Segmented Back Reflector for IR Preform Heating
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Solution Overview
Problem
Existing heating devices for preforms in stretch blow molding face inefficiencies due to radiation losses and material damage from high temperature fluctuations, leading to costly production stoppages and reduced machine efficiency.
Innovation Solution
A heating device with a segmented back reflector and filter system, using ceramic materials and a floating mount to minimize distance between IR emitters and reflectors, and a segmented structure to allow controlled expansion, reducing stress and radiation loss, and a counter-reflector to enhance energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the distance between IR emitters and reflectors is minimized to improve energy efficiency, then radiation loss is reduced and energy efficiency is improved, but the reflector material is damaged by high temperature fluctuations
Solution Approach 1:
The back reflector is divided into multiple segments that can move independently relative to each other. This segmentation allows the reflector to accommodate thermal expansion and temperature fluctuations without causing material damage, while maintaining minimal distance to IR emitters for optimal energy efficiency.
Solution Approach 2:
The reflector segments are designed to be dynamically adjustable, allowing them to move and adapt to temperature changes. This dynamic capability enables the system to maintain both close proximity to IR emitters for energy efficiency and sufficient thermal tolerance to prevent material damage.
2Use of energy by stationary object
If reflectors are placed closer to IR emitters to reduce radiation loss, then energy efficiency is improved, but stress on the reflector material increases due to high temperature
Solution Approach 1:
Dividing the reflector into segments distributes the thermal stress across multiple independent units, reducing the overall stress on any single segment while maintaining close proximity to IR emitters for high energy efficiency.
Solution Approach 2:
The reflector segments can change their physical parameters (position, orientation) in response to temperature changes, allowing them to maintain optimal distance from IR emitters for energy efficiency while adapting to thermal conditions to reduce material stress.
3Loss of energy
If a single large reflector is used to minimize radiation loss, then energy efficiency is improved, but the reflector is more susceptible to breakage from temperature fluctuations
Solution Approach 1:
The large reflector surface is segmented into multiple smaller units that can move independently. This maintains the overall reflective surface area needed for energy efficiency while reducing the susceptibility to breakage from thermal stress.
Solution Approach 2:
The segmented design provides a cushioning effect against thermal stress by allowing individual segments to move and absorb temperature-induced expansions and contractions, preventing the kind of stress concentration that would lead to breakage in a single large reflector.
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 minimizes radiation loss, allows closer placement of reflectors to IR emitters, reduces material damage, and improves energy efficiency by optimizing the reflection of radiation back onto the preforms, leading to increased production efficiency and reduced maintenance costs.
Implementation Method 1
A plurality of IR emitters (11) are arranged one above the other in a row parallel to the longitudinal axis of the preform (20) in the heating lane
Implementation Method 2
The emitters are therefore all at the same distance from the longitudinal axis of the preform being irradiated
Implementation Method 3
at least one rear reflector (15) is assigned to the IR radiators (11), which reflects the radiation emitted to the rear into the heating alley
Implementation Method 4
a segmented back reflector and filter system, using ceramic materials and a floating mount to minimize distance between IR emitters and reflectors, and a segmented structure to allow controlled expansion, reducing stress and radiation loss
Implementation Method 5
a segmented back reflector and filter system, using ceramic materials and a floating mount to minimize distance between IR emitters and reflectors
Data Source
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AI summary
The invention relates to a heating device for heating preforms prior to processing in a stretch blow molding machine. The heating device comprises a heating lane with a plurality of IR emitters arranged parallel to the longitudinal axis of the preforms to be heated. Each IR emitter is associated with at least one back reflector and/or at least one filter, which is segmented.