Segmented Inductive Welding Ribbon for Uniform Plastic Heating
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Solution Overview
Problem
Induction welding of plastic materials faces challenges in achieving stable, uniformly distributed thermal energy to prevent overheating and maintain form stability, as existing methods often result in local hotspots that can damage the plastic material and compromise mechanical stability.
Innovation Solution
A heating means with a ribbon-type structure that interrupts electrical conductivity along its circumferential course to prevent short-circuit currents, ensuring heating is solely through eddy currents, thereby achieving homogeneous heating and avoiding local overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a continuous electrically conductive heating means is used in induction welding, then heating efficiency is improved, but local hotspots and non-uniform heating occur
Solution Approach 1:
The heating means is segmented into multiple electrically conductive sections separated by electrically insulating sections along the circumferential direction. This segmentation prevents continuous current flow around the inner object while maintaining heating capability in each segment, thereby eliminating short-circuit currents and achieving more uniform heating distribution.
Solution Approach 2:
Different sections of the heating means have different electrical conductivity properties - conductive sections for heating and insulating sections for current interruption. This local differentiation of properties allows the heating means to generate heat through eddy currents in conductive areas while preventing harmful short-circuit currents through insulating areas.
2Reliability
If thermal energy is increased to ensure stable welded connection, then welding reliability is improved, but form stability of objects is endangered
Solution Approach 1:
By segmenting the heating means into conductive and insulating sections, the thermal energy is distributed more evenly around the inner object. This prevents concentration of heat in specific areas, allowing sufficient total thermal energy for reliable welding while avoiding localized overheating that would compromise form stability.
Solution Approach 2:
The electrical conductivity parameter is changed along the circumferential direction of the heating means, transitioning from continuous conductivity to segmented conductivity. This parameter change modifies the heating pattern from non-uniform with hotspots to more uniform distribution, enabling reliable welding connections without excessive thermal energy input.
3Power
If heating means is made electrically conductive for inductive heating, then heating capability is improved, but short-circuit currents are generated
Solution Approach 1:
The heating means is divided into alternating conductive and insulating sections along the circumferential direction. The conductive sections enable eddy current generation and heating capability, while the insulating sections interrupt continuous current paths, preventing short-circuit currents from forming complete loops around the inner object.
Solution Approach 2:
The electrically insulating sections act as intermediaries between the conductive sections, allowing thermal energy transfer while blocking electrical current flow. These insulating sections mediate between the need for electrical conductivity (heating capability) and the need to prevent harmful short-circuit currents.
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 approach prevents short-circuit currents, ensuring uniform heating and enhancing the mechanical stability of the welded connection by maintaining even heat distribution, reducing the risk of material damage and improving the quality of the thermal bond.
Implementation Method 1
an electromagnetic coupling is effected between a magnetic and electrically conductive material and an induction generator substantially via a magnetic field, which is variable in time and which is generated by a coil of the induction generator
Implementation Method 2
the auxiliary heating material is spatially distributed or arranged along the circumferential course such that an electrical conductivity is interrupted at at least one position along the complete circumferential course around the first inner object
Data Source
AI summary
Described is a heating means for thermally connecting two objects each having a plastic material, wherein, during the connecting, a first inner object is surrounded at least partially by a second outer object, and the heating means surrounds the first inner object at least partially along a complete circumferential course around the first inner object, and is located between the first inner object and the second outer object. The heating means has a ribbon-type structure. The ribbon-type structure has an auxiliary heating material, which is inductively heatable, wherein the auxiliary heating material is spatially distributed or arranged along the circumferential course such that an electrical conductivity is interrupted at at least one position along the complete circumferential course around the first inner object. Further described are an arrangement and a system each having such a heating means as well as a method for thermally connecting two plastic objects.