Bonding of Materials with Induction Heating

Abstract

An apparatus and process are provided for forming a two-metal flat bonded article. A flat metal sheet in solid form is placed in the indention of a heat resistant plate. A second heat resistant plate is placed over the flat metal sheet in the indentation to form a flat metal sheet enclosure. The flat metal sheet enclosure is placed in a U-shaped inductor assembly embedded with a solenoidal induction coil. Supply of alternating current to the solenoidal induction coil inductively heats the flat metal sheet after which the sheet is withdrawn from the inductor assembly. The second heat resistant plate is removed and a bond metal in liquid form is placed over the top surface of the flat metal sheet in the indentation so that the two-metal flat bonded article is formed as the bond metal solidifies.

1 . A method of bonding the adjacent sides of a pair of metal sheets, the method comprising the steps of:
 seating a flat metal sheet in solid form in an indentation in a first heat resistant plate, the indentation having a perimeter substantially equal to the perimeter of the flat metal sheet;   seating a second heat resistant plate over the first heat resistant plate containing the flat metal sheet so that an interior protruding region of the second heat resistant plate seats in the indentation in the first heat resistant plate over the top surface of the flat metal sheet, the combination of the second heat resistant plate seated over the first heat resistant plate forming a flat metal sheet container;   inserting the flat metal sheet container into a side-entry interior volume of a U-shaped inductor assembly having at least one solenoidal induction coil embedded in the top and bottom of the U-shaped inductor assembly, the side-entry interior volume having a height substantially equal to the height of the flat metal sheet container to press the interior protruding region of the second heat resistant plate over the top surface of the flat metal sheet;   supplying alternating current to the at least one solenoidal induction coil to inductively heat the flat metal sheet;   withdrawing the heated flat metal sheet container from the side-entry interior volume of the U-shaped inductor assembly;   removing the second heat resistant plate from the first heat resistant plate;   placing a bond metal in liquid form over the top surface of the flat metal sheet; and   bonding the bond metal to the top surface of the flat metal sheet as it solidifies.   
   
   
       2 . Apparatus for bonding the adjacent sides of two metal sheets together, the apparatus comprising:
 a U-shaped inductor assembly having a side opening into the interior volume of the U-shaped inductor assembly;   at least one solenoidal induction coil embedded in at least the top and bottom of the U-shaped inductor assembly;   at least one alternating current power supply connected to the at least one solenoidal induction coil; and   a flat metal sheet containment enclosure comprising a first and second heat resistant plate, the first heat resistant plate having an indentation with sufficient height for at least seating the flat metal sheet in solid form in the indentation and a bonding metal in liquid form over the flat metal sheet, the second heat resistant plate having an interior protruding region, the interior protruding region removably insertable into the indentation to a depth sufficient to touch the top surface of the first metal sheet when seated in the indentation, the interior volume of the U-shaped inductor assembly having a height substantially equal to the height of the combination of the first and second heat resistant plates when the interior protruding region of the second heat resistant plate is inserted into the indentation of the first heat resistant plate.   
   
   
       3 . The apparatus of  claim 2  wherein the first and second heat resistant plates are formed from a ceramic composition. 
   
   
       4 . A two-metal flat bonded article formed from a process comprising the steps of:
 seating a flat metal sheet in solid form in an indentation in a first heat resistant plate, the indentation having a perimeter substantially equal to the perimeter of the flat metal sheet;   seating a second heat resistant plate over the first heat resistant plate containing the flat metal sheet so that an interior protruding region of the second heat resistant plate seats in the indentation in the first heat resistant plate over the top surface of the first flat metal sheet, the combination of the second heat resistant plate seated over the first heat resistant plate forming a flat metal sheet container;   inserting the flat metal sheet container into a side-entry interior volume of a U-shaped inductor assembly having at least one solenoidal induction coil embedded in the top and bottom of the U-shaped inductor assembly, the side-entry interior volume having a height substantially equal to the height of the flat metal sheet container;   supplying alternating current to the at least one solenoidal induction coil to inductively heat the first flat metal sheet;   withdrawing the first flat metal sheet container from the side-entry interior volume of the U-shaped inductor assembly;   removing the second heat resistant plate from the first heat resistant plate;   placing a second metal in liquid form over the top surface of the first flat metal sheet; and   bonding the bond metal to the top surface of the flat metal sheet as it solidifies.