Heating Wall for Thermoplastic Resin Sheet
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heating apparatuses for thermoplastic resin sheets face challenges in achieving uniform and high-speed heating with minimal temperature variability, leading to prolonged preheating times and potential overheating, which can deteriorate the formability and physical properties of the molded bodies.
Innovation Solution
A heating apparatus with a vertically-movable heating wall indirectly heated by saturated steam, allowing for precise and uniform heating of thermoplastic resin sheets above their melting point, and a method for manufacturing thermoplastic resin-molded bodies using this apparatus, which includes a self-sensing function to selectively heat low-temperature areas and accommodate sheets with different heat capacities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If radiation heating-type apparatus is used to heat thermoplastic resin sheet, then heating speed is improved, but temperature uniformity deteriorates
Solution Approach 1:
The heating apparatus divides the heating space into multiple zones with different heating intensities. The control unit adjusts the heating power of each zone independently based on temperature feedback, allowing different parts of the thermoplastic resin sheet to receive appropriate heating amounts, thus achieving both high heating speed and temperature uniformity.
Solution Approach 2:
Temperature sensors are installed in each heating zone to continuously monitor the temperature of the thermoplastic resin sheet. The control unit receives this feedback information and automatically adjusts the heating power of each zone to maintain temperature uniformity while achieving fast heating.
2Manufacturing precision
If preheating temperature is raised above melting point to compensate for ununiform heating, then temperature uniformity is improved, but preheating time is prolonged
Solution Approach 1:
The heating apparatus dynamically adjusts the heating power of each zone based on real-time temperature feedback. Instead of using a static high temperature setting, the system continuously optimizes the heating parameters, allowing the thermoplastic resin sheet to reach uniform melting point temperature faster without overheating any particular area.
3Productivity
If continuous preheating furnace is used to improve formability, then productivity is improved, but temperature uniformity deteriorates due to outside air influence
Solution Approach 1:
The heating apparatus creates a controlled heating environment that isolates the thermoplastic resin sheet from outside air influences. By maintaining a stable atmospheric environment within the heating zones and using localized heating, the system achieves temperature uniformity while enabling continuous processing for improved productivity.
4Manufacturing precision
If multiple heating zones with different temperatures are used to heat large-sized sheet, then temperature uniformity is improved, but device complexity is increased
Solution Approach 1:
The heating apparatus uses a standardized multi-zone heating structure with programmable temperature control. By changing the temperature parameters of each zone through software control rather than physical reconfiguration, the system can adapt to different sheet sizes and heating requirements while maintaining a relatively simple device structure.
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 solution enables high-speed and uniform heating of thermoplastic resin sheets, reducing preheating time and temperature variability, resulting in improved formability and physical properties of the molded bodies, including the ability to create complex three-dimensional shapes like ribs and bosses.
Implementation Method 1
a vertically-movable heating wall indirectly heated with a saturated steam of a heat medium to heat the thermoplastic resin sheet above a melting point of the thermoplastic resin by bringing the heating wall into contact with the thermoplastic resin sheet
Implementation Method 2
indirectly heated with a saturated steam of a heat medium
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Provided is a heating apparatus for heating a thermoplastic resin sheet comprising a thermoplastic resin, wherein a wall surface of the heating apparatus is indirectly heated by heating-medium saturated steam. The heating apparatus is characterized in that: a heating wall has a vertically-elevating function; and the thermoplastic resin sheet is heated to a temperature that is equal to or greater than the melting point of the thermoplastic resin by bringing the thermoplastic-resin sheet into contact with the heating wall. The present invention provides: a heating apparatus that is capable of high-speed heating with small temperature variability when preheating to a predetermined temperature and performing heating treatment; and a method for manufacturing a high-quality thermoplastic fiber-reinforced resin-molded body by using said heating apparatus.