Flexible Induction Coil Segments for Contoured Die Susceptor Heating
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Solution Overview
Problem
Current induction forming apparatuses face energy inefficiencies due to the need for significant magnetic field filling in empty spaces between straight induction coils and contoured die susceptors, which do not match the complex geometry of the forming surfaces, leading to inefficient heating.
Innovation Solution
The use of flexible induction coil segments that conform to the contour of the die susceptor, minimizing the space between the coil and the susceptor, and the integration of coolant conduits for efficient heating and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If straight lengths of induction coil are used, then the coil structure is simple and easy to manufacture, but the coil cannot match the contour of the die susceptor, creating empty space and energy inefficiency
Solution Approach 1:
The induction coil is divided into multiple flexible segments that can independently conform to the contour of the die susceptor. Each segment can be separately manufactured and then assembled together, maintaining manufacturing simplicity while achieving the complex contour matching needed to eliminate empty spaces and improve energy efficiency.
Solution Approach 2:
The patent employs flexible coil segments that can bend and conform to the complex contours of the die susceptor surface. This flexibility allows the coil to closely follow the forming surface geometry, eliminating the empty spaces that cause energy loss while maintaining a relatively simple coil structure that can be manufactured using standard flexible conduit or tubing.
2Ease of operation
If straight induction coils are used, then the coil installation is simple, but significant empty space is created between the coil and the contoured die susceptor
Solution Approach 1:
The induction coil transitions from a static, straight configuration to a dynamic, flexible segmented structure. The segments can be easily positioned and installed in various configurations to match different susceptor contours, maintaining installation simplicity while adapting to complex geometries and eliminating empty spaces.
Solution Approach 2:
Flexible coil segments are used that can be easily installed and configured to match the die susceptor contour. These flexible segments eliminate the need for complex rigid coil structures while reducing the empty space between the coil and the contoured surface, thereby improving magnetic field efficiency.
3Device complexity
If straight induction coils are used, then the coil design is straightforward, but the magnetic field must fill empty space, requiring significant energy that does not contribute to heating
Solution Approach 1:
The coil is segmented into flexible sections that can be independently positioned to match the susceptor contour. This segmentation allows for straightforward design of each individual segment while collectively achieving complete surface coverage, eliminating the need for the magnetic field to traverse empty spaces and reducing power consumption.
Solution Approach 2:
Flexible coil segments are designed to conform to the die susceptor surface, eliminating empty spaces that would require magnetic field penetration. This approach maintains relatively simple coil design while dramatically improving energy efficiency by ensuring that the magnetic field is concentrated where needed for heating, rather than being wasted in empty spaces.
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 allows for more efficient heating of the die susceptor with reduced power consumption and rapid cooling of the formed components, enhancing the overall energy efficiency and precision in forming complex components.
Implementation Method 1
Heating of the die susceptors of the first and second tool dies may be accomplished by extending an induction coil through openings in each of the first and second tool dies
Implementation Method 2
The induction coils are typically formed of copper tubing which is relatively rigid
Implementation Method 3
Current practice, accordingly, is to extend straight lengths of the induction coil through the openings in the tool dies
Data Source
AI summary
An apparatus may have a tool die for forming a component. The tool die may have a die susceptor having a forming surface for forming the component, and at least one flexible induction coil segment for heating the die susceptor. The at least one flexible induction coil segment may be configured to conform to a contour of the forming surface of the die susceptor.