High-Frequency Heating Coil With Integrated Cooling Paths
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Solution Overview
Problem
Conventional high-frequency heating coils suffer from poor cooling efficiency, damage due to high output conditions, and manufacturing reproducibility issues, leading to dielectric breakdown and quality variations in the material being heated.
Innovation Solution
A heating coil formed using a partial welding lamination method of conductive material powder layers or melt extrusion lamination method, with integrated cooling medium flow-down paths within the grounding, supporting, and heating units, eliminating the need for silver solder bonding and enhancing durability and reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional heating coil is formed by bonding multiple components with silver solder to provide hollow coolant passage, then cooling function is provided, but continuous use under high output condition easily causes damage and cooling medium leaks
Solution Approach 1:
The patent merges the coil body and coolant passage into a single integrated structure formed by extruding a conductive material containing coolant channels. This eliminates the need for separate bonding of multiple components with silver solder, preventing damage and leaks while simplifying manufacturing.
Solution Approach 2:
The extruded conductive material serves multiple functions simultaneously: it provides electrical conductivity for the heating coil, structural integrity for the coil body, and integrated coolant passages for thermal management. This multi-functionality resolves the contradiction by eliminating separate cooling components.
2Temperature
If cooling mechanism is disposed at only the coil portion, then cooling is provided for the coil, but grounding portion and coupling portion held at high temperature causes insulating plate carbonization and dielectric breakdown
Solution Approach 1:
The patent segments the cooling function into multiple independent coolant passages distributed throughout the heating coil structure, including the coil portion, grounding portions, and coupling portions. This segmentation allows each component to be cooled independently, preventing insulating plate carbonization and dielectric breakdown.
Solution Approach 2:
The patent extends the cooling approach from a single-location cooling mechanism to a multi-dimensional cooling system where coolant passages are distributed throughout the three-dimensional structure of the heating coil. This dimensional expansion ensures comprehensive temperature control of all components.
3Manufacturing precision
If heating coil is formed by brazing multiple components, then cooling passage is provided, but manufacturing reproducibility is poor and quality variation occurs
Solution Approach 1:
The patent combines multiple brazed components into a single extruded conductive material structure that inherently contains coolant passages. This merging eliminates manufacturing variability associated with assembly processes while maintaining the necessary structural complexity for cooling functionality.
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 provides improved cooling efficiency, reduces the risk of dielectric breakdown, and allows for continuous high-output operation without damage, while ensuring consistent product quality and efficient manufacturing.
Implementation Method 1
a heating coil used for a high-frequency heater configured to heat a material to be worked using electromagnetic induction by a high-frequency current
Implementation Method 2
A sequence of a cooling medium flow-down path for flowing down a cooling medium is formed inside each of the grounding portions, each of the supporting portions, and the heating unit
Data Source
AI summary
ProblemProvided is a heating coil for a high-frequency heater that is excellent in cooling efficiency, allowed to be continuously used for a long period of time without a damage even under a high output condition, and allowed to be manufactured in the same characteristics with good reproducibility in the manufacture.SolutionA heating coil 1 is integrally formed by a modeling method repeating laying, melting, solidifying, and laminating of a powder containing a conductive material based on three-dimensional data. The heating coil 1 includes a pair of plate-shaped grounding portions 2a, 2b for contact with an electrode that generates a high-frequency current, a pair of plate-shaped supporting portions 3a, 3b disposed to be perpendicular to the grounding portions 2a, 2b, respectively, and an annular heating unit 4 disposed to connect distal ends of the supporting portions 3a, 3b to one another. Sequences of cooling medium flow-down paths 6a, 6b for flowing down a cooling medium are formed inside the grounding portions 2a, 2b, the supporting portions 3a, 3b, and the heating unit 4, respectively.