Induction Heating Element Hybrid Construction for Steam Cutting
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Solution Overview
Problem
Existing heating elements for vaporization in steam cutting and power-generating devices, such as resistance heating elements, suffer from high heat transition resistances, leading to inefficient energy transfer and potential damage due to excessive operating temperatures, and are inadequate for efficiently charging batteries with higher capacities.
Innovation Solution
The use of an induction heating element with a hybrid construction comprising a coil enclosed in a base part with laterally extending webs made of easily magnetizable and thermally conductive materials, optimized with nanocrystalline magnetic structures, reduces heat transition resistances and allows for higher power densities and more efficient vaporization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a resistance heating element is used, then the heating function is provided, but the energy density is limited due to high heat transition resistances
Solution Approach 1:
The patent replaces the resistance heating element (ohmic heating) with an induction heating element. This substitution eliminates the need for direct thermal contact between the heating element and the vaporizer, thereby removing the heat transition resistance problem. The induction heating element generates heat through electromagnetic induction, which is then transferred to the vaporizer through magnetic coupling, achieving much higher energy density and efficiency.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the heating element and the vaporizer. The induction heating element generates a magnetic field that couples with the vaporizer, enabling efficient energy transfer without direct thermal contact. This magnetic field intermediary eliminates the heat transition resistance that plagues resistance heating elements while maintaining effective heat transfer.
2Productivity
If the operating temperature of the heating element is increased to overcome heat transition resistances, then the heating efficiency improves, but the heating resistance may be destroyed
Solution Approach 1:
The patent replaces contact-based resistance heating with non-contact induction heating. This eliminates the need for high operating temperatures at the heating element surface, as the heat is generated through electromagnetic induction and transferred via magnetic coupling. The induction heating element operates at much lower temperatures, preventing destruction of the heating resistance while maintaining high vaporization efficiency.
Solution Approach 2:
The magnetic field acts as an intermediary that transfers energy from the induction heating element to the vaporizer without requiring high temperatures at the heating element. This magnetic coupling enables efficient energy transfer while keeping the heating element temperature low, thereby preventing damage to the heating resistance and improving reliability.
3Productivity
If the heating surface is increased to compensate for limited energy density, then the heating effectiveness improves, but the device size increases
Solution Approach 1:
The patent replaces resistance heating with induction heating, which provides much higher energy density. This allows the vaporization process to be achieved with a significantly smaller heating surface area, thereby reducing the overall burner size while maintaining or improving vaporization effectiveness.
Solution Approach 2:
The patent changes the heating mechanism from ohmic heating to induction heating, fundamentally altering the energy transfer parameters. This parameter change results in higher energy density and more efficient heat transfer, allowing for a compact burner design that achieves effective vaporization without requiring a large heating surface.
4Device complexity
If a worm burner is used for power generation, then the device is simple, but stable burning cannot be achieved, preventing constant temperature difference for effective power generation
Solution Approach 1:
The patent replaces the worm burner with an induction heating element. This substitution provides precise and stable temperature control through electromagnetic induction, enabling constant temperature difference necessary for effective power generation. The induction heating system responds quickly to control signals and maintains stable operation, overcoming the burning instability of worm burners while keeping the device relatively simple.
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 achieves significant reductions in temperature gradients and heat losses, enabling more efficient vaporization with lower operating frequencies and reduced size of the burner, while maintaining stable and reliable energy transfer, thus improving the efficiency and handling of steam cutting and power-generating devices.
Implementation Method 1
designed as an induction heater comprising a coil
Implementation Method 2
The coil (25a) is enclosed in a hybrid construction (31, 32) having an easily magnetisable material (35)
Implementation Method 3
thermally highly-conductive material (37)
Implementation Method 4
easily magnetisable material (35)
Implementation Method 5
optimized with nanocrystalline magnetic structures
Data Source
AI summary
The invention relates to a heating element (25) for liquids to be vaporized as well as a burner (6) of a steam cutting device (1) and a burner (38) of a power-generating device, the element being designed as an induction heater (47) comprising one coil (25a). In order to improve vaporization, the coil (25a) of the induction heater (47) is enclosed in a hybrid construction which is composed of a main part (31) with laterally extending webs (33), and which consists of an easily magnetizable material (35) and a thermally highly-conductive material, a covering element (32) consisting of nanocrystalline materials being arranged on the webs (33), and the easily magnetizable material (35) being designed to be installed on a thermally highly-conductive material (37) of a vaporizer (21).