Induction Heating Mold With Segmented Thermal Management
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Solution Overview
Problem
Large or complex-shaped molds face temperature gradient issues during induction heating and cooling, leading to shape distortion and poor thermal contact between the molding surface and the carcass, resulting in degraded cooling quality due to differential distortion and thermal barriers.
Innovation Solution
The mold design incorporates inductors enclosed in sealed sheaths capable of withstanding high temperatures, a cooling device with a heat transfer fluid or dielectric fluid, and gas injection for enhanced heat exchange, along with a secondary induction circuit and a thermally conductive strip to manage thermal expansion and ensure uniform contact between the carcass and molding zone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If induction heating and cooling circuits are added to large or complex-shaped molds, then heating and cooling capability is improved, but temperature gradients cause shape distortion and differential distortion between molding zone and carcass
Solution Approach 1:
The mold is divided into functionally independent parts: the carcass (support structure) and the molding zone (heating/cooling active area). Each part can be independently heated and cooled through separate circuits, allowing differential thermal management that prevents shape distortion while maintaining manufacturing precision.
Solution Approach 2:
The inductors are placed specifically in cavities within the molding zone rather than uniformly distributed. This localized heating approach targets only the areas requiring temperature control, minimizing thermal gradients and preventing differential distortion between the molding zone and carcass.
2Power
If inductors are placed in cavities at the interface between molding zone and carcass, then heating efficiency is improved, but thermal contact between molding zone and carcass deteriorates due to differential distortion
Solution Approach 1:
The system allows for dynamic thermal management where the molding zone and carcass can be heated and cooled at different rates and to different temperatures. This dynamic control prevents excessive differential expansion that would compromise thermal contact, while maintaining high heating efficiency when needed.
Solution Approach 2:
The invention changes the thermal parameters (temperature, heating rate, cooling rate) independently for the molding zone and carcass. By adjusting these parameters dynamically, the system maintains optimal thermal contact while achieving efficient heating through the inductors positioned at the interface.
3Temperature
If cooling circuits are drilled into the carcass away from the molding surface, then carcass cooling is improved, but cooling quality at the molding surface deteriorates due to thermal barriers from differential distortion
Solution Approach 1:
The cooling system is segmented into separate circuits: one for the carcass and another for the molding zone. This segmentation allows independent optimization of cooling for each component, ensuring that carcass cooling does not compromise molding surface cooling quality despite differential thermal effects.
Solution Approach 2:
Cooling circuits are strategically positioned with local quality considerations: the molding zone receives targeted cooling at the interface where inductors are located, while the carcass has its own cooling circuits. This localized approach ensures efficient heat removal from both regions without creating thermal barriers.
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 minimizes shape distortion, maintains effective thermal contact, and improves cooling efficiency by managing temperature gradients and thermal expansion, thereby enhancing the quality of the molding process.
Implementation Method 1
a heating device comprising inductors (132) extending in cavities (131) at the interface (115) between the molding zone (112) and the carcass (111)
Implementation Method 2
a cooling device (140), also extending to the interface (115)
Implementation Method 3
injection of a gas into the cavities around the inductors... turbulence is created in the air flow, which turbulence promotes heat exchange
Implementation Method 4
the carcass and the molding zone are made of an alloy of iron (Fe) and nickel (Ni) of the INVAR type, the Curie point of which is close to the transformation temperature of the molded material
Implementation Method 5
When, the heating material, its temperature approaches the Curie point, it becomes insensitive to induction heating
Data Source
Figure 1~3
Figure 4~6
AI summary
The invention relates to a mould which includes a first portion (101) comprising a housing (111) to which a moulding area (112) is added, forming a mechanical interface (115) between said moulding area and the housing, and comprising inductors (132) lying in a so-called longitudinal direction in recesses (131) between said interface (115) and the moulding area (112), and a cooling device (140) lying at the interface between said moulding area and the housing.