Inductive Heating Coil with Cast Ferrite Winding Body
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Solution Overview
Problem
Existing inductive hob heating systems suffer from efficiency losses due to scattering of the magnetic field and require cables for secondary heating elements, leading to inefficiencies and safety hazards.
Innovation Solution
The system employs a transformer configuration with primary and secondary windings cast in matching winding bodies and insulating casting means, with thin, hard protective layers, to precisely guide magnetic flux and eliminate scattering losses, and eliminates the need for cables by inducing voltage directly in the secondary winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If inductive hob heating systems use traditional coil configurations, then heating function is achieved, but scattering losses of the magnetic field occur reducing efficiency to around 60%
Solution Approach 1:
The patent changes the geometric parameters of the coil windings by casting them in a winding body with optimized dimensions and arrangements. The winding body confines the magnetic field more effectively, reducing scattering losses and improving energy transfer efficiency from primary to secondary coils.
Solution Approach 2:
The patent uses composite structures combining the winding body (likely ferrite or other magnetic material) with the cast-in coils. This composite approach guides the magnetic flux more efficiently and reduces scattering losses compared to traditional loose coil configurations.
2Power
If secondary heating elements are connected via cables to electrical connections, then active heating is achieved, but cable safety hazards and operational disturbances occur
Solution Approach 1:
The patent replaces the mechanical cable connection system with an inductive coupling system. Energy is transferred wirelessly from the primary winding in the cooking plate to the secondary winding in the heating element through magnetic coupling, eliminating the need for physical cables and their associated safety hazards.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary to transfer energy between the cooking plate and the heating element. The primary winding generates a magnetic flux that couples with the secondary winding, enabling power transfer without direct electrical or mechanical connection.
3Loss of energy
If winding bodies are used to guide magnetic flux precisely, then scattering losses are reduced and efficiency is improved, but device complexity increases
Solution Approach 1:
The patent merges the winding support structure with the insulating casting means into a single integrated winding body. The coils are cast directly into the winding body, combining structural support, insulation, and magnetic flux guidance functions into one component, thereby reducing overall device complexity.
Solution Approach 2:
The winding body serves multiple functions simultaneously: it provides mechanical support for the coils, acts as an insulator, guides the magnetic flux, and reduces scattering losses. This multi-functionality reduces the need for separate components and simplifies the overall device structure.
4Stability of the object's composition
If insulating casting means with matched thermal expansion coefficients are used, then mechanical stability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent selects casting materials with specific thermal expansion coefficients that match those of the winding body materials. This parameter matching prevents thermal stress and deformation during heating operations, ensuring mechanical stability. The coefficients are carefully chosen to be substantially equal to those of ferrite or other winding body materials.
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 achieves higher efficiency and safety by minimizing scattering losses and eliminating cable-related hazards, with improved energy transfer and mechanical stability through uniform thermal expansion matching.
Implementation Method 1
If a voltage is applied to the primary winding which acts as an induction coil, this produces a magnetic flux which flows in the direction of the secondary winding
Implementation Method 2
As a result of the winding body which preferably consists of ferrite, a material comprising electrically non-conducting metal oxides, good energy transfer is achieved from the primary to the secondary winding. The winding body causes the magnetic flux to be guided precisely into the secondary winding
Implementation Method 3
In the secondary winding, the magnetic flux is converted into electrical energy, in particular a voltage is induced
Implementation Method 4
The heating element is heated as a result of the voltage induced in the secondary winding
Implementation Method 5
the insulating casting means has a coefficient of thermal expansion which substantially corresponds to that of the winding body
Data Source
AI summary
A device wherein food can be warmed by means of induction, said device comprising at least one secondary coil which is formed from a current conductor, whereon at least one heating element is connected. The invention also relates to a device which is used to transfer energy in a device in order to warm food by means of induction, said device comprising a primary coil which is connected to a voltage source and which is formed from a current conductor. According to the invention, the primary and secondary coil is cast into a coil body by casting means, and the insulating casting means exhibits a coefficient of thermal expansion which essentially corresponds to the coil body.