Embroidered Induction Hob Support Structure for Heat-Resistant Insulation
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Solution Overview
Problem
Existing induction hobs face challenges in operating safely and comfortably, particularly in wireless energy transmission to electrical consumers, due to limitations in temperature resistance and electrical insulation of support structures with antennas and sensors.
Innovation Solution
A support structure with a flexible, temperature-resistant fabric and embroidered antennas/sensors, where supply lines are electrically insulated and arranged to ensure reliable operation and safety, including the use of induction heating coils and sensors for both heating and wireless communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the support structure uses conventional materials and construction methods, then manufacturing is simpler, but temperature resistance and electrical insulation are insufficient for safe operation at high temperatures
Solution Approach 1:
The support structure uses a composite construction combining a fabric carrier with embroidered conductive lines and insulating varnish layers. This composite approach integrates multiple functional properties (mechanical support, electrical conduction, electrical insulation, and temperature resistance) into a single manufactured component, achieving high temperature resistance (at least 200°C) while maintaining manufacturability through the embroidery process.
Solution Approach 2:
The support structure employs a thin, flexible fabric carrier that can be embroidered with conductive lines. This thin-film approach allows the support structure to conform to the hob plate surface while providing adequate temperature and electrical insulation when combined with the insulating varnish coating, achieving high temperature resistance without significant increase in thickness or manufacturing complexity.
2Device complexity
If supply lines and antenna lines are placed close together or cross each other to save space, then device complexity is reduced, but electrical insulation becomes compromised leading to potential faults
Solution Approach 1:
An insulating varnish layer is applied as an intermediary substance between the conductive supply lines and antenna lines embroidered on the fabric carrier. This varnish coating provides reliable electrical insulation, allowing the lines to be placed close together or to cross each other on the same surface without risk of electrical breakdown, thus enabling compact layouts while maintaining high electrical insulation reliability.
Solution Approach 2:
The electrical insulation properties are enhanced by changing the physical-chemical parameters of the insulation layer through application of insulating varnish. This varnish coating increases the dielectric strength and breakdown voltage of the fabric carrier, allowing supply lines and antenna lines to operate in close proximity or cross each other while maintaining adequate electrical insulation even at high temperatures of at least 200°C.
3Reliability
If the support structure uses materials that can withstand high temperatures of at least 200°C, then operating safety is improved, but the materials become more difficult to process and manufacture
Solution Approach 1:
The mechanical attachment methods (such as stitching or adhesive bonding) are replaced by an embroidery process that uses thermally stable conductive lines integrated directly into the fabric carrier. The embroidered lines are then coated with insulating varnish that can withstand high temperatures of at least 200°C. This substitution of mechanical assembly with an integrated embroidery and coating process simplifies manufacturing while achieving the required high temperature resistance and operating safety.
4Adaptability or versatility
If antennas and sensors are integrated onto the same support structure to enable wireless energy transmission and communication, then functionality is enhanced, but susceptibility to interference and faults increases
Solution Approach 1:
The insulating varnish layer serves as a protective intermediary between the conductive antenna lines and sensor supply lines on the fabric carrier. This varnish coating prevents electrical interference and cross-talk between the different functional elements while allowing them to be integrated on the same support structure. The result is a reliable integrated system that provides both wireless energy transmission and communication functions with reduced susceptibility to faults.
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 enables safe and comfortable operation of induction hobs with enhanced temperature resistance and electrical insulation, allowing for efficient wireless energy transfer and foreign object detection, reducing susceptibility to faults and improving user safety.
Implementation Method 1
at least one induction heating coil is arranged under the support structure for inductive heating of a cooking vessel placed on the hob plate
Implementation Method 2
the wireless transmission of energy towards an electrical consumer by means of inductive coupling
Data Source
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AI summary
An induction cooktop with a cooking surface and a flat, planar support structure features a flexible fabric substrate onto which antennas and/or sensors are attached as conductors using an embroidery process. The antennas and/or sensors have leads that are attached to the substrate using an embroidery process and that intersect with other leads on the same surface of the substrate, being electrically insulated from each other. The support structure has a temperature resistance of ≥ 200°C. It is mounted on a flat, planar holder and thus, together with the antennas and/or sensors, is pressed against the underside of the cooking surface.