Laser Heating Unit for Plastic Preforms with Staggered Emitters
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Solution Overview
Problem
Conventional halogen lamp-based heating systems for blow molding and stretch-blow molding are inefficient due to wasted electrical energy and lack of precision in heating, as only the infrared range is useful for heating, and halogen lamps are not directional, leading to inefficient and non-homogeneous heating of plastic blanks.
Innovation Solution
A processing unit configuration using laser radiation sources, such as VCSEL-type laser diodes, with specific emitter and reflector arrangements to ensure even energy distribution and improved compactness, allowing for more efficient and homogeneous heating of plastic blanks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If halogen lamps are used for heating, then continuous spectrum radiation is provided, but electrical energy is wasted and heating efficiency is low
Solution Approach 1:
The patent changes the spectral parameters of the radiation source from broadband halogen lamp spectrum to monochromatic or narrow-band laser radiation in the infrared range, specifically targeting wavelengths that are most effective for heating plastic materials. This parameter change eliminates energy waste in non-heating spectral regions while concentrating energy where it is needed.
Solution Approach 2:
The patent replaces the thermal radiation mechanism of halogen lamps with coherent laser radiation, substituting a mechanical/thermal system with an optical system that can deliver energy more precisely and efficiently to the workpiece.
2Manufacturing precision
If halogen lamps are used for heating, then omnidirectional radiation is provided, but heating precision and homogeneity are poor
Solution Approach 1:
The patent applies local quality by using laser radiation's inherent directionality and focusing capability to deliver concentrated energy precisely where needed on the plastic blank, rather than omnidirectional radiation. The laser beam can be focused to specific zones, creating localized heating zones with controlled energy distribution for homogeneous heating.
Solution Approach 2:
The patent introduces optical intermediaries such as mirrors, lenses, and beam shaping elements to control and direct the laser radiation. These intermediaries manipulate the laser beam to achieve precise spatial distribution of energy on the workpiece, ensuring homogeneous heating while maintaining the directional advantage of laser sources.
3Use of energy by moving object
If laser sources are used for heating, then directional and efficient heating is achieved, but heating homogeneity is insufficient
Solution Approach 1:
The patent segments the laser heating system into multiple independent radiation sources arranged in arrays or matrices. By using multiple laser beams instead of a single beam, the system can cover larger areas and distribute energy more uniformly across the plastic blank, maintaining high efficiency while achieving heating homogeneity through coordinated operation of multiple segmented sources.
Solution Approach 2:
The patent transitions from one-dimensional or point-source laser heating to two-dimensional or area-source laser heating by arranging multiple laser emitters in spatial arrays. This dimensional expansion allows simultaneous heating of multiple zones, improving both homogeneity and efficiency by distributing energy across the workpiece surface in a controlled pattern.
4Device complexity
If conventional heating units are designed, then simple structure is maintained, but energy distribution and compactness are poor
Solution Approach 1:
The patent designs heating unit components to serve multiple functions: laser emitters provide both the radiation source and structural mounting points, while integrated mirrors and lenses serve both beam control and spatial arrangement functions. This multi-functionality reduces the number of separate components needed, maintaining structural simplicity while achieving superior energy distribution through the coordinated arrangement of multifunctional elements.
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 configuration achieves efficient and homogeneous heating of plastic blanks with reduced processing time and increased production capacity, while maintaining compactness and high energy efficiency.
Implementation Method 1
The efficiency and the properties (in particular of optical precision) of the laser sources are much higher than those of the halogen sources, and in theory make it possible to carry out faster and more selective heating of the blanks.
Implementation Method 2
based on the use of lasers emitting in the infrared range
Implementation Method 3
a first wall 3 and a second wall 4 next to the first wall 3 which together define an enclosure 5 within which the preforms pass 2 along a path T predetermined
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Unit (1) for treating hollow plastic body preforms (2), comprising a chamber (5) comprising two opposite walls (3, 4), namely a first wall (3) and a second wall (4) opposite the first one, and which together define a chamber (5) through which the preforms (2) pass in a predetermined longitudinal path, in which: - each wall (3, 4) comprises a series of spaced-apart emitters (7) each comprising a plurality of sources of monochromatic or pseudo-mono chromatic electromagnetic radiation, - a reflective section (15) extends into each space between two adjacent emitters (7); - the emitters (7) on the second wall (4) are longitudinally offset from those on the first wall (3) such that the emitters (7) on each wall (3, 4) face a reflective section of the wall opposite.