Conductive Wire Support for Injection Molding Heating
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Solution Overview
Problem
Existing heating devices in injection molding systems require adjustments for differently shaped semi-finished products and suffer from heat-related issues due to metallic positioning aids, leading to positional changes and altered heating behavior.
Innovation Solution
A heating device with an electrically conductive wire support where selected wires can be heated to a predetermined temperature, eliminating the need for positioning aids and allowing secure holding of semi-finished products at high travel speeds, using a wire layer with parallel or intersecting wires and temperature control via adjustable voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If spring-loaded clamps are used as positioning aids, then higher travel speeds can be achieved, but the positioning aids must be individually adapted for differently designed semi-finished products and they heat up causing positional changes and altered heating behavior
Solution Approach 1:
The wire support is designed as a universal positioning structure that can accommodate variously shaped semi-finished products without requiring individual adaptations. The wires are arranged in a pattern that provides support across different product geometries, eliminating the need for product-specific clamp configurations.
Solution Approach 2:
The patent replaces the mechanical spring-loaded clamp system with an electrically conductive wire support system. Instead of using mechanical clamps that physically constrain the product, the system uses electrical heating of wires to create thermal bonding with the semi-finished product, thereby eliminating the need for mechanical positioning aids.
2Speed
If spring-loaded clamps are used as positioning aids, then higher travel speeds can be achieved, but the positioning aids heat up causing positional changes and altered heating behavior
Solution Approach 1:
The patent replaces the mechanical spring-loaded clamp system with an electrically conductive wire support system. Instead of using mechanical clamps that physically constrain the product, the system uses electrical heating of wires to create thermal bonding with the semi-finished product, thereby eliminating the need for mechanical positioning aids.
Solution Approach 2:
The wire support serves dual functions: it provides structural support for the semi-finished product and simultaneously heats the product through resistive heating when voltage is applied. The wires self-regulate their temperature through adjustable voltage control, eliminating the need for separate heating elements and positioning aids.
3Stability of the object's composition
If low travel speeds are set to avoid slipping of the semi-finished product on wire support, then positioning stability is improved, but productivity decreases
Solution Approach 1:
The patent utilizes the phase transition of the semi-finished product material from solid to molten state through controlled heating of the wire support. When the wires are heated to a predetermined temperature, they cause localized melting at the contact points between the wire support and the semi-finished product, creating a bonding effect that prevents slipping even at high travel speeds.
Solution Approach 2:
The system changes the thermal parameter of the wire support by applying adjustable voltage to heat the wires to a predetermined temperature. This temperature parameter change creates a bonding interface between the wire support and the semi-finished product, enabling stable positioning at high travel speeds without slipping.
4Device complexity
If one wire support is used for differently shaped semi-finished products, then device complexity is reduced, but the wire support contact surface must be sufficiently large for all product variations
Solution Approach 1:
The wire support is designed as a universal structure with wires arranged in a pattern that can accommodate various product shapes and sizes. The same wire support configuration serves multiple product variations without requiring adjustments or reconfigurations, achieving versatility through a single standardized design.
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
Enables the use of a single wire support for variously shaped semi-finished products without adjustments, preventing slipping and maintaining precise temperature control, thus ensuring reliable fixation and efficient processing.
Implementation Method 1
the wires of the wire support are electrically conductive and that selected wires can be applied with a voltage and thus heated
Implementation Method 2
the surface of the semi-finished product can be heated via the melting temperature of the matrix of the semi-finished product. This leads to a bonding of the semi-finished product with the wire support
Data Source
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AI summary
The invention relates to a heating device having a furnace, into which a semi-finished product to be heated can be introduced/inserted and extended, comprising a wire support formed of several spaced apart wires, onto which the semi-finished product can be positioned, and means for moving the wire support into and out of the furnace. In order to provide both a method with high travel speed, and at the same time to be able to use the same wire support for semi-finished products of different shapes, it is provided according to the invention that the wires are electrically conductive, and that selected wires can be acted upon by a voltage, and thus can be heated, wherein the voltage is adjustable and/or controllable in such a way that the wires can assume a predefinable temperature. By suitable heating of the wires, the semi-finished product can be fixed on the wire support by melting.