Hot Forming Tool Thermal Radiation Shield

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Solution Overview

Problem

Existing tools for hot forming processes suffer from inefficient energy use due to heat loss between tool parts and the environment, as well as between parts at different temperatures, leading to reduced energy efficiency and unintended heating of tool components.

Innovation Solution

A tool design featuring a device for manipulating thermal radiation, including a gap between tool parts and a reflective or absorptive coating, to reduce heat transfer between tool parts and the environment, maintaining temperature differences and enhancing spatial homogeneity of temperature profiles, thereby improving energy efficiency and achieving regionally selective hardening of workpieces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If heating cartridges are used to heat portions of the tool to high temperatures, then the workpiece can be hot formed to desired shapes, but heat is transmitted to the environment and lost, reducing energy efficiency

Engineering Contradiction:

Improvetool temperatureVSAvoidheat loss

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

A thermal radiation shield is introduced as an intermediary component between the heated tool portion and the environment. This shield reflects thermal radiation back toward the tool, preventing heat loss to the environment and reducing the energy required by heating cartridges to maintain tool temperature.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent converts the harmful effect of thermal radiation (heat loss) into a beneficial effect by using reflective surfaces to redirect thermal radiation back to the tool. The heat that would otherwise be lost is now retained and reused, improving energy efficiency.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Temperature

If heating cartridges constantly re-heat tool portions to offset heat loss, then the desired temperature is maintained, but energy efficiency is reduced

Engineering Contradiction:

Improvetool temperatureVSAvoidenergy consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The thermal radiation shield acts as a mediator that reduces the amount of energy needed by heating cartridges to maintain tool temperature. By reflecting thermal radiation back to the tool, the shield decreases the energy consumption of the heating system while maintaining the required temperature.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the thermal radiation parameters (emissivity, reflectivity) of the tool and environment interfaces by introducing reflective surfaces. This parameter change reduces heat loss and consequently reduces the energy input required from heating cartridges to maintain the same temperature.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If the entire tool is heated to high temperatures for hot forming, then the workpiece can be shaped, but parts that operate optimally at lower temperatures are inadvertently heated

Engineering Contradiction:

Improvetool temperatureVSAvoidtemperature control

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

The tool is segmented into different thermal zones by introducing thermal radiation shields between heated and unheated portions. This segmentation allows different parts of the tool to operate at different temperatures, enabling components that require lower temperatures to function optimally while still maintaining the high temperatures needed for hot forming in specific areas.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Thermal radiation shields serve as intermediaries that block or reflect thermal radiation, creating thermal barriers between different tool portions. This allows precise temperature control, where heated portions maintain high temperatures for forming while other portions remain at lower operating temperatures.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 effectively reduces heat transfer between tool parts and the environment, maintaining temperature differences and improving energy efficiency, allowing for more precise control over material properties in hot forming processes by creating spatially discernible temperature zones with narrow transition regions.

Implementation Method 1

the tool has a device for manipulating the thermal radiation

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 2

inserting a gap between tool parts with different temperatures to reduce direct heat transfer between the tool parts

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS10086421B2Tool for hot forming a workpiece and methods for selectively hot forming certain regions of a workpiece

Publication Date: 2018.10.02 THYSSENKRUPP AG

AI summary

A tool for machining a workpiece may comprise multiple parts that have different temperatures when the tool is being operated. To reduce or, in some cases, eliminate thermal radiation between the multiple parts, the tool may incorporate one or more devices that manipulate the thermal radiation. Such devices may be disposed along one or more of the multiple parts and, in some examples, between two or more parts of the tool. These devices may also help reduce and, at times, eliminate thermal radiation between the tool parts and the surrounding environment.