Forming Die Heater Insert for Uniform Heating of 3D Surfaces
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Solution Overview
Problem
Conventional hot forming dies face challenges in maintaining consistent heat distribution for complex 3D surfaces, such as automobile pillars, leading to temperature variations and increased costs due to the use of linear cartridge heaters, which are difficult to install, maintain, and result in inferior products.
Innovation Solution
A forming system with a first and second die assembly, each having a die body and surface with varying cross sections, incorporating a serpentine groove heater insert member and a flexible heater member that conforms to the die surface, allowing for uniform heating and reduced maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If linear cartridge heaters are used to heat specific regions of a part during forming, then localized heating can be achieved, but temperature variations along the die surface occur causing uneven heat distribution
Solution Approach 1:
The patent uses a flexible heater element that can be formed into a serpentine groove configuration within the die. This flexible heater conformally contacts the die surface, ensuring uniform heat distribution across complex 3D surfaces while maintaining localized heating capability. The flexibility allows the heater to adapt to varying die geometries without creating temperature variations.
Solution Approach 2:
The patent employs a serpentine groove configuration with curved paths instead of straight linear heaters. This curved/serpentine arrangement allows the heater to follow the contours of complex die surfaces, improving heat distribution uniformity across 3D geometries while maintaining localized heating zones where needed.
2Area of stationary object
If numerous linear cartridge heaters are inserted into a die, then heating coverage can be increased, but costs associated with machining, assembling, and maintenance increase significantly
Solution Approach 1:
The patent merges multiple discrete linear cartridge heaters into a single flexible heater element that can be formed into a serpentine groove configuration. This unified heater structure provides comprehensive heating coverage across the die surface while eliminating the need for multiple separate components, thereby reducing machining, assembly, and maintenance complexity.
Solution Approach 2:
The flexible heater element serves multiple functions: it provides heating coverage across various die geometries, conforms to complex 3D surfaces, and replaces numerous discrete heaters with a single multi-functional component that simplifies the overall tool system.
3Temperature
If linear cartridge heaters are used in complex 3D die surfaces, then heating can be provided, but installation and maintenance become difficult and costly
Solution Approach 1:
The flexible heater element can be easily formed into serpentine grooves within the die structure and is simple to install and remove. Its flexibility allows it to adapt to complex die geometries without requiring complex installation procedures, and replacement is straightforward without special cleaning procedures.
Solution Approach 2:
The flexible heater element is designed as a simpler, more replaceable component compared to numerous linear cartridge heaters. If damaged or worn, it can be easily replaced without the complex assembly and disassembly required for multiple discrete heaters, reducing maintenance time and costs.
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 system achieves uniform heat distribution across complex 3D surfaces, reducing temperature discrepancies and production costs while forming high-strength and ductile regions in vehicle parts, resulting in higher quality products with tailored properties.
Implementation Method 1
the first flexible heater member is disposed in the first serpentine groove and configured to conform with the shape of the first serpentine groove
Data Source
Figure 1A
Figure 1B
Figure 1C~1F
AI summary
Disclosed is a forming system having a first die assembly and a second die assembly with dies having die surfaces that are configured to cooperate with each other to form a die cavity therebetween so as to receive a workpiece therein. One or both of the dies includes a heater insert member that has a serpentine groove therein for receiving a flexible heater member. The flexible heater member is configured to conform with the shape of the serpentine groove. The heater insert member is position adjacent to the die surface and provides more uniform heating of the surface to form complex 3D surfaces with tailored properties.