Susceptor Rod Array Induction Heating for Uniform Melting

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Solution Overview

Problem

Existing methods for heating and melting non-electrically conductive materials are inefficient as they rely on indirect heat transfer from susceptor components, which can lead to contamination and uneven heating profiles.

Innovation Solution

An electric induction heating furnace with an array of susceptor rods and a susceptor base within a crucible, where alternating current through induction coils generates magnetic flux for inductive heating of the susceptor components, and optional resistive heating is used to supplement the process, with a defective rod sensor and fastening mechanism for efficient operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If indirect heat transfer from susceptor components is used to heat non-electrically conductive materials, then the materials can be heated and melted, but the heating efficiency is low and contamination occurs

Engineering Contradiction:

Improveheating efficiencyVSAvoidcontamination

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The susceptor system is segmented into multiple susceptor rods arranged in an array around the crucible interior, allowing distributed heating zones that improve heat transfer efficiency to the material while reducing localized contamination risks

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Susceptor rods act as intermediary elements between the induction coil magnetic field and the non-conductive material, converting electromagnetic energy to thermal energy in the susceptor material which then transfers heat to the workpiece, enabling heating of non-conductive materials without direct electromagnetic exposure

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If indirect heat transfer from susceptor components is used, then non-electrically conductive materials can be melted, but uneven heating profiles result

Engineering Contradiction:

Improvemelting capabilityVSAvoidheating profile uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Multiple susceptor rods create multiple heat source zones around the crucible, distributing thermal energy more uniformly across the material and eliminating hot spots or cold zones that occur with single-point heating

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different susceptor rods can be positioned at specific locations around the crucible to provide localized heating zones where needed, allowing customization of the heating profile to match the material geometry and thermal requirements

Inventive Principle:

Principle #3Local quality

3Productivity

If an array of susceptor rods is used with induction heating, then heating efficiency improves, but device complexity increases

Engineering Contradiction:

Improveheating efficiencyVSAvoidsusceptor array configuration

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The susceptor rods serve multiple functions: they act as heating elements, structural supports for the material, and heat distribution conduits, reducing the need for separate components and simplifying the overall system design despite the array configuration

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

This setup enables efficient heating and melting of non-electrically conductive materials with controlled heat transfer, reducing contamination risks and allowing for continuous molten discharge, while maintaining precise control over heating profiles.

Implementation Method 1

Alternating current flow through one or more induction coils surrounding the exterior of the crucible generate magnetic flux fields that couple with the susceptor components to inductively heat the susceptor components

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

electric induction heating of the susceptor vessel and transfer of heat from the susceptor vessel to the materials in the vessel

Methodology Applied

Scientific EffectInduction heating: Induction Heating

Implementation Method 3

Heat from the susceptor components transfers to the material in the furnace to heat and melt the material

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

resistive heating of the susceptor materials

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentEP2379975B1Heating and melting of materials by electric induction heating of susceptors

Publication Date: 2015.04.01 INDUCTOTHERM CORP

Figure 1(a)~1(b)
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Figure 3

AI summary

Apparatus and method are provided for heating and melting of materials by electric induction heating of susceptor components in a crucible of the furnace. The susceptor components comprise at least an array of susceptor rods arranged around the inner perimeter of the crucible. A susceptor base may also be provided in the crucible with connection to one end of the susceptor rods. One or more susceptor tubes may also be used within the interior volume of the crucible. Alternating current flow through one or more induction coils surrounding the exterior of the crucible generate magnetic flux fields that couple with the susceptor components to inductively heat the susceptor components. Heat from the susceptor components transfers to the material in the crucible to heat and melt the material.