Induction Preform Heating Device with Magnetic Flow Concentrator
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Solution Overview
Problem
Existing preform heating devices for blow moulding face issues with overheating, high energy consumption, non-precise heat focalization, and maintenance due to direct conduction heating and traditional resistance-based systems, leading to inefficient and slow preform heating.
Innovation Solution
A preform heating device utilizing induction means to create a magnetic flow for heating a conductor ring, which then irradiates heat to the preform, allowing for precise and localized heating with reduced energy consumption and improved thermal profile through the use of a magnetic dielectric flow concentrator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If direct conduction heating is used to heat the preform, then the heating element can reach the required temperature, but it causes overheating problems and significant temperatures in device components
Solution Approach 1:
The patent introduces an intermediary heating element (the ring-shaped conductor) that is heated by induction and then transfers heat to the preform through radiation. This mediator allows the preform to be heated to the required temperature without directly heating other device components to excessive temperatures, as the induction field is localized to the conductor ring.
Solution Approach 2:
The induction heating system creates a localized heating zone precisely where needed (the ring-shaped conductor in contact with the preform) while keeping other parts of the device at lower temperatures. The magnetic field and heating effect are concentrated locally rather than being distributed throughout the entire device structure.
2Temperature
If traditional resistance heating elements are used, then the preform can be heated, but electric resistances wear over time requiring greater maintenance
Solution Approach 1:
The patent replaces traditional resistance heating elements with an induction heating system. Instead of using resistive heating that causes wear and degradation over time, the system uses electromagnetic induction to heat a conductor ring, which then radiates heat to the preform. This substitution eliminates the wear associated with traditional heating elements.
3Temperature
If high power is dissipated to reach project temperature in resistance elements, then the required temperature can be achieved, but heat flow focalisation becomes non-precise
Solution Approach 1:
The induction heating system concentrates the heating effect precisely at the ring-shaped conductor that contacts the preform. The magnetic field and heat generation are localized to this specific region, allowing precise focalisation of heat flow. The ring geometry and its contact points with the preform enable controlled and precise heating of specific areas.
Solution Approach 2:
The ring-shaped conductor acts as an intermediary that receives energy from the induction field and transfers it locally to the preform through radiation. This mediator enables precise heat focalisation by confining the energy transfer to the specific contact region between the ring and preform, rather than distributing heat broadly.
4Temperature
If traditional heating structures are used, then heating can be achieved, but preform heating rapidity is reduced due to significant thermal inertia
Solution Approach 1:
The patent replaces traditional resistance heating with induction heating, which heats the conductor ring directly through electromagnetic induction rather than through thermal conduction from a heat source. This eliminates the thermal inertia of large heating structures, as the induction field can rapidly energize the conductor ring and transfer heat to the preform much faster.
5Ease of manufacture
If the heating structure is difficult to customise, then manufacturing is simplified, but heat flow focalisation precision is reduced
Solution Approach 1:
The ring-shaped conductor provides a simple geometric form that is easy to manufacture, while its specific geometry (ring shape with controlled cross-section) enables precise heat focalisation at the contact points with the preform. The simplicity of the ring structure facilitates manufacturing while the controlled geometry ensures precise heating localization.
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 efficient and precise preform heating with reduced energy consumption, improved thermal profile, and lower maintenance needs, enabling faster and more stable heating processes with enhanced heating precision and efficiency compared to traditional hot air jet systems.
Implementation Method 1
at least one induction means (2) suitable for inducing, when current passes therein, a magnetic flow on at least one heat transmission means (4)
Implementation Method 2
The inductor does not directly heat the piece, also because the preform is constituted by a non-conductive material but, by means of a magnetic flow, it takes to temperature a ring of conductor material
Implementation Method 3
transmit by irradiation a predefined quantity of heat to at least one preform (10)
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5B
AI summary
Preform heating device able to perform a precise and strongly localised heating of the preforms before the blow moulding phase of the plastic bottle or container production process. This device has an innovative construction configuration, thus allowing high efficiency thanks to the significant reduction in the energy required to reach the project temperatures in the heating element in a very rapid way. The inductor does not heat the preform directly, but takes to the temperature set, through the concentration of the magnetic flow, generated by the passage of current, a conductor material of a particular form that, by irradiation and convection, in turn heats the PET.