WO2024037088A1 - 一种多层感应加热体及其制备方法和应用 - Google Patents

一种多层感应加热体及其制备方法和应用 Download PDF

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WO2024037088A1
WO2024037088A1 PCT/CN2023/095852 CN2023095852W WO2024037088A1 WO 2024037088 A1 WO2024037088 A1 WO 2024037088A1 CN 2023095852 W CN2023095852 W CN 2023095852W WO 2024037088 A1 WO2024037088 A1 WO 2024037088A1
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layer
induction heating
heating body
temperature
body according
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PCT/CN2023/095852
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English (en)
French (fr)
Inventor
韩达
张恒
邹凌芳
周宏明
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深圳麦克韦尔科技有限公司
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Publication of WO2024037088A1 publication Critical patent/WO2024037088A1/zh

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    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
    • A24F40/46—Shape or structure of electric heating means
    • A24F40/465—Shape or structure of electric heating means specially adapted for induction heating
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/70—Manufacture
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02—Compacting only
    • B22F3/04—Compacting only by applying fluid pressure, e.g. by cold isostatic pressing [CIP]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/1003—Use of special medium during sintering, e.g. sintering aid
    • B22F3/1007—Atmosphere
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers

Definitions

  • This application belongs to the technical field of induction heating materials, and specifically relates to a multi-layer induction heating body and its preparation method and application.
  • Iron-based alloys have high magnetic permeability and fast electromagnetic induction heating rates. Therefore, wireless temperature control sensors used for inductively heating aerosol-forming substrates generally use iron or iron-based alloys, and the most typical material is stainless steel.
  • the sensor made of a single material, stainless steel has the disadvantage of low temperature control accuracy, that is: usually the required temperature control range is much lower than the Curie temperature point of the stainless steel material, and small changes in heating current within its temperature control range will correspond to the sensor. Large changes in temperature will lead to low temperature control accuracy or even inaccurate temperature control.
  • the Curie temperature point of iron-based alloys is very high, using a single-layer stainless steel strip as a sensor can only heat it to form an aerosol, but cannot limit the maximum temperature through the characteristics of the material itself.
  • Typical 430L stainless steel The Curie temperature is above 700°C, and based on the national standard, the maximum temperature at which aerosols are usually generated is lower than 350°C. Therefore, a temperature threshold control program needs to be added to the microcontroller, which will make the structure of the induction heating device complex.
  • the purpose of this application is to overcome the low temperature control accuracy of single-material sensors in the prior art, as well as the high Curie temperature point of the existing single-material heating element, which only requires heating within the required controllable temperature range. It is practical and has no self-limiting temperature problem, thus providing a multi-layer induction heating body and its preparation method and application.
  • the present application provides a multi-layer induction heating body, including a first susceptor material layer and a second susceptor material layer, and a transition layer disposed between the first susceptor material layer and the second susceptor material layer.
  • the thickness of the first sensor material layer is 20-150 microns
  • the thickness of the second sensor material layer is 20-150 microns
  • the thickness of the transition layer is 5-50 microns.
  • the first sensor material, the transition layer, and the second sensor material layer are formed by sintering.
  • the multi-layer induction heating body further includes a protective layer disposed on the outside of the first susceptor material layer and/or the second susceptor material layer away from the transition layer.
  • the thickness of the protective layer is 1-10 microns.
  • the multi-layer induction heating body is of sheet type, tube type, cup type or pot type.
  • the material of the transition layer is metal, alloy, ceramic or any combination between them.
  • the material of the first sensor layer is at least one of nickel and nickel-chromium alloy
  • the material of the second sensor layer is at least one of iron and iron-based alloy.
  • This application also provides a method for preparing the above-mentioned multi-layer induction heating body, which includes the following steps:
  • the temperature of the hot isostatic pressing treatment is 65-85°C
  • the time is 0.1-1h
  • the pressure is 5-45MPa.
  • the debinding treatment temperature is 250-550°C and the time is 1-10h;
  • the sintering temperature is 1100-1400°C and the sintering time is 0.5-15h.
  • the following steps are also included: according to the composition of the raw materials of each layer, add PVB binder and alcohol solvent to the powder of the corresponding material, and put it into a ball mill tank. Perform ball milling to prepare the corresponding slurry for tape casting.
  • the ball milling time for preparing the corresponding slurry for tape casting is 2-4 hours.
  • the multi-layer induction heating body can be a sheet type, or a tube type, cup type or pot type that is processed from the sheet type.
  • This application also provides an application of the above-mentioned multi-layer induction heating body or the multi-layer induction heating body prepared by the above-mentioned preparation method in the field of magnetic induction heating.
  • the present application provides a multi-layer induction heating body in which the first sensor material and the second sensor material have different Curie temperature points, and at least one of the materials has a Curie temperature point lower than 400°C.
  • the Curie temperature of the first susceptor material is between 200-400°C; optionally, it is above 380°C.
  • the Curie temperature of the second susceptor material is between 400-1000°C.
  • the material of the first sensor layer can be elemental nickel, nickel-chromium alloy, surface-treated nickel, surface-treated nickel-chromium alloy, etc.
  • the Curie temperature point of nickel is around 350°C.
  • the material of the second sensor layer can be iron or an iron-based alloy, such as ferritic stainless steel.
  • a typical ferritic stainless steel is 430L.
  • the Curie temperature point of 430L is around 700°C.
  • a transition layer is provided between the first susceptor and the second susceptor, and the material of the transition layer is a metal element, an alloy, a ceramic, or any combination thereof;
  • the transition layer between the first susceptor material layer and the second susceptor material layer is preferably a metal element, alloy or composite metal with high thermal conductivity and high electrical conductivity.
  • the transition layer material can be weakly magnetic or non-magnetic metal, such as austenitic stainless steel 316L.
  • Magnetic metal materials can also be used as transition layer materials.
  • the transition layer can be iron-chromium-aluminum alloy.
  • the surface of iron-chromium-aluminum alloy has a natural protective film of aluminum oxide, which has good high-temperature chemical compatibility with most metals and is very suitable for use as a transition layer material.
  • Ceramics can also be used as transition layer materials. Considering the good high-temperature compatibility between ceramics and metals, ceramics are an ideal transition layer material.
  • a protective layer can be selectively provided on one or both sides of the multi-layer susceptor.
  • the protective layer material can be metal, ceramic, glass or any combination between them. things.
  • the multi-layer induction heating body provided by this application can provide a characteristic temperature point.
  • the temperature of the heating element can be controlled near this characteristic temperature through electronic control, and the characteristic temperature can be adjusted according to the material composition.
  • a typical temperature can be at Control between 150-400°C.
  • heating can be achieved in two temperature ranges between 150-260°C and 250-400°C.
  • wireless temperature control can be achieved based on the one-to-one current-temperature relationship.
  • the multi-layer induction heating body provided by this application is suitable for induction heating aerosol-forming sensor heating materials for electronic cigarettes, aerosol-forming sensor heating materials for medical atomization, or beauty instruments and other scenarios that require induction heating and temperature control.
  • the multi-layer induction heating body temperature control logic provided by this application:
  • the multi-layer induction heating body is heated.
  • the electronic control will detect an initial current; as the temperature of the heating body increases, the magnetic resistance of the heating body will increase, and the corresponding electronic control will detect that the current becomes smaller;
  • the temperature of the heating body continues to rise, and the temperature rises close to the Curie temperature point of the low Curie temperature material in the multi-layer induction heating body, the low Curie temperature material begins to gradually lose magnetism, which will lead to the overall magnetic field of the heating body. The resistance becomes smaller, so the apparent current detected by the electronic control will gradually increase. At this time, a minimum current inflection point (I 1 ) will appear.
  • the current detected by the electronic control is different from the temperature of the heating body.
  • One-to-one correspondence through this one-to-one correspondence between the current and the temperature of the heating body, a standard curve can be established, so that wireless temperature control can be achieved; as the temperature further increases, the material at the low Curie temperature point in the heating body continues to lose Magnetism, when the sensor material completely loses magnetism at the low Curie temperature point, another maximum current inflection point (I 2 ) will appear.
  • I 2 maximum current inflection point
  • electromagnetic induction heating is dominated by materials with high Curie temperature points.
  • the current will become smaller due to the increase in the magnetic resistance of materials with high Curie temperature points.
  • the multi-layer induction heating body proposed in this application can control the characteristic current value I 1 , the characteristic temperature value T 1 , the temperature control standard curve and the maximum threshold temperature T 2 by regulating the metal phase components at the high Curie temperature point and the low Curie temperature point. adjustable.
  • a sensor with a conventional two-layer physical bonding structure is composed of a first sensor material and a second sensor material.
  • the resistance-temperature curve of the sensor component (Fig. 6, refer to Chinese patent document CN112739229A) has a minimum resistance value within a temperature range of ⁇ 5°C near the Curie temperature of the second sensor material. This minimum resistance value is used to calibrate the temperature at a certain point to achieve temperature control.
  • the first susceptor material is mainly used for heating, and the second susceptor material is used as a temperature marker.
  • the magnetic properties of the second susceptor change from ferromagnetic or ferrimagnetic to paramagnetic. , accompanied by a temporary change in its resistance.
  • This temperature control logic can only calibrate the temperature point of the Curie temperature of the second sensor material, which is limited by the material and has a single temperature point, so interval temperature control cannot be performed.
  • the other is to use a single stainless steel piece for the susceptor.
  • the temperature of the susceptor is between the apparent ohmic resistance determined by the DC supply voltage of the DC power supply and the DC current drawn from the DC power supply.
  • the temperature control logic has high requirements on the change amount of the apparent ohmic resistance of the stainless steel sheet and the corresponding relationship between temperature.
  • the corresponding relationship between the common stainless steel sheets usually means that the change amount of the apparent ohmic resistance is too small when the temperature range is certain, and it cannot be accurately controlled. temperature.
  • the multi-layer induction heating body provided by this application includes at least a three-layer structure of a first sensor material layer, a second sensor material layer and a transition layer, so that the multi-layer induction heating body has the functions of heating and temperature control at the same time, and the temperature control accuracy is high.
  • the heating process is uniform and stable, and there will be no cracking, deformation, etc.
  • the thermal stability of the multi-layer induction heating body is significantly improved, thereby ensuring the stability and consistency of the induction heating sheet during the heating process.
  • This application provides a new method for preparing multi-layer sensor sheets based on powder sintering.
  • Adding a transition layer between the first sensor and the second sensor can effectively solve the problem of mechanical, physical and chemical incompatibility between the two sensor materials and facilitate full Take advantage of the temperature control properties of both receptors.
  • the setting of the transition layer can also avoid the mutual influence of the first susceptor material layer and the second susceptor material layer during the heating process, achieving precise heating and temperature control.
  • the transition layer is very thin, only 5-50 microns.
  • This arrangement can accelerate the direct heat exchange between the first susceptor and the second susceptor, which is conducive to the first susceptor and the second susceptor directly and quickly reaching thermal equilibrium. Effect. Combining the first sensor and the second sensor as a whole allows the whole to quickly reach thermal equilibrium during the heating process, which is conducive to precise temperature control.
  • the transition layer can be prevented from affecting the heating characteristics induced by the first susceptor material layer and the second susceptor material layer.
  • the multi-layer induction heating body limits the molding method to the sintering method, so that the two susceptor materials can be easily combined, effectively expanding the range of susceptor material combinations. In addition, it can also improve the interface bonding force between the two susceptor material layers and avoid the peeling of the interface microstructure, deformation and even cracking of the heating body due to the difference in the physical properties of the two susceptor materials in the physical pressing method in the existing technology. and other problems, which is greatly conducive to maintaining the consistency of the temperature control characteristics of the heating body during the heating process. In addition, in the multi-layer heating body in the prior art, the first susceptor material layer and the second susceptor material layer are generally arranged in close contact.
  • the multi-layer induction heating body provided by the present application also includes a protective layer disposed on the outside of the first sensor material layer and/or the second sensor material layer away from the transition layer. This arrangement can improve the resistance of the multi-layer induction heating body. High temperature and corrosion resistance.
  • the preparation method of the multi-layer induction heating body provided by this application has a simple and mature preparation process, is easy to implement, and greatly reduces the manufacturing cost.
  • Figure 1 is a schematic structural diagram of the multi-layer induction heating body provided by this application.
  • Figure 2 is a current-temperature corresponding relationship curve during the electromagnetic induction heating process of the heating body provided in Embodiment 1 of the present application;
  • Figure 3 shows the current-temperature during the electromagnetic induction heating process of the heating body provided in Embodiment 2 of the present application. Correspondence relationship curve;
  • Figure 4 is a current-temperature corresponding relationship curve during the electromagnetic induction heating process of the heating body provided in Embodiment 3 of the present application;
  • Figure 5 is a current-temperature corresponding relationship curve during the electromagnetic induction heating process of the heating body provided in Embodiment 4 of the present application;
  • Figure 6 is a resistance-temperature relationship curve in the process of using electromagnetic induction to heat a sensor prepared by conventional physical bonding methods in the prior art.
  • This embodiment provides a multi-layer induction heating body, as shown in Figure 1, including three layers: first sensor material layer 1 (Ni powder)/transition layer 2 (stainless steel 316L)/second sensor material layer 3 (stainless steel 430L)
  • the preparation method of the composite metal sheet includes the following specific steps:
  • the obtained blanks are sequentially laminated according to Ni blanks, stainless steel 316L blanks and stainless steel 430L blanks and then subjected to hot isostatic pressing to obtain a composite blank, which is to be fired; among them, the hot isostatic pressing treatment
  • the temperature is 70°C
  • the pressure is 20MPa
  • the time is 10 minutes.
  • the multi-layer induction heating body provided in this embodiment is heated by electromagnetic induction (electromagnetic heating frequency 6.78MHz).
  • electromagnetic induction electromagnetic heating frequency 6.78MHz.
  • I 1 and I 2 are respectively The current inflection point, whose corresponding temperatures are T 1 and T 2 ), and this interval of different temperatures corresponding to the sudden change stage of the current (the T 1 and T 2 temperature intervals corresponding to I 1 and I 2 ), can be used as the temperature of the heating body. control interval.
  • the heating body has the characteristic of a maximum temperature that it can be heated to. As shown in Figure 2, neither the current nor the temperature continues to increase. This characteristic can play a temperature self-protection role in the sensor assembly.
  • This embodiment provides a multi-layer induction heating body, as shown in Figure 1, including a first sensor material layer
  • the preparation method of the three-layer composite metal sheet of 1 (Ni powder)/transition layer 2 (La 0.6 Sr 0.4 Fe 0.8 Sc 0.2 O 3 )/second sensor material layer 3 (stainless steel 430L) includes the following specific steps:
  • the obtained green body is sequentially laminated according to the Ni green body, La 0.6 Sr 0.4 Fe 0.8 Sc 0.2 O 3 green body and stainless steel 430L green body, and then subjected to hot isostatic pressing treatment to obtain a composite green body, which is to be fired;
  • the temperature of hot isostatic pressing is 70°C
  • the pressure is 20MPa
  • the time is 10 minutes;
  • This embodiment provides a multi-layer induction heating body.
  • the difference from Embodiment 1 is that nickel alloy is used. 1J36 powder, instead of Ni powder.
  • This embodiment provides a multi-layer induction heating body.
  • the difference from Embodiment 1 is that other ferritic stainless steel 420 is used instead of stainless steel 430L.
  • Example 1 of this application specifically including:
  • Step 1 Cut the prepared induction metal sheet into standard sizes with a width of 8.6mm and a length of 16mm;
  • Step 2 Attach a thermocouple to the above-mentioned standard size metal sheet, and the thermocouple is used for temperature measurement;
  • Step 3 Place the above-mentioned induction heating piece attached to the thermocouple at the center of the electromagnetic induction heating coil, and fix the heating element;
  • Step 4 Set the voltage of the electromagnetic induction heating coil to 7.5V, set the current to 2.7A, 2.8A, 2.85A, 2.9A and 2.95A respectively, and read the stable temperature of the thermocouple in different current modes (heat for 60s, Test the final stable temperature).
  • Step 5 Repeat steps 1-4, test 4 heating pads, and evaluate the consistency of the heating pads.
  • test results are as follows: for a single heating piece, there is a one-to-one correspondence between the current and the temperature of the induction piece; for different heating elements (4 randomly selected heating pieces are selected to test the consistency of the heating pieces), the consistency of the heating pieces
  • the positive and negative deviations of the temperature control temperatures of different metal sheets under different currents are within 3°C.
  • the specific test results are shown in the table below (the positive and negative deviations of the temperature control temperatures of other embodiments are also within 3°C, and will not be shown one by one. Specific test results):

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Abstract

一种多层感应加热体及其制备方法和应用，多层感应加热体，包括至少三层结构，使多层感应加热体同时具有加热和控温的功能，加热过程均匀、稳定，不会出现开裂、变形等状况，通过在第一感受器材料层（1）与第二感受器材料层（3）之间设置过渡层（2），提高了多层感应加热体的热稳定性，从而能够保证感应加热片在加热过程中的稳定性和一致性，能够有效解决两种感受器材料机械、物理和化学不相容问题，便于充分利用两种感受器的控温特性；过渡层（2）的设置，还能避免第一感受器材料层（1）、第二感受器材料层（3）在加热过程中的相互影响，实现精准加热、控温。

Description

一种多层感应加热体及其制备方法和应用
相关申请的交叉引用
本申请要求在2022年08月19日提交中国专利局、申请号为202211000959.6、发明名称为“一种多层感应加热体及其制备方法和应用”的中国专利申请的优先权，其全部内容通过引用的方式并入本文中。
技术领域
本申请属于感应加热材料技术领域，具体涉及一种多层感应加热体及其制备方法和应用。
背景技术
铁基合金磁导率高，电磁感应加热速率快。因此，用于感应加热气溶胶形成基质的无线控温感受器一般采用铁或者铁基合金，最典型的材料为不锈钢。
采用单一材料不锈钢制备的感受器存在控温精度低的缺点，即：通常所需控温范围远低于不锈钢材料的居里温度点，而在其温控区间内微小的加热电流变化会对应着感受器温度的大幅变化，这会导致控温精度低，甚至是控温不准。此外，因为铁基合金居里温度点非常高，所以采用单层不锈钢条作为感受器使用时只能起到加热形成气溶胶作用，而不能通过材料本身的特性进行最高温度限制，典型的430L不锈钢的居里温度温度在700℃以上，而基于国标通常产生气溶胶的最高温度要低于350℃，因此需在微控制器中增加温度阈值控制程序，这会使得感应加热装置结构复杂。
发明内容
因此，本申请的目的在于克服现有技术中的单一材料感受器控温精度低，以及现有单一材料发热体的居里温度点高，在所需可控温度范围内只有加热作 用、没有自限温作用的问题，从而提供一种多层感应加热体及其制备方法和应用。
为此，本申请提供如下技术方案：
本申请提供一种多层感应加热体，包括第一感受器材料层和第二感受器材料层，以及设置在所述第一感受器材料层和第二感受器材料层之间的过渡层。
可选的，所述第一感受器材料层的厚度为20-150微米；
和/或，所述第二感受器材料层的厚度为20-150微米；
和/或，所述过渡层的厚度为5-50微米。
可选的，所述第一感受器材料，所述过渡层，所述第二感受器材料层之间采用烧结方式成型。
可选的，所述多层感应加热体还包括设置于所述第一感受器材料层和/或所述第二感受器材料层的远离所述过渡层的外侧的保护层。
可选的，所述保护层的厚度为1-10微米。
可选的，所述多层感应加热体为片式、管式、杯式或锅式。
可选的，所述过渡层的材料为金属单质、合金、陶瓷或者它们之间的任意组合物。
可选的，所述第一感受器层的材料为镍、镍铬合金中的至少一种；
和/或，所述第二感受器层的材料为铁、铁基合金中的至少一种。
本申请还提供一种上述的多层感应加热体的制备方法，包括以下步骤：
S1，根据各层原料的组成，通过流延方法分别制备得到各层的素坯；
S2，将各层的素坯按序叠层，热等静压处理，得到待烧坯；
S3，将待烧坯进行排胶，烧结。
可选的，所述热等静压处理的温度为65-85℃，时间为0.1-1h，压力为5-45MPa。
可选的，所述排胶的排胶处理温度为250-550℃，时间为1-10h；
和/或，所述烧结的烧结温度为1100-1400℃，时间为0.5-15h。
可选地，通过流延方法分别制备得到各层的素坯前，还包括以下步骤：分别根据各层原料的组成，将相应材料的粉末中加入PVB粘结剂和酒精溶剂，放入球磨罐中进行球磨制备相应的用于流延的浆料。
可选地，所述球磨制备相应的用于流延的浆料的球磨时间为2-4小时。
进一步，多层感应加热体可以是片式，也可以是由片式后加工成的管式，杯式或者锅式。
本申请还提供一种上述的多层感应加热体或上述的制备方法制备得到的多层感应加热体在磁感应加热领域中的应用。
典型非限定性的，本申请提供的多层感应加热体，其第一感受器材料和第二感受器材料具有不同的居里温度点，其中至少有一种材料的居里温度点低于400℃。可选的，第一感受器材料的居里温度在200-400℃之间；可选地，在380℃以上。第二感受器材料的居里温度在400-1000℃之间。
例如，第一感受器层的材料可以选用单质镍、镍铬合金、经表面处理后的镍、经表面处理的镍铬合金等，镍的居里温度点在350℃左右。例如，第二感受器层的材料可以选用铁或者铁基合金，例如铁素体不锈钢，典型的铁素体不锈钢430L，430L的居里温度点在700℃左右。
处于第一感受器和第二感受器之间设置过渡层，所述过渡层的材料为金属单质、合金、陶瓷或者它们之间的任意组合物；
本申请提供的多层感应加热体，处于第一感受器材料层和第二感受器材料层之间的过渡层优选具有高热导率和高电导率的金属单质，合金或者复合金属。
过渡层材料可以选用弱磁性或者非磁性金属，例如可以选用奥氏体不锈钢316L。
过渡层材料也可以选用磁性金属材料。例如，当第一感受器材料选用镍，第二感受器材料选用430L，过渡层可以选用铁铬铝合金。铁铬铝合金的表面有一层天然的氧化铝保护膜，与大多数金属高温化学相容性好，很合适用作过渡层材料。
过渡层材料也可以选用陶瓷，考虑到陶瓷与金属高温相容性好，陶瓷是理想的过渡层材料。
为了提高多层感受器抗氧化性和耐腐蚀性，可以有选择性的在多层感受器单侧或者两侧设置一层保护层，保护层材料可以是金属，陶瓷，玻璃或者他们之间任意的组合物。
本申请提供的多层感应加热体，能够提供一特征温度点，通过电控能够将发热体温度控制在这一特征温度附近，且该特征温度可以根据材料组分进行调控，典型的温度可以在150-400℃之间进行调控。
根据组分和电控匹配，可以实现在150-260℃之间和250-400℃之间两个温度段进行加热。并且，根据一一对应的电流-温度关系，可以实现无线温控。
本申请提供的多层感应加热体，适用于电子烟用感应加热气溶胶形成感受器加热材料、医疗雾化用气溶胶形成感受器加热材料或美容仪等其他需要感应加热控温的场景。
本申请提供的多层感应加热体控温逻辑：
在加热起初阶段多层感应加热体被加热，此时电控会检测一个初始电流；随着加热体温度升高，加热体的磁阻会增大，相对应电控会检测到电流变小；当加热体的温度继续升高，温度升高到接近多层感应加热体中低居里温度材料的居里温度点时，低居里温度材料开始逐渐失磁，这会导致加热体总的磁阻变小，因此电控检测到视在电流会逐渐增大，此时会出现一最低电流拐点(I1)，在接下来一段升温过程中，电控检测到的电流与加热体的温度有一一对应关系；通过这种电流与加热体的温度的一一对应可以建立起标准曲线，从而可以实现无线控温；随着温度的进一步升高，加热体中低居里温度点材料继续失磁，当低居里温度点感受器材料完全失磁，会导致另一最大电流拐点(I2)出现。随着电流继续升高，电磁感应加热以高居里温度点材料为主导，随着加热温度继续升高，由于高居里温度点材料磁阻增加，电流会变小。本申请提出的多层感应加热体通过调控高居里温度点和低居里温度点金属相成分，可以实现对特征电流值I1、特征温度值T1、控温标准曲线和最高阈值温度T2的可调。
现有技术中的控温逻辑分为两种：
一种为常规的两层物理贴合结构的感受器，该感受器由第一感受器材料和第二感受器材料组成，在该感受器组件从室温开始的预热期间，该感受器组件的电阻-温度曲线(图6，参考中国专利文献CN112739229A)在该第二感受器材料的居里温度附近的±5℃的温度范围内具有最小电阻值。通过这一最小电阻值来对一定点温度进行标定而达到控温目的。同时在这种感受器中，第一感受器材料做主要的加热用，第二感受器材料作为温度标记物，在其居里温度下，第二感受器的磁性性质从铁磁性或亚铁磁性变为顺磁性，伴随着其电阻的临时变化。通过监测由感应源吸收的电流的对应改变，可检测到第二感受器材料何时达到其居里温度，因此可以知道何时达到预定的工作温度。该控温逻辑中仅能标定第二感受器材料居里温度的温度点，受材料限制，且温度点单一，不能进行区间控温。
另一种为感受器采用单一的不锈钢片，该材料在感应加热装置中的加热过程中，感受器的温度和通过DC电源的DC供电电压及通过从DC电源汲取的DC电流确定的视在欧姆电阻之间存在严格单调的关系。由于视在欧姆电阻的每个单一值代表的温度唯一，这种严格的单调关系可以就通过在不接触感应加热装置的前提下通过视在欧姆电阻的大小确定感受器的相应温度。该控温逻辑中对不锈钢片的视在欧姆电阻和温度对应关系的变化量要求高，目前常见不锈钢片的该对应关系中通常是温度区间一定时视在欧姆电阻变化量过小，不能精准控温。
本申请技术方案，具有如下优点：
本申请提供的多层感应加热体，包括第一感受器材料层、第二感受器材料层和过渡层至少三层结构，使多层感应加热体同时具有加热和控温的功能，控温精度高，加热过程均匀、稳定，不会出现开裂、变形等状况。通过在第一感受器材料层与第二感受器材料层之间设置过渡层，显著提高了多层感应加热体的热稳定性，从而能够保证感应加热片在加热过程中的稳定性和一致性。本申请提供一种基于粉末烧结方式制备多层感应片新方法，在第一感受器与第二感受器之间加入过渡层，能够有效解决两种感受器材料机械、物理和化学不相容问题，便于充分利用两种感受器的控温特性。另外，过渡层的设置，还能避免第一感受器材料层、第二感受器材料层在加热过程中的相互影响，实现精准加热、控温。
本申请提供的多层感应加热体，过渡层设置很薄只有5-50微米，如此设置，具有加速第一感受器和第二感受器直接热交换，有利于第一感受器和第二感受器直接快速达到热平衡的效果。将第一感受器与第二感受器结合在一起作为一个整体，在加热过程中使得整体快速达到热平衡，有利于精准控温。
本申请提供的多层感应加热体，通过对各层厚度的限定，可以避免过渡层影响第一感受器材料层和第二感受器材料层感应的加热特性。
本申请提供的多层感应加热体，限定成型方式为烧结方式，如此能够轻松的将两种感受器材料结合在一起，有效拓展了感受器材料组合范围。另外，还能够提高两种感受器材料层之间的界面结合力，避免现有技术中物理压合方式中因两种感受器材料物理特性差异而出现的界面微观结构的剥离，加热体变形、甚至开裂等问题，进而极大有利于保持加热体在加热过程中控温特性的一致性。此外，现有技术中的多层加热体一般是第一感受器材料层和第二感受器材料层紧密贴合设置，如果直接采用烧结的方式成型，第一感受器材料层和第二感受器材料层之间会产生相互影响，最终影响加热体性能的发挥，本申请通过设置过渡层，还能有效避免二者之间的影响。
本申请提供的多层感应加热体，还包括设置于第一感受器材料层和/或第二感受器材料层的远离所述过渡层的外侧的保护层，如此设置能够提升多层感应加热体的耐高温和耐腐蚀性能。
本申请提供的多层感应加热体的制备方法，制备工艺简单成熟，易于实现，极大的降低了制造成本。
附图说明
为了更清楚地说明本申请具体实施方式或现有技术中的技术方案，下面将对具体实施方式或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图是本申请的一些实施方式，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1是本申请提供的多层感应加热体的结构示意图；
图2是本申请实施例1提供的加热体进行电磁感应加热的过程中电流-温度对应关系曲线；
图3是本申请实施例2提供的加热体进行电磁感应加热的过程中电流-温度 对应关系曲线；
图4是本申请实施例3提供的加热体进行电磁感应加热的过程中电流-温度对应关系曲线；
图5是本申请实施例4提供的加热体进行电磁感应加热的过程中电流-温度对应关系曲线；
图6是现有技术中采用常规物理贴合方式制备的感受器采用电磁感应进行加热的过程中电阻-温度关系曲线。
附图标记：
1、第一感受器材料层；2、过渡层；3、第二感受器材料层。
具体实施方式
提供下述实施例是为了更好地进一步理解本申请，并不局限于所述最佳实施方式，不对本申请的内容和保护范围构成限制，任何人在本申请的启示下或是将本申请与其他现有技术的特征进行组合而得出的任何与本申请相同或相近似的产品，均落在本申请的保护范围之内。
实施例中未注明具体实验步骤或条件者，按照本领域内的文献所描述的常规实验步骤的操作或条件即可进行。所用试剂或仪器未注明生产厂商者，均为可以通过市购获得的常规试剂产品。
实施例1
本实施例提供一种多层感应加热体，如图1所示，包括第一感受器材料层1(Ni粉)/过渡层2(不锈钢316L)/第二感受器材料层3(不锈钢430L)三层复合金属片层，其制备方法包括以下具体步骤：
(1)称取100g的Ni粉，加入3gPVB粘结剂和40g酒精溶剂，将上述配 料放入球磨罐中进行球磨，球磨3小时后取出即得浆料，然后通过流延方法使用80微米流延刀高，制备得到Ni素坯。
(2)称取40g的不锈钢316L粉，加入1.25gPVB粘结剂和18g酒精溶剂，将上述配料放入球磨罐中进行球磨，球磨3小时后取出即得浆料，然后通过流延方法使用30微米流延刀高，制备得到不锈钢316L素坯。
(3)称取100g的不锈钢430L粉，加入3gPVB粘结剂和40g酒精溶剂，将上述配料放入球磨罐中进行球磨，球磨3小时后取出即得浆料，然后通过流延方法使用80微米流延刀高，制备得到不锈钢430L素坯。
(4)将所得素坯按照Ni素坯，不锈钢316L素坯和不锈钢430L素坯顺次叠层后进行热等静压处理得到复合素坯，即待烧坯；其中，热等静压处理的温度为70℃，压力为20MPa，时间为10分钟。
(5)将上述待烧坯放入真空炉中进行排胶烧结，升温速度为3℃/min，升温至450℃后进行保温，保温时间为60min，随后以5℃/min速度升温至1300℃，保温30min，保温结束后随炉冷却。
(6)上述烧结体出炉后进行裁剪即得所需成品。
将本实施例提供的多层感应加热体通过电磁感应进行加热(电磁加热频率6.78MHz)，加热过程中存在单调稳定的电流-温度对应关系(如图2所示，I1和I2分别是电流拐点，其对应温度为T1和T2)，在电流突变阶段所对应的不同温度的这一区间(I1和I2对应的T1和T2温度区间)，可以作为加热体温度的控制区间。此外，该加热体具有一个能被加热到的最高温度的特性，如图2所示，电流和温度都不继续增加，这一特性可在感受器组件中起到温度自保护作用。
实施例2
本实施例提供一种多层感应加热体，如图1所示，包括第一感受器材料层 1(Ni粉)/过渡层2(La0.6Sr0.4Fe0.8Sc0.2O3)/第二感受器材料层3(不锈钢430L)三层复合金属片层，其制备方法包括以下具体步骤：
(1)称取100g的Ni粉，加入3gPVB粘结剂和40g酒精溶剂，将上述配料放入球磨罐中进行球磨，球磨3小时后取出即得浆料，然后通过流延方法使用80微米流延刀高，制备得到Ni素坯；
(2)称取50g的La0.6Sr0.4Fe0.8Sc0.2O3粉，加入1.5gPVB粘结剂和20g酒精溶剂，将上述配料放入球磨罐中进行球磨，球磨3小时后取出即得浆料，然后通过流延方法使用50微米流延刀高，制备得到La0.6Sr0.4Fe0.8Sc0.2O3素坯；
(3)称取100g的不锈钢430L粉，加入3gPVB粘结剂和40g酒精溶剂，将上述配料放入球磨罐中进行球磨，球磨3小时后取出即得浆料，然后通过流延方法使用80微米流延刀高，制备得到不锈钢430L素坯；
(4)将所得素坯按照Ni素坯，La0.6Sr0.4Fe0.8Sc0.2O3素坯和不锈钢430L素坯顺次叠层后进行热等静压处理得到复合素坯，即待烧坯；其中，热等静压处理的温度为70℃，压力为20MPa，时间为10min；
(5)将上述待烧坯放入真空炉中进行排胶烧结，升温速度为3℃/min，升温至450℃后进行保温，保温时间为60min，随后以5℃/min速度升温至1300℃，保温30min，保温结束后随炉冷却；
(6)上述烧结体出炉后进行裁剪即得所需成品。
本实施例提供的加热体进行电磁感应加热过程中电流-温度对应关系曲线如图3所示。
实施例3
本实施例提供一种多层感应加热体，与实施例1的区别在于，采用镍合金 1J36粉末，代替Ni粉。
本实施例提供的加热体进行电磁感应加热过程中电流-温度对应关系曲线如图4所示。
实施例4
本实施例提供一种多层感应加热体，与实施例1的区别在于，采用其它铁素体不锈钢420，代替不锈钢430L。
本实施例提供的加热体进行电磁感应加热过程中电流-温度对应关系曲线如图5所示。
测试例(实施例1的测试例)
对本申请实施例1提供的加热体进行测试，具体包括
第一步：将所制备感应金属片切割成宽度8.6mm和长度16mm的标准尺寸；
第二步：在上述标准尺寸金属片上贴合热电偶，热电偶用于测温；
第三步：将上述贴合热电偶的感应加热片置于电磁感应加热线圈正中心内部位置，并将发热体固定；
第四步：设置电磁感应加热线圈电压为7.5V，设置电流分别为2.7A，2.8A，2.85A，2.9A和2.95A，分别读取热电偶在不同电流模式下的稳定温度(加热60s，测试最终的稳定温度)。
第五步：重复步骤1-4，测试4个发热片，评估发热片一致性。
测试结果如下：就单个发热片而言，电流与感应片温度有一一对应关系；就不同发热体(随机选取4个发热片测试发热片一致性)而言，发热片一致性 较好，在不同电流下不同金属片的控温温度正负偏差在3℃以内，具体测试结果见下表(其它实施例的控温温度正负偏差也在3℃以内，不再一一展示具体测试结果)：
表1
显然，上述实施例仅仅是为清楚地说明所作的举例，而并非对实施方式的限定。对于所属领域的普通技术人员来说，在上述说明的基础上还可以做出其它不同形式的变化或变动。这里无需也无法对所有的实施方式予以穷举。而由此所引申出的显而易见的变化或变动仍处于本申请的保护范围之中。

Claims (19)

  1. 一种多层感应加热体，其特征在于，包括第一感受器材料层和第二感受器材料层，以及设置在所述第一感受器材料层和第二感受器材料层之间的过渡层。
  2. 根据权利要求1所述的多层感应加热体，其特征在于，所述第一感受器材料层的厚度为20-150微米；
    和/或，所述第二感受器材料层的厚度为20-150微米；
    和/或，所述过渡层的厚度为5-50微米。
  3. 根据权利要求1所述的多层感应加热体，其特征在于，所述第一感受器材料层，所述过渡层，所述第二感受器材料层之间采用烧结方式成型。
  4. 根据权利要求1所述的多层感应加热体，其特征在于，所述多层感应加热体还包括设置于所述第一感受器材料层和/或所述第二感受器材料层的远离所述过渡层的外侧的保护层。
  5. 根据权利要求4所述的多层感应加热体，其特征在于，所述保护层的厚度为1-10微米。
  6. 根据权利要求1所述的多层感应加热体，其特征在于，所述多层感应加热体为片式、管式、杯式或锅式。
  7. 根据权利要求6所述的多层感应加热体，其特征在于，所述过渡层的材料为金属单质、合金、陶瓷或者它们之间的任意组合物。
  8. 根据权利要求1-7任一项所述的多层感应加热体，其特征在于，所述第一感受器材料层的材料为镍、镍铬合金中的至少一种；并且/或者
    所述第二感受器材料层的材料为铁、铁基合金中的至少一种。
  9. 根据权利要求1-7任一项所述的多层感应加热体，其特征在于，所述第一感受器材料层的材料和第二感受器材料层的材料具有不同的居里温度点，其中至少有一种材料的居里温度点低于400℃。
  10. 根据权利要求9所述的多层感应加热体，其特征在于，所述第一感受器材料层的材料的居里温度点在200-400℃。
  11. 根据权利要求10所述的多层感应加热体，其特征在于，所述第一感受器材料层的材料的居里温度点在380℃以上；并且/或者
    第二感受器材料的居里温度点在400-1000℃。
  12. 根据权利要求1-7任一项所述的多层感应加热体，其特征在于，所述多层感应加热体在电磁感应加热过程中在150-400℃之间的温度区间内存在单调稳定的电流-温度对应关系。
  13. 根据权利要求1-7任一项所述的多层感应加热体，其特征在于，所述多层感应加热体在电磁感应加热过程中在150-260℃和250-400℃两个温度区间内存在单调稳定的电流-温度对应关系。
  14. 一种权利要求1-13任一项所述的多层感应加热体的制备方法，其特征在于，包括以下步骤：
    S1，根据各层原料的组成，通过流延方法分别制备得到各层的素坯；
    S2，将各层的素坯按序叠层，热等静压处理，得到待烧坯；
    S3，将待烧坯进行排胶，烧结。
  15. 根据权利要求14所述的多层感应加热体的制备方法，其特征在于，所 述热等静压处理的温度为65-85℃，时间为0.1-1h，压力为5-45MPa；并且/或者
    所述排胶的排胶处理温度为250-550℃，时间为1-10h；并且/或者
    所述烧结的烧结温度为1100-1400℃，时间为0.5-15h。
  16. 根据权利要求14或15所述的多层感应加热体的制备方法，其特征在于，通过流延方法分别制备得到各层的素坯前，还包括以下步骤：
    分别根据各层原料的组成，将相应材料的粉末中加入PVB粘结剂和酒精溶剂，放入球磨罐中进行球磨制备相应的用于流延的浆料。
  17. 根据权利要求16所述的多层感应加热体的制备方法，其特征在于，所述球磨制备相应的用于流延的浆料的球磨时间为2-4小时。
  18. 一种多层感应加热体在磁感应加热领域中的应用，其特征在于，所述多层感应加热体为权利要求1-13任一项所述的多层感应加热体或由权利要求14-17任一项所述的制备方法制备得到的多层感应加热体。
  19. 根据权利要求18所述的多层感应加热体在磁感应加热领域中的应用，其特征在于，所述应用包括在电子烟用感应加热气溶胶形成感受器加热材料、医疗雾化用气溶胶形成感受器加热材料或美容仪中的应用。
PCT/CN2023/095852 2022-08-19 2023-05-23 一种多层感应加热体及其制备方法和应用 WO2024037088A1 (zh)

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