Induction Heating End Stripper for Polymer-Coated Screen Frame Welding
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Solution Overview
Problem
The manufacturing of flexible window screens is labor-intensive and inefficient, with manual processes leading to inferior welds due to polymer coating contamination and the need for manual removal and application of heat shrink tubes, which hampers rapid production and quality.
Innovation Solution
A table with a clamping assembly and induction heating and end stripping assembly, utilizing induction coils and stripping dies to automatically strip the polymer coating from flexible screen frames, ensuring efficient and clean welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual processes are used to strip polymer coating and apply heat shrink tubes, then labor flexibility is maintained, but manufacturing efficiency and productivity are reduced
Solution Approach 1:
The patent replaces manual mechanical stripping processes with an induction heating system that uses electromagnetic fields to rapidly heat and strip the polymer coating. This substitution of mechanical labor with automated thermal processing significantly increases manufacturing efficiency while eliminating the time-consuming manual operations of stripping and heat shrink tube application.
Solution Approach 2:
The invention utilizes phase transitions of the polymer coating material through controlled heating. The induction heating system raises the polymer above its melting point, causing it to transition from solid to molten state, facilitating easy removal. This phase transition approach enables rapid, automated stripping without manual intervention, directly addressing the productivity-automation contradiction.
2Reliability
If polymer coating is present during welding, then corrosion protection is maintained, but weld quality deteriorates due to contamination
Solution Approach 1:
The patent applies preliminary action by stripping the polymer coating from the welding area before the welding process occurs. The induction heating system selectively heats and removes the polymer coating in advance, ensuring the welding surface is clean and free of contaminants. This preliminary preparation guarantees high weld integrity while maintaining corrosion protection through subsequent re-coating after welding.
Solution Approach 2:
The invention implements local quality by selectively removing the polymer coating only from the specific areas where welding will occur, rather than removing it from the entire frame. The induction heating system targets precise locations, stripping polymer locally at the welding zones while preserving the protective coating elsewhere, thus maintaining both weld quality and overall corrosion protection.
3Reliability
If heat shrink tubes are manually applied before welding, then corrosion protection is preserved, but manufacturing time increases
Solution Approach 1:
The patent extracts the heat shrink tube application step from the manufacturing process entirely. Instead of manually applying heat shrink tubes before welding, the system strips the polymer coating, performs welding on the exposed metal, and then reapplies polymer coating afterward. This extraction eliminates the time-consuming manual heat shrink tube application while maintaining corrosion protection through the reapplication of polymer material.
Solution Approach 2:
The invention enables continuity of useful action by creating an uninterrupted manufacturing flow. The induction heating system continuously strips the polymer coating, welding immediately follows without interruption, and re-coating proceeds seamlessly afterward. This continuous process eliminates the stop-start nature of manual heat shrink tube application, significantly reducing manufacturing cycle time while maintaining protective coverage throughout.
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
Facilitates rapid, high-quality production of flexible screen frames by automating the stripping process, improving weld integrity and reducing manual labor, thus enhancing manufacturing efficiency and screen frame durability.
Implementation Method 1
an induction coil (64) accessible from both ends to receive an end of a portion of flexible screen frame material. The induction coil (64) is positioned between two end stripping dies (78, 92).
Implementation Method 2
the screen mesh is fused to the flexible screen frame by the application of heat which renders the polymer material of the screen frame, the screen mesh or both at least partially molten during the manufacturing of the screen
Data Source
AI summary
An end stripper that strips a polymer coating from flexible screen frame material, the end stripper including a table having a tabletop and ground engaging legs, an induction coil coupled to an induction power supply, a clamping assembly located proximate the tabletop and sized to receive a first end portion of flexible screen frame material therein. The induction coil positioned and shiftable to receive the first end portion of the flexible screen frame material therein and operable to heat the first end portion by induction thus softening a polymer coating of the flexible screen frame material. A first stripping jaw strips the polymer coating from the first end portion.