Planar Multi-Loop Induction Coil for Wider Thermoplastic Weld Seams
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Solution Overview
Problem
Existing induction welding technologies fail to produce a wide, robust weld seam effectively, particularly when joining fiber-reinforced thermoplastic materials, resulting in inadequate bonding strength.
Innovation Solution
The induction welder features a conductive element configured into multiple loops within a common plane, with segments oriented parallel and angularly offset to align with the fiber reinforcement patterns in the thermoplastic bodies, ensuring efficient energy distribution and enhanced weld seam formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional induction welding coil configuration is used, then the welding process is simple, but the weld seam width and robustness are insufficient
Solution Approach 1:
The induction welding coil is divided into multiple discrete segments or zones along its length, with each segment capable of being independently controlled. This segmentation allows different portions of the weld seam to receive optimized electromagnetic energy distribution, creating wider and more robust welds while maintaining manageable system complexity through modular control architecture
Solution Approach 2:
The coil configuration is designed with varying properties along its length, including changes in turn density, wire diameter, or spacing to create localized zones with different electromagnetic field characteristics. This local quality variation enables optimization of weld seam width and strength at specific locations without requiring complete redesign of the entire coil, balancing performance improvement with design complexity
2Use of energy by moving object
If conventional coil configuration is used, then manufacturing is straightforward, but energy distribution efficiency is poor for fiber-reinforced materials
Solution Approach 1:
The coil design incorporates variations in geometric parameters such as turn spacing, wire diameter, and coil dimensions to optimize electromagnetic energy distribution. By carefully controlling these parameters, the system achieves improved energy efficiency for heating fiber-reinforced thermoplastic materials while maintaining manufacturing feasibility through standardized production techniques for the modified geometry
3Area of stationary object
If simple coil configuration is used, then device operation is easy, but weld seam width is insufficient
Solution Approach 1:
The coil configuration transitions from a simple planar or single-dimensional arrangement to a multi-dimensional spatial structure with variations in multiple geometric parameters simultaneously. This dimensional complexity enables broader energy distribution across the weld area, achieving wider weld seams while the modular nature of the dimensional changes keeps operational complexity manageable
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 configuration produces a wider, more robust weld seam, improving the bonding strength between fiber-reinforced thermoplastic components by aligning the conductive elements with the fiber orientations, thereby increasing the weld's durability and consistency.
Implementation Method 1
induction welder includes a first lead, a second lead and an induction welding coil. The induction welding coil is electrically coupled with the first lead and the second lead
Implementation Method 2
The induction welding coil is configured as or otherwise includes a conductive element. This conductive element is configured into at least a plurality of loops arranged within a common plane
Implementation Method 3
The first segment is at least substantially parallel with the parallel first fibers. The second segment is at least substantially parallel with the parallel second fibers
Data Source
Figure 1
Figure 2~5
Figure 4
AI summary
An induction welder (20) is provided that includes a first lead (28), a second lead (30) and an induction welding coil (32). The induction welding coil (32) is electrically coupled with the first lead (28) and the second lead (30). The induction welding coil (32) is configured as or otherwise includes a conductive element (58). This conductive element (58) is configured into at least a plurality of loops (62A, 62B) arranged within a common plane.