Compact Heating Device for Edge Strip Application with Rapid Preheating
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Solution Overview
Problem
Conventional heating devices for edge strip application are large, require long warm-up times, and are inefficient in achieving high working speeds, limiting their industrial application.
Innovation Solution
A compact heating device design featuring a dual-pressure body structure with a heat-resistant seal, allowing pressurized gas to flow around the heating unit, providing forced cooling and rapid preheating, enabling high-pressure operation with adjustable air flow for efficient hot air injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional industrial hot air blower is used, then the heating device can achieve sufficient power, but the working speed is limited to 5-6 m/min
Solution Approach 1:
The heating device is divided into multiple heating zones with independent heating elements arranged in series along the air flow path. This segmentation allows the air to be heated progressively through multiple stages, achieving higher temperatures and faster heating rates without requiring a single high-power heater that would take longer to warm up.
Solution Approach 2:
The heating elements are nested within the air flow channels, which are themselves nested within the pressure body structure. This nested arrangement maximizes the heating efficiency by ensuring direct contact between the heating elements and the air flow, while maintaining a compact overall device size that enables faster response time.
2Device complexity
If a conventional heating device is used, then the structure is simple, but the device is large in volume and requires long warm-up time
Solution Approach 1:
The pressure body is pre-charged with air before heating begins. This preliminary action ensures that the air is already in position and under pressure, so that when heating starts, the air can be rapidly heated and immediately delivered at high speed without waiting for both heating and pressurization to occur sequentially.
Solution Approach 2:
The heating elements are arranged in a three-dimensional configuration within the air flow channels, maximizing the heating surface area exposed to the air flow. This spatial optimization allows for rapid heat transfer without increasing the overall device volume, reducing warm-up time while maintaining structural simplicity.
3Productivity
If the heating device operates at high temperature, then the heating efficiency is high, but the operational safety is reduced
Solution Approach 1:
A cooling channel with water circulation is introduced as an intermediary system between the high-temperature heating elements and the external environment. This cooling system actively removes excess heat from critical components and the housing, maintaining safe operating temperatures for surrounding structures while allowing the air heating process to reach the high temperatures needed for efficient edge strip activation.
Solution Approach 2:
Different parts of the device have different thermal characteristics - the heating zone maintains high temperature for efficient heating, while the housing and surrounding structures are actively cooled to maintain safe temperatures. This local differentiation of thermal properties allows high heating efficiency in the air stream while ensuring operational safety for the device structure and operators.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The compact heating device achieves higher working speeds (up to 25-30 m/min) with reduced warm-up times and enhanced operational safety, while maintaining high temperatures, and can be used in edge strip application and cutting devices for plastics and rigid foams.
Implementation Method 1
At least one heating element is accommodated in each of the air flow channels, by means of which the pressurized gaseous medium flowing through the respective air flow channel can be heated
Implementation Method 2
the pressurized, gaseous medium can flow around the heating unit before entering the air flow channels in order to be heated thereby effecting a forced cooling of the heating unit
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a heating device (1), in particular for an edge banding device or for a cutting device for cutting films or workpieces made of plastic or rigid foam or for a device for welding workpieces, comprising a heating unit (2) with a housing (4) within which a base body (5) is arranged, which has a plurality of air flow channels (50) extending between an air inlet end (51), through which a pressurized gaseous medium, in particular air, can flow into the base body (5), and an air outlet end (52), through which the pressurized gaseous medium can flow out of the base body (5), wherein at least one heating element (6) is housed in each of the air flow channels (50), by means of which the pressurized gaseous medium flowing through the respective air flow channel (50) can be heated.wherein the heating device (1) has a pressure body (3) within which the heating unit (2) is housed, wherein the pressure body (3) comprises an air inlet (304) through which the pressurized gaseous medium can flow into the pressure body (3) and an air outlet (303) through which the pressurized gaseous medium can flow out of the pressure body (3) after heating, and wherein an intermediate space (33) is formed between the housing (4) of the heating unit (2) and an inner wall of the pressure body (3) so that the pressurized gaseous medium can flow around the housing (4) before entering the airflow channels (50).