Description:TECHNICAL FIELD
[0001] The present disclosure relates, in general, to fabric appliances, and more specifically, relates to a electronic iron for controlled electronic induction-based ironing of clothes.

BACKGROUND
[0002] Conventional electronic irons typically utilize resistive heating elements, which rely on direct electrical resistance to generate heat. While effective, these designs suffer from inefficiencies such as slow heating times, uneven heat distribution, and relatively high energy consumption. Moreover, the thermal management in such irons can lead to excessive energy wastage, particularly during prolonged use, as the resistive elements can overheat and require continuous regulation. Additionally, many conventional models lack precision in temperature control, leading to inconsistencies in ironing results.
[0003] Induction heating, a more efficient and advanced technique, has been gaining popularity in various heating applications due to its ability to generate localized heat directly within the material (e.g., the soleplate) without requiring direct contact with a heating element. This method reduces heat loss and allows for faster, more controlled heating, thereby improving energy efficiency. However, despite its benefits, the application of induction heating in electronic irons has been limited by several challenges, such as the complexity of ensuring uniform heating, managing power efficiency, and maintaining precise temperature regulation.
[0004] Therefore, it is desired to overcome the drawbacks, shortcomings, and limitations associated with existing solutions, and develop a means to optimize energy efficiency, improve heat distribution, and provide precise temperature control, thus enhancing the overall performance of the electronic iron.

OBJECTS OF THE PRESENT DISCLOSURE
[0005] An object of the present disclosure is to provide a device that enhances the efficiency of an electronic iron by incorporating ZVS and ZCS technology and equipping the circuit with a PID controller and K-type IR sensors, allowing for precise temperature control, power savings, and improved safety.
[0006] Another object of the present disclosure is to provide a device that improves the performance of the induction coil in electronic irons by optimizing the coil's capacitance, increasing the number of turns, and utilizing multi-layer construction to enhance inductance and control the electromagnetic field for faster and more efficient heating.
[0007] Another object of the present disclosure is to provide a device that improves thermal efficiency in the electronic iron by using a special ceramic fibre board and mica sheet for better heat management, heat retention, and durability, with optimized thermal conductivity and high-temperature resistance.
[0008] Another object of the present disclosure is to provide a device that increases the capacity of an electronic iron by incorporating a magnetic shunt using iron core ferrite, along with Henry tuning of the coil, to enhance the efficiency and heating performance.
[0009] Yet another object of the present disclosure is to provide a device that optimizes the compact design and power efficiency of the electronic iron by integrating a high-frequency induction generator, with a frequency range of 15 kHz to 50 kHz, for efficient sole plate heating while ensuring compatibility with international voltage standards via a converter.

SUMMARY
[0010] The present disclosure relates in general, to fabric appliances, and more specifically, relates to a electronic iron for controlled electronic induction-based ironing of clothes. The main objective of the present disclosure is to overcome the drawbacks, limitations, and shortcomings of the existing device and solution, by providing a heating device that includes a mechanical assembly configured to facilitate the controlled application of heat, including a soleplate adapted to apply controlled heat to the garments. Further, a heat-resistant aluminum paint is applied to the surface of the soleplate to facilitate uniform heat distribution across it for efficient thermal management. A ceramic fiber board is positioned above the soleplate, providing enhanced thermal insulation to minimize heat loss. The ceramic fiber board is equipped with at least one hole on its surface to accommodate one or more temperature sensors for temperature monitoring. Moreover, a mica sheet is disposed above the ceramic fiber board to protect underlying components from thermal stress. In addition, an induction coil positioned above the mica sheet generates a high-frequency electromagnetic field to induce eddy currents within the soleplate, thereby generating heat. Above the induction coil, a ferrite core is provided as a magnetic shunt to reduce magnetic leakage and improve energy transfer efficiency.
[0011] Besides, a layer of heat-resistant wool is disposed above the ferrite core to provide additional thermal insulation, preventing heat dissipation and safeguarding surrounding components from excessive temperatures. A mechanical weight-enhancing MS sheet is positioned above the wool, contributing to the structural balance of the device. A lid encloses the mechanical components of the assembly, providing a protective covering, while a handle is securely attached to the lid, ensuring stability during operation.
[0012] In another aspect, the induction coil is configured such that inductance is (±) less than and greater than a predetermined limit of 20 to 300 henry, the induction coil includes a wire made of copper-coated aluminum or copper having a number of turns in the range from 0 to 35, which is (±) less than and greater than the predetermined limit wherein concentric turns contain such number of turns as (12 ± 7), (27 ± 7), (21 ± 7) and (35 ± 7) turns or any combination thereof so as to increase efficiency of the induction coil and a multilayer structure with arranged curved layers having (±) less and more than a predetermined range of 0 to 3, with a number of turns as (7 ± 2), (3 ± 1), and (2 ± 1) turns, which increase surface area and inductance for energy transfer and optimized heating characteristics.
[0013] Further, the device operates according to a set of heating parameters, including a temperature change of 280°C to heat a steel sheet from 20°C to 300°C within a heating time of 1 to 5 minutes. The induction coil generates a flux density ranging from 1 to 5 ± Tesla, with an intensity of 100-500 kA/m/kVA. Material properties, including magnetic permeability, a specific heat capacity of approximately 0.5 kcal/kg°C, and a density of approximately 7.9 g/cm³, are evaluated to heat a 3mm thick 430 MS steel sheet to 300°C.Moreover, the ceramic fiber board used for heat management has a classification temperature range of 1260°C to 1425°C, with thermal conductivity measured at a mean temperature of 600°C. Its chemical composition includes Aluminum Oxide (Al2O3), Silicon Dioxide (SiO2), and Zirconium Oxide (ZrO2), ensuring efficient heat management within the specified temperature range.
[0014] In addition, the device is operatively coupled to an induction generator including a microcontroller unit. This unit monitors operation, switching AC voltage from an AC converter unit to the appropriate level, filtering noise, and converting the input AC voltage into DC. The DC power is then converted into high-frequency AC power using an IGBT gate driver. The induction coil generates a high-frequency magnetic field, inducing eddy currents in the soleplate to apply controlled heat to the garments. A proportional-integral-derivative (PID) control unit regulates the temperature based on feedback from one or more temperature sensors mounted on the soleplate.
[0015] Besides, the microcontroller unit is coupled to a power factor correction (PFC) unit to optimize the input power factor and minimize harmonic distortion from the AC voltage. The IGBT gate driver includes a fan and a sensor mounted on a heat sink to regulate its temperature. The PID control unit continuously adjusts the power supplied to the induction coils, ensuring the desired temperature is maintained. The induction generator enables the device to operate on a 120V, 60Hz power supply for global compatibility, and it can also function with a 110/120-volt converter or a solar boost converter, offering flexible power source options.
[0016] Moreover, the device includes a steam injector accommodated on the soleplate, configured as a pump without moving mechanical parts, designed to generate steam for steam ironing of garments. The steam injector includes a solenoid valve coupled to a rear portion of the steam injector through a supply pipe, wherein the steam injector is operatively coupled to a water source through the supply pipe, and the solenoid valve controls the regulated flow of water into the steam injector. A copper coil wound around a middle portion of the steam injector over an insulating tape, the copper coil configured to generate eddy currents when powered by a resonant inverter in the induction generator, causing the temperature of the steam injector to exceed 400°C. Incoming water is mixed with air under high pressure, and the pressurized mixture is heated to form steam within the steam injector. A plurality of steam discharge jets positioned at the front portion of the steam injector, the plurality of steam discharge jets configured to release high-pressure steam in a predefined range of 1 to 5 bar for steam ironing.
[0017] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The following drawings form part of the present specification and are included to further illustrate aspects of the present disclosure. The disclosure may be better understood by reference to the drawings in combination with the detailed description of the specific embodiments presented herein.
[0019] FIG. 1A illustrates an exemplary view of a mechanical assembly of a heating device, in accordance with an embodiment of the present disclosure.
[0020] FIG. 1B illustrates an exemplary view of electronic iron, in accordance with an embodiment of the present disclosure.
[0021] FIG. 1C illustrates an exemplary view of induction coil in the electronic iron, in accordance with an embodiment of the present disclosure.
[0022] FIG. 1D illustrates an exemplary view of the cables of heating device, in accordance with an embodiment of the present disclosure.
[0023] FIG. 1E illustrates an exemplary view of a heating device coupled to induction generator, in accordance with an embodiment of the present disclosure.
[0024] FIG. 2A and FIG. 2B illustrate exemplary block diagrams of the induction generator of electronic iron, in accordance with an embodiment of the present disclosure.
[0025] FIG. 3A illustrates a side view of the metal steam injector, in accordance with an embodiment of the present disclosure.
[0026] FIG. 3B illustrates a back view of the metal steam injector, in accordance with an embodiment of the present disclosure.
[0027] FIG. 3C illustrates a detailed representation of a steam discharge jet, in accordance with an embodiment of the present disclosure.
[0028] FIG. 3D illustrates a schematic view of the metal steam injector, in accordance with an embodiment of the present disclosure.
[0029] FIG. 3E illustrates a schematic view of the metal steam injector in electronic iron, in accordance with an embodiment of the present disclosure

DETAILED DESCRIPTION
[0030] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[0031] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0032] The present disclosure provides a heating device that includes a mechanical assembly configured to facilitate the controlled application of heat, including a soleplate adapted to apply controlled heat to the garments. A heat-resistant aluminum paint is applied to the surface of the soleplate to facilitate uniform heat distribution across it for efficient thermal management. A ceramic fiber board is positioned above the soleplate, providing enhanced thermal insulation to minimize heat loss. The ceramic fiber board is equipped with at least one hole on its surface to accommodate one or more temperature sensors for temperature monitoring. Moreover, a mica sheet is disposed above the ceramic fiber board to protect underlying components from thermal stress. In addition, an induction coil positioned above the mica sheet generates a high-frequency electromagnetic field to induce eddy currents within the soleplate, thereby generating heat. Above the induction coil, a ferrite core is provided as a magnetic shunt to reduce magnetic leakage and improve energy transfer efficiency.
[0033] Besides, a layer of heat-resistant wool is disposed above the ferrite core to provide additional thermal insulation, preventing heat dissipation and safeguarding surrounding components from excessive temperatures. A mechanical weight-enhancing MS sheet is positioned above the wool, contributing to the structural balance of the device. A lid encloses the mechanical components of the assembly, providing a protective covering, while a handle is securely attached to the lid, ensuring stability during operation. The present disclosure relates, in general, to fabric appliances, and more specifically, relates to a heating device for controlled heating of garments. The present disclosure can be described in enabling detail in the following examples, which may represent more than one embodiment of the present disclosure.
[0034] The advantages achieved by the device of the present disclosure can be clear from the embodiments provided herein. The device for efficient voltage regulation, is capable of stepping down or up the input AC voltage according to system requirements, ensuring that all components receive the required voltage levels for optimal performance. The present disclosure provides the device that improves energy efficiency by adjusting the voltage to appropriate levels for downstream components, thus minimizing energy wastage. The present disclosure provides a device that enhances the efficiency of electronic ironing by utilizing induction heating, which enables rapid and uniform heating of the soleplate for effective ironing. The present disclosure provides the device that enhances stability by filtering out voltage fluctuations and noise, ensuring smooth and reliable operation. The present disclosure provides the device that enhances safety by ensuring correct voltage handling, preventing over-voltage or under-voltage conditions that could damage components or compromise user safety. The description of terms and features related to the present disclosure shall be clear from the embodiments that are illustrated and described; however, the invention is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents of the embodiments are possible within the scope of the present disclosure. Additionally, the invention can include other embodiments that are within the scope of the claims but are not described in detail with respect to the following description.
[0035] FIG. 1A illustrates an exemplary view of mechanical assembly of a electronic iron, in accordance with an embodiment of the present disclosure.
[0036] Referring to FIG. 1A, heating device 100 (also referred to as device 100, herein) for controlled heating of garments or clothes. In an exemplary embodiment, the device 100 may be an electronic iron, integrating multiple components to enhance heat management, energy efficiency, and structural durability. The mechanical assembly 102 of the device 100 includes soleplate 104, heat-resistant aluminum paint 106, mica sheet(108-1 to 108-3), ceramic fiber board 110, dome nuts(112-1, 112-2 (which are collectively referred to as nuts 112, herein)), induction coil 114, ferrite core 116, a layer of heat-resistant wool 118, mild steel (MS) sheet 120, lid 122, a handle 124, MS sheet fitting studs 126, bush 128 and hole 130 in the ceramic fiber board 110 to accommodate one or more temperature sensors.
[0037] The soleplate 104is fabricated from MS 430, which replaces earlier materials such as stainless steel and mild steel. MS 430 provides superior magnetic properties for compatibility with induction heating, along with rust resistance and rapid thermal conductivity. The term MS 430 refers to grade 430 stainless steel, a specific type of ferritic stainless steel. It is commonly used for applications requiring good corrosion resistance, moderate mechanical properties, and magnetic properties.
[0038] The heat-resistant aluminum paint 106 is applied to the surface of the soleplate 104 to facilitate efficient heat distribution and thermal management. The heat-resistant aluminum paint 106 is consistent with earlier designs. The heat-resistant aluminum paint 106 is further applied to the mica sheet 108-1 to augment heat management capabilities, the application of heat-resistant aluminum paint 106 to the mica sheet 108-1 is adopted from preceding models.
[0039] The ceramic fiber board 110 is integrated above the mica layer 108-1, replacing the conventional fiber board. The ceramic fiber board 110 is accommodated above the soleplate 104, the ceramic fiber board 110 providing enhanced thermal insulation to minimize heat loss, where the ceramic fiber board 110 is equipped with at least one hole 130 on the surface to accommodate one or more temperature sensors for temperature monitoring. This enhances thermal insulation and minimizes heat loss. The mica sheet 108-2is newly introduced above the ceramic fiber board 110 to improve the heat management process, providing additional thermal stability and insulation.
[0040] The induction coil 114 is positioned over the mica sheet 108-2, with improvements made to increase energy efficiency. The induction coil 114 positioned above the mica sheet 108-2, is configured to generate a high-frequency electromagnetic field, so as to induce eddy currents within the soleplate 104 to generate heat. This enhances the overall performance of the electronic iron 100.The ferrite core 116 is placed above the induction coil 114, and its properties are optimized to enhance energy transfer and reduce thermal losses. The ferrite core 116 is positioned above the induction coil 114, the ferrite core 116optimized to concentrate the magnetic field generated by the induction coil 114, so as to increase energy transfer
[0041] The layer of heat-resistant wool 118 is positioned over the ferrite core 116 to provide additional thermal insulation and protect adjacent components from excessive heat. The layer of heat-resistant wool 118 disposed above the ferrite core 116, providing additional thermal insulation to prevent heat dissipation and safeguard surrounding components from exposure to excessive temperatures
[0042] The MS sheet 120 is installed over the layer of heat-resistant wool 118 to serve a dual purpose of weight enhancement for improved user handling and structural balance. The MS sheet 120 is positioned above the heat-resistant wool 118, providing mechanical weight enhancement to the device for structural balance. The assembly includes the lid 122, which encases the mechanical components of the electronic iron 100and provides a protective covering. The handle 124 attached to the lid 122, securely fastened to the mechanical assembly, ensuring stability during operation. The handle 124 is attached to the MS sheet 120 for user operation. The handle 124 is ergonomically designed and securely fastened to ensure durability during use.
[0043] The MS sheet fitting studs 126 are utilized to attach the MS sheet 120 to the structural components of the device 100, providing stability to the assembly. The Teflon bobbins128 (also referred to as bush 128) are incorporated within the fitting studs 126 to ensure electrical insulation and secure positioning of the MS sheet 126. The nuts 112 are used to fasten the handle and other components securely to the mechanical assembly, ensuring robustness and reliability.
[0044] In an embodiment, the heating device 100 is for the controlled heating of garments, the heating device 100 including the mechanical assembly 102 configured to facilitate controlled application of heat. The mechanical assembly 102 includes the soleplate 104 adapted to apply controlled heat to the garments. The heat-resistant aluminum paint 106 is applied to a surface of the soleplate 104, facilitating uniform heat distribution across the soleplate for thermal management. The ceramic fiber board 110 is accommodated above the soleplate, providing enhanced thermal insulation to minimize heat loss. The ceramic fiber board 110 is equipped with at least one hole 130 on its surface to accommodate one or more temperature sensors for temperature monitoring. The mica sheet 108-2 is disposed above the ceramic fiber board 110 to protect underlying components from thermal stress. In a further aspect, the ceramic fiber board 110 is configured for heat management, having a classification temperature range of 1260°C to 1425°C, thermal conductivity at a mean temperature of 600°C, and a chemical composition including Aluminum Oxide (Al2O3), Silicon Dioxide (SiO2), Zirconium Oxide (ZrO2) and any combination thereof. The ceramic fiber board 110 is configured to manage heat within the specified temperature range.
[0045] The induction coil 114, positioned above the mica sheet 108-2, is configured to generate a high-frequency electromagnetic field to induce eddy currents within the soleplate 104 to generate heat. The ferrite core 116, positioned above the induction coil 114, is provided as a magnetic shunt to reduce magnetic leakage. The layer of heat-resistant wool 118, disposed above the ferrite core 116, provides additional thermal insulation to prevent heat dissipation and safeguard surrounding components from exposure to excessive temperatures. The MS sheet 120, positioned above the heat-resistant wool 118, provides mechanical weight enhancement to the device for structural balance. The lid 122 encloses the mechanical components of the device 102, providing a protective covering for the mechanical assembly. The handle 124, attached to the lid 122, is securely fastened to the mechanical assembly, ensuring stability during operation.
[0046] In an embodiment, the induction coil 114 is configured such that inductance falls within a predefined range of 20 to 300 Henry. The induction coil includes a wire made of copper-coated aluminum or copper, with a number of turns ranging from 0 to 35, with concentric turns including 12 ± 7 and 27 ± 7 turns. Additional concentric turns of 21 ± 7 and 35 ± 7 enhance the efficiency of the induction coil. The induction coil 114 also includes a multi-layered structure with winding layers arranged in the predefined range from 0 to 3, including layers of 7 ± 2, 3 ± 1, and 2 ± 1, increasing surface area and inductance for energy transfer and optimized heating characteristics. In another aspect, the device 100 is configured to operate according to a set of heating parameters, including a temperature change of 280°C, heating a steel sheet from 20°C to 300°C, a heating time ranging from 1 to 5 minutes, and utilizes the induction coil with a flux density ranging from 1 to 5 ± Tesla, with an intensity of 100 - 500 kA/m/kVA. The material properties, pertaining to magnetic permeability, a specific heat capacity of approximately 0.5 kcal/kg°C, and a density of approximately 7.9 g/cm³, are evaluated. The set of heating parameters are used to heat a 3mm thick 430 MS steel sheet to a predefined temperature of 300°C.
[0047] The present disclosure provides a technological enhancement to increase the efficiency of an electronic iron 100 by incorporating improved Zero Voltage Switching (ZVS) and Zero Current Switching (ZCS) technology within the electronic circuitry. Zero Voltage Switching (ZVS) refers to a switching technique wherein the power switch transitions between on and off states at or near zero voltage, thereby minimizing switching losses and electromagnetic interference. Zero Current Switching (ZCS) is a switching method where the power switch transitions at or near zero current, effectively reducing power dissipation and improving overall system efficiency.
[0048] The enhanced circuitry is further equipped with a Proportional-Integral-Derivative (PID) circuit with K-type and infrared (IR) sensors. The PID circuit, in conjunction with the sensors, facilitates precise control and regulation of the temperature of the electronic iron 100. This enhancement not only improves operational accuracy but also optimizes power consumption, thereby ensuring energy efficiency and prolonged device performance.
[0049] Improvements have been made to the induction coil 114 to enhance the electronics in both domestic and commercial irons, while increasing the efficiency of the induction coil 114. To achieve higher efficiency and increased inductance (measured in Henry), the capacitance of the coil 114 has been optimized, and the number of turns has been adjusted. In an exemplary embodiment, the coil 114 includes copper-coated aluminum wire and copper wire configured with a number of turns ranging from 0 to 35 that may be (±) less and more than a predetermined range, including (12 ± 7) concentric turns, (27 ± 7) concentric turns, (21 ± 7) concentric turns, and (35 ± 7) concentric turns. The coil is constructed using a multi-layered design with rewinding on top of layers ranging from 0 to 3 which may be (±) less and greater than the predetermined range, and additional configurations involving (7 ± 2), (3 ± 1), and (2 ± 1) layers. The improved induction coil 114 featuring inductance values ranging from 20 to 300 Henry which may be (±) less and greater than the predetermined range, increases the heating rate by precisely controlling the intensity and direction of the electromagnetic field and reduces the heating time of the metal plate by controlling the depth and wavelength of the electromagnetic flux interacting with the metal plate.
[0050] In another exemplary embodiment, the device 102for heating a 3mm thick 430 MS steel sheet to 300°C, wherein the device is configured with material properties including magnetic permeability, a specific heat capacity of approximately 0.5 kcal/kg°C, and a density of approximately 7.9 g/cm³; induction heating parameters comprising a temperature change of 280°C (from 20°C to 300°C), a heating time of 1 to 5 minutes, and a coil current intensity ranging from 100 to 500 kA/m/kVA; and a flux density ranging from 1 to 5 ± Tesla, wherein the coil design is optimized based on the material properties and heating parameters to efficiently heat the steel sheet to the desired temperature.
[0051] The device 102includes a special ceramic fibre board 110 used in conjunction with the mica sheet 108 for enhanced heat management and improved heat retention during ironing, thereby increasing thermal efficiency. The ceramic fibre board 110 has a classification temperature ranging from 1260°C to 1425°C, a thermal conductivity of 600 W/m·K at a mean temperature of 600°C, and a chemical composition comprising Al2O3, SiO2, and ZrO2. In another exemplary embodiment, to increase the capacity of the electronic iron 100 during ironing in a commercial clothes iron, additional weight is required. For this purpose, an MS metal plate (±10 mm thick) or any other suitable metal plate is positioned over the element coil, forming a "magnetic shunt" with an iron core ferrite. Additionally, the inductance (Henry) of the iron core ferrite coil is precisely tuned to optimize its performance. The capacity and efficiency of the electronic iron 100 may be enhanced while maintaining a compact size for the electronic iron, the induction generation board is connected using a specialized cable and installed separately in an external housing. In order to enhance the capacity and efficiency of the electronic iron 100, a specialized copper cable is constructed using 26-gauge 6-6 wires twisted into a two-wire cable for the induction coil. Additionally, a "2" tinned wire with Teflon insulation is utilized for the temperature sensor.
[0052] Further, to increase the efficiency and power of the electronic iron 100, a high-frequency current, ranging from 15 kHz to 50 kHz, is used to heat the soleplate. Various types of induction coils for the electronic iron are displayed with their respective labels. In countries where the input power is 110/120 volts, a converter is used to step down the voltage to 110/120 volts at 60Hz for the induction generator to operate the electronic iron.
[0053] In an implementation of an embodiment, the present disclosure provides a method wherein the input alternating current (AC) voltage is passed through an AC line filter, which absorbs harmonic currents generated during the AC-to-DC conversion process. The AC voltage is then stepped up or stepped down, as required, using an Silicon Controlled Rectifier (SCR) or triode for alternating current (TRIAC), and sent to the AC/DC unit. The switching process for stepping up or stepping down the voltage, facilitated by the SCR or TRIAC, is controlled by a microcontroller unit.
[0054] The alternating current (AC) is converted into direct current (DC) in the AC/DC unit 208, supplying the required DC voltage to various sections, including the microcontroller unit 210, PID unit 214, and IGBT drive (resonant inverter) 212. The soleplate 104 is heated by an induction coil generating eddy currents, with the IGBT drive 212 operating at a frequency between 18 kHz and 30 kHz. To control the temperature of the soleplate 104, a K-type thermocouple or infrared (IR) sensor is installed on the soleplate and connected to the PID unit 214, which is controlled by the microcontroller 210. Similarly, the IGBT drive (resonant inverter) 212 is also controlled by the microcontroller 210.To regulate the temperature of the IGBT 212, a sensor and fan are installed on the IGBT heat sink, with the IGBT protection sensor being monitored and controlled by the microcontroller.
[0055] The microcontroller 210 is programmed to execute all tasks and monitor the overall functionality of the device. Additionally, the induction generator 100 is connected to convert 120V, 60Hz AC voltage for use in foreign countries where the AC power supply operates at 120V, 60Hz. The induction generator 200 can also be used to power the clothes iron by connecting it to a separate voltage solar boost converter (DC to AC) in locations without an AC power grid. This device is also applicable in the manufacturing of induction generators and steam clothes irons.
[0056] FIG. 1B illustrates an exemplary view of electronic iron, in accordance with an embodiment of the present disclosure. The induction coil 114for use in the electronic iron is depicted. The induction coil 114 is configured in a continuous, concentric loop pattern to provide uniform heat distribution across the surface of the heating plate. The assembly is geometrically shaped with approximate dimensions of 171 mm in height and 237 mm in width, featuring consistent spacing of 5 mm between adjacent loops of the coil to optimize thermal efficiency and minimize localized overheating. The induction coil 114 includes a central aperture or elongated slot, which is strategically positioned to accommodate auxiliary components, such as temperature sensor or any combination thereof. Additionally, a connector segment extends outward from one side of the plate, measuring approximately 130 mm in length, with a narrower channel of 1 mm thickness to facilitate electrical connections for power transmission to the induction coil. The device ensures effective heat management, energy efficiency, and structural durability, making it particularly suitable for applications requiring precise temperature control, such as garment pressing in electronic irons.
[0057] FIG. 1C illustrates an exemplary view of the induction coil in the electronic iron, in accordance with an embodiment of the present disclosure. The induction coil 114 is configured with a design comprising 18 turns, arranged in a concentric and evenly spaced pattern to ensure uniform heat distribution across the surface of the iron. This configuration enhances the overall performance of the electronic iron 100 by enabling rapid and even heating of the baseplate, thereby improving energy efficiency and the effectiveness of garment pressing operations.
[0058] FIG. 1D illustrates an exemplary view of cables of heating device, in accordance with an embodiment of the present disclosure. The assembly of heating device 100 can includes copper wire 132, tinned wire with teflon insulation 134 and special cables 136. The primary conductor is the copper wire 132, specified as 36-gauge, consisting of six strands. This wire serves as the core heating element, optimized for efficient electrical conductivity and heat generation. Surrounding the copper wire 132, the tinned wire with Teflon insulation 134 is employed to provide thermal resistance and electrical insulation. This feature ensures safety and durability under high-temperature operating conditions. Additional specialized cables 136, identified as "X" in the illustration, are integrated into the assembly for enhanced electrical connectivity. These cables may function as supporting conductors or signal pathways, contributing to the overall functionality of the device.
[0059] FIG. 1E illustrates an exemplary view of heating device coupled to induction generator, in accordance with an embodiment of the present disclosure. The heating device 100coupled to induction generator 200, as depicted in FIGs. 2A and 2B, and described in detail below. The heating device 100 is operatively connected to the induction generator 200, enabling efficient energy transfer for heating applications. The induction generator 200 supplies high-frequency alternating current to the heating device 100, which contains an induction coil configured to generate heat through electromagnetic induction.
[0060] Thus, the present invention overcomes the drawbacks, shortcomings, and limitations associated with existing solutions, and provides a device for efficient voltage regulation, capable of stepping down or up the input AC voltage according to system requirements, ensuring that all components receive the required voltage levels for optimal performance. The present disclosure provides the device that improves energy efficiency by adjusting the voltage to appropriate levels for downstream components, thus minimizing energy wastage. The present disclosure provides the device that enhances the efficiency of electronic ironing by utilizing induction heating, which enables rapid and uniform heating of the soleplate for effective ironing. The present disclosure provides the device that enhances stability by filtering out voltage fluctuations and noise, ensuring smooth and reliable operation. The present disclosure provides the device that enhances safety by ensuring correct voltage handling and preventing over-voltage or under-voltage conditions that could damage components or compromise user safety.
[0061] FIG. 2A and FIG. 2B illustrate exemplary block diagrams of induction generator of electronic iron, in accordance with an embodiment of the present disclosure.
[0062] Referring to the FIG. 2A, the electronic iron 100can include induction generator 200 that can include AC voltage convertor unit 202, AC voltage filter unit 204, power factor correction (PFC) unit 206, AC/DC unit 208, microcontroller unit 210, resonant inverter/IGBT gate driver unit 212, induction work coils114 (also referred to as induction coil 114, herein) and PID control unit 214.
[0063] The AC voltage convertor unit 202 converts the incoming AC voltage to the appropriate level required by other system components, ensuring compatibility with varying voltage standards and optimizing system performance across regions with different power supply configurations. The AC voltage filter unit 204 is designed to filter out undesirable noise or fluctuations in the incoming AC voltage, providing a stable and consistent input voltage to the system, thus improving overall reliability and performance. The Power Factor Correction (PFC) unit 206 ensures the input power factor is optimized for efficient power consumption and minimal harmonic distortion in the AC supply, enabling smoother operation and reducing energy wastage.
[0064] The AC/DC unit 208 is responsible for rectifying the AC voltage to direct current (DC), providing a stable DC power supply to the subsequent system components. This conversion is essential for powering the induction generator 200 and control systems. The microcontroller unit 210 serves as the central control unit, executing the software algorithms for managing all functions. It monitors and adjusts the operation in real-time, including the power supply, heating process, and safety features, ensuring seamless operation and precision control. The resonant inverter/IGBT gate driver unit 212 converts the DC power into high-frequency alternating current (AC) by using a resonant inverter, which efficiently drives the induction coil 114. The IGBT gate driver unit controls the switching of the IGBT transistors that regulate the power output, allowing for precise control of the induction heating process.
[0065] The induction work coils114 generate a high-frequency magnetic field that induces currents in the soleplate 104 of the electronic iron 100. These currents create heat through the principle of electromagnetic induction, allowing for rapid heating of the soleplate 104 without direct contact with the heating element. The Proportional-Integral-Derivative (PID) control unit 214 regulates the temperature of the induction coil 114 by continuously adjusting the power supplied to the coils based on feedback from temperature sensors. This unit ensures that the soleplate 104 reaches and maintains the desired temperature, improving the efficiency and accuracy of the heating process.
[0066] Referring to the FIG. 2B, the electronic iron can include AC voltage converter unit 202, AC voltage filter unit 204, AC voltage step down/up switching unit 216, AC/DC unit 208,microcontroller unit 210, resonant inverter/IGBT gate driver unit 212, induction work coils114,PID control unit 214.
[0067] The AC voltage converter unit 202 converts incoming AC voltage to the appropriate level required by other system components, ensuring compatibility with varying voltage standards and optimizing system performance across regions with different power supply configurations. The AC voltage filter unit 204 is designed to filter out undesirable noise or fluctuations in the incoming AC voltage, providing a stable and consistent input voltage to the system, thus improving overall reliability and performance.
[0068] The AC voltage step down/up switching unit 216 is configured to adjust the input alternating current (AC) voltage to a desired level, either stepping it down or up depending on the requirements of the system. This unit uses components such as Silicon-Controlled Rectifiers (SCR) or TRIACs, which are controlled by the microcontroller unit 210. The switching process enables efficient voltage regulation to meet the operational demands of downstream components, ensuring optimal performance of the connected system, such as the electronic iron 100 or other appliances requiring specific voltage levels for operation.
[0069] The AC/DC unit 208 is responsible for rectifying the AC voltage to direct current (DC), providing a stable DC power supply to the subsequent system components. This conversion is essential for powering the induction generator and control systems. The microcontroller unit 210 serves as the central control unit, executing the software algorithms for managing all functions. It monitors and adjusts the operation in real-time, including the power supply, heating process, and safety features, ensuring seamless operation and precision control. The resonant inverter/IGBT gate driver unit 212 converts the DC power into high-frequency alternating current (AC) by using a resonant inverter, which efficiently drives the induction coils. The IGBT gate driver unit controls the switching of the IGBT transistors that regulate the power output, allowing for precise control of the induction heating process.
[0070] The induction work coils114 generate a high-frequency magnetic field that induces currents in the soleplate of the electronic iron 100. These currents create heat through the principle of electromagnetic induction, allowing for rapid heating of the soleplate without direct contact with the heating element. The proportional-integral-derivative (PID) control unit 214 regulates the temperature of the induction coils by continuously adjusting the power supplied to the coils based on feedback from temperature sensors. This unit ensures that the soleplate reaches and maintains the desired temperature, improving the efficiency and accuracy of the heating process.
[0071] The induction generator 200 includes the microcontroller unit 210, which is configured to monitor the operation of the device. The microcontroller unit 210 is further configured to switch, by the AC switching unit 216, an input AC voltage received from an AC converter unit 202 to a suitable level for operating the device. It is also configured to filter, by the AC voltage filter unit 204, the noise from the input AC voltage to provide a stable AC input, where the noise pertains to harmonic distortion of the input AC voltage. The microcontroller unit 210 is also configured to convert, by the AC/DC unit 208, the input AC voltage to direct current (DC) and to convert, by the IGBT gate driver 212, the DC power into high-frequency AC power. This high-frequency AC power is used to generate, by the induction coil 114 coupled to the soleplate, a high-frequency magnetic field to induce eddy currents in the soleplate to apply controlled heat to the garments.
[0072] Additionally, the microcontroller unit 210 regulates, by the PID control unit 214, the temperature of the soleplate 104 based on feedback from one or more temperature sensors, where the temperature sensors are mounted on the soleplate and coupled to the PID control unit 214. In one aspect, the microcontroller unit 210 is coupled to the PFC unit, configured to optimize the input power factor and minimize harmonic distortion from the input AC voltage. In another aspect, the IGBT gate driver 212 includes a fan and a sensor mounted on a heat sink to regulate the temperature of the IGBT drive. The PID control unit 214 continuously adjusts the power supplied to the induction coils to maintain the desired temperature of the soleplate.
[0073] FIG. 3A illustrates a side view 300 of the metal steam injector 302, FIG. 3B depicts the back view of the metal steam injector 302, FIG. 3C provides a detailed representation of a steam discharge jet 304, FIG. 3D offers a schematic diagram of the metal steam injector 302 and FIG. 3Eillustratesa schematic view of the metal steam injector in electronic iron.
[0074] In an embodiment, the metal steam injector 302 is configured for integration into the soleplate 104, where the metal steam injector 302 includes a front portion connected to three or more steam discharge jets 304. A copper coil 306 is wound around the middle portion of the metal steam injector 302 over an insulation tape 308, where the copper coil 306 is operatively connected to and powered by the resonant inverter 212 within the induction generator 200.
[0075] The rear portion of the metal steam injector 302 is connected via a supply pipe 310 to a solenoid valve 314, the solenoid valve 314 being mounted on the metal plate 312 and further connected to the supply pipe 310 leading from an input water jar/source.
[0076] In an embodiment, the device 100 includes the steam injector 302 configured as a pump without moving mechanical parts, designed to generate steam for steam ironing of garments. The steam injector 302 includes solenoid valve 314 coupled to a rear portion of the steam injector 302 through the supply pipe 310, where the steam injector 302 is operatively coupled to the water source through the supply pipe 310, and the solenoid valve 314 controls the regulated flow of water into the steam injector 302. The copper coil 306 wound around the middle portion of the steam injector 302 over the insulating tape 308, the copper coil 306 configured to generate eddy currents when powered by the resonant inverter 212 in the induction generator 200, causing the temperature of the steam injector 302 to exceed 400°C, where incoming water is mixed with air under high pressure, and the pressurized mixture is heated to form steam within the steam injector 302. The plurality of steam discharge jets 304 positioned at the front portion of the steam injector 302, the plurality of steam discharge jets 304 configured to release high-pressure steam in a predefined range of 1 to 5 bar for steam ironing.
[0077] In an implementation of an embodiment, steam injector 302, configured as a pump with no moving parts, utilizes principles of thermodynamics and fluid mechanics to pump water into a boiler for steam generation, incorporating the Venturi effect and energy conversion mechanisms. When water enters the steam injector 302 through the solenoid valve 314, simultaneous activation of the steam injector coil 306 causes the temperature of the steam injector 302 to exceed 400 degrees Celsius due to eddy current heating. This elevated temperature facilitates the mixing of air and water under high pressure within the steam injector 302, resulting in the generation of high-pressure steam. The generated steam, under a pressure range of 1 to 5 bar, is discharged from the steam discharge jets 304, making it suitable for steam ironing of clothes.
[0078] It will be apparent to those skilled in the art that device 100 of the disclosure may be provided using some or all of the mentioned features and components without departing from the scope of the present disclosure. While various embodiments of the present disclosure have been illustrated and described herein, it will be clear that the disclosure is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the disclosure, as described in the claims.

ADVANTAGES OF THE PRESENT INVENTION
[0079] The present disclosure provides a device for efficient voltage regulation, capable of stepping down or up the input AC voltage according to system requirements.
[0080] The present disclosure provides a device that improves energy efficiency by ensuring appropriate voltage levels for downstream components.
[0081] The present disclosure provides a device that enhances the efficiency of electronic ironing by utilizing induction heating, which allows for rapid and uniform heating of the soleplate.
[0082] The present disclosure provides a device that enhances stability by filtering out voltage fluctuations and noise.
[0083] The present disclosure provides a device that enhances safety by ensuring correct voltage handling and preventing over-voltage or under-voltage conditions.
, Claims:1. A heating device (100) for controlled electronic induction-based ironing of garments, the heating device comprising:
a mechanical assembly (102) of the heating device configured to facilitate controlled application of heat, the mechanical assembly comprising:
a soleplate (104) adapted to apply controlled heat to the garments;
a heat-resistant aluminum paint (106) applied to a surface of the soleplate (104), facilitating uniform heat distribution across the soleplate for thermal management;
a ceramic fiber board (110) accommodated above the soleplate, the ceramic fiber board (110) providing enhanced thermal insulation to minimize heat loss, wherein the ceramic fiber board (110) is equipped with at least one hole (130) on surface to accommodate one or more temperature sensors for temperature monitoring;
a mica sheet (108-2) disposed above the ceramic fiber board (110), serves to protect underlying components from thermal stress;
an induction coil (114) positioned above the mica sheet (108-2), configured to generate a high-frequency electromagnetic field, so as to induce eddy currents within the soleplate (104) to generate heat;
a ferrite core (116) positioned above the induction coil (114), the ferrite core (116) provided as a magnetic shunt to reduce magnetic leakage;
a layer of heat-resistant wool (118) disposed above the ferrite core (116), providing additional thermal insulation to prevent heat dissipation and safeguard surrounding components from exposure to excessive temperatures;
amild steel (MS) sheet (120) positioned above the layer of heat-resistant wool (118), providing mechanical weight enhancement to the device for structural balance;
a lid (122) enclosing the mechanical assembly of the device (102), providing a protective covering for the mechanical assembly; and
a handle (124) attached to the lid (122), securely fastened to the mechanical assembly, ensuring stability during operation.
2. The device as claimed in claim 1, wherein the induction coil (114) is configured such that inductance is (±) less than and greater than a predetermined limit of 20 to 300 henry, the induction coil comprises:
a wire made of copper-coated aluminum or copper having a number of turns in the range from 0 to 35, which is (±) less than and greater than the predetermined limit wherein concentric turns contain such number of turns as (12 ± 7), (27 ± 7), (21 ± 7) and (35 ± 7) turns or any combination thereof so as to increase efficiency of the induction coil; and
a multilayer structure with arranged curved layers having (±) less and more than a predetermined range of 0 to 3, with a number of turns as (7 ± 2), (3 ± 1), and (2 ± 1) turns, which increase surface area and inductance for energy transfer and optimized heating characteristics.
3. The device as claimed in claim 1, wherein the device is configured to operate according to a set of heating parameters:
a temperature change of 280°C, heating a steel sheet from 20°C to 300°C;
a heating time ranging from 1 to 5 minutes;
utilizes the induction coil with a flux density ranging from 1 to 5 ± Tesla, with an intensity of 100 - 500 kA/m/kVA;
evaluate material properties, pertaining to magnetic permeability, a specific heat capacity of approximately 0.5 kcal/kg°C, and a density of approximately 7.9 g/cm³, wherein the set of heating parameters are used to heat a 3mm thick 430 MS steel sheet to a predefined temperature of 300°C.
4. The device as claimed in claim 1, wherein the ceramic fiber board (110) for heat management, having a classification temperature range of 1260°C to 1425°C, thermal conductivity at a mean temperature of 600°C, and a chemical composition comprising:
Aluminum Oxide (Al2O3)
Silicon Dioxide (SiO2); and
Zirconium Oxide (ZrO2), wherein the ceramic fiber board is configured to manage heat within specified temperature range.
5. The device as claimed in claim 1, wherein the device is operatively coupled to an induction generator, the induction generator comprises:
a microcontroller unit (210) configured to monitor operation of the device, the microcontroller unit configured to:
switch, by an alternating current (AC) switching unit (216), an input AC voltage received from an AC converter unit (202) to a suitable level for operating the device;
filter, by an AC voltage filter unit (204) coupled to the AC switching unit, the noise from the input AC voltage to provide a stable AC input, the noise pertains to harmonic distortion of the input AC voltage;
convert, by an AC/DC unit (208) coupled to the AC switching unit, the input AC voltage to direct current (DC);
convert, by an insulated-gate bipolar transistor (IGBT) gate driver (212) coupled to the AC/DC unit, DC power into high-frequency AC power;
generate, by the induction coil (114) coupled to the soleplate, a high-frequency magnetic field to induce eddy currents in the soleplate to apply controlled heat to the garments;
regulate, by a proportional-integral-derivative (PID) control unit (214) coupled to the induction coil, temperature of the soleplate based on feedback from one or more temperature sensors, wherein the one or more temperature sensors are mounted on the soleplate and coupled to the PID control unit.
6. The device as claimed in claim 1, wherein the microcontroller unit (210) coupled to a power factor correction (PFC) unit, configured to optimize input power factor and minimize harmonic distortion from the input AC voltage.
7. The device as claimed in claim 1, wherein the IGBT gate driver (212) comprises a fan and a sensor mounted on a heat sink to regulate the temperature of the IGBT drive.
8. The device as claimed in claim 1, wherein the PID control unit (214) continuously adjusts power supplied to the induction coil to maintain a desired temperature of the soleplate.
9. The device as claimed in claim 1, wherein the induction generator (200) is configured to adapt the heating device to operate on a 120V, 60Hz power supply for use in global regions.
10. The device as claimed in claim 1, wherein the device comprises a steam injector (302) accommodated on the soleplate (104), configured as a pump without moving mechanical parts, generate steam for steam ironing of the garments, the steam injector comprises:
a solenoid valve (314) coupled to a rear portion of the steam injector through a supply pipe (310), the steam injector (302) operatively coupled to a water source through the supply pipe (310), the solenoid valve (314) controls regulated flow of water into the steam injector (302);
a copper coil (306) wound around a middle portion of the steam injector (302) over an insulating tape (308), the copper coil (306) configured to generate eddy currents when powered by the resonant inverter (212) in the induction generator (200), causing the temperature of the steam injector (302) to exceed 400°C, wherein incoming water with air is mixed under high pressure, the pressurized mixture being heated to form steam within the steam injector (302); and
a plurality of steam discharge jets (304) positioned at the front portion of the steam injector (302), the plurality of steam discharge jets (304) configured to release high-pressure steam in a predefined range of 1 to 5 bar, for steam ironing.