Far-Infrared Heater Support for Hot Stamping Furnaces
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Solution Overview
Problem
Flexible far-infrared radiation heaters in multi-stage heating furnaces for steel sheets used in hot stamping suffer from non-uniform heating due to deflection, operational hazards from reduced space, and high maintenance costs, with existing support materials prone to thermal deformation or breakage.
Innovation Solution
The design incorporates thermal insulation blocks with far-infrared radiation heaters supported by expandable and contractible metal strips made of heat-resistant alloys, aligned to prevent deflection and thermal stress, and additional metal strips intersecting the first direction to maintain heater stability and uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If flexible far-infrared radiation heaters are used in multi-stage heating furnaces, then heating uniformity and compactness are improved, but heater deflection occurs causing non-uniform heating and operational hazards
Solution Approach 1:
The patent uses flexible far-infrared radiation heaters constructed from numerous insulator elements arranged in rows and knitted together to form a flexible panel. This flexible structure allows the heater to conform to the heating space while maintaining its heating function, resolving the contradiction between flexibility for compactness and stability for reliability
Solution Approach 2:
The patent introduces dynamic adjustment mechanisms including means for adjusting the position of the flexible far-infrared radiation heater and means for adjusting the tension applied to the heater. These dynamic adjustments allow the heater to maintain optimal position and tension during operation, preventing deflection while preserving flexibility
2Strength
If heater support members are made of metal materials, then structural strength is improved, but thermal deformation occurs at high temperatures
Solution Approach 1:
The patent employs composite construction for the heater support members, combining metal materials with thermal insulation materials. The metal provides structural strength while the thermal insulation material compensates for thermal expansion and deformation at high temperatures, resolving the contradiction between strength and dimensional stability
Solution Approach 2:
The patent introduces expansion compensation mechanisms in the support structure that allow for thermal expansion and contraction of metal components. This compensation prevents dimensional instability and deformation while maintaining the structural strength needed to support the heater
3Temperature
If heater support members are made of ceramic materials, then thermal resistance is improved, but breakage occurs due to thermal shock
Solution Approach 1:
The patent uses composite construction combining ceramic materials with metal materials in the support structure. The ceramic provides thermal resistance while the metal provides impact resistance and toughness, preventing breakage under thermal shock while maintaining thermal performance
4Productivity
If multi-stage configuration is used, then mass production capability is improved, but installation area increases
Solution Approach 1:
The patent arranges multiple heating spaces in a vertical stacked configuration rather than horizontal arrangement. This vertical multi-stage design enables processing of multiple steel sheets simultaneously (improving productivity) while minimizing the horizontal installation footprint by utilizing the vertical dimension
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
This configuration ensures consistent heating, reduces maintenance needs, and enhances the capacity and compactness of the heating furnace while preventing deflection and thermal deformation of the heaters, leading to improved operational efficiency and cost-effectiveness.
Implementation Method 1
far-infrared radiation heaters (14-1 to 14-7) positioned above and below the steel sheets for hot stamping (15-1 to 15-6) to heat the steel sheets for hot stamping
Implementation Method 2
support pieces that support the plurality of first metal strips (26) in such a manner that the first metal strips are expandable and contractible in a longitudinal direction by thermal expansion or thermal contraction
Data Source
AI summary
A far-infrared radiation multi-stage type heating furnace for steel sheets for hot stamping, the furnace including far-infrared radiation heaters having flexibility that are prevented from deflecting even during heating at temperatures ranging from the Ac3 transformation temperature to 950° C. The furnace includes: multiple-staged heating units that accommodate steel sheets, each heating unit formed by thermal insulation materials disposed around the periphery; and far-infrared radiation heaters positioned above and below the heating units. A far-infrared radiation heater is received by first metal strips. The first metal strips are disposed so that their strong axis direction approximately corresponds to the direction of gravity and supported by support pieces so as to be expandable and contractible in a longitudinal direction by thermal expansion or thermal contraction. The support pieces are disposed outside the thermal insulation materials in the heating units and a ceiling unit.