IR/NIR Preform Heating with Contoured Reflective Geometry
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Solution Overview
Problem
Current heating apparatuses for thermoplastic preforms are inefficient, requiring long heating tunnels and ventilation systems, which reduce the useful reflective surface and increase energy consumption.
Innovation Solution
The apparatus features a combination of IR/NIR lamps with a rear reflective body and a front reflective element, comprising alternately spaced and closer plate-like surfaces to enhance radiation reflection and reduce the need for ventilation, using metal components like aluminum for increased efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ventilation devices are introduced to cool lamps and preforms, then cooling capability is improved, but the useful reflective surface is reduced and apparatus efficiency decreases
Solution Approach 1:
The invention extracts and eliminates the ventilation cooling devices from the heating apparatus. By removing these devices that caused harm (reduced reflective surface and efficiency), the patent achieves full reflective surface coverage without ventilation openings, thereby eliminating the contradiction between cooling capability and energy efficiency.
2Temperature
If ventilation openings are increased in heating and reflective walls, then heat removal capability is improved, but the useful reflective surface is reduced
Solution Approach 1:
The invention removes ventilation openings from the heating and reflective walls, extracting the harmful element that reduced the reflective surface area. This allows the walls to be fully reflective, maximizing the useful surface area while eliminating the need for heat removal through openings.
Solution Approach 2:
The patent converts the previously harmful situation (need for ventilation openings) into a benefit by designing a system where the reflective walls themselves manage thermal conditions, eliminating the need for separate ventilation openings and thereby maximizing reflective surface area.
3Use of energy by moving object
If tunnel length is increased to improve heating efficiency, then heating effectiveness is improved, but apparatus length and complexity increase
Solution Approach 1:
The invention changes the parameters of the heating system by using high-power-density IR/NIR lamps with optimized reflective geometry. This allows achieving the same heating effectiveness in a shorter tunnel by intensifying the heating parameters rather than extending the tunnel length.
Solution Approach 2:
The patent transitions from a one-dimensional solution (longer tunnel) to a two-dimensional solution (optimized reflective surface geometry and lamp arrangement). By optimizing the spatial arrangement and reflective surfaces in multiple dimensions, the system achieves efficient heating in a compact configuration.
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 configuration results in a 10-30% reduction in tunnel length and electric power consumption, potentially eliminating the need for cooling ventilation, leading to a more efficient, cost-effective, and simplified heating process.
Implementation Method 1
The heating means can comprise incandescent lamps, infrared lamps, NIR lamps, which emit radiation in a specific region of the electromagnetic field (Near-Infra-Red)
Implementation Method 2
heating means designed to heat the preforms by emitting radiation in a specific region of the electromagnetic field
Implementation Method 3
The heating tunnels are constituted essentially by at least two side walls which are mutually opposite with respect to the path of the preforms and in particular by a first heating wall, which is associated with heating means designed to heat the preforms, and by a second reflective wall
Data Source
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AI summary
An apparatus (1) for heating preforms (10) made of thermoplastic material, comprising a conveyance device (2) for preforms (10) having a longitudinal axis of extension (100), intended to move the preforms along a predefined path (200), and heating means (3) arranged along at least one portion of the predefined path (200); the heating means (3) comprise at least one heating element (4) and at least one front reflective element (5), which are mutually opposite with respect to the predefined path (200) in order to form between them a transit tunnel for the preforms (10); the heating element (4) comprises a plurality of IR (Infra-Red) and/or NIR (Near-Infra- Red) lamps (4a); the front reflective element (5) comprises at least one contoured plate-like body in order to form, in the direction of extension of the predefined path (200), an alternation of closer portions (6a) and spaced portions (6b) with respect to the predefined path (200) that is extended substantially parallel to the axes of extension (100) of the preforms (10).