Development of advanced handheld induction heater

Purpose and goal

The ultimate objective for the project is to develop a new type of handheld induction heater with increased efficiency and reduced cooling requirement. The objectives for the pre-study have been to develop materials and processes for critical subsystems. It is shown that primarily coil and flux conductor have to be improved through research. A new soft magnetic material has been developed, as well as isolation and forming technology. In combination with the developed coil forming technology, the project objectives are met.

Results and expected effects

An analysis of existing induction heating systems shows that these are robust but inefficient, expensive and heavy. An improved system should be able to claim a large part of the market in a short time. In order to meet the desired performance, the new system has to be given much improved energy effiency. Two major challenges are to replace the existing coil based on a single loop of copper tube with a litz based compacted coil, and to develop a highly efficient soft magnetic flux conducting unit.

Approach and implementation

Based on knowledge of existing systems and interviews with experienced users, a requirement specification was established. Demands on coils and flux conductor are based on optimizations focusing on energy efficiency and power density. The coils have been pressed and compacted in developed tools, with special consideration to a complete isolation between strands. An improved flux conductor material has been developed including isolation technology and press technology for forming and compaction.