Inductor for Mold Preheating via Transverse Electromagnetic Field
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Solution Overview
Problem
Existing mold heating systems, particularly those using heating planes, suffer from long preheating times and inefficiencies due to heat diffusion issues, high costs, and reliability concerns, limiting their effectiveness in production processes.
Innovation Solution
An inductor for electromagnetic induction heating is placed between the two parts of a mold, comprising a non-conductive outer frame and a spiral coil assembly that generates a transverse electromagnetic field, reducing preheating time while maintaining the advantages of heating plane systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heating planes are used to heat molds, then the mold can be heated, but the preheating time becomes excessively long
Solution Approach 1:
The patent replaces the mechanical thermal conduction system (heating planes contacting the mold) with an electromagnetic induction system. The inductor generates an electromagnetic field that induces eddy currents directly in the mold, converting electrical energy to thermal energy without mechanical contact. This substitution of heating mechanism dramatically reduces preheating time while achieving the same temperature control objective.
Solution Approach 2:
The patent introduces an inductor as an intermediary device between the power source and the mold. Instead of direct thermal contact through heating planes, the inductor serves as a mediator that converts electrical energy to electromagnetic fields, which then induce currents in the mold to generate heat. This intermediary approach enables faster, more efficient heating while maintaining the ability to control mold temperature.
2Power
If fluid heating systems are used, then high power and good temperature control are achieved, but the cost and complexity increase significantly
Solution Approach 1:
The patent replaces the complex fluid-based thermal conduction system with an electromagnetic induction system. Instead of requiring pumps, pipes, and fluid circulation infrastructure, the invention uses an inductor that directly generates electromagnetic fields to induce heating in the mold. This substitution maintains high heating power capability while dramatically simplifying the overall system architecture and reducing operational complexity.
3Device complexity
If heating planes are used, then the system remains simple, but heat diffusion efficiency is poor and preheating time increases
Solution Approach 1:
The patent replaces the inefficient thermal conduction mechanism of heating planes with electromagnetic induction. The inductor generates electromagnetic fields that directly induce eddy currents in the mold, converting energy directly into heat within the mold material itself. This eliminates the inefficiencies of heat diffusion through intermediate materials and achieves rapid, uniform heating throughout the mold structure.
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
Significantly reduces preheating time by generating heat directly in the mold through induced currents, achieving faster temperature uniformity across the mold without the need for direct contact, thus improving production efficiency.
Implementation Method 1
the winding axis of the coil is perpendicular to the main plane of the inductor so as to generate, crossed by an alternating electric current, an electromagnetic field transverse to the main plane of the inductor, such that the lines of the magnetic induction field, produced by the coil, come out from the surface of one of the two parts of the mold through the inductor inside the coil, enter the second part of the mold and then come out again through the inductor on outside the coil, and close inside the first part of the mold
Data Source
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AI summary
Inductor (200) for electromagnetic induction preheating of molds, to be placed between the two parts (101) and (102) of a mold, comprising an outer frame (8) made of non-conductive and nonmagnetic material and an internal assembly (201), consisting of a coil (5), made with an electrical conductor, in the form of a spiral or a winding, arranged coplanar between two support elements and thermal insulation in semi-flexible, non-conductive and non-magnetic material, in which the the winding axis of the coil (5) is perpendicular to the main plane of the inductor so as to generate, crossed by an alternating electric current, an electromagnetic field transverse to the main plane of the inductor, such that the lines of the magnetic induction field, produced by the reel, come out from the surface of one of the two parts of the mold through the inductor (200) inside the coil (5), enter the second part of the mold and then come out again through the inductor (200) on the outside of the coil (5), and they are closed inside the first part of the mold.