Induction Heating Coil Carrier with Integrated Winding Cores
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Solution Overview
Problem
Existing household appliance induction heating devices face challenges in achieving low costs, high quality, and simple production, particularly in the design and assembly of induction heating coils, which often require complex and error-prone winding processes.
Innovation Solution
The design features a household appliance induction heating device with tightly wound inner and outer coil sections supported by a coil carrier, where the induction heating line is wound around an inner support core and an outer carrier core, allowing for a simplified production process and high magnetic field density, using stranded aluminum lines with self-insulation and a silicone adhesive for fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate winding device is used to wind the induction heating cable and then transfer it to a coil carrier, then the coil sections can be formed, but the production process becomes complex and error-prone
Solution Approach 1:
The coil carrier is integrated with the winding device, combining two separate components (carrier and winding mechanism) into a single unit. This allows the induction heating cable to be wound directly onto the carrier without transfer operations, eliminating positioning errors and simplifying the production process while maintaining coil section positioning accuracy
Solution Approach 2:
The coil carrier is pre-configured with the winding device before the winding process begins. This preliminary arrangement ensures that the cable is wound directly onto the carrier in the correct position from the start, avoiding the need for subsequent transfer operations and reducing the risk of positioning errors
2Power
If the coil sections are tightly wound to achieve high magnetic field density, then the inductor performance improves, but the production process becomes more difficult
Solution Approach 1:
By integrating the winding device with the coil carrier, the system enables precise control of winding tension and spacing directly during the winding process. This allows tight winding for high magnetic field density while simplifying the operation through a single integrated device rather than multiple separate operations
3Quantity of substance
If the induction heating cable is wound tightly with turns spaced less than 0.5 mm apart, then the magnetic field density increases, but the winding process requires higher precision
Solution Approach 1:
The integrated coil carrier and winding device includes built-in positioning features and tension control mechanisms that automatically maintain consistent turn spacing. This allows achievement of tight winding with less than 0.5 mm spacing through the combined functionality of the integrated system rather than requiring separate high-precision winding and positioning 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 configuration simplifies the production process, reduces costs, and achieves high winding density and magnetic field density, enabling the creation of small inductors with high performance, while eliminating the need for complex coil transfer steps and providing a defined position for coil sections.
Implementation Method 1
The induction heating line, in particular with a coupled heating means, has an inductance of at least 0.1 μH... to be traversed. In particular, the induction heating cable is provided in at least one operating state to convert a heating output of at least 100 W, in particular at least 300 W, advantageously at least 1000 W, preferably at least 2000 W, provided by the high-frequency alternating current, into an alternating magnetic field
Implementation Method 2
which in turn is used in a heating means , in particular a cooking utensil, advantageously a cooking utensil base, alternatively a cooking tube heater, to be converted into heat by eddy current effects and/or magnetic reversal effects
Implementation Method 3
which in turn is used in a heating means , in particular a cooking utensil, advantageously a cooking utensil base, alternatively a cooking tube heater, to be converted into heat by eddy current effects and/or magnetic reversal effects
Data Source
AI summary
The device (12) has an induction heating line (16), a tightly wound inner coil section (18) and an outer coil section (19). A coil support (20) is provided to bear the induction heating line and is provided with an inner support core (31) by which the induction heating line is wound around the inner coil section. The coil support is provided with an outer support core (41) by which the induction heating line is wound around the outer coil section. The coil support is formed by two partial beams (30,40). An independent claim is included for a method for manufacturing induction heating device.