Patent Grant
10462851
The present invention relates to a molten metal holding furnace for holding a molten metal.
Conventionally, there has been disclosed a molten metal holding furnace for holding a molten metal of aluminum in patent document 1. The molten metal holding furnace disclosed in Patent Document 1 has a furnace body for holding a molten metal. The furnace body has a side wall formed with a hole through which a heating tube is inserted into the molten metal.
Another heating tube which is available for the molten metal holding furnace is disclosed in patent document 2.
Patent Document 1: JP 2013-170801 A
Patent Document 2: JP 5371784 B
Each of the molten metal holding furnaces disclosed in patent documents 1 and 2 uses the transversely immersed heating tube to heat the molten metal through natural convection, which is advantageous in that the molten metal is not excessively heated and, therefore, the oxidation of the molten metal in this furnace is reduced than in another molten metal holding furnace in which the surface of the molten surface is heated.
For an aluminum molten metal holding furnace, a temperature of the molten metal is controlled to, for example, 700 degrees Celsius which is slightly higher than the aluminum melting temperature, i.e., 660 degrees Celsius. The solidification temperature of aluminum is about 550 degrees C. Therefore, the temperature of a proximal end portion of the heating tube (i.e., a portion located outside a furnace wall) is controlled to 550 degrees Celsius or less, preventing the molten aluminum from leaking through cracks possibly generated in the material filled around the heating tube.
If the temperature of the proximal end portion of the heating tube were lowered to a temperature far less than 550 degrees Celsius, an amount of heat released from the proximal end portion of the heating tube increases, which is disadvantageous in terms of thermal efficiency.
The heating tube disclosed in patent document 2 has an inwardly tapered proximal end portion supported by the furnace wall. The side wall of the molten metal holding furnace using the heating tube has an associated tapered through-hole in which the corresponding tapered portion of the heating tube is wedgedly fitted. This results in that the material filled between the heating tube and the through-hole is tightly retained due to the wedge-effect, effectively preventing the leakage of the molten metal. The tapered member of patent document 2 is outwardly and inversely tapered and the maximum cross section of the taper is located at the outermost end of the wall thereof. This arrangement is advantageous in terms of heat radiation, but it might be disadvantageous in terms of heat retention.
It is therefore an object of the present invention to provide a new molten metal holding furnace having appropriate heat dissipation and retention properties.
For this purpose, a molten metal holding furnace according to one embodiment of the present invention comprises
a furnace body (11) including a bottom wall (12), a ceiling wall, and a side wall (13) extending between the bottom wall (12) and the ceiling wall to form a molten metal containing space (18) defined by the bottom wall (12), the ceiling wall, and the side wall (13), the furnace body (11) including at least one insertion hole (20) formed to extend through the side wall (13) or the ceiling wall; and
a heating tube (30) including a heat generator (51) and inserted in the insertion hole (20),
the molten metal holding furnace (10) for holding a molten metal contained in the molten metal containing space (18) at a predetermined temperature by using heat generated by the heat generator (51),
wherein the insertion hole (20) includes an inside cylindrical portion (21) and an outside cylindrical portion (22) in a region from an inside end portion to an outside end portion of the side wall (13) or the ceiling wall, the inside cylindrical portion (21) extending from a starting point (23) at or adjacent the inner end portion to an intermediate point (24) between the inside and outside end portions, the outside cylindrical portion (22) extending from the intermediate point (24) to a terminal point (25) at or adjacent the outside end portion, the inside cylindrical portion (21) having an inner diameter increasing gradually from the starting point (23) to the intermediate point (24) and the outside cylindrical portion (22) having a constant inner diameter,
wherein the heating tube (30) includes a distal cylindrical portion (35) corresponding to the inside cylindrical portion (21) and a proximal cylindrical portion (36) corresponding to the outside cylindrical portion (22), the distal cylindrical portion (35) having an outer diameter increasing gradually from the starting point (23) to the intermediate point (24) and the proximal cylindrical portion (36) having a constant outer diameter smaller than an outer diameter of the distal cylindrical portion (35) at the intermediate point (24),
wherein the heating tube (30) is inserted and positioned in the insertion hole (20) with the distal cylindrical portion (35) of the heating tube (30) located at the inside cylindrical portion (21) of the insertion hole (20) and with the proximal cylindrical portion (36) of the heating tube (30) located at the outside cylindrical portion (22) of the insertion hole (20), and
wherein a filling material (60) is filled between the distal cylindrical portion (35) of the heating tube (30) and the inside cylindrical portion (21) of the insertion hole (20).
According to another embodiment of the present invention, the heating tube (30) has a stepped portion (37) formed of an annular surface extending radially between the distal cylindrical portion (35) and the proximal cylindrical portion (36) of the heating tube (30),
a tubular member (61, 77) is disposed between the proximal cylindrical portion (36) of the heating tube (30) and the outside cylindrical portion (22) of the insertion hole (20), and
the tubular member (61, 77) is pressed against the stepped portion (37) of the heating tube (30).
The tubular member (61, 77) may be made of either a heat conductive metal material or a heat insulating material.
According to another embodiment of the present invention, a fixing member (62) is disposed outside the tubular member (61, 77),
the fixing member (62) is coupled to the furnace wall (14) through a fastening means (63, 64), and
the tubular member (61, 77) is pressed against the stepped portion (37) of the heating tube (30) by the fastening means (63, 64).
According to another embodiment of the present invention, the distal cylindrical portion (35) and the proximal cylindrical portion (36) of the heating tube (30) is made up of one member.
According to another embodiment of the present invention, the distal cylindrical portion (35) and the proximal cylindrical portion (36) of the heating tube (30) are formed of different members, and the distal cylindrical portion (35) and the proximal cylindrical portion (36) are connected by heat.
According to another embodiment of the present invention, the distal cylindrical portion (35) of the heating tube (30) has an outer diameter continuously increasing from the starting point (23) toward the intermediate point (24).
According to another embodiment of the present invention, the inside cylindrical portion (21) of the insertion hole (20) has an inner diameter discontinuously increasing from the starting point (23) toward the intermediate point (24).
According to another embodiment of the present invention, the distal cylindrical portion (35) of the heating tube (30) has an outer diameter discontinuously increasing from the starting point (23) toward the intermediate point (24).
According to another embodiment of the present invention, the inside cylindrical portion (21) of the insertion hole (20) has an inner diameter continuously increasing from the starting point (23) toward the intermediate point (24).
According to the molten metal holding furnace (10) so constructed, the heat of the molten metal moves through the heating tube (30) in a direction from the distal end (inside of the furnace) toward the proximal end (outside of the furnace). Because the cross-sectional area is significantly reduced at the boundary between the distal cylindrical portion (35) and the proximal cylindrical portion (36), the heat transmitted beyond the boundary from the distal cylindrical portion (35) to the proximal cylindrical portion (36) is limited so that the proximal cylindrical portion (36) is maintained at a considerably low temperature. Therefore, a molten metal moving from the inside of the furnace to the outside of the furnace along the outer circumferential surface of the heating tube (30) is solidifies on the way and does not flow out of the furnace. An amount of heat which would be dissipated to the atmosphere is significantly reduced. Therefore, the molten metal holding furnace with an enhanced heat dissipation and retention properties is provided.
A molten metal holding furnace of one embodiment according to the present invention will now be described with reference to the accompanying drawings. In the description of the molten metal holding furnace, portions thereof located inside and outside the furnace are indicated by accompanying positional languages “inside” and “outside”, respectively. In the description of a heating tube inserted through a furnace wall of the molten metal holding furnace, portions of the heating tube located inside and outside the furnace are indicated by accompanying positional languages such as “distal” and “proximal,” respectively.
As shown in
In the region surrounding the periphery of the tube insertion hole 20, the inside fireproof layer 17 of the furnace body 11 is larger in thickness than the outside heat insulating layer 15. The inside cylindrical portion 21 is formed in the fireproof layer 17 and the outside cylindrical portion 22 is formed in the backup layer 16 and the heat insulating layer 15.
The heating tube 30 has a heater protection tube 31. The heater protection tube 31, which is made of silicon nitride-based ceramic, for example, has a substantially cylindrical shape with a closed distal end portion 32 protruding into the molten metal holding chamber 18 and an opened proximal end portion 33 protruding from the side wall 13.
An inner surface of the heater protection tube 31 is defined by a cylindrical surface having a constant diameter and extending entirely from the proximal end portion 33 to the distal end portion 32. An outer surface of the heater protection tube 31 has a constant diameter cylindrical surface portion 34, a tapered cylindrical surface portion (distal cylindrical surface portion) 35, and a constant diameter non-tapered cylindrical surface portion (proximal cylindrical surface portion) 36. When the heater protection tube 31 is inserted in the tube insertion hole 20, the constant diameter cylindrical surface portion 34 is positioned in the molten metal holding chamber 18 and the distal and proximal cylindrical surface portions 35 and 36 are positioned in the vicinities of the fireproof and insulating layers 17 and 15, respectively. The taper angle of the distal cylindrical portion 35 is the same as that of the inside cylindrical portion 21 of the tube insertion hole 20. As shown in the drawings, the proximal cylindrical portion 36 of the heater protection tube 31 has a diameter smaller than that of the outside cylindrical portion 22 of the tube insertion hole 20. A stepped portion 37 is formed of an annular surface extending radially from the distal end of the proximal cylindrical portion 36 toward the proximal end of the distal cylindrical portion 35.
A proximal end opening of the heater protection tube 31 is closed by an end plate 40. The end plate 40 has a first electrode insertion hole 43 extending along a central axis 41 of the heater protection tube 44 and a second electrode insertion hole 44 which extends parallel to the central axis 41 and is radially displaced away from the central axis 41. Electrode bars (terminals) 45 and 46 are inserted through the first and second electrode insertion holes 43, 44 into the interior of the heater protection tube 31.
As shown in the drawings, the first electrode bar 45 disposed on the central axis 41 is extended through the end plate 40 to terminate in the vicinity of the distal end of the heater protection tube 31, and the second electrode bar 46 disposed on the axis 42 away from the central axis 41 is extended through the end plate 40 to terminate in the vicinity of the distal end (the starting point 23) of the distal cylindrical portion 35 of the heater protection tube 31. The proximal ends of the first electrode bar 45 and the second electrode bar 46 are projected outside of the end plate 40.
Two annular or tubular insulating heat-resistant supporting members 47 and 48 are fixed on distal portions of the first electrode bar 45, located in the molten metal holding chamber 18 and spaced apart from each other in the axial direction, to position the first electrode bar 45 on or in the vicinity of the central axis 41. The proximal heat resisting supporting member 48 supports the distal end of the second electrode bar 46. The heat-resistant supporting members 47 and 48 support a hollow insulating heat-resistant cylindrical body 49 externally mounted on the first electrode bar 45 around the central axis 41. Helical grooves 50 are formed on an outer circumferential surface of the heat-resistant cylindrical body 49 mounted on the first electrode bar 45, and a heat generator (electric heater) 51 is fitted in the grooves 50. The heat generator 51 is electrically connected at opposite ends thereof to the first and second electrode bars 45 and 46.
As shown in the drawings, preferably, a heat insulating material 52 is disposed inside a portion of the heater protection tube 31, positioned between the proximal end plate 40 and the proximal heat-resistant supporting member 48.
As shown in the drawings, the first electrode bar 45 may be made of a hollow cylindrical tube to accommodate a thermocouple 53 therein.
The heating tube 30 so constructed, in particular the heater protection tube 31 in which the electrode bar or the heat insulating material has not been assembled is inserted from outside into the tube insertion hole 20 in the side wall 13. Before the insertion of the heater protection tube 31, a filling material 60 of a cement paste or a mortar cement is applied on one or both of the tapered surface (the inside cylindrical portion 21) of the tube insertion hole 20 and the distal cylindrical surface 35 of the heating tube 30 which would be brought into contact with the tapered surface. The heater protection tube 31 is then inserted in the tube insertion hole 20. In this process, the tapered surface (the distal cylindrical portion) 35 of the heater protection tube 31 is fitted into the corresponding tapered surface (the inside cylindrical portion) 21 of the tube insertion hole 20 and thereby indisplaceably fixed in a precise manner. Because the tapered surface (the distal cylindrical portion) 35 of the heater protection tube 31 is wedgedly fitted on the tapered surface (the inside cylindrical portion) 21 of the tube insertion hole 20, the filling material 60 held between the tapered surfaces extends evenly between the tapered surfaces to form a filling material layer having a constant thickness around the heater protection tube 31.
A tubular member 61 may be coaxially and externally mounted on the proximal cylindrical portion 36 of the heating tube 30. In this embodiment, the tubular member 61 is a cylindrical body made of a heat conductive material (e.g., metal such as stainless steel) and the distal end thereof is brought into contact with the stepped portion 37. Therefore, in this embodiment, the tubular member 61 functions as a heat dissipating member. The tubular member 61 may be mounted on the proximal cylindrical portion 36 of the heater protection tube 31 before inserting the heater protection tube 31 into the tube insertion hole 20 or may be mounted on the proximal cylindrical portion 36 of the heater protection tube 31 after inserting the heater protection tube 31 into the tube insertion hole 20. In either case, the filling material 60 such as a cement paste or a cement mortar is filled in an annular gap formed between the outside cylindrical portion 22 of the tube insertion hole 20 and the tubular member 61 and an annular gap between the proximal cylindrical portion 36 of the heating tube 30 and the tubular member 61.
An annular fixing member 62 is disposed on the proximal end of the tubular member 61. The tubular member 61 and the fixing member 62 may be different members or may be integrally connected with each other into a single member. The fixing member 62 is tightened to the outer wall 14 facing thereto by a suitable fastening means (fastener) such that the tightened force can be adjusted. For example, the fastening means has bolt insertion holes (not shown) formed in the outer wall 14 and the fixing member 62 at predetermined intervals in the circumferential direction, bolts 63 inserted through these bolt insertion holes, and nuts 64 externally mounted on the bolts 63. In this embodiment, the distal end of the tubular member 61 is pressed against the stepped portion 37 of the heater protection tube 31 by tightening the nuts 64, which results in that the heater protection tube 31 is firmly fixed in the tube insertion hole 20.
Subsequently, an assembly made by combining the electrode bars 45 and 46, the heat-resistant supporting members 47 and 48, the insulating heat-resistant cylindrical body 49, the heat generator 51, the heat insulating material 52, the thermocouple 53, and the end plate 40 is inserted inside the heater protection tube 31.
Finally, metal fittings (angle members) 68 are arranged outside the fixing member 62 at regular intervals in the circumferential direction around the central axis 41. Then, bolts 69 are inserted through screw holes (not shown) formed in the fixing member 62 and also holes (not shown) formed in the metal fittings. Lastly, nuts 70 are tightened on the bolts to fix the end plate 40 to the fixing member 62 and the furnace body 11.
The proximal ends of the first and second electrode bars 45, 46 are connected to a power source.
As shown in the figures, preferably, a tubular frame 74 having an opening/closing plate 73 is fixed to the outer wall 14 around the electrode bars 45, 46, the end plate 40, and the fixing member 62 to prevent the electrode bar 45, 46 from being exposed.
According to the molten metal holding furnace 10 so constructed, an electric power is supplied through the electrode bars 45 and 46 to heat the heat generator 51. Using the heat from the heat generator 51, the molten metal in the molten metal holding furnace 10 is maintained at a predetermined melting temperature.
The influence of heat transmitted from the heat generator 51 to the heater protection tube 31 and the heat transmitted from the molten metal may cause cracks in the filling material 60 filled around the heater protection tube 31 over time, allowing the molten metal to advance along the cracks from the inside toward the outside. According to the present invention, the filling material 60 filled between the distal cylindrical portion (tapered surface) 35 of the heater protection tube 31 and the inside cylindrical portion (tapered surface) 21 of the tube insertion hole 20 is evenly filled with the aid of pressing force applied from the outside toward the inside, i.e., a force applied from the tubular member 61 on the stepped portion 37 of the heater protection tube 31 by tightening of the bolts 63. This minimizes the occurrence of the crack and. Also, even if occurred, the cracks are so small. In addition, an amount of heat moving from the distal end toward the proximal end of the heater protection tube 31, in particular, the amount of heat capable of moving from the distal cylindrical portion 35 to the reduced diameter proximal cylindrical portion 36 is reduced significantly at the boundary of the distal and proximal cylindrical portions 35 and 36 and, therefore, the resultant heat reaching the proximal end of the proximal cylindrical portion 36 is considerably small, which in turn means that only a small amount of heat is discharged into the atmosphere.
In this embodiment, the heat in the distal cylindrical portion 35 is transmitted through the proximal cylindrical portion 36 adjacent thereto and also through the tubular member 61 in contact with the proximal end stepped portion 37 of the distal cylindrical portion 35 into the atmosphere. Therefore, when designing the aluminum molten metal furnace, for example, cross sections of the distal and proximal cylindrical portions 35 and 36 and the tubular member 61 and also a cross section ratio between the proximal and distal cylindrical portions 36 and 61 (i.e., heat dissipation and heat insulation properties) are determined to compromise the heat dissipation and insulation to maintain the temperature of the stepped portion 37 at about 550 Celsius.
The present invention is not limited to the embodiments described above and may be modified in various ways. For example, although in the embodiment described above the heat dissipating tubular member 61 is provided around the proximal cylindrical portion 36 of the heater protection tube 31 to release a portion of the heat through the tubular member 61 to the atmosphere, as shown in
The metal-made tubular member 61 has a thermal expansion coefficient larger than those of the surrounding heat insulating and backup layers 15 and 16, allowing the tubular member 61 to force the stepped portion 37 strongly and thereby to prevent the leakage of the molten metal effectively. Also, even in operation of the molten metal holding furnace, the tubular member 61 may be replaced by another member made from different material or with different shape for controlling the heat dissipation and insulation properties of the furnace.
In this embodiment, the distal cylindrical portion 36 may have a thickness larger than that of the previous embodiment in order to ensure a suitable heat dissipation property. In this instance, preferably the cross section of the distal and proximal cylindrical portions 35 and 36 of the heater protection tube 31 is determined so that the temperature at the stepped portion 37 is controlled to be about 550 degrees Celsius.
Although in either of the two embodiments described above the proximal cylindrical portion 36 of the heater protection tube 31 has a fixed outer diameter, it may be an inwardly or outwardly tapered cylindrical portion of which outer diameter decreases gradually in a direction from outside to inside or from inside to outside.
As shown in
Although in the previous embodiment the distal cylindrical portion 35 of the heater protection tube 31 is formed integrally with the heater protection tube 31, it may be made by combining a non-tapered tube having a constant outer diameter and a tapered tube securely mounted on the outer periphery of the non-tapered tube. Those tubes may be made of the same or different materials.
Also, although in the previous embodiment the proximal cylindrical portion 36 of the heater protection tube 31 is formed integrally with the distal cylindrical portion 35, they may be connected by heat. Those tubes may be made of the same or different materials.
Further, in the previous embodiments, either the distal cylindrical portion 35 or the proximal cylindrical portion 36 or both may have annular or helical convex portions (grooves) or concave portions (projections) formed on the peripheral surfaces thereof. The convex or concave portions may extend in a continuous or discontinuous manner in the peripheral direction.
Although in the above descriptions the tube insertion tube 20 is provided in the side wall 13, it may be formed in a ceiling wall through which the heating tube is vertically inserted. A molten metal holding furnace including the vertical heating tube is also included in the technical scope of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2015-100381 | May 2015 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2015/074615 | 8/31/2015 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2016/185624 | 11/24/2016 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 1416897 | Simon | May 1922 | A |
| 1651861 | Abbott | Dec 1927 | A |
| 2159414 | Wilcox | May 1939 | A |
| 3688007 | McKenna | Aug 1972 | A |
| 4520487 | Graniou | May 1985 | A |
| 5948352 | Vender Jagt | Sep 1999 | A |
| 7993574 | Wisdom | Aug 2011 | B2 |
| 8422871 | Mochizuki | Apr 2013 | B2 |
| 20100278208 | Andersson | Nov 2010 | A1 |
| 20100290766 | Mochizuki | Nov 2010 | A1 |
| Number | Date | Country |
|---|---|---|
| 203801092 | Aug 2014 | CN |
| H022933 | Jan 1990 | JP |
| H02-042755 | Mar 1990 | JP |
| 4-000198 | Jan 1992 | JP |
| H09185983 | Jul 1997 | JP |
| 2013170801 | Sep 2013 | JP |
| Entry |
|---|
| International Search Report dated Dec. 1, 2015, from related Application No. PCT/JP2015/074616, 3 pages. |
| Non-Final Office Action, dated Jul. 16, 2018, in connection with U.S. Appl. No. 15/541,084. |
| International Search Report dated Dec. 1, 2015, from related Application No. PCT/JP2015/074615, 3 pages. |
| English Translation of International Preliminary Report on Patenability dated Nov. 16, 2017, from International Application No. PCT/JP2015/074616, 12 pages. |
| English Translation of International Preliminary Report on Patenability dated Nov. 16, 2017, from International No. PCT/JP2015/074615, 11 pages. |
| Number | Date | Country | |
|---|---|---|---|
| 20180124877 A1 | May 2018 | US |
