Sintering Apparatus Microwave Susceptor Hybrid Heating
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Solution Overview
Problem
Existing sintering methods for dental restoration materials like zirconia face inefficiencies due to long sintering times and risk of distortion or breakage from uneven heating, where internal microwave heating causes excessive temperature differences between the inside and outside of the material.
Innovation Solution
A sintering apparatus that combines internal microwave heating with external heating using a susceptor unit, featuring a specific design with a base, roof, and side members to control microwave exposure, and a cooling unit with an intake and exhaust fan system to rapidly cool the material, minimizing temperature differences and preventing distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a method of irradiating the to-be-sintered material with microwaves is used, then sintering speed is improved, but temperature difference between inside and outside of the material increases causing distortion or breakage
Solution Approach 1:
The patent combines two heating methods: microwave irradiation (internal heating) and susceptor unit heating (external heating). The control unit coordinates both heating sources to work simultaneously, merging their effects to achieve both rapid sintering and uniform temperature distribution, thereby resolving the contradiction between sintering speed and shape uniformity
Solution Approach 2:
The patent employs temperature sensors to monitor the temperature distribution within the to-be-sintered material in real-time. The control unit receives this feedback information and dynamically adjusts the power output of both the microwave generator and the susceptor unit heating elements, ensuring uniform temperature distribution while maintaining high sintering speed
2Manufacturing precision
If electric heater method is used to sinter the to-be-sintered material, then heating is uniform, but sintering time is excessively long resulting in low work efficiency
Solution Approach 1:
The patent merges conventional electric heater heating (external) with microwave irradiation (internal) in a hybrid heating system. The control unit coordinates both heating sources to work simultaneously, combining the uniformity advantage of electric heating with the speed advantage of microwave heating, thereby achieving both heating uniformity and high work efficiency
Solution Approach 2:
The patent changes the heating parameters by introducing microwave irradiation alongside conventional electric heating. The control unit dynamically adjusts the power distribution between the two heating sources, optimizing the combination of heating rates to achieve uniform temperature distribution while significantly reducing sintering time compared to pure electric heater method
3Temperature
If the susceptor unit is fully enclosed, then external heating is effective, but microwave penetration is blocked reducing internal heating efficiency
Solution Approach 1:
The patent applies local quality by creating selective openings in specific regions of the susceptor unit enclosure. Rather than uniformly enclosing the entire chamber, openings are strategically positioned to allow microwave penetration in areas where internal heating is most needed, while maintaining enclosed structure in areas where external heating effectiveness is prioritized
Solution Approach 2:
The susceptor unit enclosure is segmented into different regions with different degrees of openness. The control unit coordinates the heating strategy based on the segmented structure, allowing microwaves to penetrate through designated openings while maintaining thermal confinement in other areas, thereby balancing external heating effectiveness with internal heating efficiency
4Loss of time
If rapid cooling is implemented, then cooling time is reduced, but temperature gradient may cause thermal stress
Solution Approach 1:
The patent uses temperature sensors to continuously monitor the temperature distribution during cooling. The control unit receives real-time temperature feedback and dynamically adjusts the cooling rate, intensifying cooling when temperature is high and reducing it when temperature differences become significant, thereby achieving rapid cooling while preventing excessive thermal stress
Solution Approach 2:
The cooling process is made dynamic rather than static. The control unit continuously adjusts cooling parameters based on real-time temperature conditions, transitioning between different cooling rates during the cooling process. This dynamic adjustment allows rapid cooling overall while preventing dangerous temperature gradients that would cause thermal stress
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 apparatus achieves uniform heating and rapid cooling of sintered materials, reducing sintering time and preventing material distortion, while efficiently managing heat generation and dissipation.
Implementation Method 1
a magnetron coupled to the case and oscillating microwaves toward the internal space
Implementation Method 2
external heating of the to-be-sintered material using a susceptor unit
Implementation Method 3
a cooling unit cooling at least one of the case or the chamber space
Data Source
AI summary
A sintering apparatus is provided. The sintering apparatus includes a case having an internal space formed therein and including a door provided in a front portion thereof to open and close the internal space, a magnetron coupled to the case and oscillating microwaves toward the internal space, a heat insulating unit disposed in the internal space to form a chamber space and blocking transmission of heat of the chamber space to the internal space, a susceptor unit disposed in the chamber space and having a sintering space in which a to-be-sintered material is accommodated, and a cooling unit cooling at least one of the case or the chamber space.