Multi-Layer Parallel-Plane Inductor With Field Pockets for Precise Heating
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Solution Overview
Problem
Existing induction heating inductors face challenges in maintaining a precise and localized heating pattern, especially in high current applications, due to adjustments in coil dimensions and cooling requirements affecting heat distribution and repeatability.
Innovation Solution
A multi-layer parallel plane inductor with electrically conductive layers folded back and forth, featuring coil control pockets and adjustable thickness and separation gaps, allows for precise heating patterns and enhanced magnetic energy distribution, supported by natural or forced convection cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of turns and diameter of inductor winding are increased to improve power supply interaction, then the induced power increases, but the heat distribution pattern changes and manufacturing complexity increases
Solution Approach 1:
The inductor is divided into multiple discrete turns with independently controllable dimensions. Each turn can be precisely manufactured with consistent geometry, allowing the overall inductor to achieve high induced power through multiple turns while maintaining uniform heat distribution pattern through standardized turn design and spacing.
2Temperature
If cooling fluid flow rate is increased to cool the inductor in high current applications, then the cooling effectiveness improves, but the tubing pipe size increases and restricts design flexibility
Solution Approach 1:
The cooling approach transitions from internal tubular cooling to external cooling methods. Cooling fluid flows over the external surfaces of the inductor turns rather than through internal tubes, eliminating the need for large-diameter tubing while effectively removing heat from high current applications.
3Power
If the inductor dimensions are modified to conform to energy requirements, then the power supply interaction improves, but the heat pattern control becomes less precise
Solution Approach 1:
The inductor design allows independent adjustment of turn dimensions, spacing, and number of turns to optimize both power interaction and heat pattern. The modular structure enables dynamic configuration where turn geometry can be precisely controlled while overall inductor dimensions are adjusted to match power supply requirements, achieving both goals simultaneously.
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 inductor achieves localized and precise heating with adjustable dimensions, improved magnetic energy strength, and enhanced repeatability, while eliminating tubing size restrictions and frequency matching limitations.
Implementation Method 1
When a conductive object is exposed to the variable magnetic field, eddy electric currents are induced in the electrically conductive object itself. The eddy electric currents produce Joule power losses that heat the induced object.
Implementation Method 2
The eddy electric currents produce Joule power losses that heat the induced object. The power losses in the induced object increase as the magnitude and frequency of the inductor's electric current increases.
Implementation Method 3
Generally, flow of a cooling medium, such as water, is injected into the hollow interior of the tubing pipe to avoid overheating and resultant damage to the inductor.
Data Source
AI summary
A high current multi-layer parallel plane inductor is formed from a plurality of electrically conductive continuous layers folded back and forth to form a compact series inductor with each one of the plurality of electrically conductive layers having one or more layer pocket holes with layer edge notches forming one or more coil control pockets that generate a magnetic field pattern when alternating current is applied to the inductor.