Inductively Heated Mold Modules for Rapid Thermal Cycling
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Solution Overview
Problem
Conventional molding systems face challenges with lengthy thermal cycling times due to the tight gap between heating and cooling components, which leads to inefficient heating and cooling processes, especially in molds requiring rapid temperature changes.
Innovation Solution
An inductively heated mold system utilizing a ferromagnetic layer on the mold body, heated by an inductive coil, with a large offset cooling channel distance for rapid cooling and a modular design allowing for efficient heating and cooling of various mold sizes, eliminating the need for direct heating rods or cooling channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a tight gap is maintained between the heater module and mold body to promote rapid heating, then heating speed is improved, but cooling time increases due to thermal expansion causing engagement between parts
Solution Approach 1:
The patent introduces a ferromagnetic layer as an intermediary between the inductive coil and the mold body. This layer enables rapid inductive heating while the cooling channels are positioned to cool the mold body directly, avoiding the thermal expansion engagement issue that would occur with direct contact heating methods
Solution Approach 2:
The patent replaces conventional contact-based heating (heating rods or heating modules requiring tight mechanical gaps) with inductive heating. This substitution eliminates the mechanical constraint of maintaining a tight gap, allowing the mold body to be cooled independently without engagement issues during thermal expansion
2Temperature
If conventional conductive heating with heating rods or heating modules is used, then heating can be achieved, but thermal cycling time increases due to the need to maintain tight gaps and manage thermal expansion
Solution Approach 1:
The patent replaces mechanical contact heating systems (heating rods or modules requiring tight gaps) with inductive heating using a ferromagnetic layer. This allows rapid heating without the mechanical constraints of gap maintenance, and enables independent cooling channel positioning to reduce thermal cycling time
Solution Approach 2:
The patent changes the heating mechanism from conductive (requiring physical contact or tight gaps) to inductive (using electromagnetic fields). This parameter change allows the mold body to be heated rapidly through the ferromagnetic layer while cooling channels can be positioned optimally without mechanical engagement constraints
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
Enables rapid heating and cooling cycles, reducing thermal expansion issues and allowing for quicker mold processing times without the complexity of direct heating and cooling configurations.
Implementation Method 1
an inductive coil in a heater module that inductively heats a ferromagnetic layer configured on the mold body
Implementation Method 2
The ferromagnetic layer is configured to be heated by the inductive coil
Implementation Method 3
the ferromagnetic layer is configured to heat the mold body through thermal conduction
Implementation Method 4
A cooling channel may be configured between the inductive coil and the ferromagnetic layer on the mold body to allow a fluid to be passed between the mold body and the heater module to rapidly cool the mold body
Data Source
Figure 1
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AI summary
An inductively heated mold system enables rapid heating of the mold and rapid cooling to reduce thermal cycling times by employing an inductive coil in a heater module that inductively heats a ferromagnetic layer configured on the mold body, such as around the outside perimeter of the mold body. A cooling channel may be configured between the inductive coil and the ferromagnetic layer on the mold body to allow a fluid to be passed between the mold body and the heater module to rapidly cool the mold body for removal of the molded part. A plurality of heater modules may be employed that can be coupled together such that the cooling fluid passes through the coupled cooling channels from one module to a second module. In this way heater modules can be combined to provide an inductively heated mold system for a variety of mold body sizes, or lengths.