Induction-Heated Server Sealing Structure Against Water Infiltration
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Solution Overview
Problem
Current induction heated servers face issues with water infiltration, unreliable welding seams, trapped air leading to high internal pressure, and heat loss, which compromise their ability to maintain food temperature effectively.
Innovation Solution
The server design features a bottom element with a cavity encapsulating a heat retentive disc, sealed by a top element with a dependent flange, using an overmolding process that eliminates welding and incorporates a pre-molded ring member and vermiculite to prevent moisture and air infiltration, enhancing thermal insulation and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to join the upper and lower elements, then the server can be manufactured with sealed construction, but the welding seam becomes unreliable and allows water infiltration
Solution Approach 1:
The patent replaces the mechanical ultrasonic welding system with an overmolding process where molten resin is injected to form an integral seal between elements. This substitution eliminates the unreliable welding seam by using a chemical bonding process (molding) instead of mechanical welding, creating a more reliable hermetic seal that prevents water infiltration.
2Temperature
If the server is heated to high temperatures for inductive charging, then heat storage capacity is improved, but trapped air expands creating high internal pressure
Solution Approach 1:
The patent performs preliminary action by providing pressure relief features (vents or compliant structures) before the high pressure condition develops during heating. This allows the trapped air to be safely vented or accommodated before it reaches dangerous pressure levels, preventing structural failure while still allowing the server to reach the necessary heating temperature for effective heat storage.
3Reliability
If the server structure is made complex with multiple elements and welding seams, then sealing capability is improved, but water infiltration risk increases
Solution Approach 1:
The patent merges the upper and lower elements into a single integral structure through overmolding, where the molten resin bonds the elements together to form one unified component. This eliminates the separate welding seam interface that was prone to water infiltration, reducing structural complexity while maintaining or improving the hermetic seal and water protection capability.
4Ease of manufacture
If welding seams are used to seal the server, then construction is achieved, but heat loss through seams occurs
Solution Approach 1:
The patent replaces the mechanical welding seam construction with an overmolding process that creates an integral bonded structure. This substitution eliminates the discontinuous welding seam that acts as a thermal bridge, reducing heat loss while still achieving effective construction and assembly of the server components.
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 creates a hermetically sealed, reliable, and efficient server that maintains food temperature effectively by preventing water infiltration, reducing heat loss, and managing air pressure, ensuring consistent performance over extended periods.
Implementation Method 1
The base assembly includes an encapsulated 'load' or heat retentive disc which is (1) susceptible to electromagnetic excitation and converts electromagnetic energy into equivalent heat energy
Implementation Method 2
The latent energy stored in the load is slowly transferred to the food by thermal conduction to maintain the food at an elevated temperature above 140° F.
Data Source
AI summary
An induction heatable server comprises a base element having top and bottom elements, said bottom element having a peripheral wall defining an upwardly opening cavity in which are disposed a heat retentive disc and a ring member which is bonded to the peripheral wall. A top element extends over the ring member and seals the cavity. The top element and ring member are bonded to the peripheral wall of the bottom element to preclude moisture penetration into the cavity.