Induction Heating Device Uniform Surface Temperature
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Solution Overview
Problem
Existing methods for heating metal surfaces using induction for molding or transformation of thermoplastic or thermosetting composite materials suffer from non-homogeneous heating, slow cooling, and mechanical property alterations due to the use of resin, leading to cosmetic and structural defects.
Innovation Solution
A device with a heat-conductive body featuring closed cavities surrounded by magnetic material walls, where induction heating is efficiently transferred via conduction to ensure uniform temperature, using a combination of magnetic and non-magnetic materials to optimize heating and cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If inductive wires are buried in resin to heat the surface, then heating is achieved, but the heating becomes non-homogeneous with maximum temperature at wire positions and lower temperature between them
Solution Approach 1:
The heating system is segmented into multiple discrete inductive wires embedded in the resin layer, with each wire creating a localized heating zone. The wires are spaced apart to allow heat diffusion zones to overlap and merge, creating a uniform temperature distribution across the heating surface while maintaining high heating efficiency at each wire position.
2Object-affected harmful factors
If resin is used as the heating medium, then insulation is provided, but cooling between duty cycles becomes difficult and time-consuming
Solution Approach 1:
A thermally conductive plate is introduced as an intermediary element between the resin layer containing inductive wires and the workpiece. This plate serves dual functions: it provides a uniform heating surface by conducting heat laterally from the wire positions, and it enables rapid cooling by conducting heat away from the workpiece interface during idle cycles, thus reducing cooling time while maintaining insulation benefits.
3Manufacturing precision
If sufficient heating time is allowed between cycles to achieve uniform temperature, then temperature homogeneity is achieved, but productivity decreases
Solution Approach 1:
The system maintains continuous useful action by using the thermally conductive plate to rapidly redistribute heat laterally during the heating phase, achieving temperature uniformity much faster than conventional resin-only systems. The plate's high thermal conductivity allows quick thermal equilibrium, enabling shorter heating cycles and higher productivity while maintaining the required temperature uniformity for defect-free workpieces.
4Power
If magnetic material with high electrical resistivity is used for cavity walls, then induction heating efficiency increases, but thermal conductivity decreases and uniform temperature takes longer to achieve
Solution Approach 1:
The cavity walls are constructed with magnetic material having high electrical resistivity localized at the inner surface in contact with the resin, where maximum induction heating is required. The outer portions of the cavity walls or the underlying structure use materials with higher thermal conductivity to facilitate heat distribution. This local differentiation of material properties optimizes both heating efficiency at the resin interface and thermal diffusion to achieve uniform temperature across the heating surface.
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 achieves rapid and uniform heating of the metal surface, enhancing the mechanical properties of the workpiece and reducing defects by minimizing temperature differences and allowing efficient cooling.
Implementation Method 1
the heating is obtained by electromagnetic coupling between the inductors and the magnetic plate, the eddy current induced by the inductors running through the 'susceptor' and producing heat
Implementation Method 2
the eddy current induced by the inductors running through the 'susceptor' and producing heat
Implementation Method 3
the heat produced by induction on the part of the walls made a of magnetic material is transferred by conduction to the heating surface
Data Source
AI summary
The invention concerns a device for heating a surface by induction, in particular for molding or transforming a part made of thermoplastic or thermosetting composite material. The device comprises a body having at least one portion made of magnetic and heating conducting material wherein is provided a plurality of closed cavities proximate the surface to be heated, each cavity surrounding a field winding. The heat produced by induction on the walls of the cavity is transferred by conduction to the heating surface. The distance between the cavities and the position of said cavities relative to the heating surface are such that the heating is substantially uniform on said surface.