Infrared Preform Heater with Segmented Reflecting Wall
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Solution Overview
Problem
Conventional heating techniques for plastic preforms, such as those made of polyethylene terephthalate (PET), face inefficiencies in energy consumption and lack precision in heating non-uniformly shaped containers, particularly due to the need for additional cooling systems and imprecise transitions between hot and cool sectors.
Innovation Solution
A method involving the regulation of infrared radiation intensity along a predetermined path to selectively heat specific angular sections of the preform, using a matrix of laser diodes and a reflecting wall to achieve precise temperature control, with heating profiles such as sinusoidal or crenellated patterns to optimize energy use and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If masks or recesses are added to the reflecting wall to create non-uniform heating, then selective heating of angular sectors is achieved, but energy consumption increases due to cooling systems and the transition between hot and cool sectors lacks sharpness
Solution Approach 1:
The reflecting wall is segmented into multiple independent adjustable sections, each capable of being individually positioned to control radiation reflection. This allows precise control over which angular sectors receive reflected radiation, enabling sharp transitions between hot and cool sectors without requiring cooling systems, thus reducing energy consumption while maintaining heating precision.
Solution Approach 2:
The reflecting wall sections are made dynamically adjustable during the heating process, allowing real-time control of radiation distribution. This dynamic adjustment enables precise targeting of hot sectors while minimizing energy waste, eliminating the need for static masks or recesses that require additional cooling energy.
2Manufacturing precision
If masks are placed in front of the reflecting wall to absorb radiation, then non-uniform heating is achieved, but the transition between hot and cool sectors lacks sharpness
Solution Approach 1:
The reflecting wall is divided into multiple independent adjustable sections that can be individually positioned. This segmentation replaces the complex mask system with a simpler adjustable wall structure, achieving sharp transitions between hot and cool sectors through precise positioning rather than through multiple overlapping masks.
Solution Approach 2:
The mechanical mask system is replaced with an adjustable reflecting wall mechanism that uses controlled positioning rather than physical absorption. This substitution simplifies the device by eliminating the need for multiple masks and their associated mounting and adjustment mechanisms.
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 reduces energy consumption and enhances heating precision, allowing for the production of containers with complex shapes by creating distinctively hotter and cooler sectors, improving the manufacturing process and reducing energy waste.
Implementation Method 1
heating the preform along said path by means of infrared radiation sources, the intensity of the emitted radiation being regulated along the path
Implementation Method 2
a reflecting wall whereby that fraction of the radiation not absorbed by the preforms is reflected onto them
Data Source
Figure 1~3
Figure 4~6
AI summary
Method of heating a plastic preform (1) for the manufacture of a container by forming it from the preform (1)-, this method comprising: a step of transporting the preform (1 ) along a predetermined path with rotation of the preform (1) about its axis (A); and a step of heating the preform (1) along said path by means of infrared radiation sources (11 ), wherein the intensity of the emitted radiation is regulated along the path so as to heat selectively at least one angular section (7, 7a, 7b) of the preform (1). A heater device for heating plastic preforms is also claimed.