Induction Heating Roller With Pressed Heat Equalizer Contact
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Solution Overview
Problem
The existing heating rollers with heat pipes face issues of uneven temperature distribution due to large heat capacity, which hinders effective heating, and the use of high thermal conductivity but low expansion coefficient materials like carbon fiber composites leads to thermal expansion differences causing gaps and reduced heat equalization effectiveness.
Innovation Solution
A cylindrical heat equalizer with a pressing mechanism is used to maintain contact with the roller surface, ensuring consistent heat transfer and preventing thermal expansion-induced gaps, while the pressing mechanism is strategically placed outside the heat equalization pieces to maintain rotation balance and reduce magnetic flux penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heat pipe (jacket chamber) is provided in the roller main body to equalize temperature, then temperature distribution is equalized, but the roller main body must be thick which increases heat capacity and reduces heating efficiency
Solution Approach 1:
The invention extracts the heat pipe function from the roller main body and places it on the outer surface as a separate heat equalizer. This allows the roller main body to be thin for efficient heating while the external heat equalizer handles temperature equalization through its heat pipe functionality.
Solution Approach 2:
The heat equalizer is positioned to wrap around the roller main body, with the heating target located between them. This nested arrangement allows the heat equalizer to contact both the heating target and the roller main body, transferring heat effectively while maintaining a compact structure.
2Productivity
If a cylindrical heat equalizer made of carbon fiber composite is used to reduce roller thickness, then heating efficiency is improved, but thermal expansion difference creates gaps that reduce heat equalization effectiveness
Solution Approach 1:
The invention changes the physical state of the heat equalizer from rigid to flexible, allowing it to deform and maintain contact with the heating target despite thermal expansion differences. This flexibility compensates for the gap formation that would occur with rigid materials like carbon fiber composite.
Solution Approach 2:
The heat equalizer is designed as a flexible cylindrical structure that can deform radially to maintain contact with the heating target. This flexibility allows it to accommodate thermal expansion differences between the heat equalizer and roller main body, preventing gap formation and maintaining effective heat transfer.
3Stability of the object's composition
If the roller main body is made thick to accommodate heat pipe, then temperature equalization is achieved, but heat capacity increases making effective heating difficult
Solution Approach 1:
The heat pipe functionality is extracted from the roller main body and implemented as a separate external heat equalizer. This allows the roller main body to remain thin with low heat capacity for efficient heating, while the external heat equalizer provides temperature stability through its heat pipe mechanism.
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 solution effectively equalizes temperature distribution along the axial direction of the heating roller, improving heat transfer efficiency and maintaining high-quality yarn production by preventing heat equalization deterioration, even under induction heating.
Implementation Method 1
a coil which is provided radially inside the heating target, and the heating target being induction-heated by the coil
Implementation Method 2
an induction heating roller which is configured to heat a roller surface by induction heating using a coil
Implementation Method 3
the heating target being induction-heated by the coil
Implementation Method 4
a cylindrical heat equalizer having higher heat conduction than the roller main body to be in contact with an inner circumferential surface of a heating target
Implementation Method 5
Because the heat equalizer in contact with the roller main body functions as a heat pipe, the temperature distribution in the axial direction of the roller surface is equalized
Implementation Method 6
a pressing mechanism which is configured to press each of the heat equalization pieces toward the inner circumferential surface of the heating target
Implementation Method 7
The linear expansion coefficient of the carbon fiber composite, however, is very small. For this reason, the roller main body expands significantly more than the heat equalizer in the induction heating
Data Source
Figure 1
Figure 2
Figure 3(a)~3(c)
AI summary
In a heating roller including a cylindrical heat equalizer which is higher in thermal conductivity than and lower in linear expansion coefficient than a roller main body, deterioration of a heat equalizing effect of the heat equalizer due to a gap formed by a thermal expansion difference is prevented. The heating roller includes a roller main body 31 which includes a cylindrical heating target 33; and a cylindrical heat equalizer 36 which is provided to be in contact with an inner circumferential surface 33a of the heating target 33, the heat equalizer 36 being higher in heat conductivity than and lower in linear expansion coefficient than the roller main body 31, heat equalization pieces 37 each extending in an axial direction being lined up in a circumferential direction so as to form the cylindrical heat equalizer 36, and the heating roller further comprising a pressing mechanism 40 which is configured to press each of the heat equalization pieces 37 toward the inner circumferential surface 33a of the heating target 33.