Inline Resistive Heating for Uniform Thermal Treatment of Continuous Products
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Solution Overview
Problem
Existing methods for removing organic contaminants from continuous products, such as lubricants and coatings, are inefficient and costly, particularly in batch thermal treatment processes which require substantial energy and result in non-uniform heating.
Innovation Solution
An inline thermal treatment system using resistive, plasma, or laser heating methods to rapidly and uniformly treat continuous conductive or non-conductive products, allowing for direct heating and removal of contaminants as the products move through the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If batch thermal treatment in a furnace is used to remove organic contaminants, then the contaminants are removed from the product surface, but the process consumes substantial energy and requires additional time for loading, transporting, and cooling
Solution Approach 1:
The patent extracts the heating function from the entire furnace environment and concentrates it directly onto the product surface through radiant heating elements positioned in close proximity. This allows thermal treatment to occur only where needed (on the product surface) rather than heating the entire furnace chamber, thereby reducing overall energy consumption while maintaining effective contaminant removal
Solution Approach 2:
The patent replaces the conventional convection-based furnace heating system with a radiant heating system that uses electromagnetic radiation (infrared or other radiant energy) to directly heat the product surface. This substitution eliminates the need to heat large volumes of air and furnace structure, significantly reducing energy consumption while achieving the same contaminant removal effect
2Object-affected harmful factors
If batch thermal treatment in a furnace is used to remove organic contaminants, then the contaminants are removed from the product surface, but the process requires substantial time for loading, transporting, heating, cooling, and unloading
Solution Approach 1:
The patent extracts the thermal treatment process from the batch furnace environment and integrates it into a continuous production line. Products move continuously through the radiant heating zone without interruption, eliminating the time required for loading and unloading operations while maintaining effective contaminant removal
Solution Approach 2:
The patent transforms the batch thermal treatment process into a continuous operation where products are constantly moving through the heating zone. This continuity eliminates idle time between batches, removes the need for loading/unloading cycles, and maintains consistent heating conditions, thereby significantly reducing total processing time while effectively removing contaminants
3Object-affected harmful factors
If batch thermal treatment in a furnace is used to remove organic contaminants, then the contaminants are removed from the product surface, but the heating is non-uniform with outer portions heating at different rates than inner portions
Solution Approach 1:
The patent employs multiple radiant heating elements positioned at different locations and angles to target specific zones of the product surface. Each heating element is strategically placed to ensure uniform heat distribution across the entire product surface, addressing the non-uniform heating problem by creating localized heating zones that collectively achieve overall uniformity
Solution Approach 2:
The patent transitions from volumetric heating (heating the entire furnace chamber and its contents) to surface-based radiant heating. By positioning heating elements to radiate energy directly onto the product surface from multiple angles and locations, the system achieves uniform surface heating without the non-uniform temperature gradients that occur in batch furnace environments
4Object-affected harmful factors
If organic solvents are used to clean the product surface, then organic contaminants are dissolved and removed, but additional cost and equipment are required for managing solvent fumes and recycling
Solution Approach 1:
The patent replaces the chemical cleaning process (using organic solvents) with a physical thermal treatment process (radiant heating). This substitution eliminates the need for solvent storage, handling, fume management systems, and recycling equipment, thereby significantly reducing device complexity while achieving effective contaminant removal through thermal decomposition and volatilization
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 significantly reduces time and operational costs by enabling efficient, uniform heating and removal of contaminants, improving product quality and reducing energy consumption compared to batch processes.
Implementation Method 1
a first electrode and a second electrode that are spaced apart from one another and that are disposed above and below, respectively, a portion of the continuous product positioned within the heating zone such that application of an electrical bias between the first and second electrodes heats the portion of the continuous product between the electrodes by resistive heating
Implementation Method 2
an inline plasma thermal treatment system including one or more plasma arcs that heat a portion of the continuous product
Implementation Method 3
an inline thermal treatment system using resistive, plasma, or laser heating methods to rapidly and uniformly treat continuous conductive or non-conductive products
Data Source
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AI summary
An inline thermal treatment system for thermally treating a continuous conductive product includes a first electrode configured to contact a continuous conductive product and a second electrode configured to contact the continuous conductive product such that a portion of the continuous conductive product is disposed between the first and second electrodes. The inline thermal treatment system includes a power source coupled to the first electrode and to the second electrode, wherein the power source is configured to apply an electrical bias between the first electrode and the second electrode to resistively heat the portion of the continuous conductive product disposed between the first and second electrodes.