Magnetic Inserts for Induction Heating Enhancing Field
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Solution Overview
Problem
Existing induction heating devices for transversal sealing in liquid product packaging face high manufacturing costs due to sintering processes and have limited design freedom and lifetime expectancy due to fatigue from intermittent pressing actions.
Innovation Solution
Magnetic inserts are manufactured using a mouldable polymer matrix and soft magnetic material, allowing for injection moulding, thermo forming, or 3D printing, which enhances design flexibility and durability, and are integrated with a stainless steel base structure and coil to improve mechanical robustness and induction heating efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic inserts are manufactured by sintering soft magnetic material into rigid pieces, then magnetic field enhancement is achieved, but manufacturing cost increases and design freedom is restricted
Solution Approach 1:
The patent applies composite materials by combining soft magnetic material particles with a polymer matrix to create magnetic inserts that maintain magnetic field enhancement capabilities while enabling injection molding manufacturing. This composite approach allows complex geometries to be produced cost-effectively without requiring sintering processes, thus resolving the contradiction between magnetic performance and manufacturing ease.
Solution Approach 2:
The patent changes the manufacturing parameter from sintering to injection molding, and modifies the material state from rigid sintered pieces to moldable composite material. This parameter change enables design freedom and cost-effective manufacturing while preserving the magnetic field enhancement function through proper formulation of the composite material with 30-70 volume percent soft magnetic material.
2Ease of operation
If induction heating devices use intermittent pressing action towards packaging material, then transversal sealing is provided, but body structure becomes fatigued and device lifetime is limited
Solution Approach 1:
The patent segments the pressing function from the main body structure by introducing a separate pressing element that can be independently replaced. This segmentation allows the pressing element to absorb fatigue from intermittent pressing actions, while the main body structure remains intact, thus extending device lifetime while maintaining the transversal sealing function.
3Ease of manufacture
If magnetic inserts use high percentage of polymer matrix for easy manufacturing, then manufacturing ease increases, but magnetic permeability and field enhancement may be insufficient
Solution Approach 1:
The patent optimizes the concentration parameter of soft magnetic material in the composite, specifying 30-70 volume percent as the optimal range. This parameter change ensures sufficient magnetic permeability and field enhancement while maintaining adequate polymer matrix content for injection molding manufacturability, thus resolving the contradiction between ease of manufacture and magnetic performance.
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 solution reduces manufacturing costs, increases design freedom, and extends the lifetime of induction heating devices by providing efficient and robust magnetic inserts that enhance the magnetic field and reduce heat losses, while allowing for precise shaping of the magnetic field for improved transversal sealing.
Implementation Method 1
A coil 204 is arranged adjacent to the inserts 203
Implementation Method 2
induction heating device for providing transversal sealing to packages having a conductive layer
Implementation Method 3
inserts 203 of soft magnetic material are provided on the mounting core, for locally boosting the magnetic field of the induction heating device
Implementation Method 4
soft magnetic material
Data Source
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AI summary
A magnetic insert for enhancing the magnetic field of an induction heating device is provided. The magnetic insert (302) is manufactured by use of a composition comprising a mouldable polymer matrix and a soft magnetic material.