Heater Box Module Uniform Heating Coated Glass
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Solution Overview
Problem
Existing heating box modules for laminated safety glass production face inefficiencies in heating uniformity and energy usage, particularly with coated glass panes, leading to potential overheating and inadequate bonding due to reflected infrared radiation and high energy losses.
Innovation Solution
A heating box module design featuring upper and lower infrared radiators combined with circulating air systems that recirculate hot air directly over the glass package, using nozzle assemblies to ensure even heat distribution and minimize energy loss by feeding hot air back into the system, thereby optimizing thermal energy transfer and reducing overheating risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If infrared radiators are used to heat glass packages, then heating speed is improved, but energy loss increases due to reflection from coated glass surfaces
Solution Approach 1:
The patent combines infrared radiators and convection heating elements into a single heating box module, allowing simultaneous radiation and convection heating. This merging enables the system to overcome the reflection problem of coated glass by supplementing infrared radiation with convection heat transfer, thereby maintaining heating speed while reducing energy loss.
Solution Approach 2:
The patent changes the heating parameters by introducing adjustable convection heating elements that can compensate for reflected infrared radiation. By modifying the heating mode from pure radiation to a combination of radiation and convection, the system adapts to different glass coating conditions and optimizes energy utilization.
2Manufacturing precision
If hot air is blown directly onto glass package, then heating uniformity is improved, but energy loss increases due to air escape
Solution Approach 1:
The patent employs multiple independently controllable heating zones with localized convection elements that can be adjusted according to specific heating requirements. Each zone has its own hot air circulation system, allowing precise control of heat distribution and minimizing energy loss by targeting only the areas that need heating.
Solution Approach 2:
The heating system incorporates temperature sensors and control mechanisms that monitor heat distribution and adjust convection airflow accordingly. This feedback control ensures uniform heating while optimizing energy usage by adjusting air flow rates based on actual temperature conditions.
3Reliability
If multiple heating modules are used in sequence, then heating effectiveness is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple heating functions (infrared radiation and convection heating) into a single integrated heating box module. This consolidation maintains the heating effectiveness of multiple sequential modules while reducing overall system complexity by eliminating the need for separate heating zones and control systems.
Solution Approach 2:
The heating box module is designed as a multi-functional unit that performs both infrared radiation heating and convection heating simultaneously. This universal design allows a single module to replace multiple specialized heating modules, simplifying the overall production line while maintaining comprehensive heating capability.
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 design achieves rapid, uniform, and energy-efficient heating of glass packages, including those with reflective coatings, by combining infrared radiation with targeted convection heat, minimizing energy losses, and ensuring precise control over the lamination process.
Implementation Method 1
thermal radiation is generated in the second heating box module, which penetrates the glass layers and acts on the foil or foils
Implementation Method 2
thermal radiation is generated in the second heating box module, which penetrates the glass layers and acts on the foil or foils
Implementation Method 3
hot air by means of an upper circulating air system into an upper heating zone
Implementation Method 4
hot air by means of an upper circulating air system into an upper heating zone for heating a glass package
Data Source
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AI summary
The heater box module comprises an upper heater box (1), and transport rollers in a lower heater box (2) for conveying a glass package from which heat is delivered by an upper infrared radiator (17a, 17b, 17c) and a hot air is delivered by an upper air circulation system (11, 12, 19) in an upper heating zone for heating the glass package promoted by a glass flow zone. The upper air circulation system comprises: an upper nozzle holder, where the hot air is directly blown onto an upper side of the glass package; and an upper exhaust unit for returning the hot air. The heater box module comprises an upper heater box (1), and transport rollers in a lower heater box (2) for conveying a glass package from which heat is delivered by an upper infrared radiator (17a, 17b, 17c) and a hot air is delivered by an upper air circulation system (11, 12, 19) in an upper heating zone for heating the glass package promoted by a glass flow zone. The upper air circulation system comprises: an upper nozzle holder, where the hot air is directly blown onto an upper side of the glass package; and an upper exhaust unit for returning the hot air directly from the upper side of the glass package into the upper air circulation system. The upper nozzle holder between the upper infrared radiator disposed on an upper hot air supply duct (13, 14, 15) comprises a slot nozzle directed on the upper side of the glass package. The upper hot air supply duct with the slot nozzles: parallely lies adjacent to each other; is arranged over the upper side of the glass package distributed into the upper heating zone; and extends itself over the entire width of the upper heating zone. The upper exhaust unit of the upper air circulation system comprises upper suction slots, which are directly arranged above the upper infrared radiator. A distance of the upper air circulation system and the upper infrared radiator is adjustable to the upper side of the glass package by a unit to a height adjustment of the upper heater box. A flow velocity of the hot air is adjustable into the upper air circulation system and a lower air circulation system so that a predetermined value assumes over the upper and a lower nozzle holder on the upper side of the glass package directed on a volume flow of the hot air. A lower hot air supply duct is arranged below the transport roller and comprises a pair of slot nozzles, which are laterally directed on both sides of the overlying transport roller towards the top of an underside of the glass package. A lower exhaust unit of the lower air circulation system comprises lower suction slots, which are directly arranged below a lower infrared radiator.