Induction Burner Frames with Integrated Ferrous Coils
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Solution Overview
Problem
Existing induction cooktops with multiple induction coils face challenges in efficiently directing electromagnetic fields to cooking utensils due to complex coil configurations and separate housing for ferrous materials and wound coils, leading to inefficiencies in heating zones and increased manufacturing complexity.
Innovation Solution
The use of injection molded frames with integrated upper and lower cavities, where ferrous members are positioned within lower cavities and wound coils within upper cavities, separated by a medial divider, allows for electromagnetic communication and simplifies the manufacturing process by forming a single piece induction burner with concentric configurations using formable plastic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate housing is used for ferrous materials and wound coils, then manufacturing flexibility is improved, but device complexity and assembly steps increase
Solution Approach 1:
The patent combines the ferrous material housing and wound coil housing into a single integrated induction coil assembly. The ferrous material is positioned within a housing that also contains the wound coil, eliminating the need for separate housings and reducing assembly steps while maintaining manufacturing flexibility through the modular assembly structure.
2Adaptability or versatility
If complex coil configurations are used, then heating zone coverage is improved, but electromagnetic field direction efficiency decreases
Solution Approach 1:
The patent employs multiple induction coils with different configurations (e.g., concentric and radial arrangements) to create distinct heating zones. Each coil is optimized for its specific heating zone, with the ferrous material and wound coil positioned to maximize electromagnetic field direction efficiency for that particular zone, thereby maintaining overall heating coverage while improving energy efficiency.
3Manufacturing precision
If multiple individual components are used, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent integrates multiple components into a unified induction coil assembly where the ferrous material, wound coil, and housing form a single integrated unit. This integration maintains manufacturing precision through precise positioning features built into the integrated structure while reducing the total number of components and simplifying assembly operations.
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 solution enhances the efficiency of electromagnetic field direction to cooking utensils, simplifies the manufacturing process, and reduces the number of individual components, resulting in improved heating performance and reduced complexity in induction burner design.
Implementation Method 1
A wound coil is disposed in each coil channel, wherein the wound coil and ferrous member are in electromagnetic communication with one another
Implementation Method 2
A ferrous member is disposed within the at least one lower cavity for each injection molded frame... wherein the wound coil and ferrous member are in electromagnetic communication with one another
Data Source
AI summary
An induction burner element for a cooking appliance includes a plurality of injection molded frames positioned in a spaced and concentric relationship, each injection molded frame having an upper cavity an at least one lower cavity. A ferrous member is disposed within the at least one lower cavity for each injection molded frame. A plurality of wound coils are disposed within the upper cavity for each injection molded frame, wherein each wound coil corresponds to a respective injection molded frame.