Insulated Clamshell Container for Butt Welding Heating Plates

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Solution Overview

Problem

Conventional containers for heating plates used in butt welding pipes result in significant heat loss due to the 'stack effect,' leading to high energy consumption and potential damage from rising hot air affecting electrical components.

Innovation Solution

A container with a clamshell design and insulation means, such as solid insulating panels, to minimize heat exchange between the heating plate and the environment, allowing for efficient energy retention and safe storage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the heating plate is stored in an open metal container, then the container is simple and easy to manufacture, but significant heat loss occurs due to the stack effect, leading to high energy consumption

Engineering Contradiction:

Improvecontainer simplicityVSAvoidheat loss

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The container is divided into a base portion and a cover portion that can be separated. The base portion contains the heating plate storage space, while the cover portion can be opened for insertion/removal of the heating plate and closed to prevent heat loss. This segmentation allows easy manufacture of simple components while achieving energy conservation when closed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An insulating barrier (such as a reflective foil or insulating material) is introduced as an intermediary between the heating plate and the container walls, and between the heated air and the external environment. This intermediary reduces heat transfer and prevents the stack effect, significantly reducing energy loss while maintaining container simplicity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the heating plate remains on during prolonged inactivity to maintain optimal temperature, then welding readiness is improved, but power consumption reaches significant amounts

Engineering Contradiction:

Improvewelding readinessVSAvoidpower consumption

Core Design Contradiction:

Ease of operationVSUse of energy by moving object

Solution Approach 1:

The heating plate is preheated before storage in the container. When the cover is closed, the heat is retained, maintaining the plate at optimal temperature for welding without requiring continuous power consumption. This preliminary heating action, combined with thermal retention, achieves welding readiness while reducing energy use during inactivity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The insulating barrier maintains thermal continuity within the container, allowing the heating plate to retain heat over prolonged periods. This continuous thermal retention enables the plate to remain ready for welding operations without requiring continuous or frequent reheating, significantly reducing power consumption while maintaining operational readiness.

Inventive Principle:

Principle #20Continuity of useful action

3Ease of operation

If the container is open on top for easy insertion and removal of the heating plate, then ease of operation is improved, but hot air rises and affects electrical components, causing damage

Engineering Contradiction:

Improveinsertion and removal easeVSAvoidhot air damage to electrical components

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The container is segmented into a base portion for storage and a separate cover portion that can be opened for insertion/removal of the heating plate. When the cover is closed, it prevents hot air from rising and contacting electrical components located outside the container, protecting them from thermal damage while maintaining ease of operation during plate insertion and removal.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An insulating or reflective barrier is positioned within the container to act as an intermediary that blocks the upward movement of hot air. This barrier prevents hot air from reaching electrical components and handles, protecting them from thermal damage while allowing the container to remain open during plate insertion and removal operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

The container achieves a primary energy saving of approximately 70% when the heating plate is not in use and reduces operational costs while preventing damage from hot air, maintaining mechanical toughness and simplicity.

Implementation Method 1

an insulation means (20a, 20b, 20c) surrounding the receptacle (3) so as to thermally insulate the receptacle (3) from the surrounding environment

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

at least one electric heat source is embedded in a heat-conducting manner

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS20230364723A1Container for heating plates for butt welding pipes

Publication Date: 2023.11.16 RITMO SRL

AI summary

A container for heating plates for butt welding pipes has one or more walls forming at least one receptacle for containing a heating plate; an insulation means surrounds the receptacle and is adapted to thermally insulate the receptacle from the surrounding environment.