Multi-layer-multi-turn high efficiency inductors for an induction heating system

• US 8,803,649 B2
• Filed: 03/12/2013
• Issued: 08/12/2014
• Est. Priority Date: 03/09/2009
• Status: Active Grant

• Current Assignee: Nucurrent, Inc.
• Original Assignee: Nucurrent, Inc.
• Inventors: Singh, Vinit, Babcock, Jacob, Frysz, Christine A.
• Primary Examiner(s): NGUYEN, TUYEN T
• Application Number:
  US13/797,593
• Publication Number:
  US 20130200070A1
• Time in Patent Office: 518 Days
• Field of Search: 336/65, 336/83, 336/200, 219/10.77, 219/10.79
• US Class Current: 336/200
• CPC Class Codes: A61N 1/0553 Paddle shaped electrodes, e.g. for laminotomy
• CPC Class Codes: A61N 1/3605 Implantable neurostimulators for stimulating central or peripheral nerve system
• CPC Class Codes: A61N 1/37229 Shape or location of the implanted or external antenna
• CPC Class Codes: A61N 1/3756 Casings with electrodes thereon, e.g. leadless stimulators
• CPC Class Codes: A61N 1/3787 from an external energy source
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: H01F 17/00 Fixed inductances of the signal type coils in general H01F5/00; inductors without a potential-jump or surface barrier specially adapted for integrated circuits, details thereof and multistep manufacturing processes therefor H01L28/10
• CPC Class Codes: H01F 17/0006 Printed inductances printed coils for dynamo-electric machines H02K3/26; printed circuits H05K
• CPC Class Codes: H01F 17/0013 with stacked layers
• CPC Class Codes: H01F 2027/2809 on stacked layers
• CPC Class Codes: H01F 27/2804 Printed windings
• CPC Class Codes: H01F 29/02 with tappings on coil or winding; with provision for rearrangement or interconnection of windings
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: H01F 41/00 Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
• CPC Class Codes: H01F 41/04 for manufacturing coils coils for transformer or inductances H01F27/28
• CPC Class Codes: H01F 41/041 Printed circuit coils apparatus or processes for manufacturing printed circuits in general H05K3/00
• CPC Class Codes: H01F 5/00 Coils superconducting coils H01F6/06; fixed inductances of the signal type H01F17/00
• CPC Class Codes: H01F 5/003 Printed circuit coils
• CPC Class Codes: H01F 7/06 Electromagnets; Actuators including electromagnets electric coils H01F5/00; devices for holding workpieces using electric force B23Q3/15; load-engaging elements for lifting articles electromagnetically B66C1/06; electromagnetic couplings F16D27/00; magnetic brakes F16D63/002; electromagnetically operated valves F16K11/24, F16K31/00; analysing materials by magnetic means G01N27/72, G01N27/80; electromagnets for winding mechanical clocks G04C1/02; electromagnetic relays H01H51/00; windings for salient poles of dynamo-electric machines H02K3/18; electromagnets for telegraphic communication H04L; for arc lamps H05B31/28
• CPC Class Codes: H01Q 1/38 formed by a conductive layer on an insulating support patch antennas H01Q9/0407; microstrip dipole antennas H01Q9/065; microstrip slot antennas H01Q13/106; transmission line microstrip antennas H01Q13/206; manufacturing reflecting surfaces using insulating material for supporting the reflecting surface H01Q15/142
• CPC Class Codes: H01Q 7/00 : Loop antennas with a substantially uniform current distribution around the loop and having a directional radiation pattern in a plane perpendicular to the plane of the loop
• CPC Class Codes: H01R 43/00 : Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors of trolley lines B60M1/28
• CPC Class Codes: H02J 2310/23 : The load being a medical device, a medical implant, or a life supporting device
• CPC Class Codes: H02J 50/005 : Mechanical details of housing or structure aiming to accommodate the power transfer means, e.g. mechanical integration of coils, antennas or transducers into emitting or receiving devices
• CPC Class Codes: H02J 50/12 : of the resonant type
• CPC Class Codes: H02P 13/00 : Arrangements for controlling transformers, reactors or choke coils, for the purpose of obtaining a desired output
• CPC Class Codes: H03H 7/01 : Frequency selective two-port networks
• CPC Class Codes: H04B 5/24 : Inductive coupling
• CPC Class Codes: H04B 5/45 : Transponders
• CPC Class Codes: H04B 5/72 : for local intradevice communication
• CPC Class Codes: H04B 5/77 : for interrogation
• CPC Class Codes: H04B 5/79 : for data transfer in combination with power transfer
• CPC Class Codes: H05B 6/06 : Control, e.g. of temperature, of power
• CPC Class Codes: H05B 6/1245 : with special coil arrangements
• CPC Class Codes: H05B 6/36 : Coil arrangements
• CPC Class Codes: H05B 6/362 : with flat coil conductors
• CPC Class Codes: H05K 1/165 : incorporating printed inductors
• CPC Class Codes: H05K 2201/0352 : Differences between the conductors of different layers of a multilayer
• CPC Class Codes: Y02B 40/00 : Technologies aiming at improving the efficiency of home appliances, e.g. induction cooking or efficient technologies for refrigerators, freezers or dish washers
• CPC Class Codes: Y10T 29/49005 : Acoustic transducer
• CPC Class Codes: Y10T 29/4902 : Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/4908 : Acoustic transducer
• CPC Class Codes: Y10T 29/49117 : Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49155 : Manufacturing circuit on or in base
• CPC Class Codes: Y10T 29/49195 : with end-to-end orienting

Abstract

A multi-layer, multi-turn structure for an inductor having a plurality of conductor layers separated by layers of insulator is described. The inductor further comprises a connector electrically connected between the conductor layers. The structure of the inductor may comprise a cavity therewithin. The structure of the inductor constructed such that electrical resistance is reduced therewithin, thus increasing the efficiency of the inductor. The inductor is particularly useful at operating within the radio frequency range and greater.

Claims

1. An induction heating system, comprising:

a) an input electrical power source;

b) a first control circuit electrically connected to the input electrical power source;

c) a load circuit comprising an inductor, electrically connected to the input electrical power source and control circuit, the inductor comprising;

i) a first conductor layer;

ii) a second conductor layer spaced apart from the first conductor layer;

iii) an insulator layer positioned in the space between the first conductor layer and the second conductor layer; and

iv) at least one connector electrically connecting the first conductor layer and the second conductor layer;

d) wherein when an electrical current, supplied by the input electrical power source is propagated within at least the first conductor layer, a magnetic flux is generated within the inductor when a change in at least one of a frequency, a magnitude, or a waveform shape of the propagated electrical current occurs; and

e) wherein when a ferromagnetic material is positioned adjacent the inductor, heat is generated.

2. The induction heating system of claim 1 wherein an electromotive force is generated when at least one of the frequency, the magnitude, or the waveform shape is changed.

3. The induction heating system of claim 2 wherein a magnitude of the magnetic flux is proportional to the amount of change of at least one of the frequency, the magnitude, or the waveform shape of the electrical current.

4. The induction heating system of claim 1 wherein, an electrical resistance of at least one of the first conductor layer or the second conductor layer is reducable when a cross-sectional area of a conducting skin depth within at least the first conductor layer or the second conductor layer is increased, wherein the increased cross-sectional area is a result of electrically connecting at least a third conductor layer to the second conductor layer, a second insulator layer positioned therebetween.

5. The induction heating system of claim 1 wherein a thickness of the first conductor layer is about equal to a thickness of a skin depth of the first conductor layer at a given frequency.

6. The induction heating system of claim 1 wherein a thickness of the first conductor ranges from about 1.25 times to about 4 times a thickness of a skin depth of the first conductor layer at a given frequency.

7. The induction heating system of claim 1 wherein a thickness of the second conductor ranges from about 1.25 times to about 4 times a thickness of a skin depth of the second conductor layer at a given frequency.

8. The induction heating system of claim 1 wherein a first conductor layer thickness is about the same as a second conductor layer thickness.

9. The induction heating system of claim 1 wherein a first conductor layer thickness is different from a second conductor layer thickness.

10. The induction heating system of claim 1 wherein a thickness of a first skin depth of the first conductor layer is about the same as a thickness of a second skin depth of the second conductor layer.

11. The induction heating system of claim 1 wherein a thickness of a first skin depth of the first conductor layer is different than a thickness of a second skin depth of the second conductor layer.

12. The induction heating system of claim 1 wherein a thickness of the insulating layer is less than about 5 cm.

13. The induction heating system of claim 1 wherein the inductor has an inductor quality factor greater than about 5.

14. The induction heating system of claim 13 wherein the inductor quality factor is defined by the equation

15. The induction heating system of claim 1 wherein the frequency is at least 3 kHz.

16. The induction heating system of claim 1 wherein at least one of the first and second conductor layers is formed from a thermally or electrically conductive material.

17. The induction heating system of claim 1 wherein the at least one connector comprises at least one of a via, a solder, a tab, a wire, a pin, a rivet, a filled mesh structure, a conductive polymer, a conductive composite, a conductive adhesive, a liquid metal, or a foamed metal.

18. The induction heating system of claim 1 wherein the at least one connector electrically connects the first conductor layer and the second conductor layer in parallel.

19. The induction heating system of claim 1 wherein the first conductor layer and the second conductor layer form a structure in which the first and second conductor layers are positioned in about a parallel orientation, a perpendicular, or at an angular relationship therebetween.

20. The induction heating system of claim 1 comprising a third conductor layer and a fourth conductor layer electrically connected in parallel wherein the first and second conductive layers are connected electrically in parallel and are further connected electrically in series with the third and fourth conductor layer.

21. The induction heating system of claim 1 wherein the inductor is electrically connectable with an electrical circuit operating at about 100 kHz or greater.

22. The induction heating system of claim 21 wherein the electrical circuit is selected from the group consisting of a mixer circuit, an impedance matching circuit, an upconverting mixer circuit, a downconverting mixer circuit, a modulator, a demodulator, a synthesizing circuit, a PLL synthesizing circuit, an amplifying circuit, an electrical driver circuit, an electrical detecting circuit, an RF log detector, an RF RMS detector, an electrical transceiver, a power controller, and combinations thereof.

23. The induction heating system of claim 1 wherein the inductor is electrically connectable to a second induction heating circuit.

24. The induction heating system of claim 1 wherein a second control circuit is electrically connectable to the inductor.

25. The induction heating system of claim 1 wherein at least the first and second conductor layers has at least a partial revolution.

26. The induction heating system of claim 1 wherein the first conductor layer or the second conductor layer comprises a material selected from the group consisting of copper, titanium, platinum, platinum and iridium alloys, tantalum, niobium, zirconium, hafnium, nitinol, cobalt-chromium-nickel alloys, stainless steel, gold, a gold alloy, palladium, carbon, silver, a noble metal, a conductive polymer, a conductive adhesive, a conductive composite, a liquid metal, a foamed metal, a conductive tape, a conductive ribbon, a conductive foil, a conductive leaf, a wire, a deposited metal, a biocompatible material, and combinations thereof.

27. The induction heating system of claim 1 wherein at least one insulator layer is formed from an electrically or thermally insulative material.

28. The induction heating system of claim 1 wherein the insulator layer comprises an insulative material selected from the group consisting of air, polystyrene, silicon dioxide, a biocompatible ceramic, a conductive dielectric material, a non-conductive dielectric material, a piezoelectric material, a pyroelectric material, and a ferrite material.

29. The induction heating system of claim 1 wherein a computer processor adjusts an amount of electrical current within the load circuit.

30. The induction heating system of claim 1 further comprising a power factor corrector.

31. The induction heating system of claim 1 further comprising an electrical power driver.

32. The induction heating system of claim 1 further comprising a rectifier.

33. The induction heating system of claim 1 further comprising a capacitor.

34. The induction heating system of claim 1 wherein a cooking vessel comprises the ferromagnetic material.

37. The inductive heating system of claim 1 further comprising an inverter circuit, electrically connected to the input electrical power source.

35. An induction heating system, comprising:

a) an input electrical power source;

b) a control circuit electrically connected to the input power source;

c) an inverter circuit, electrically connected to the input electrical power source;

d) a load circuit comprising an inductor, electrically connected to the input electrical power source and control circuit, the inductor comprising;

i) a first inductor subassembly comprising a first conductor layer and a second conductor layer spaced apart from the first conductor layer;

ii) a first insulator layer positioned in the space between the first conductor layer and the second conductor layers;

iii) a first connector electrically connecting the first conductor layer and the second conductor layer;

iv) a second inductor subassembly comprising a third conductor layer and a fourth conductor layer spaced apart from the third conductor layer;

v) a second insulator layer positioned in the space between the third conductor layer and the fourth conductor layers;

vi) a second connector electrically connecting the third conductor layer and the fourth conductor layer; and

vii) wherein the first inductor subassembly is electrically connected in series to the second inductor subassembly;

e) wherein when an electrical current, supplied by the input electrical power source is propagated within at least the first conductor layer, a magnetic flux is generated within at least the first inductor subassembly when a change in at least one of a frequency, a magnitude, or a waveform shape of the propagated electrical current occurs; and

f) wherein when a ferromagnetic material is positioned adjacent the first or second inductor subassemblies of the inductor, heat is generated.

36. The induction heating system of claim 35 wherein the first inductor subassembly and the second inductor subassembly are oriented such that the first and second inductor subassemblies are positioned about parallel, about perpendicular, or at an angular relationship therebetween.