Bonding of Materials with Induction Heating

Abstract

An apparatus and process are provided for bonding of materials by induction heating of an electrically conductive material upon which a second material is bonded. The electrically conductive material is induction heated between a first induction heating plate, and the combination of a frame and a second induction heating plate that is disposed within the frame. The second induction heating plate is removed from the surface of the electrically conductive sheet, while the frame continues to hold the electrically conductive sheet flat, and the second material, in liquid form, is poured into the interior opening of the frame in which the second induction heating plate was originally placed. The liquid material solidifies and bonds to the electrically conductive sheet to produce a bonded product. A continuous sheet of an electrically conductive material may be bonded to a continuous sheet of a second material by pressing them together and moving the pressed together materials through an induction coil to inductively heat the electrically conductive material and bond it with the second material.

1 . An electric induction bonding apparatus comprising: 
 a first induction heating plate having a surface for placement of an electrically conductive sheet, the first induction heating plate comprising one or more first induction coils disposed within a heat resistant material;    a second induction heating plate selectively locatable over the surface of the first induction heating plate, the second induction heating plate comprising one or more second induction coils disposed within a heat resistant material;    a frame disposed around the second induction heating plate, the frame selectively locatable over the surface of the first induction heating plate to form a dam over the surface of the first induction heating plate; and    at least one or more ac power supplies connected to the one or more first and second induction coils.    
   
   
       2 . The electric induction bonding apparatus of  claim 1  wherein the frame further comprises one or more third induction heating coils disposed within a heat resistant material.  
   
   
       3 . The electric induction bonding apparatus of  claim 1  further comprising one or more fluid cooling passages in at least the first or second induction heating plate.  
   
   
       4 . The electric induction bonding apparatus of  claim 1  wherein the one or more first induction coils are orthogonally oriented to the one or more second induction heating coils.  
   
   
       5 . The electric induction bonding apparatus of  claim 1  wherein the first or second induction heating plates further comprises one or more temperature sensing devices disposed in the heat resistant material.  
   
   
       6 . A method of producing a bonded product by electric induction heating, the method comprising the steps of: 
 placing an electrically conductive sheet between a first induction heating plate and a second induction heating plate disposed within a separable frame;    supplying ac current to one or more induction heating coils in the first and second induction heating plates to establish magnetic fields that couple with the electrically conductive sheet to inductively heat the sheet;    separating the first induction heating plate and the frame from the second induction heating plate; and    pouring a liquid bonding material into the volume bounded by the frame and a surface of the electrically conductive sheet.    
   
   
       7 . The method of  claim 6  further comprising the step of quenching the liquid bonding material on the electrically conductive sheet.  
   
   
       8 . The method of  claim 6  further comprising the step of cooling at least the first induction heating plate, the second induction heating plate, or the frame.  
   
   
       9 . The method of  claim 6  further comprising the step of sensing the temperature of the first or second induction heating plate prior to the step of separating the first induction heating plate and the frame from the second induction heating plate.  
   
   
       10 . The method of  claim 6  further comprising the step of supplying ac current to one or more induction coils in the frame.  
   
   
       11 . An electric induction bonding apparatus comprising: 
 a first induction heating plate having an indented surface area for placement of an electrically conductive sheet, the first induction heating plate comprising one or more first induction coils disposed within a heat resistant material;    a second induction heating plate having a surface area substantially the same as the indented surface area of the first induction heating plate, the surface area of the second induction heating plate selectively locatable over the indented surface area of the first induction heating plate, the second induction heating plate comprising one or more second induction coils disposed within a heat resistant material;    a frame disposed around the second induction heating plate, the frame selectively locatable over the surface of the first induction heating plate; and    at least one or more ac power supplies connected to the one or more first and second induction coils.    
   
   
       12 . The electric induction bonding apparatus of  claim 11  wherein the frame further comprises one or more third induction heating coils disposed within a heat resistant material.  
   
   
       13 . The electric induction bonding apparatus of  claim 11  wherein the one or more first induction coils are orthogonally oriented to the one or more second induction coils.  
   
   
       14 . The electric induction bonding apparatus of  claim 11  wherein the first or second induction heating plates further comprises one or more temperature sensing devices disposed in the heat resistant material.  
   
   
       15 . A method of producing a bonded product by electric induction heating, the method comprising the steps of: 
 placing an electrically conductive sheet between a first induction heating plate and a second induction heating plate disposed within a separable frame;    supplying ac current to one or more induction heating coils in the first and second induction heating plates to establish magnetic fields that couple with the electrically conductive sheet to inductively heat the sheet;    pressing the electrically conductive sheet into an indentation in the first induction heating plate with the second induction heating plate;    moving the second induction heating plate away from the electrically conductive sheet; and    pouring a liquid bonding material into the indentation over the electrically conductive sheet.    
   
   
       16 . The method of  claim 15  further comprising the step of quenching the liquid bonding material over the electrically conductive sheet.  
   
   
       17 . The method of  claim 15  further comprising the step of supplying ac current to one or more induction coils in the frame.  
   
   
       18 . The method of  claim 15  further comprising the step of cooling at least the first induction heating plate, the second induction heating plate, or the frame.  
   
   
       19 . The method of  claim 15  further comprising the step of sensing the temperature of the first or second induction heating plate prior to the step of pressing the electrically conductive sheet into the indentation in the first induction heating plate with the second induction heating plate.  
   
   
       20 . The method of  claim 15  further comprising the step of sensing the temperature of the first or second induction heating plate prior to the step of moving the second induction heating plate away from the electrically conductive sheet.