Induced Eddy Current Heating Apparatus with Sewn Susceptor Wire
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current induced eddy current heating assemblies for composite material curing are complex and time-consuming to manufacture, necessitating improved designs for streamlined processes and automation.
Innovation Solution
The use of a flexible substrate with a conductor wire overlaid in a predetermined path and a susceptor wire that extends through and across the substrate to sew the conductor wire, generating a magnetic field and inducing eddy currents for heating, which can be achieved using a CNC embroidery machine for efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a coaxial arrangement of susceptor wire and conductor wire is used to generate induced eddy current heating, then the heating function is achieved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The heating assembly is segmented into discrete components: conductor wires laid in patterns on the substrate and susceptor wires sewn through the substrate at specific locations. This segmentation allows independent placement and assembly of components, simplifying manufacturing compared to complex coaxial arrangements.
Solution Approach 2:
Conductor wires are preliminarily laid in predetermined patterns on the flexible substrate before the susceptor wires are added. This preliminary arrangement enables automated placement and simplifies subsequent assembly steps, reducing overall manufacturing complexity and time.
2Reliability
If traditional manufacturing processes are used for induced eddy current heating assemblies, then the products meet heating requirements, but production efficiency is low and automation is difficult to implement
Solution Approach 1:
Conductor wires are preliminarily laid in predetermined patterns on the flexible substrate using automated equipment before final assembly. This preliminary positioning enables high-precision, repeatable configurations that maintain heating performance while enabling automated manufacturing processes.
Solution Approach 2:
Traditional manual assembly operations are replaced with automated wire laying and sewing systems. The conductor wires are precisely positioned using automated placement equipment, and susceptor wires are automatically sewn through the substrate, dramatically increasing productivity while maintaining product quality.
3Ease of manufacture
If conductor wire is simply placed on substrate without secure attachment, then manufacturing is simple, but the heating apparatus lacks reliability and structural integrity
Solution Approach 1:
The conductor wire and flexible substrate are merged into a single integrated unit by sewing the conductor wire through the substrate with susceptor wires. This merging provides secure mechanical attachment while maintaining manufacturing simplicity, ensuring the conductor wire remains firmly positioned during operation.
Solution Approach 2:
The susceptor wire serves as an intermediary element that simultaneously performs two functions: it secures the conductor wire to the substrate through sewing, and it acts as the heating element that generates eddy currents. This intermediary component resolves the conflict between simple assembly and reliable attachment.
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 approach simplifies the manufacturing of induced eddy current heating apparatuses, enabling efficient generation of controlled heat within specific temperature ranges, from 65°F to 400°F, and allows for the use in various applications, including composite material curing and consumer products.
Implementation Method 1
generating a magnetic field in a region around the conductor wire in response to the AC electrical signal
Implementation Method 2
inductively receiving energy from the magnetic field at a susceptor wire
Implementation Method 3
generating eddy currents in the susceptor wire in response to the inductively received energy
Implementation Method 4
radiating heat from the susceptor wire in response to the eddy currents
Data Source
AI summary
An induced eddy current heating apparatus includes a flexible substrate, a conductor wire and a susceptor wire. The conductor wire is overlaid on a major surface of the flexible substrate. The susceptor wire extends back and forth through the flexible substrate and back and forth across the conductor wire to sew the conductor wire to the major surface of the flexible substrate. A method for generating induced eddy current heating using the induced eddy current heating apparatus is provided. A method of manufacturing the induced eddy current heating apparatus is also provided.