Modular Induction Heating Device for Thermoplastic Preforms
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Solution Overview
Problem
Existing heating devices for preforms in blow moulding require replacement when changing preform shapes or sizes, leading to significant costs and time losses due to their fixed configuration and energy inefficiency.
Innovation Solution
A modular heating device with multiple separate heating modules, each equipped with induction means and independent power supply, allowing precise temperature control and easy adaptation to different preform shapes and sizes by adding or removing modules, and featuring interchangeable heater rings for varying cross-sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed configuration heating device is used, then the heating structure is simple, but it requires replacement when changing preform shapes or sizes, leading to significant costs and time losses
Solution Approach 1:
The heating device is divided into multiple independent heating modules that can be selectively assembled. Each module contains a heating element and can be independently positioned along the longitudinal axis to match different preform configurations, eliminating the need to replace the entire heating device when changing preform types.
Solution Approach 2:
The heating modules are designed to be movable and reconfigurable along the longitudinal axis of the heating cavity. This dynamic arrangement allows the heating zones to be adjusted according to different preform shapes and sizes, providing adaptability without requiring complete device replacement.
2Manufacturing precision
If a single heating element is used, then the device structure is simple, but it cannot achieve precise temperature distribution in different zones of the preform
Solution Approach 1:
The heating system is segmented into multiple independent heating modules, each capable of being controlled separately. This allows different zones of the preform to receive customized heating, achieving precise temperature distribution along the longitudinal extent while maintaining manageable device complexity through modular design.
Solution Approach 2:
Each heating module is designed to provide localized heating to specific portions of the preform. The independent control of each module enables tailored temperature profiles for different zones, ensuring precise temperature distribution according to the specific requirements of each preform region.
3Reliability
If the entire heating device is replaced when changing preform types, then the heating performance is optimized for each specific preform, but it results in considerable cost and time loss
Solution Approach 1:
By segmenting the heating device into interchangeable modules, the system maintains optimized heating performance for different preform types while eliminating the need to replace the entire device. Only the necessary modules need to be swapped, significantly reducing both time and cost losses.
Solution Approach 2:
The modular design allows for easy discarding of modules that are no longer needed for a specific preform type and recovering/reusing them in future applications. This reduces waste and minimizes the time and resources required for device reconfiguration between different production runs.
4Use of energy by stationary object
If traditional heating methods are used, then the device structure is simple, but it requires high energy consumption to reach design temperatures
Solution Approach 1:
The patent replaces traditional resistive heating with induction heating technology, which uses electromagnetic fields to directly induce currents in the heating elements. This substitution significantly reduces energy consumption and heating time while maintaining manageable device complexity through the use of standard induction heating components.
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
Enables precise temperature distribution along the preform's longitudinal extent, reduces energy consumption, and allows for easy adaptation to various preform shapes and sizes, optimizing heating performance and reducing production time and costs.
Implementation Method 1
each heating module comprises induction means suited to inducing, on applying a current to them, a magnetic flux on a respective heat transfer element
Implementation Method 2
induction means suited to inducing, on applying a current to them, a magnetic flux on a respective heat transfer element, so as to transmit a predetermined amount of heat by irradiation
Implementation Method 3
transmit a predetermined amount of heat by irradiation to a corresponding portion of the preform
Data Source
AI summary
Heating device for preforms, capable of accurate and highly localized heating of the preforms before the blow molding step of the process of producing bottles or containers from plastic materials. This device comprises two or more heating modules (11-16), each comprising a through opening (100) in the direction of the thickness of the heating module and a heating element (5) positioned in the vicinity of the through opening. The modules (11-16) are assembled such that the through openings (100) are aligned reciprocally with each other to define a conditioning cavity for the heating device (1). Each heating module (11-16) comprises induction means (2).