Induction Coil Flat Turn for Magnetic Field Concentration
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Solution Overview
Problem
Existing induction coils for inductive heating of workpieces lack sufficient magnetic field concentration and energy efficiency, leading to suboptimal heating effects.
Innovation Solution
The induction coil design incorporates at least one partially flat turn that extends over the area covered by other turns, either forming a ring-shaped or cylindrical structure within the helical turns, enhancing magnetic field concentration and energy input with a lower output power from the high-frequency generator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional induction coils with helical or flat turns are used, then the magnetic field is generated, but the magnetic field concentration and heating efficiency are insufficient
Solution Approach 1:
The patent applies the nesting principle by placing a flat turn inside the area covered by helical turns, creating a nested structure where the flat turn is positioned within the spatial envelope of the helical turns. This nested configuration allows the flat turn to concentrate the magnetic field in a specific region while the helical turns generate the overall magnetic field, thereby improving heating efficiency and energy concentration at the workpiece location.
2Temperature
If higher output power from the high-frequency generator is used, then better heating effect is achieved, but power consumption increases
Solution Approach 1:
The patent applies the local quality principle by using a flat turn with a specific geometry (such as a rectangular or circular cross-section) that concentrates the magnetic field locally at the workpiece position. This localized field concentration allows for effective heating with lower overall power consumption, as the energy is focused precisely where needed rather than being dispersed throughout the entire coil structure.
3Shape
If the induction coil uses only helical turns, then the coil structure is compact, but the magnetic field concentration at the workpiece location is insufficient
Solution Approach 1:
The patent applies the merging principle by combining two different coil configurations - helical turns and a flat turn - into a single integrated induction coil structure. The helical turns provide the compact coil structure and generate the magnetic field, while the flat turn inserted within the helical turns' area provides magnetic field concentration at the workpiece location. This merged structure achieves both compactness and effective field concentration simultaneously.
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 design significantly increases the magnetic field concentration and energy input into workpieces, achieving better heating efficiency with reduced power consumption compared to prior art induction coils.
Implementation Method 1
The electromagnetic field of the induction coil deliberately generates eddy currents in the electrically conductive components of the workpieces, which lead to heating
Implementation Method 2
The electromagnetic field of the induction coil deliberately generates eddy currents in the electrically conductive components of the workpieces, which lead to heating
Implementation Method 3
The electromagnetic field of the induction coil deliberately generates eddy currents in the electrically conductive components of the workpieces, which lead to heating
Implementation Method 4
it is connected in series with a number of the remaining coil turns. In a device according to the invention for induction heating, the induction coil therefore consists of several turns, with at least one of the turns being at least partially flat, and with this flat turn or partial turn of at least some of the remaining turns inductively, i.e. is influenced by the electromagnetic field of the other turns
Data Source
Figure 1~2a
Figure 2b~3
Figure 4a~4b
AI summary
The induction coil has multiple coils and one of the coils is formed in partly flat manner. The coils are arranged for inductive inducement by a part of the remaining coil. The part of the remaining coil is arranged, for inductive inducement, directly adjacent, parallel or enclose to the flat coil (6d). The flat coil has an area with lesser measurement than the total size of the flat coil, which is determined for receiving a workpiece to be heated. An independent claim is also included for a device for inductive heating of workpiece.