Mold Induction Heating with Recessed Coil Housing
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Solution Overview
Problem
Conventional induction heating methods for molds face inefficiencies in heating uniformity and magnetic flux leakage, leading to inadequate heating and corrosion of induction coils by corrosive gases.
Innovation Solution
A mold induction heating device with recessed housing portions for induction coils on metal plates, enclosed by metal covers, and gas-liquid two-phase heating medium chambers for efficient magnetic flux transfer and uniform heating, while protecting the coils from corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If induction coils are arranged outside the mold to heat the mold directly, then heating time is shortened and clean energy is used, but magnetic flux leaks out without passing into the mold, preventing adequate heating
Solution Approach 1:
The patent introduces a magnetic flux guide structure (yoke) as an intermediary component between the induction coil and the mold. This yoke is designed to channel and concentrate the magnetic flux generated by the induction coil, ensuring it efficiently penetrates into the mold rather than leaking outward. The yoke acts as a mediator that transforms the diffuse magnetic field into a concentrated flux path that effectively heats the mold.
2Power
If induction coils are arranged outside the mold, then heating can be applied, but temperature unevenness occurs in the mold, preventing uniform heating
Solution Approach 1:
The patent divides the heating system into multiple independent induction coil units arranged around the mold perimeter, with each coil responsible for heating a specific zone. This segmentation allows for localized control of heating zones, enabling uniform temperature distribution across the entire mold by coordinating the operation of multiple coils. Each coil can be independently controlled to compensate for variations in heat transfer across different mold regions.
3Ease of operation
If induction coils are exposed to the outside environment, then heating can be performed, but the coils are corroded by corrosive gases
Solution Approach 1:
The patent extracts the induction coils from the corrosive environment by housing them within a protective structure. The coils are placed inside a chamber or enclosure that isolates them from corrosive gases while still allowing the magnetic flux to pass through the bottom or side walls into the mold. This extraction protects the coils from corrosion while maintaining their heating function.
4Loss of energy
If induction coils are housed in recessed housing portions with metal covers, then magnetic flux leakage is reduced and heating efficiency improves, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into the recessed housing structure: the housing provides mechanical support for the induction coil, the metal cover contains the magnetic flux, and the combined structure serves as both a protective enclosure and a magnetic flux guide. By combining these functions into a single integrated component rather than separate parts, the overall device complexity is minimized while achieving effective magnetic flux containment and heating efficiency improvement.
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 enables efficient and uniform heating of molds, improves heating efficiency and power factor, and prevents induction coil corrosion, allowing for high-quality tire manufacturing.
Implementation Method 1
passing magnetic flux that is produced by the induction coils into the mold so as to directly heat the mold with electrical heat (Joule heating) resulting from the induced current
Implementation Method 2
directly heat the mold with electrical heat (Joule heating) resulting from the induced current
Implementation Method 3
a plurality of jacket chambers in which a gas-liquid two phase heating medium is enclosed are formed in the metal plate body
Implementation Method 4
gas-liquid circulation of the heating medium inside the jacket chambers is promoted, enabling the temperature to be more readily equalized
Data Source
AI summary
For heating a mold efficiently and uniformly and for protecting an induction coil from corrosive gases, an upper plate that contacts an upper end face of a mold, and a lower plate that contacts a lower end face of the mold are provided, and an induction coil, provided to each plate, has a voltage applied by a commercial power supply. Each plate has a metal plate body in which a recessed housing portion that houses the induction coil is formed, and a cover that closes the recessed housing portion in a state where the induction coil is housed therein. A cover placement portion having a step that is greater than or equal to the thickness of the metal cover is formed in the metal plate body, and a plurality of jacket chambers in which a gas-liquid two phase heating medium is enclosed are formed in the metal plate body.