Furnace for the high-temperature processing of materials with a low dielectric loss factor

• US 6,163,020 A
• Filed: 08/12/1999
• Issued: 12/19/2000
• Est. Priority Date: 01/04/1997
• Status: Expired due to Fees

• Current Assignee: GERO Hochtemperaturoefen GmbH
• Original Assignee: GERO Hochtemperaturoefen GmbH
• Inventors: Muller, Gunter, Bartusch, Wolfgang
• Primary Examiner(s): Leung, Philip H.
• Application Number:
  US09/341,175
• Time in Patent Office: 495 Days
• Field of Search: 219/756, 219/759, 219/745, 219/746, 219/762, 219/748, 219/750
• US Class Current: 219/756
• CPC Class Codes: H05B 6/6402 Aspects relating to the microwave cavity
• CPC Class Codes: H05B 6/705 using microwave tuning
• CPC Class Codes: H05B 6/708 in particular slotted waveguides

Abstract

In the furnace (10) for the high-temperature processing of materials with a relatively low dielectric loss factor (tan δ) by heating the material by absorption of microwave energy in a resonant cavity (16), a uniform energy intensity of the microwave field is to be achieved for example by irradiating the microwave energy over a broad band and/or by varying in time the frequency of the irradiated microwave energy. The resonant cavity (16) and the radiation source (13) are tuned to each other such that the relation: (V/λ³). B≧20 is satisfied. V stands for the volume of the resonant cavity (16), λ for the wavelength of the microwave radiation and B its band width. V/λ³ equals at least 300 and the clear dimensions 1x, ly and lz of the resonant cavity (16) in the direction of the co-ordinates x, y and z are approximately equal to the cubic root of V. The wall (16₁ to 16₆) of the resonant cavity is made of graphite and can be heated by a heating device (28) up to the temperature of the material to be treated. The heating device is arranged outside the resonant cavity, and a heat insulting envelope (38) encloses the unit of resonant cavity (16) and heating device.

Claims

1. Furnace for the high-temperature processing of materials with relatively low dielectric loss factor (tan δ

) by heating the material by absorption of microwave energy in a resonant cavity, in which the material to be treated is arranged within a central area of the resonant cavity, wherein a uniform energy density of the microwave field is achieved so that in each volume element of the treatment area the square of the electric field strength of the microwave field has the same value, at least over time, within a minor tolerance, wherein an electric heating device is provided, with which the resonant cavity wall can be heated to the same temperature as within the material to be treated and wherein a heat insulating envelope is provided, which insulates the furnace against heat loss into the environment, characterized by the following features;

a) the resonant cavity (16) and the radiation source (13) are sufficiently attuned to each other, so that the relation ##EQU8## is satisfied, wherein V is the volume of the resonant cavity (16), λ

is the wavelength of the microwave radiation and B is their band width, further the amount V/λ

³ has a value of at least 300 and the transparent dimensions 1_x, 1_y and 1_z of the resonant cavity (16) in the coordinate directions x, y and z have a value of approximately

space="preserve" listing-type="equation">∛

V

each;

b) the heating device (28) is arranged outside of the resonant cavity (16) in the immediate vicinity of the resonant wall, and the heat insulating envelope (38) is arranged so that it encompasses the resonant cavity (16) and the heating device (28) from the outside,

c) the resonant wall (16₁ through 16₆) consists of graphite or equivalent temperature maintaining and electrically conductive material.

2. Furnace according to claim 1, wherein a magnetron is provided as microwave radiation source (13), which is tunable about a basic frequency f within a band width B=Δ

f/f of approximately 1/100.

3. Furnace according to claim 1, wherein time intervals within which within a continuous or stepwise variation of the oscillation frequency of the microwave radiation source (13) occurs, lies between 0.05 and 1 s.

4. Furnace according to claim 3, wherein said time intervals are approximately 100 ms.

5. Furnace according to claim 1, wherein an amount n of magnetrons are provided, which are operable at various central frequencies f_i (i=1 through n) and each have characteristic band widths B_i.

6. Furnace according to claim 5, wherein the frequency separations of the center frequencies of the magnetrons which are next to each other in the frequency scale satisfy the equation (Δ

f_i +Δ

f_i+i)/2.

7. Furnace according to claim 1, wherein the resonant cavity (16) has a cuboidal design, such that the outer lengths 1_x, 1_y and 1_z of the resonant cavity boundary correspond at least to the 10-fold of the wavelength of the microwave radiation.

8. Furnace according to claim 1, wherein the resonant cavity (16) has a polygonal cross-section.

9. Furnace according to claim 1, wherein the resonant cavity (16) is comprised of plate-shaped graphite material (16₁ through 16₆).

10. Furnace according to claim 9, wherein said graphite material is plate-shaped.

11. Furnace according to claim 1, wherein for introduction of the microwave energy into the resonant cavity (16) an antenna-arrangement (14) is provided, which has an omnidirectional characteristic.

12. Furnace according to claim 11, wherein the antenna-arrangement (14) is formed as a group emitter comprising multiple individual emitters, wherein the individual emitters can be supplied by a statistically distributed phase position.

13. Furnace according to claim 12, wherein the group emitter is designed as a slit emitter, which includes a plurality of radiation slits with a slit length of between λ

/4 and λ

/2 and, in comparison thereto, a small slit width w, which viewed in the direction of radiation of the microwave field in the feeding wave guide, are distributed in such a manner over the length thereof, that per slit the same or approximately similar amount of microwave energy can be introduced into the resonant cavity, wherein, viewed in the direction of propagation of the microwave field in the wave guide, the extension of the individual slits corresponds to between w and λ

/2, of which further in the distance measured in the direction of radiation of the microwave field in the wave guide sequential slits of the slit antenna have a value of between λ

/2 and 3λ

/4, and, with reference to the center plane of the wave guide running in the direction of propagation, the sideways separation of the slits from this center plane, over the length of the wave guide, increases stepwise, and wherein a statistic distribution of the longitudinal slits, which form the individual radiation elements, is provided with respect to the longitudinal center plane of the wave guide.

14. Furnace according to claim 13, wherein over the length of the wave guide (21) provided to feed the antenna slits (18) at least 20 individual slits are provided.

15. Furnace according to claim 14, wherein at least some of its slits run perpendicular to the direction of propagation of the microwave field in the wave guide.

16. Furnace according to claim 11, wherein for introduction of the microwave energy into the resonant cavity (16) at least two group emitters are provided.

17. Furnace according to claim 16, wherein the group emitters (14) are arranged symmetrically with regard to a significant or distinct axis of the resonant cavity.

18. Furnace according to claim 16, wherein said group emitters are provided with slit-antenna arrangement.

19. Furnace according to claim 11, wherein the corresponding antenna-arrangement (14) is arranged in a strip-shaped outer area of the resonant wall, which runs very close to the inner outer of the resonant wall.

20. Furnace according to claim 1, wherein for the adjustment of a controllable heating device (28) for achievement of equalization of the temperature profile within the resonant cavity, which maintains the temperature of the resonant walls (16₁ through 16₆) at a value which corresponds to the value of the temperature-value in a central area of batch of material being sintered (12), which is sensed as actual value, and which for its part in accordance with a control program follows a specific temperature profile over time.

21. Furnace according to claim 20, wherein various wall areas (16₁ -16₆) of the resonant cavity (16) are provided with associated temperature sensors (29₁ through 29₆), by means of which the possibly varying resonant wall temperatures may be sensed, and that the heating device (28) includes various heater elements (28₁ through 28₆) for heating the various walls being monitored, which are individually controllable.

22. Furnace according to claim 20, wherein said controllable heating device (28) is an electric resistance heater.

23. Furnace according to claim 1, wherein the heat insulating arrangement intended for heat insulation of the resonant cavity (16) against the outer surroundings of the furnace (10) is formed internal to furnace housing (36) for receiving the resonant cavity (16) and to the heating device (28), and for its part is made of graphite material with a minimally conductive outer layer.

24. Furnace according to claim 23, wherein said graphite material is graphite felt.

25. Furnace as in claim 1, wherein the uniform energy density of the microwave field is achieved by irradiating with broadband microwave energy.

26. Furnace as in claim 1, wherein the uniform energy density of the microwave field is achieved by varying the frequency of the irradiated microwave energy over time.

27. Furnace as in claim 1, wherein the resonant cavity wall is heated to the same temperature as within the material to be treated via a servo control such that the temperature of the resonant cavity wall follows the temperature of the material to be treated.

28. A furnace for the high-temperature processing of a grouping of workpieces made of materials with relatively low dielectric loss factor (tan δ

), and including;

a microwave energy source for producing electromagnetic radiation in the microwave range;

a waveguide in communication with said microwave energy source for propagating microwave radiation into a resonant cavity;

a resonant cavity in communication with said waveguide and dimensioned for receiving a grouping of individual workpieces made of materials with relatively low dielectric loss factor;

a detector for detecting the temperature within said grouping of the workpieces placed in said resonant cavity;

an electric heating device for heating the resonant cavity wall(s);

means for adjusting the output of said electric heating device to thereby adjust the temperature of the resonant cavity wall(s) to correspond to the temperature within said grouping of workpieces as detected by said detector; and

a thermal insulating means provided outside said resonant cavity for insulating said furnace against heat loss into the environment,

wherein said microwave generator generates broadband microwave energy and/or wherein means are provided for varying the frequency of the irradiated microwave energy over time, such that a uniform energy density of the microwave field can be achieved within said resonant cavity and such that the workpieces within said grouping receive a substantially uniform high-temperature processing, and wherein the following conditions are satisfied;

a) the resonant cavity (16) and the microwave radiation source (13) are sufficiently attuned to each other, so that the relation ##EQU9## is satisfied, wherein V is the volume of the resonant cavity (16), λ

is the wavelength of the microwave radiation and B is their band width, further the amount V/λ

³ has a value of at least 300 and the transparent dimensions 1_x, 1_y and 1_z of the resonant cavity (16) in the coordinate directions x, y and z have a value of approximately

space="preserve" listing-type="equation">∛

V

each;

c) the heating device (28) is arranged outside of the resonant cavity (16) in the immediate vicinity of a resonant cavity wall(s), and the heat insulating envelope (38) is arranged so that it envelopes the resonant cavity (16) and the heating device (28) from the outside, and

c) the resonant cavity walls (16₁ through 16₆) consist of graphite or an equivalent temperature maintaining and electrically conductive material.