Induction Heating Mold Shielding Layer
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Solution Overview
Problem
Existing induction heating devices for molding thermoplastic or thermosetting materials face challenges in controlling temperature distribution, especially when rapid heating and cooling phases occur, and inefficiencies due to heating large mold casings compared to the material volume.
Innovation Solution
A device with two mobile, electrically conductive mold casings and a shielding layer made of non-magnetic material, generating a magnetic field to induce currents only on the molding surface, controlling temperature distribution and reducing energy consumption by localizing heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If induction heating is applied to mold casings, then heating speed is improved, but energy consumption increases due to heating large volume of mold material
Solution Approach 1:
The patent applies local quality by using a shielding layer made of non-magnetic material with low electrical resistivity on specific portions of the mold casing. This shielding layer is strategically positioned to control the path of induced currents, concentrating heating only on the molding surface and die areas that require temperature control, while preventing currents from traveling through the entire mold casing volume. This resolves the contradiction by maintaining fast heating speed on the molding surface while reducing overall energy consumption.
2Use of energy by moving object
If induction heating is applied to mold casings, then heating efficiency is improved, but temperature distribution control deteriorates during rapid heating and cooling phases
Solution Approach 1:
The shielding layer is designed with specific electrical resistivity properties (lower than the mold casing material) and is applied only to portions of the mold casing that require temperature control. This creates localized heating zones on the molding surface while preventing unwanted heat generation in other areas, enabling precise temperature distribution control during rapid heating and cooling cycles.
Solution Approach 2:
The patent enables dynamic control of temperature distribution by adjusting the shielding layer's electrical resistivity and geometric configuration. The shielding layer's properties can be optimized for different phases of the molding process, allowing the system to adapt to rapid heating and cooling requirements while maintaining efficient energy use.
3Temperature
If magnetic field penetrates into mold casings, then heating is achieved, but heating is not localized and energy is wasted
Solution Approach 1:
The shielding layer acts as an intermediary element between the induction heating source and the mold casing. It has specific electrical and magnetic properties that allow it to guide and concentrate the induced currents on the molding surface while preventing the magnetic field from penetrating deeply into the mold casing bulk. This intermediary layer achieves effective heating where needed while minimizing energy waste in unnecessary areas.
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
Achieves uniform temperature distribution and increased productivity with reduced heating and cooling times by concentrating the magnetic field and thermal effects on the molding surface, improving energy efficiency and manufacturing speed.
Implementation Method 1
induction means enveloping the casing of the mold for generating a magnetic field with a frequency F ranging from 25 kHz to 100 kHz
Implementation Method 2
heating the material by conduction
Implementation Method 3
the faces of at least one of the two mold casings situated so as to be facing the induction means, being coated with a shielding layer made of a non-magnetic material having a second electrical resistivity which is lower than the first electrical resistivity preventing the magnetic field from penetrating into the mold casings
Implementation Method 4
said shielding layer extends over a part of the molding surface outside of the die surface and is electrically connected to the molding surface to form an electrical pathway between the shielding layer and the molding surface
Data Source
AI summary
The present invention concerns a device for molding of thermoplastic matrix composite materials or thermosetting materials. Two mold casings that are mobile relative to each other, electrically conductive material include a molding zone designed to be in contact with the material to be transformed, and an induction circuit for generating a magnetic field. The faces of one of the two mold casings are situated so as to be facing induction circuit, except for the molding zones, being coated with a shielding layer made of a non-magnetic material preventing the magnetic field from penetrating into the mold casings. The mold casings are electrically insulated from each other during the molding phase to define an air gap wherein flows the magnetic field that induces currents at the surface of the molding zones, thus localizing the heating at the interface between the molding zone and the material to be transformed.