Patterned Conductors for Increased Resistance in Induction Heating
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Solution Overview
Problem
Existing heating systems using conductors face inefficiencies due to unwanted heating in connecting cables and electronic components, and strain on these components, primarily caused by high-frequency currents leading to uncontrolled current paths.
Innovation Solution
Conductors with a predetermined surface pattern of peaks and valleys or varying wall thicknesses are designed to create non-linear current paths, increasing effective resistance and controlling current flow, thereby reducing unwanted heating and strain.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If high-frequency currents are used for heating conductive materials, then heating efficiency is improved, but unwanted heating in connecting cables and electronic components increases
Solution Approach 1:
The conductor surface is modified with a non-linear pattern (peaks and valleys) that creates localized variations in current density. This non-linear surface geometry concentrates the high-frequency current path within the conductor body while preventing current flow along connecting cables and electronic components, thereby achieving localized heating control.
Solution Approach 2:
The conductor surface incorporates curved features (peaks and valleys) that alter the current path geometry. This curvature transforms the linear current path into a non-linear path that remains confined within the conductor, reducing electromagnetic radiation and unwanted heating in surrounding components.
2Power
If high-frequency currents are applied to heat conductive materials, then heating performance is improved, but strain on electronic components increases
Solution Approach 1:
The non-linear surface pattern creates localized current concentration within the conductor, ensuring high-power heating effects are confined to the target material. This prevents high-frequency currents from flowing through and straining electronic components while maintaining effective heating performance.
3Loss of energy
If a non-linear current path is created in the conductor, then resistance increases and heating is controlled, but current flow distribution becomes non-uniform
Solution Approach 1:
The non-linear surface pattern intentionally creates localized variations in current density, with higher current concentration in peak regions and lower density in valley regions. This controlled non-uniformity increases overall resistance and improves heating efficiency while preventing current leakage to external 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
The non-linear current paths enhance resistance and control heating, ensuring efficient and targeted heating while minimizing unwanted heating in connecting cables and electronic components.
Implementation Method 1
Induction heating is based on inducing an eddy current(s) in a conductive material by using an AC electromagnetic field generated by an oscillating circuit
Implementation Method 2
The eddy currents cause Joules heating of the conductive material
Implementation Method 3
The skin depth is a function of resistivity, permeability, permittivity and frequency of the AC electromagnetic field or applied AC
Data Source
AI summary
Conductors for use in heating systems are provided. The conductors are configured to have an extended current path for the current and increased resistance as seen by the current. The heating system may be an induction system. For example, the conductor may comprise a conductive material having a surface which faces an induction coil of an oscillating circuit. This surface may have a predetermined pattern of peaks and valleys. The peaks and valleys form a non-linear current path for the induced current when exposed to an electromagnetic field generated by the oscillating circuit. Other conductors such as a heat pipe may be used. The pipe may have walls with varying thicknesses over its length. The varying thicknesses may include a first thickness and a second thickness which alternate. The heat pipe may be used in an induction or direct contact heating system where AC is directly applied to the pipe.