Bi-metallic induction heating blanket
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Solution Overview
Problem
Conventional smart susceptors face challenges in achieving uniform temperature distribution and have limited adjustable leveling temperature ranges, leading to inefficiencies in heating processes, particularly due to inductive coupling and restricted power supply limitations.
Innovation Solution
A smart susceptor assembly comprising bi-metallic susceptor tabs with susceptor elements and conductor elements, where the conductor elements alter thermal and electrical operations to extend the range of available leveling temperatures and improve temperature uniformity by reducing inductive coupling and allowing for more precise thermal control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional smart susceptors use a susceptor material wrapped around a litz wire, then the susceptor can self-regulate temperature, but the temperature distribution becomes non-uniform and the leveling temperature range is limited
Solution Approach 1:
The susceptor is divided into multiple discrete susceptor elements arranged in a grid pattern, each element independently interacting with the electromagnetic field. This segmentation allows for more uniform temperature distribution across the entire susceptor surface while maintaining the self-regulating property of each individual element.
Solution Approach 2:
The invention uses a composite structure combining susceptor material elements with conductor elements in a specific geometric arrangement. This composite design enables both uniform temperature distribution and extended leveling temperature range by leveraging the different electromagnetic and thermal properties of the constituent materials.
2Adaptability or versatility
If the susceptor material is placed in an electromagnetic flux field, then inductive heating occurs, but inductive coupling limits the adjustable leveling temperature range
Solution Approach 1:
Different regions of the susceptor are designed with locally optimized properties through the arrangement of susceptor elements and conductor elements. This allows different areas to operate at different effective leveling temperatures, extending the overall adjustable temperature range of the device.
Solution Approach 2:
The invention transitions from a conventional wire-based geometry to a planar grid arrangement of susceptor elements and conductor elements. This dimensional change alters the electromagnetic coupling characteristics, reducing inductive coupling effects and enabling a broader range of adjustable leveling temperatures.
3Productivity
If the susceptor is made highly permeable at low temperatures, then heating efficiency is high, but temperature control precision decreases
Solution Approach 1:
The susceptor elements and conductor elements are designed to dynamically adjust their electromagnetic and thermal characteristics as temperature changes. This dynamic behavior allows the system to maintain high heating efficiency at lower temperatures while automatically providing more precise temperature control as the temperature approaches the leveling point.
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 enhances temperature uniformity and extends the range of leveling temperatures, enabling more efficient and controlled heating processes by altering the thermal and electrical operation of the susceptor assembly, thus improving heating efficiency and precision.
Implementation Method 1
the susceptor begins to inductively heat due to the initially small skin depth and high magnetic permeability
Implementation Method 2
the susceptor elements using the electromagnetic flux field; and heating the article using heat from the plurality of susceptor elements
Implementation Method 3
an electrical resistance of the susceptor is high. When placed into the electromagnetic flux field generated, for example, by an induction coil that is part of the smart susceptor assembly, the susceptor begins to inductively heat
Implementation Method 4
heating the article using heat from the plurality of susceptor elements
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A smart susceptor assembly includes a plurality of susceptor elements and a plurality of conductor elements. Each susceptor element can be paired with one conductor element to form a susceptor tab. When exposed to a magnetic flux field, the plurality of susceptor elements heat to a leveling temperature. During the heating, the plurality of conductor elements alter both a thermal performance and an electrical operation of the smart susceptor assembly and, more particularly, the susceptor elements. Various configurations of the susceptor elements and conductor elements are described.