Induction Heater Bobbin Design for Coolant Bubble Discharge
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Solution Overview
Problem
Induction type coolant heaters in electric and fuel cell vehicles face issues with air bubble formation, leading to increased flow resistance and decreased heat exchange efficiency, as well as overheating of heating elements due to poor coolant distribution and lack of effective overheating sensing and control mechanisms.
Innovation Solution
The design includes a cylindrical bobbin structure with an induction coil wound around it, spaced apart from a heating element to improve coolant flow and air bubble discharge, along with a control system using current and temperature sensors to prevent overheating by blocking power supply when overheating is detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the induction coil is wound closely around the heating element to improve heating efficiency, then heating efficiency is improved, but air bubble discharge performance deteriorates and overheating risk increases
Solution Approach 1:
The patent introduces a bobbin as an intermediary component between the induction coil and the heating element. The bobbin serves as a spacer that maintains a specific distance between the coil and heating element, preventing direct contact while still allowing effective magnetic coupling for induction heating. This resolves the contradiction by enabling close coupling for efficiency while maintaining separation for safety and bubble discharge.
Solution Approach 2:
The patent employs an asymmetric arrangement where the bobbin provides selective spacing - closer distance in some regions for efficient heating while maintaining adequate clearance in critical areas for bubble discharge and overheating prevention. This asymmetric spacing optimizes both heating efficiency and safety simultaneously.
2Use of energy by moving object
If the induction coil is positioned close to the heating element to enhance heat exchange, then heat exchange efficiency is improved, but coolant flow distribution deteriorates
Solution Approach 1:
The bobbin acts as a mediator that structures the coolant flow path between the induction coil and heating element. It creates defined channels that guide coolant flow, ensuring both efficient heat exchange in contact regions and proper flow distribution through the cooling system.
3Power
If no spacing is provided between the induction coil and heating element to maximize heating performance, then heating performance is maximized, but air bubble discharge performance deteriorates
Solution Approach 1:
The bobbin serves as a mediator that maintains optimal spacing between the induction coil and heating element. This spacing is sufficient to allow air bubbles to escape while maintaining strong magnetic coupling for high heating performance. The bobbin's geometry is designed to create escape paths for bubbles while preserving induction heating efficiency.
4Power
If the induction coil is placed in direct contact with the heating element to improve coupling, then magnetic coupling is improved, but overheating of components increases
Solution Approach 1:
The bobbin serves as a thermal and magnetic intermediary. It maintains strong magnetic coupling for efficient power transfer while providing thermal isolation and spacing that prevents overheating of the induction coil and surrounding components. The bobbin material is selected to allow magnetic field penetration while providing thermal management.
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 configuration enhances coolant flow distribution, prevents overheating of heating elements and components, and ensures safety by effectively controlling the induction heater to avoid faults and fires through real-time sensing and power management.
Implementation Method 1
an eddy current is generated in the coolant flow pipe 2 by a magnetic field changed when an alternating current (AC) current flows in an induction coil 31
Implementation Method 2
the coolant flow pipe 2 may thus be heated by Joule's heat
Data Source
AI summary
The induction heater and a method for controlling overheating of an induction heater, and to an induction heater in which overheating of a heating element may be prevented by allowing a coolant to be introduced from a lower side, flow upwardly while being in contact with the heating element, and be then discharged to an upper side to improve air bubble discharge performance of the coolant, in the induction heater heating a heating element in an induction heating manner. In addition, the present invention relates to an induction heater and a method for controlling overheating of an induction heater in which a fault of the induction heater or a fire due to overheating may be prevented by deciding whether or not a heating element is overheated using one or more of a current sensing means and a temperature sensing means capable of sensing overheating of the heating element and performing a control to supply power to an induction coil or block power supplied to the induction coil depending on a decision result.