Fired Foil Heating Layer on Hot Runner Pipe
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Solution Overview
Problem
Existing electric heating units for hot runner systems are bulky, leading to high energy consumption and long heating and cooling phases, and are not easily exchangeable or repairable, with limited material selection for integrated designs due to firing temperature constraints.
Innovation Solution
A compact electric heating unit with a tubular or muff-like support and fired foil or thick-film heating layer, integrated with a temperature sensor and insulating layers, allowing for easy assembly and disassembly, and manufactured using screen printing techniques to minimize space and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a separate component heating unit with winding heating element and tubular casing is used, then the heating unit provides sufficient heating output, but it occupies much space and increases device complexity
Solution Approach 1:
The heating unit is integrated directly into the material feed pipe by depositing heating layers on the pipe wall, eliminating the separate tubular casing and bracing components. This merging of the heating function with the pipe structure itself reduces space occupation while maintaining heating output.
Solution Approach 2:
The heating element is implemented as a thin fired layer with heating conductor tracks deposited directly on the pipe wall, replacing the bulky tubular casing. This thin-film approach maintains heating functionality while dramatically reducing the volume occupied by the heating unit.
2Reliability
If a separate component heating unit with rigid casing and bracing is used, then the heating unit provides stable heating, but it increases manufacturing complexity and cannot be easily exchanged
Solution Approach 1:
The heating unit is manufactured as an integral part of the material feed pipe through direct deposition of layers on the pipe wall, eliminating the need for separate assembly of casing and bracing components. This integration simplifies manufacturing while ensuring stable heating through direct thermal coupling.
Solution Approach 2:
The heating unit consists of multiple deposited layers including insulating layers and heating layers with conductor tracks, forming a composite structure that provides stable heating while being manufactured as a single integrated component through firing processes.
3Volume of moving object
If heating layers are deposited by direct coating on material feed pipe wall, then the heating unit occupies little space and achieves high compactness, but the material selection is restricted by firing temperature constraints
Solution Approach 1:
The firing temperature parameter is optimized to enable the use of tool steel for the material feed pipe while allowing deposition of insulating and heating layers. By controlling the firing temperature within specific ranges, the patent achieves both compactness and material versatility, permitting the pipe material to be selected from tool steels with appropriate thermal and mechanical properties.
4Productivity
If integrated layered deposition is used to eliminate bulky components, then heating output density is raised and heating is more rapid, but the heating unit cannot be exchanged in case of emergency
Solution Approach 1:
The material feed pipe is designed with a modular structure where the heating layers are deposited on the outer surface, allowing the pipe to be segmented into replaceable sections. This enables the heating unit to be exchanged by replacing the entire pipe section, maintaining high heating speed while providing repairability through module replacement.
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 solution provides a compact, efficient, and cost-effective heating unit with uniform temperature distribution, enabling rapid heating and reduced energy consumption, while being easily exchangeable and maintainable, and allowing for precise temperature control.
Implementation Method 1
at least one heating layer fitted with heating conductor tracks, said heating layer being a fired foil or a fired thick film
Implementation Method 2
at least one electrically insulating cover layer is present above the heating layer
Data Source
AI summary
An electric heating unit for hot runner systems, and in particular for hot runner nozzles and/or hot runner manifolds includes at least one tubular or muff-like support and at least one heating layer fitted with heating conductor tracks. The heating layer is a fired foil or a fired thick-film paste and the muff-like support is able to be slipped onto a material feed pipe.