Compact vacuum experimental furnace: technical analysis, application scenarios and industry development

In the field of scientific research and production, the demand for precision in material handling and experimental environment is increasing day by day. With its compact size, flexible operation performance and stable vacuum environment control ability, small vacuum experimental furnace has become an indispensable equipment for many researchers and enterprise R & D departments.XVACUUM Technology (Jiangsu) Co., Ltd. with its profound accumulation and continuous innovation ability in the field of vacuum technology, has achieved remarkable results in the research and development of small vacuum experimental furnace, which provides powerful support for the promotion of scientific research development and industrial technology upgrading. To promote scientific research development and industrial technology upgrading provides strong support.

First, the working principle and structure of small vacuum experimental furnace composition

(A) the core working principle

The working principle of the small vacuum experimental furnace is based on the influence of the vacuum environment on the physical and chemical changes in matter. In the conventional atmospheric environment, the material surface will be adsorbed in the air oxygen, water and other impurities, in the high temperature treatment process, these substances will be oxidized with the material, hydrolysis and other reactions, affecting the material properties. In the vacuum environment, the air pressure is greatly reduced, and the gas molecules adsorbed on the surface and inside of the material are more likely to escape, which effectively avoids the undesirable chemical reaction between the material and the components in the air. At the same time, the vacuum environment can also change the material phase transition temperature, diffusion rate and other physical properties, providing unique conditions for material processing and experiments. When the small vacuum experimental furnace is started, the furnace chamber is first pumped by the vacuum system to reduce the internal air pressure to a predetermined level, creating a vacuum environment. Subsequently, the heating system starts to work and raises the temperature inside the chamber to a set value by means of heating elements. Under the dual action of vacuum and high temperature, the samples placed in the furnace chamber undergo various physicochemical changes, such as sintering, annealing, quenching and coating. During the whole process, the control system monitors and adjusts the vacuum, temperature, heating time and other key parameters in real time to ensure that the experimental process is carried out accurately according to the preset program, so as to obtain accurate and reliable experimental results or to achieve the expected results of material treatment.

(B) Structure

Small vacuum experimental furnace mainly consists of furnace body, vacuum system, heating system, control system and safety protection devices and other components. Furnace body is the main body of the small vacuum experimental furnace, usually made of high-strength, high-temperature resistant stainless steel or alloy materials, the internal design of the thermal insulation layer to reduce heat loss and improve energy efficiency. The relatively small size of the furnace body facilitates flexible placement in the laboratory or small production workshop. The interior space of the furnace chamber is designed to accommodate samples of different sizes and shapes according to actual needs and is equipped with sample trays or holders for easy placement and fixation of samples. The furnace body is equipped with an observation window, through which the operator can observe the real-time changes in the state of the samples in the furnace chamber. Meanwhile, the observation window is made of special high-temperature-resistant and vacuum-resistant materials to ensure safety and sealing in high-temperature and vacuum environments. Vacuum system is the key component to realize the vacuum environment, which generally consists of vacuum pump, vacuum pipeline, vacuum valve and vacuum measuring instrument. Vacuum pumps, as the core component, are commonly available in the types of rotary vane mechanical pumps, turbomolecular pumps, and so on. The rotary vane mechanical pump is often used for rough pumping, which can quickly reduce the air pressure in the furnace chamber; the turbo molecular pump is used for fine pumping, which can make the furnace chamber reach a higher vacuum degree and meet the requirements of different experiments on the vacuum environment. Vacuum piping and valves are used to connect the various components, control the gas transmission path and flow rate to ensure the smooth pumping process. The vacuum measuring instrument monitors the vacuum level in the furnace chamber in real time and feeds the data back to the control system, so that the operator can understand the current vacuum status intuitively through the instrument.

The heating system utilizes highly efficient heating elements such as resistance wires, silicon molybdenum rods and silicon carbide rods. These heating elements are evenly distributed around the furnace chamber to ensure the temperature uniformity inside the chamber. The heating elements are connected to the temperature control system, which monitors the temperature in the furnace chamber in real time through temperature sensors and automatically adjusts the heating power according to the set temperature profile to achieve precise temperature control. The temperature control accuracy is usually ±1℃ or even higher, which can meet the strict requirements of temperature for various precision experiments and material processing. Control system is a small vacuum experimental furnace “brain”, generally using programmable logic controller (PLC) or computer control system. The operator can easily set the process parameters such as vacuum, temperature, heating rate, holding time, etc. through the human-computer interaction interface, such as touch screen or computer terminal. The control system can automatically coordinate the work of the vacuum system and heating system to realize the automatic operation of the equipment. At the same time, the system also has a data recording and storage function, which can record the parameters in the experimental process in real time, so as to facilitate the subsequent data processing and analysis. In the event of abnormalities, such as over-temperature, vacuum drop, etc., the control system will immediately issue an alarm and take appropriate protective measures to ensure the safety of the equipment and samples. Safety protection device is an important part to guarantee the normal operation of small vacuum experimental furnace and personnel safety. In addition to the basic over-temperature protection and over-voltage protection functions, it is also equipped with leakage protection, short circuit protection and other devices. For example, when the temperature in the furnace chamber exceeds the set safety value, the over-temperature protection device will automatically cut off the heating power supply; if there is an abnormality in the vacuum system leading to high pressure in the furnace chamber, the over-pressure protection device will be activated to release the pressure in order to prevent danger. In addition, the equipment shell adopts grounding design, effectively preventing electric leakage accidents, to protect the personal safety of the operator.

Second, the application of small vacuum experimental furnace

(A) the field of scientific research experiments

In the field of scientific research experiments, small vacuum experimental furnace is widely used. In materials science research, researchers use small vacuum experimental furnace to study the materials in the vacuum and high temperature environment of the phase transition process, crystal growth mechanism, element diffusion law. For example, the study of new alloy materials in the vacuum sintering process of organizational evolution, through precise control of the temperature and vacuum, to explore the appropriate sintering process parameters, in order to improve the alloy's strength, toughness and other properties. In the preparation of nanomaterials, small vacuum experimental furnace can be used to prepare nanoparticles, nanofilms and other materials, through the adjustment of experimental conditions, control the size, morphology and structure of nanomaterials, to provide the basis for the application of nanomaterials research. In physical chemistry experiments, small vacuum experimental furnace can be used to simulate the extreme environment, the study of chemical reaction kinetics and thermodynamics of substances in vacuum and high temperature conditions. For example, it is used to study the reaction rate and reaction path of certain chemical reactions in a vacuum environment, which provides a basis for the development of new chemical reactions and synthesis methods. In addition, in semiconductor physics research, small vacuum experimental furnace can be used to anneal semiconductor materials, improve the electrical properties of semiconductor materials, and study the preparation process of semiconductor devices.

(B) New materials research and development

New materials research and development is one of the important application direction of small vacuum experimental furnace. In the research and development of new ceramic materials, small vacuum experimental furnace can be used for ceramic vacuum sintering. Compared with conventional atmospheric sintering, vacuum sintering can avoid ceramic materials at high temperatures in the process of oxidation reactions with oxygen in the air, to prevent the ceramic surface from producing pores, cracks and other defects, to improve the density and strength of ceramics. At the same time, by controlling the vacuum degree and temperature, it can also adjust the grain size and microstructure of the ceramic material, giving the ceramic material special properties, such as high hardness, high wear resistance, good dielectric properties. For the research and development of metal matrix composites, small vacuum experimental furnace can be used to prepare composite materials and optimize their properties. Under the vacuum environment, the gases and impurities in the reinforcing phase and matrix can be effectively removed to enhance the interfacial bonding between the two and improve the comprehensive performance of the composites. For example, in the preparation process of carbon fiber reinforced metal matrix composites, the use of small vacuum experimental furnace for vacuum hot pressing treatment can make carbon fiber and metal matrix better combination, improve the strength and toughness of the composite material, to meet the aerospace, automotive and other fields of high-performance materials needs.

(C) electronic components manufacturing

In the electronic components manufacturing industry, small vacuum experimental furnace is commonly used in the treatment of electronic materials and packaging of components. In the semiconductor chip manufacturing, the chip in the manufacturing process requires multiple heat treatment processes, such as annealing, diffusion and so on. Small vacuum experimental furnace can provide precise temperature control and clean vacuum environment to avoid contamination of the chip in the heat treatment process and improve the performance and reliability of the chip. For example, when annealing the chip, the vacuum environment can eliminate the stress inside the chip, improve the crystal structure, and improve the electrical performance of the chip. For electronic ceramic devices, such as multilayer ceramic capacitors (MLCC), ceramic filters, etc., small vacuum experimental furnace can be used for ceramic billet sintering and component packaging. In the vacuum sintering process, it can make the ceramic grain grow uniformly and improve the dielectric properties and mechanical strength of ceramics. In the electronic components packaging, small vacuum furnace can be used for vacuum potting, vacuum welding and other processes to ensure that the packaging process will not be mixed with air and impurities, to improve the sealing and reliability of components, to extend the service life of components.

(D) jewelry processing and protection of cultural relics

In the field of jewelry processing, small vacuum experimental furnace can be used for optimization of jewelry and jade. For example, vacuum heating treatment of some poorly colored gemstones can improve the color and transparency of gemstones, and enhance the quality and value of gemstones. At the same time, processing in a vacuum environment can avoid the gemstone in the high temperature process and the oxygen in the air oxidation reaction, to protect the original structure and properties of the gemstone. In the protection of cultural relics, small vacuum experimental furnace can be used for some metal cultural relics, paper cultural relics and other restoration and protection treatment. For metal cultural relics, heating treatment in a vacuum environment can remove the rust and corrosion products on the surface of cultural relics, while avoiding further oxidation of cultural relics in the treatment process. For paper cultural relics, you can use a small vacuum experimental furnace for drying treatment, to remove the moisture in the paper, to prevent the paper from mold, decay, and extend the preservation time of cultural relics.

Third, the technical advantages and contributions of XVACUUM Technology (Jiangsu) Co.

(A) the ability of technological innovation

XVACUUM Technology (Jiangsu) Co., Ltd. in the small vacuum experimental furnace research and development process, always adhere to technological innovation, showing strong technical strength. The company's R&D team studies vacuum technology, material science and thermal principles in depth, and constantly explores new technologies and processes to improve the performance and quality of the equipment. In terms of vacuum system design, the pumping efficiency and the stability of vacuum degree have been improved by optimizing the selection and combination method of vacuum pumps and improving the layout of vacuum pipelines. The new vacuum sealing structure developed effectively reduces the air leakage rate of the furnace body, enabling the equipment to reach a higher vacuum level in a shorter time and meet the strict requirements of different experiments on the vacuum environment. On the innovation of heating system, new heating material and intelligent temperature control algorithm are adopted. The new heating material has the advantages of high heating efficiency, long service life, high temperature resistance, etc., which can quickly and evenly heat the furnace chamber. Intelligent temperature control algorithm combined with high-precision temperature sensor realizes precise control and fast response to the temperature, which can flexibly adjust the temperature change curve according to different experimental needs and ensure the accuracy and stability of the temperature in the experimental process. In addition, the company also applies the Internet of Things technology to the small vacuum experimental furnace to realize the remote monitoring and data transmission of the equipment. Operators can view the operating status and experimental data of the equipment in real time through cell phones, computers and other terminals, set and adjust process parameters remotely, and conveniently and quickly carry out experimental operations and management.

(B) Product customization service

Principal Vacuum Technology takes into full consideration of the diversified needs of different customers for small vacuum experimental furnace and provides a full range of customized product solutions. The company's technical staff will deeply understand the customer's specific application scenarios, experimental needs and special requirements, from the overall structural design of the equipment, the configuration of the functional modules to the process parameter settings, personalized customization. For scientific research institutions, according to their different research directions and experimental needs, customized with a specific temperature range, vacuum and size specifications of the small vacuum experimental furnace. For example, for research teams engaged in high-temperature superconducting materials research, we customize furnaces that can reach higher temperatures and vacuum levels, and are equipped with precise temperature and vacuum control systems to meet the stringent requirements of researchers for experimental conditions. At the same time, according to the characteristics of the experimental samples, the design of flexible sample loading methods and observation windows, convenient for researchers to carry out experimental operations and observation. For enterprise R&D department, according to the enterprise's production process and product demand, customized small vacuum experimental furnace suitable for small batch production. For example, we customize the experimental furnace with automation control function and rapid temperature rise and fall capability for the electronic components manufacturing enterprises, so as to improve the production efficiency and product quality. At the same time, according to the production environment and space layout, optimize the appearance of the equipment design and size, so that the equipment can be better integrated into the production process.

(C) perfect after-sales service system

XVACUUM Technology attaches great importance to after-sales service and has established a perfect after-sales service system. The company has a professional after-sales service team, which can provide customers with all-round and one-stop service. In the stage of equipment installation and commissioning, the technicians will go to the customer's site for equipment installation and commissioning to ensure the normal operation of the equipment, and provide systematic training to the customer's operators to make them skillful in the operation of the equipment, daily maintenance and troubleshooting skills. In the process of equipment use, the after-sales service team regularly visits and maintains the equipment, finds and solves potential problems in time, and prolongs the service life of the equipment. When equipment failure occurs, the after-sales service team can quickly respond by remote diagnosis or send technicians to the scene for maintenance, greatly reducing equipment downtime, to protect the customer's experiments and production work smoothly. In addition, the company also provides customers with equipment upgrading and remodeling services, according to technological development and changes in customer demand, the performance of the equipment to enhance and expand the function, so that customers can always use the advanced, reliable equipment.

Fourth, the market status and development trend of small vacuum experimental furnace

(A) the current market situation

At present, with the increase in scientific research investment and new materials, electronics and other industries, the rapid development of the market demand for small vacuum experimental furnace showed a sustained growth trend. In the market, there are many suppliers of small vacuum experimental furnace, and the competition is relatively fierce. Some well-known international companies with its advanced technology, long brand history and perfect sales and service network, in the high-end market to occupy a larger share, mainly serving the equipment performance and precision requirements of scientific research institutions and large enterprises. XVACUUM Technology (Jiangsu) Co., Ltd. as a representative of the rapid development of domestic enterprises in recent years, through continuous increase in R & D investment, improve product quality and technical level, in the domestic market has gradually gained a firm foothold, and began to expand to the international market. With in-depth understanding of the local market demand, high cost-effective and good customized services, domestic enterprises have won the recognition of many customers in scientific research institutes, small and medium-sized enterprises and other market areas, and the market share is gradually expanding.

(B) Development trend

Intellectualization and automation: in the future, the small vacuum experimental furnace will develop in the direction of intellectualization and automation. The introduction of artificial intelligence, machine learning and other technologies, so that the equipment can automatically analyze the experimental data, according to the characteristics of the experimental samples and the purpose of the experiment, automatically optimize the vacuum, temperature, heating time and other process parameters to achieve intelligent operation. At the same time, it realizes the automatic operation of the equipment, including automatic loading, automatic heating, automatic cooling, automatic testing and other functions, which reduces human error in operation and improves the efficiency of the experiment and the accuracy of the data.

High precision and high stability: With the increasing requirements of scientific research and production on the accuracy and reliability of experimental results, the precision and stability of the small vacuum experimental furnace has also put forward higher requirements. In the future, the equipment will adopt more advanced sensor technology, control algorithms and manufacturing processes to further improve the precision of vacuum and temperature control and ensure that the equipment maintains stable performance during long-time operation. For example, higher precision temperature sensors and vacuum measuring instruments will be developed, and control system algorithms will be optimized to achieve more precise control of experimental conditions.

Multi-functional integration: In order to meet the diversified needs of customers, the small vacuum experimental furnace will be integrated with more functional modules. In addition to the existing heating and vacuuming functions, it will also integrate gas atmosphere control, sample rotation, online testing and other functions to realize multi-purpose, providing customers with more comprehensive experimental solutions. At the same time, through the modular design, the functional modules of the equipment can be flexibly combined and replaced according to customer needs, which is convenient for equipment upgrading and maintenance.

Green and energy saving: In the context of increasing environmental awareness, small vacuum experimental furnace will pay more attention to green and energy-saving design. Adopt energy-saving heating elements, vacuum pumps and control systems, optimize the energy management system of the equipment and reduce the energy consumption of the equipment. At the same time, reduce the emissions of waste gas, waste water and waste residue produced in the experimental process, and adopt environmentally friendly materials and processes to achieve sustainable development. For example, develop new energy-saving heating materials to improve energy utilization efficiency; adopt environmentally friendly vacuum sealing materials to reduce the use of harmful substances.