Induction welding with an electromagnetic field concentrator
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Solution Overview
Problem
Existing induction welding technologies lack the capability to provide an enhanced and tuned electromagnetic field, which is necessary for effective joining of thermoplastic bodies.
Innovation Solution
The use of an induction welder equipped with a concentrator and a coil, where the coil generates an electromagnetic field that is concentrated onto a specific region of the thermoplastic material using a receptacle with varying geometries to focus the field, allowing for improved welding efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a conventional induction welder without a concentrator is used, then the device complexity is reduced, but the electromagnetic field cannot be enhanced or tuned effectively
Solution Approach 1:
The patent introduces an electromagnetic field concentrator as an intermediary component between the induction coil and the thermoplastic workpiece. This concentrator focuses and enhances the electromagnetic field in the welding region without requiring changes to the coil itself, thus achieving field enhancement while maintaining relative device simplicity.
Solution Approach 2:
The concentrator modifies the electromagnetic field parameters (intensity, distribution, concentration) in the target region by its geometric design. The varying cross-sectional area and specific shape of the concentrator alter the field parameters to achieve enhanced welding effectiveness without changing the fundamental operating parameters of the induction coil.
2Productivity
If the electromagnetic field is concentrated onto a specific region, then welding efficiency is improved, but the device complexity increases due to the concentrator structure
Solution Approach 1:
The concentrator serves as a mediating structure that focuses the electromagnetic energy onto the specific welding region. This intermediary component enables precise energy delivery to improve welding efficiency while keeping the overall system architecture relatively simple and manageable.
Solution Approach 2:
The concentrator creates local quality enhancement of the electromagnetic field by concentrating energy specifically at the welding interface. This localized field enhancement improves welding efficiency at the critical region without requiring the entire device to be complex, as only the concentrator geometry needs to be specifically designed.
3Use of energy by moving object
If the receptacle has varying geometries to focus the field, then the electromagnetic field concentration is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The concentrator achieves electromagnetic field concentration through controlled changes in its geometric parameters (cross-sectional area, shape, dimensions) along its length. By carefully designing these parameter variations, the patent focuses the electromagnetic field effectively while providing clear manufacturing specifications that balance precision requirements with manufacturability.
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 enhances the welding process by concentrating the electromagnetic field, leading to stronger bonds between thermoplastic bodies and increased efficiency in the induction welding of thermoplastic materials.
Implementation Method 1
generating an electromagnetic field with the coil
Implementation Method 2
The coil is configured to generate an electromagnetic field
Implementation Method 3
concentrating the electromagnetic field with the concentrator onto a region of the first thermoplastic body
Data Source
AI summary
During a manufacturing method, an induction welder is provided that includes a concentrator and a coil. The concentrator includes a receptacle and a face surface. The receptacle projects vertically into the concentrator from the face surface to an end of the receptacle. The receptacle extends laterally within the concentrator between opposing sides of the receptacle. The receptacle extends longitudinally within the concentrator along a centerline. The coil is seated and extends longitudinally along the centerline within the receptacle. A first thermoplastic body arranged with a second thermoplastic body are provided. The first thermoplastic body is located vertically next to the face surface. The first thermoplastic body is induction welded to the second thermoplastic body. The induction welding includes: generating an electromagnetic field with the coil; and concentrating the electromagnetic field with the concentrator onto a region of the first thermoplastic body.