Smart Susceptor Induction Heating for Non-Planar Parts
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Solution Overview
Problem
Current inductively heated smart susceptor systems have limitations in achieving uniform heating across large areas and are restricted to processing specific part shapes, with prolonged heating/cooling cycles when handling multiple parts.
Innovation Solution
A heating apparatus with a lower and upper heating assembly, featuring thermally conductive tables and blankets with parallel induction coil circuits and smart susceptors, allowing for uniform temperature generation across larger areas and accommodating non-planar part shapes through contoured tooling surfaces and pressure-controlled heating blankets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single heating assembly is used, then the device complexity is reduced, but the heating area is limited and cannot provide uniform heating across large areas
Solution Approach 1:
The heating system is divided into separate heating assemblies (lower and upper) that can be independently configured. Each assembly contains multiple induction coil circuits distributed across heating surfaces, allowing the heating area to be expanded by adding more assemblies or coils without creating a single overly complex monolithic structure.
Solution Approach 2:
The heating system transitions from a single-plane heating approach to a multi-dimensional heating configuration with lower and upper heating assemblies heating from opposite sides. This allows uniform heating across large areas by distributing heat sources in three-dimensional space rather than relying on a single heating surface.
2Adaptability or versatility
If rigid heating surfaces are used, then manufacturing precision is improved, but the ability to accommodate non-planar part shapes is reduced
Solution Approach 1:
The heating system employs different surface characteristics in different locations - rigid precision surfaces where dimensional stability is needed and flexible conforming surfaces where adaptability to non-planar shapes is required. This allows the system to maintain manufacturing precision for critical features while accommodating varied part geometries.
Solution Approach 2:
The heating system incorporates flexible heating blankets that can dynamically conform to different part shapes and sizes. These flexible elements adapt their configuration based on the specific part being processed, enabling the system to handle non-planar shapes while maintaining consistent heating performance through dynamic adjustment rather than fixed rigid structures.
3Productivity
If sequential heating and cooling cycles are used for multiple parts, then energy consumption is reduced, but the processing time increases
Solution Approach 1:
The heating system enables continuous processing by maintaining heating capability across multiple parts simultaneously. With distributed heating assemblies and surfaces, parts can be processed in sequence without complete cooling cycles between them, as the system can sustain thermal energy and quickly transfer it to subsequent parts, eliminating idle time between processing cycles.
Solution Approach 2:
The system prepares heating surfaces and assemblies in advance to maintain optimal temperature readiness. By pre-heating and maintaining thermal energy in the heating assemblies, the system minimizes the time required to start processing each part and reduces the need for lengthy heating/cooling cycles between multiple parts, thereby increasing overall productivity.
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
Enables efficient and uniform heating of parts across larger areas, including non-planar shapes, with reduced heating/cooling cycles, improving processing efficiency and versatility.
Implementation Method 1
induction coil circuits electrically coupled in parallel with each other, wherein each of the plurality of table induction coil circuits includes a table electrical conductor and a table smart susceptor having a Curie temperature
Implementation Method 2
induction coil circuits electrically coupled in parallel with each other, wherein each of the plurality of table induction coil circuits includes a table electrical conductor and a table smart susceptor having a Curie temperature
Implementation Method 3
table smart susceptor having a Curie temperature
Implementation Method 4
a lower heating assembly and an upper heating assembly. The lower heating assembly includes a table formed of a thermally conductive material
Implementation Method 5
a first flexible layer extending over the table to form a first pressure chamber between the table and the first flexible layer
Data Source
AI summary
Heating apparatus and methods for forming a part with a non-planar shape include a table formed of a thermally conductive material and defining a table surface. A tool, also formed of a thermally conductive material, has a base surface configured to engage the table surface of the table and a tooling surface opposite the base surface, wherein the tooling surface has a contoured shape that is non-planar. A heating blanket is provided above the table and defines a heating surface. The tooling surface of the tool is configured to engage a first surface of the part and the heating surface of the heating blanket is configured to engage a second surface of the part opposite the first surface of the part. The table and the heating blanket are heated to a processing temperature so that the part at least partially conforms to the tooling surface of the tool.