Microwave Generator Component Carrier Segmentation and Cooling

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Solution Overview

Problem

Existing microwave generators for microwave ovens lack a compact and efficient design that allows for high power density and effective cooling, making them bulky and difficult to extend for multiple channels.

Innovation Solution

A single, continuous component carrier with distinct power and control regions on a conventional circuit board material, incorporating an RF substrate and heat sinks for efficient heat dissipation, and using SMD and THT components to maximize component density and simplify assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single component carrier is used for all electrically functional components, then device complexity is reduced and structure is simplified, but heat dissipation becomes more difficult due to concentrated heat sources

Engineering Contradiction:

ImprovestructureVSAvoidheat dissipation

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The component carrier is divided into distinct power regions and control regions. Power regions concentrate power switches and RF substrates for microwave generation, while control regions house control components. This segmentation allows targeted thermal management strategies for each region, resolving the contradiction between structural simplicity and heat dissipation efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Heat sinks are introduced as intermediary components between the power switches and the component carrier substrate. These heat sinks act as thermal mediators that conduct heat away from the concentrated power regions without requiring separate component carriers, thus maintaining structural simplicity while enabling effective heat dissipation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If power switches and heat sinks are arranged on the same side of the component carrier, then assembly is simplified, but power density increases and cooling efficiency decreases

Engineering Contradiction:

ImproveassemblyVSAvoidpower density

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The design transitions from planar arrangement to three-dimensional vertical stacking. Power switches are mounted on the upper side of the component carrier, while heat sinks are positioned on the lower side. This dimensional change allows high power density on the upper surface while maintaining efficient cooling from the lower surface, resolving the contradiction between assembly simplicity and cooling efficiency.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Quantity of substance

If control components are arranged on both flat sides of the component carrier, then component density increases and control region size decreases, but manufacturing complexity increases

Engineering Contradiction:

Improvecomponent densityVSAvoidmanufacturing complexity

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

Control components are segmented and distributed across both flat sides of the component carrier. This segmentation increases component density and reduces the required control region area. The segmentation is implemented in a modular fashion that maintains manufacturing simplicity through standardized mounting procedures.

Inventive Principle:

Principle #1Segmentation

4Adaptability or versatility

If the microwave generator is designed for multiple channels, then functionality and versatility increase, but device complexity and space requirements increase

Engineering Contradiction:

Improvemulti-channel capabilityVSAvoidstructure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The component carrier is designed as a universal platform that can accommodate multiple power regions and control regions for different microwave channels. Each channel shares the same basic structure of power switches, RF substrates, and heat sinks, enabling multi-channel functionality without proportionally increasing overall device complexity. The modular regional design allows flexible configuration for 1, 2, or more channels.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The design achieves a compact, high-functionality microwave generator with improved cooling and reduced space requirements, enabling efficient generation of microwaves across multiple channels while minimizing material costs and assembly complexity.

Implementation Method 1

Heat sinks, cooling means or the like, but no electrically functional components, are arranged on the other flat side in the power region

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10667338B2Microwave generator for a microwave device and microwave device

Publication Date: 2020.05.26 E G O ELEKTRO GERAETEBAU GMBH

AI summary

A microwave generator for a microwave device includes a single component carrier for control components and power components, which includes a continuous carrier material. Two power regions and one control region are provided on the component carrier. In the control region, electrically functional components are arranged on both flat sides of the component carrier, while in the power regions, electrically functional components with at least one power switch are arranged only on an upper flat side, heat sinks being arranged on the lower flat side. An RF substrate is provided in regions on the upper flat side of the power region.