Laminated Printed Heating Coil Board for High-Current Induction Heating
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Solution Overview
Problem
Existing induction heating apparatuses face challenges in efficiently managing high current flow through printed heating coils, leading to overheating and complex insulation design issues, particularly in multi-layered coil structures.
Innovation Solution
The induction heating apparatus incorporates a heating coil board with multiple layers of printed heating coils, insulated by prepreg layers, and includes a temperature sensor for overheating prevention, connected via board-to-board connectors, reducing interlayer connections and coil losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the heating coil is printed onto a board, then productivity is improved, but the heating coil cannot conduct sufficient current due to thickness and width constraints
Solution Approach 1:
The patent transitions from a single-plane coil structure to a multi-layer three-dimensional structure. By stacking multiple heating coil pattern layers (at least two layers) with insulating layers between them, the design increases the effective conduction cross-section without increasing the planar footprint, thereby enabling sufficient current conduction while maintaining printed coil productivity benefits
Solution Approach 2:
The patent employs composite material construction by combining multiple heating coil pattern layers with insulating layers (having resin content of 60-80%) to create a laminated board structure. This composite approach allows the heating system to achieve both the productivity advantages of printed coils and the current conduction capabilities needed for high-power induction heating
2Power
If multiple heating coil layers are stacked, then current conduction capability is improved, but insulation design becomes complex and overheating risk increases
Solution Approach 1:
The patent specifies precise parameter ranges for the insulating layers, including resin content (60-80%) and thickness (140 μm or less before hot pressing). These parameter controls ensure adequate insulation between heating coil layers while preventing overheating, simplifying the design process by providing clear design criteria rather than requiring complex iterative insulation design
Solution Approach 2:
The insulating layers serve as intermediary elements between adjacent heating coil pattern layers. These insulating layers with controlled resin content and thickness act as thermal and electrical barriers, managing the complexity of multi-layer insulation by providing a standardized intermediate component that simplifies the overall insulation design
3Power
If the conductor height is increased to 60 μm or more, then current conduction capability is improved, but the board thickness increases before hot pressing
Solution Approach 1:
The patent establishes specific parameter ranges: conductor height of 60 μm or more for adequate current conduction, combined with insulating layer thickness of 140 μm or less before hot pressing. The hot pressing process then consolidates these layers into a compact final structure, resolving the apparent contradiction by distinguishing between pre-pressing and post-pressing dimensions
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 enhances durability, simplifies assembly, reduces manufacturing complexity, and maintains efficiency by minimizing heat generation and power loss while allowing flexible placement of cooking vessels.
Implementation Method 1
The induction heating method is a method that uses a magnetic field generated around a coil when high-frequency power of a certain magnitude is applied to the coil to generate eddy currents in an object to be heated, which is made of metal, so that the object itself is heated
Implementation Method 2
Each of the plurality of insulating layers may include at least two pre-impregnated material (prepreg) insulation layers
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
An induction heating device having a patterned heating coil is provided. The induction heating device comprises: a container detection coil for detecting a cooking container; a plurality of heating coil pattern layers patterned through printing of the heating coil; and a heating coil board generated by pressing laminated boards, which includes at least two prepreg insulating layers positioned between two heating coil pattern layers, in order to insulate and bond the plurality of heating coil pattern layers.