Hot Stamping Heating Device with Dual Infrared Tanks
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Solution Overview
Problem
Existing heating devices for hot stamping struggle to quickly heat metallic materials to high temperatures, leading to inefficiencies and variability in temperature distribution.
Innovation Solution
A heating device with a first and second heating tank in a continuous space, using an infrared heater, where the first tank provides a larger heating amount than the second, allowing for longer stay time and rapid temperature increase, ensuring the material reaches the Ac3 point without exceeding the plating's boiling point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If a conventional heating device is used, then the heating process is simple, but the heating time is long and temperature distribution is variable
Solution Approach 1:
The heating device is divided into multiple heating zones (first heating zone with first heating means, second heating zone with second heating means) along the conveyance path. Each zone provides different heating amounts, allowing optimized heating control in different stages of the heating process, thereby reducing total heating time while maintaining temperature uniformity.
Solution Approach 2:
Different heating means are provided in different zones along the conveyance path, with each zone having different heating characteristics. The first heating zone provides higher heating amount to rapidly increase temperature, while the second heating zone provides lower heating amount to maintain and uniformize temperature, achieving local optimization of heating quality.
2Manufacturing precision
If gas burner is used as heat source, then the heating capability is strong, but the temperature distribution becomes unclear and variability increases
Solution Approach 1:
The patent replaces conventional gas burner heating with infrared radiation heating. The infrared heating means radiate thermal energy directly to the plated metallic material, providing strong heating capability while ensuring uniform and controllable temperature distribution through the inherent properties of infrared radiation, eliminating the temperature variability associated with gas burner convection heating.
3Productivity
If single heating zone is used, then the device structure is simple, but the heating speed is insufficient
Solution Approach 1:
The heating process is segmented into multiple zones with different heating characteristics. The first heating zone provides intensive heating to rapidly raise temperature, while the second heating zone provides gentle heating to maintain and uniformize temperature. This segmentation enables high heating speed without sacrificing temperature control, resolving the contradiction between productivity and device complexity.
4Manufacturing precision
If longer staying time is provided in second heating tank, then the temperature uniformity improves, but the total heating time increases
Solution Approach 1:
The first heating zone performs preliminary intensive heating to rapidly bring the material to the target temperature range. Then the second heating zone performs gentle heating with longer staying time to uniformize the temperature. This preliminary action approach achieves temperature uniformity without requiring excessively long total heating time, as the bulk of temperature increase occurs in the first zone.
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 enables rapid heating of metallic materials to a high temperature state, reduces heating time, and maintains consistent temperature distribution, enhancing efficiency and accuracy while downsizing the heating device.
Implementation Method 1
the first heating tank and the second heating tank may be formed in a continuous space and may use an infrared heater as a heat source
Implementation Method 2
the plated metallic material is heated mainly by emitted heat (radiant heat)
Data Source
AI summary
A method of heating for hot stamping is configured to heat a plated metallic material while conveying the plated metallic material. A heating device for hot stamping comprises: a first heating tank provided in a conveyance path for the plated metallic material; and a second heating tank provided downstream of the first heating tank in the conveyance path. A heating amount provided by the second heating tank is configured such that a temperature of the plated metallic material becomes equal to or higher than Ac3 point and less than a boiling point of a plating of the plated metallic material, and a heating amount provided by the first heating tank is configured to be larger than the heating amount provided by the second heating tank.