched on continuously to keep the block in high and uniform temperature, because it will take much time to heat the whole block up to high temperature from low temperature.
It is an object of the present invention to provide a rapid heating equipment having a small and simple structure, consuming less energy and being easy for repair and replacement and a method for rapid heating.
According to a first aspect of the present invention, there is provided a heating equipment for a plate material to be heated, wherein a contact-heating surface or surfaces is/are configured by arranging a plurality of heating elements at predetermined intervals, in a planar fashion and in a predetermined pattern on a base plate having a heat-insulating property, and the contact-heating surface(s) is/are directly contacted with the plate material to be heated for heating the plate material.
Preferably, the heating element is rod-shaped or strip-shaped with a rectangular section or rod-shaped with a circular or ellipsoidal section.
When the heating element has a rectangular section, preferably, a surface contacting with the plate material to be heated has a convex curved (profiled) surface along the whole length of the heating element.
Preferably, an insulation material is provided between the plurality of heating members and the insulation member is elastic or structured such that the insulation member can change its position in an orthogonal direction relative to the contact-heating surface.
Preferably, a plurality of the base plates, each having a heat-insulating property and configuring the contact-heating surface(s) by arranging the plurality of heating elements, is arranged on both sides of the plate material to be heated and the plate material is sandwiched by the base plates to make a direct contact with the contact-heating surface of the heating elements for heating the plate material.
Preferably, the plurality of heating elements arranged on both sides of the plate material to be heated are arranged alternately on both sides and such that orthogonal projections of the heating elements on both sides on a plane parallel to the base plates overlap partially each other.
Preferably, for overlapping the heating elements, the heating elements is arranged such that, in a case where the heating elements on the base plates on both sides are contacted with each other without the plate material to be heated, a contacting point corresponds to a cross point of convex curved surface portions and a line connecting both curvature centers of the convex curved surface portions of both of the heating elements near the contacting point.
Preferably, the base plate is configured by a plurality of units including a plurality of the heating elements.
Preferably, heating abilities of the plurality of heating elements can be controlled for every heating element or every unit, and can be determined in a desired heating pattern.
Preferably, the base plate is comprised of ceramics.
According to a second aspect of the present invention, there is provided a heating method for a plate material to be heated, which comprises: configuring a contact-heating surface or surfaces by arranging a plurality of heating elements at predetermined intervals, in a planar fashion and in a predetermined pattern on a base plate having a heat-insulating property, and providing the base plates on both sides of the plate material to be heated and sandwiching the plate material to make a direct contact with the contact-heating surface or surfaces of the heating elements for heating the plate material.
Effect of the Invention
According to the present invention, the equipment becomes small in size, simple in structure and low in cost because a block is eliminated (i.e., not used). It is possible to heat a material to be heated quickly because heating elements are directly contacted with a material. The equipment may be replaced by each unit and therefore repairs of the equipment become easy. A degree of freedom of heating is high because control of heating by each unit or each heating element may be possible. In addition, heating source may be off during a non-use period because the equipment can be heated in a short time and therefore, energy saving can be achieved.
As for explanation of signs, refer to the end of the description.
Two or more heating elements are arranged at specified intervals and in planar fashion on a base plate having a heat-insulating property. It is designated as a “unit”. Ceramics etc. can be used for the base plate. The heating element has a rod-type or strip-type shape of a rectangular section or has a rod-type shape of a circular or oval (ellipsoidal) section, and the heating elements are arranged such that heating surfaces of the heating elements contacting with a material to be heated should contact with the material uniformly as a whole. When sections of the heating elements are rectangular, each contact surface with the material to be heated may be flat; however, more tight contact may be obtained by making the contact surfaces into convex curved surfaces and by press-contacting with load (or pressure). It is preferable that a ratio of a height of the convex curved surface to a width of the heating element has certain specified value. A contact-heating surface having a necessary heating area is obtained by arranging the one or more units in planar fashion.
The material to be heated is heated by directly contacting the contact-heating surface with the material. By this method the material to be heated can be rapidly heated efficiently. A width of the unit may range approximately 50 to 200 mm and a length may range approximately 100 to 1500 mm. A heating area which is necessary for a material to be heated can be obtained by combining sufficient number of the units. The area is not limited but may be, presumably, approximately 4000 mm×3000 mm at the largest.
Basically every kind of heating element may be used. A known heater such as an electric heater, sheath heater or gas heater (radiant tube heater), and the like may be used with respect to a temperature required. The heater is generally used having a rod-shape or strip-shape with a length, approximately, of 100 to 1500 mm and having a rectangular, round or oval section with one side length or diameter, approximately, of 5 to 200 mm.
Insulators are provided between heating elements. They have a role to heat a material to be heated uniformly by suppressing heat radiation from portions without heaters and, when the heating elements are arranged alternately on both sides, to make a tight contact of the heating elements and the material to be heated by pressing the material from opposite side of the heating element. In addition, they have an effect to make it easy to separate the material to be heated and the heating elements when the pressing force from the heating elements is released after heating. When heating elements are arranged alternately on both sides, heat insulation members have elasticity or a structure so as to change its vertical position or horizontal position, etc. so as to make the heating elements contact tight with a material to be heated when the heating elements ware press-contacted with the material to be heated. Glass wool or asbestos and the like is used for the heat insulation member.
A material to be heated may be heated from only one side. However, a plate material to be heated may be heated from both sides of the plate material by arranging a plurality of units on both sides and press-contacting the intervened plate material. Generally a material to be heated may be sandwiched from upside and downside; however, it may be possible to sandwich from right side and left side or in an oblique direction tilted from the up and down (vertical) direction or the right and left (horizontal) direction. A contact surface of a heating element with a material to be heated may be flat; however, the contact of the heating element with the material may become more secured by forming the contact surfaces of the heating elements in a convex curved (profiled) surface (convex curved surface portion) and press-contacting them against the material from both sides. In this case, the heating elements on both sides are arranged alternately. That is, heating elements are not arranged on regions where heating elements are arranged at corresponding opposite side and heating elements are arranged on regions where no heating element is arranged at corresponding opposite side. However, it is preferable to arrange the heating elements such that parts (edges) of the heating elements are overlapping each other. The “partial overlapping” means that when the heating elements on both sides are perpendicularly projected on a plane parallel to a base plate, the projected images overlap partially each other.
When arranging the heating elements partially overlapped, it is preferable to arrange such that the material to be heated should contact with at least one of the heating elements on both sides and that an area which contacts with the heating elements on both sides at the same time should be minimized. For this purpose the arrangement may be performed according the following concept. When contacting heating elements on both sides with each other without a material to be heated, both edge portions (correspond to edge portions of a section orthogonal to longitudinal axis of a rod-type heating element) of convex curved surface portions of the heating elements will contact with each other. The heating elements may be arranged such that a contacting point corresponds to a cross (intersection) point of a line connecting both curvature centers of convex curved surface portions (of both of the heating elements) containing the contacting point and the convex curved surface portion of the heating element.
An effect of uniform heating of whole material to be heated can be obtained by arranging the heating elements on both sides in partially overlapping manner in such a way, contacting whole of the material to be heated with at least one of the heating elements and reducing an area which contacts with the heating elements on both sides at the same time.
The present heating equipment has a heating control system that can control heating capacity of every heating element or every unit. Thus any heating patterns or heating temperatures can be freely selected according to sizes or shapes of a material to be heated. It contributes to energy saving because unnecessary heating elements are not heated up and heating of whole equipment can be turned off during a waiting time since it can be heated up quickly.
The heaters 2 of the example are sheath heaters having a rod shape. A section of each heater perpendicular to its longitudinal direction is nearly rectangular and a contacting surface with the plate material 1 has a convex curved (profiled) surface. The number of the heaters 2 is not limited; however, in this example, four heaters 2 are arranged in planar fashion (so as to contact with the plate material 1 uniformly) on each base plate. A base plate on which two or more heaters 2 are arranged is called as a unit and a unit on the upper side of the material to be heated is called as an upper unit 6 and a unit on the lower side of the material to be heated is called as a lower unit 7.
As shown in
As shown in
As shown in
When arranging the heaters overlapped, it is preferable to arrange the heaters such that a region of the plate material 1 that contacts with the heaters 2 on both upper and lower sides should be minimized while the whole of the plate material 1 contacts with at least one heater 2 of the upper and lower heaters.
For this purpose, the heaters are arranged as follows.
Although a curved surface may be formed on the plate material 1 as a material to be heated because the contacting surface (convex curved surface portion 2a) of the heater 2 to the plate material 1 is curved, it does not become a problem because the curved surface of the plate material 1 is eliminated during a processing of the plate material 1 into a determined shape at a press step after heating.
The heating equipment according to the present invention can form a wide heating area by arranging a plurality of base plates (units) each having two or more heating elements. Further, a heating ability (capacity) may be controlled by every heater or every unit using a heating control system 15 according to a size or shape of a material to be heated.
In
Although only an arrangement of lower units 7 is shown in
The heating equipment of the present invention is applicable in the case where a part of a material should be heated at a higher temperature and the other part of the material may be heated at a lower temperature.
Although the present invention has been elucidated by way of the disclosed exemplary embodiment, which are not restrictive to the present invention, and modes or examples of the invention can be modified or adjusted according to the person skilled in the art within the entire disclosure of the present invention.
(Explanation Of Reference Signs)
Number | Date | Country | Kind |
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2008-014434 | Jan 2008 | JP | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP2008/069117 | 10/22/2008 | WO | 00 | 7/14/2010 |
Publishing Document | Publishing Date | Country | Kind |
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WO2009/093365 | 7/30/2009 | WO | A |
Number | Name | Date | Kind |
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6578399 | Haas et al. | Jun 2003 | B1 |
Number | Date | Country |
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13537 | Jan 1977 | JP |
59-165395 | Sep 1984 | JP |
61-259482 | Nov 1986 | JP |
1-146528 | Oct 1989 | JP |
11-145166 | May 1999 | JP |
2003-53437 | Feb 2003 | JP |
2006-110549 | Apr 2006 | JP |
Entry |
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Official Action dated Dec. 17, 2010, issued by the Japanese Patent Office in corresponding Japanese Patent Application No. 2008-014434, and English translation of Official Action. |
International Search Report mailed on Dec. 9, 2008 by the Japanese Patent Office as the International Searching Authority in International Application No. PCT/JP2008/069117. |
Written Opinion mailed on Dec. 9, 2008 by the Japanese Patent Office as the International Searching Authority in International Application No. PCT/JP2008/069117. |
English translation of the International Preliminary Report on Patentability issued Sep. 10, 2010 by the International Bureau of WIPO in International Application No. PCT/JP2008/069117. |
Extended European Search Report issued on Dec. 6, 2012 by the European Patent Office in corresponding European Patent Application No. 08871425.8 (7 Pgs). |
Number | Date | Country | |
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20110042369 A1 | Feb 2011 | US |