Induction Brazing Heating Conductor Configuration for Uniform Heat

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Solution Overview

Problem

Conventional brazing techniques using flame are limited by safety restrictions on the execution location, and existing induction heating methods require precise positioning of heating conductors to ensure uniform heating, which can be challenging, especially when obstacles are present.

Innovation Solution

An induction heating device with a first and second heating conductor that circumferentially cover the periphery of the heated bodies, with the second heating conductor positioned at a specific ratio of length to diameter to ensure efficient and uniform heating, allowing for brazing even with obstacles and varying thermal resistances.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If flame brazing is used to join components, then the joining process can be performed, but the execution location is limited to places where flame can be safely handled

Engineering Contradiction:
Improveexecution location flexibilityVSAvoidsafety restrictions
Core Design Contradiction:
Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the flame-based thermal system with an induction heating system that uses electromagnetic fields to generate heat directly in the workpiece through eddy currents. This substitution eliminates the need for open flames and associated safety restrictions, allowing brazing to be performed in locations previously inaccessible to flame brazing while maintaining the joining capability.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the heating method from external flame heating to internal electromagnetic induction heating. By altering the fundamental heating parameter from external thermal radiation to internally generated eddy currents, the system achieves the same heating effect without the harmful factors associated with flame, thereby improving location flexibility.

Inventive Principle:
Principle #35Parameter changes

2Manufacturing precision

If a single heating conductor is used for induction heating, then the device structure is simple, but uniform heating is difficult to achieve, especially when obstacles are present

Engineering Contradiction:
Improveheating uniformityVSAvoidheating conductor configuration
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent divides the heating conductor into multiple separate conductors positioned at different locations around the workpiece. This segmentation allows each conductor to target specific areas independently, enabling uniform heating around the entire circumference of the workpiece and overcoming the heating non-uniformity problem that occurs with a single conductor, especially when obstacles are present.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent applies different heating zones by positioning multiple conductors at specific locations (e.g., first heating conductor at one circumferential position, second heating conductor at another position). Each conductor provides localized heating tailored to its position, ensuring that heat is distributed uniformly around the workpiece while accommodating the presence of obstacles in specific areas.

Inventive Principle:
Principle #3Local quality

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 uniform and excellent brazing by inducing heat through eddy currents, effectively joining components with improved precision and flexibility in placement, even with obstacles and large contact thermal resistances.

Implementation Method 1

a high frequency current is caused to flow in the heating conductor. Thereby, an eddy current is induced in the surfaces of the components

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

The induced eddy current generates heat in the surface layers of the components based on a loss by Joule heat

Methodology Applied
Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS10056796B2Induction heating device, joining method, joined component and rotary electric machine including the same
Publication Date: 2018.08.21 KK TOSHIBA
  • US10056796B2 patent drawing
  • US10056796B2 patent drawing
  • US10056796B2 patent drawing

AI summary

A joined component comprises a first heated body, a second heated body, a brazing material, a first heated portion and a second heated portion. The first body comprises an insertion opening and an inserted portion coupled with the insertion opening. The second body comprises an insertion portion inserted into the inserted portion through the insertion opening. The first heated portion is provided at a first position including at least a part of the inserted portion and at least a part of the insertion portion. The second heated portion is provided at a second position separate from the insertion portion where a ratio “L/D” satisfies being 0.4 or more and 0.8 or less, where “L” is a length from the insertion opening to the second portion and “D” is an outer diameter of the second heated body.