Overlapping Induction Heaters for Flexible Tube Welding
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Solution Overview
Problem
The existing methods for producing flexible tube bodies for packaging using induction heating devices face challenges such as high temperature fluctuations, wear, and energy inefficiency due to the spatial separation of heating coils, which shorten the service life of contact strips and increase energy consumption.
Innovation Solution
The induction heating devices for the inner and outer contact strips are arranged in a partially overlapping manner in the transport direction, allowing for simultaneous heating closer to the area where the longitudinal weld seam is formed, reducing temperature gradients and energy consumption, and extending the service life of the contact strips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If induction heating devices for inner and outer contact strips are arranged in spatially separated manner to prevent mutual interference, then the heating process can be performed, but the inner contact strip must be heated to very high temperatures (300°C and more) which causes high wear and shortens service life
Solution Approach 1:
The induction heating devices for the inner and outer contact strips are arranged in spatial overlap in the transport direction, merging their heating zones. This allows the outer contact strip to be heated first, providing thermal insulation that reduces the temperature required for heating the inner contact strip, thereby reducing wear and extending service life.
2Reliability
If induction heating devices are arranged in spatially separated manner, then mutual interference is prevented, but the device length in transport direction must be extended
Solution Approach 1:
The induction heating devices are arranged in spatial overlap in the transport direction, utilizing the third dimension (vertical stacking) to resolve the spatial conflict. This allows both heating devices to be positioned close together in the transport direction while preventing mutual interference through vertical separation, thus reducing device length without compromising heating effectiveness.
3Reliability
If inner contact strip is heated strongly to compensate for spatial separation, then sufficient heat is available for weld seam formation, but energy consumption increases
Solution Approach 1:
The outer contact strip is heated in advance by the outer induction heating device before the inner contact strip is heated. This preliminary heating action provides thermal insulation that reduces the energy required to heat the inner contact strip to the necessary temperature for weld seam formation, thereby reducing overall energy consumption while maintaining weld quality.
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
This arrangement results in a more energy-efficient process with reduced wear on the inner contact band, enabling the formation of high-quality longitudinal weld seams while minimizing the device's length and energy usage.
Implementation Method 1
inductive heating or corresponding induction heating devices have become established as heating mechanisms for such contact strips, in particular an inner contact strip and an outer contact strip, which preferably use corresponding induction coils of the induction heating devices, which are arranged statically relative to the contact strips, to locally heat the contact strips, preferably at least partially metallic, preferably by effecting the necessary heating of the contact strip via inductive energy transfer
Implementation Method 2
to locally heat the contact strips, preferably at least partially metallic, preferably by effecting the necessary heating of the contact strip via inductive energy transfer
Implementation Method 3
The longitudinal edge surfaces are held between these belts and heated during transport or concurrent transport, and optionally pressurized, to enable at least partial melting of the longitudinal edge surfaces and the formation of a longitudinal weld seam
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a device for producing flexible tube bodies for packaging tubes from a film substrate (02), preferably having a print on one outer surface, which has or consists of at least one weldable plastic layer and which comprises a first longitudinal edge extending in a longitudinal direction and a second longitudinal edge parallel to and spaced apart from it, wherein the device has forming means for forming the film substrate (02) into a tube shape and wherein the device (01) further comprises an outer (04) and an inner (03), preferably continuously driven, contact band (03, 04), between which the two longitudinal edge sides are received for guiding and/or heating to form a longitudinal weld seam and are carried along in a transport direction (T), wherein the outer (04) and the inner contact band (03) are each associated with respective induction heating devices (07,08) in particular, it is provided that an induction heating device (07, 08) associated with the inner contact band (03) is arranged in the transport direction at least partially overlapping with an induction heating device (07, 08) associated with the outer contact band (04).