Induction Heating Membrane Welding Device
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for connecting sheets of bituminous or synthetic membranes, such as flame heating and self-adhesive membranes, are inefficient, time-consuming, and pose fire risks, while also compromising the integrity of the membrane at low temperatures, leading to potential water leaks.
Innovation Solution
A system utilizing a connection device with electrical resistors and a ferromagnetic material heated by electromagnetic induction to thermally weld the membrane edges, eliminating the need for flames and ensuring a strong, waterproof seal across overlaps in various conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flame heating is used to weld membrane sheets, then the sheets can be connected together, but the processing time is long and the material deteriorates
Solution Approach 1:
The patent replaces the mechanical flame heating system with an electromagnetic induction heating system. The connection device includes an inductor that generates an electromagnetic field to induce eddy currents in a ferromagnetic layer of the membrane, which generates heat through resistive heating. This substitution eliminates the need for flame heating while achieving faster and more controlled heating, directly resolving the contradiction between connection reliability and processing time.
Solution Approach 2:
The patent changes the heating parameter from open flame to controlled electromagnetic induction heating. By using a ferromagnetic layer with specific magnetic properties and an inductor with optimized geometry, the heating process becomes highly controllable in terms of temperature distribution and heating rate. This allows for rapid heating without material deterioration, resolving the time-loss issue while maintaining connection quality.
2Reliability
If flame heating is used to weld membrane sheets, then the sheets can be connected together, but fire risks increase
Solution Approach 1:
The patent replaces the flame heating system with an electromagnetic induction heating system. The inductor generates an electromagnetic field that directly induces currents in the ferromagnetic layer of the membrane, heating it without requiring open flame. This eliminates the fire hazard associated with flame heating while maintaining the ability to reliably connect membrane sheets, directly resolving the contradiction between connection reliability and fire risk.
Solution Approach 2:
The patent introduces a ferromagnetic layer as an intermediary between the inductor and the membrane material. This ferromagnetic layer acts as a mediator that converts electromagnetic energy into heat through eddy currents and hysteresis losses, providing controlled heating without direct flame contact. This intermediary mechanism eliminates fire risks while ensuring reliable connection, resolving the contradiction between connection reliability and fire hazard.
3Object-affected harmful factors
If self-adhesive membranes are used, then flame risks are eliminated, but sealing effectiveness decreases at low temperatures
Solution Approach 1:
The patent changes the temperature parameter control by using electromagnetic induction heating instead of relying on ambient temperature or self-adhesive properties. The induction heating system can generate sufficient heat at any ambient temperature to activate the adhesive layer and create a reliable seal. This resolves the contradiction by maintaining sealing effectiveness across all temperature conditions while eliminating fire risks through non-flame heating.
Solution Approach 2:
The patent applies preliminary heating through electromagnetic induction before the bonding process occurs. The inductor heats the ferromagnetic layer and adhesive interface in advance, ensuring that the adhesive reaches its optimal bonding temperature regardless of ambient conditions. This preliminary thermal action ensures reliable sealing at low temperatures while maintaining the safety benefits of non-flame heating.
4Object-affected harmful factors
If hot air flow is used to heat membrane edges, then fire risks are reduced, but processing time remains long
Solution Approach 1:
The patent replaces the hot air flow heating system with an electromagnetic induction heating system. Instead of using convective heat transfer from hot air, the invention uses electromagnetic fields to directly induce currents in the ferromagnetic layer, which generates heat internally through resistive heating. This substitution provides much faster and more efficient heating, reducing processing time while maintaining the safety advantage of eliminating open flame.
Solution Approach 2:
The patent employs periodic alternating current in the inductor to generate time-varying electromagnetic fields. This periodic action induces eddy currents in the ferromagnetic layer that continuously generate heat through hysteresis losses and resistive heating. The periodic nature of the electromagnetic field allows for efficient and rapid heating, significantly reducing processing time compared to continuous hot air flow while maintaining safety.
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 enables quick, safe, and reliable connection of membrane sheets, avoiding fire risks and membrane deterioration, while maintaining effective sealing even at low temperatures, thus ensuring a durable and watertight waterproof cover.
Implementation Method 1
two electrical resistors (14, 15), forming branches of an electrical circuit, which are mechanically connected to the body (13, 23)
Implementation Method 2
a ferromagnetic material heated by electromagnetic induction
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
A device for heating and connecting sheets (11, 12, 111, 121) of bituminous or synthetic membranes (100), comprising at least one sheet (11, 12, 111, 121) of a bituminous or synthetic membrane (100) which is laid or applied to at least one base layer (141), said membrane (100) being formed with a single compound or having at least one bottom layer including a compound or a bituminous mixture and at least one upper layer including a polymeric material and an electrically conductive material, which is heated; in particular, a body (13, 23) having a mainly longitudinal (A) development and placed on a first edge (11a, 21a) of a first sheet (11, 21, 111, 121) of the membrane (100) in order to connect said first edge to a second edge (12a, 22a) of a second sheet (12, 22, 111, 121) of the membrane (100) is provided with an upper face (13a, 23a), which is substantially flat and which is constituted by or covered with adhesive material and which comprises a film (16, 26) covering the upper face (13a, 23a) of said body (13, 23) and removable from said upper face (13a, 23a).