Microwave Preform Heating with Shared Rectifier Across Resonators
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Solution Overview
Problem
Existing microwave heating devices for plastic preforms are costly and inefficient due to the need for multiple independent heating stations with duplicate components, leading to increased costs and potential unsatisfactory results.
Innovation Solution
A centralized microwave heating system with a central rectifier unit, high-voltage source, and microwave generator supplies multiple resonator units, reducing redundancy and costs by sharing these components across multiple stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple independent heating stations with individual low-power components are used, then the heating function is provided for multiple resonator units, but the device complexity and manufacturing costs increase due to the large number of functional groups required
Solution Approach 1:
The patent merges the high-voltage generation functionality into a single centralized high-voltage generator that supplies multiple resonator units, instead of having separate low-power high-voltage generators at each station. This consolidation reduces the total number of functional groups while maintaining the ability to heat multiple resonator units simultaneously or sequentially.
Solution Approach 2:
The centralized high-voltage generator serves multiple resonator units, making it a universal component that performs the high-voltage generation function for the entire system rather than being dedicated to a single station. This multi-functional approach reduces overall device complexity.
2Adaptability or versatility
If multiple independent heating stations with individual low-power components are used, then the heating capability is distributed across stations, but the manufacturing costs increase
Solution Approach 1:
By combining multiple low-power high-voltage generation functions into a single centralized high-voltage generator, the patent reduces the total component count and manufacturing complexity. The centralized design allows for standardized production and reduces the need for multiple identical functional groups, thereby lowering manufacturing costs.
3Productivity
If multiple independent heating stations are operated in parallel, then the heating capacity is sufficient for multiple resonator units, but the system reliability decreases due to the large number of components
Solution Approach 1:
The patent consolidates multiple high-voltage generation functions into a single reliable centralized unit, reducing the number of potential failure points. With fewer components, the system has lower complexity and fewer opportunities for component failure, thereby improving overall system reliability while maintaining the capacity to heat multiple resonator units.
4Ease of operation
If individual low-power components are installed at each station, then the power distribution is simplified at the station level, but the overall device complexity increases
Solution Approach 1:
The patent segments the power distribution function by providing separate controllable connections from the centralized high-voltage generator to each resonator unit. This allows each station to be independently controlled and operated, simplifying station-level operations while the centralized generation reduces overall device complexity.
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
Reduces installation space and manufacturing costs while maintaining reliability by using a central rectifier and high-voltage source to supply multiple resonator units, allowing flexible power distribution based on machine design.
Implementation Method 1
at least one rectifier unit for providing a rectified voltage
Implementation Method 2
a microwave generation unit for generating microwaves
Implementation Method 3
a feed device for feeding the microwaves generated by the microwave generation unit to at least one resonator unit
Implementation Method 4
plastic preforms are moved into a resonator and heated within this resonator by being exposed to microwaves
Data Source
Figure 1~2
Figure 3~4
AI summary
Device (1) for heating plastic preforms (10) with a plurality of resonator units (2a, 2b, 2c), into each of which plastic preforms (10) can be inserted for heating, with at least one microwave generating unit (4a, 4b, 4c) for generating microwaves and with a feed device (6) for supplying the microwaves generated by the microwave generating unit (4a, 4b, 4c) to at least one resonator unit (2a, 2b, 2c), and with at least one rectifier unit (12) for providing a rectified voltage. According to the invention, at least one rectifier unit (12) provides voltage for operating at least two resonator units (2a, 2b, 2c).