Induction Hob Polymeric Frame Segmentation
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Solution Overview
Problem
Existing induction cooking heaters face challenges in production complexity, energy efficiency, and material costs due to the use of thick plastic frames that increase the distance between inductor windings and ceramic glass, making the manufacturing process difficult and inefficient.
Innovation Solution
A polymeric frame with a first support element for coil winding and a second support element for magnetic field concentration bars, assembled through a snap engagement mechanism, reduces the distance between windings and glass, allowing for a more efficient design that uses less material and simplifies the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a thick plastic frame is used to support the inductor and ferrite bars, then the structural stability is improved, but the distance between the inductor windings and ceramic glass increases, leading to decreased energy efficiency
Solution Approach 1:
The plastic frame is divided into two separate elements: a first support element for the inductor windings and a second support element for the ferrite bars. This segmentation allows each element to be optimized independently - the first element can be thin to maintain energy efficiency, while the second element provides necessary support for the ferrite bars.
Solution Approach 2:
A snap engagement mechanism acts as an intermediary connection between the first and second support elements. This allows the two elements to be assembled together to form a complete frame structure without requiring a thick monolithic frame, thus maintaining both structural stability and energy efficiency.
2Device complexity
If a single plastic frame is used for both coil winding and ferrite bar support, then the device complexity is reduced, but the production process becomes complicated and difficult to automate
Solution Approach 1:
The frame is segmented into two separate support elements that can be manufactured independently and then assembled through snap engagement. This segmentation enables each element to be produced using optimized processes and allows for easier automation of the assembly line, as the elements can be prepared separately and joined automatically.
Solution Approach 2:
The first and second support elements are prepared in advance as separate components with predetermined features (such as snap engagement protrusions and receptacles). This preliminary preparation simplifies the final assembly process and enables automated assembly operations.
3Ease of manufacture
If a single polymeric material is used for the entire frame, then the manufacturing process is simplified, but the material cost increases due to the need to withstand high temperatures
Solution Approach 1:
Different polymeric materials are used for the first and second support elements based on their specific temperature requirements. The first support element (for windings) can use a material optimized for its temperature range, while the second support element (for ferrite bars) uses a material suited for its different thermal conditions. This local differentiation reduces overall material costs while maintaining manufacturing simplicity.
Solution Approach 2:
The frame structure employs composite construction with different polymeric materials in different sections. This allows each section to use the most cost-effective material for its specific operational conditions, rather than using a single expensive high-temperature resistant material throughout the entire frame.
4Ease of manufacture
If the inductor is wound from above on the first plastic frame, then the winding process is simplified, but the assembly line becomes complicated due to the need to flip over the upper frame
Solution Approach 1:
The frame is segmented into two separate elements that can be assembled in a fixed orientation. The first support element can be positioned with its upper surface facing upward for winding, while the second support element is positioned below it. The snap engagement mechanism connects them in this orientation, eliminating the need to flip the frame during assembly and simplifying the assembly line process.
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 energy efficiency, reduces production costs, and streamlines the manufacturing process by eliminating the need for flipping frames, enabling higher productivity and cost savings while maintaining mechanical robustness and thermal efficiency.
Implementation Method 1
induction coils present a strong part to part variation
Implementation Method 2
induction cooking heater includes an inductor having a number of magnetic field concentration bars located beneath the inductor
Implementation Method 3
Transform Electrical Energy to Thermal Energy
Implementation Method 4
magnetic field concentration bars located beneath the inductor
Implementation Method 5
The first support element and the second support element are assembled together through a central ring-shaped zone having a snap engagement
Data Source
AI summary
An induction cooking heater including an inductor having a number of magnetic field concentration bars located beneath the inductor. The inductor having the magnetic field concentration bars is supported by a polymeric frame. The polymeric frame includes a first support element on which the inductor is wound and a second support element that supports the magnetic field concentration bars. The first support element and the second support element are assembled together through a central ring-shaped zone having a snap engagement. The inductor is wound on an upper surface of the first support element opposite to the second support element.