Coupler and electric equipment

Abstract

The invention provides a coupler and electric equipment. The coupler comprises a receiving end, a transmitting end and at least one flexible nanocrystalline magnetic core. Wherein the receiving end is provided with a receiving coil with a curved surface; the transmitting end is provided with a transmitting coil with a curved surface. When wireless transmission is carried out between the transmitting end and the receiving end, the transmitting end is located on one side of the receiving end in the vertical direction, a distance is formed between the transmitting end and the receiving end, and the transmitting coil corresponds to the receiving coil in the vertical direction. The at least one flexible nanocrystalline magnetic core is attached to at least one of a curved side of the receiving coil away from the transmitting coil and a curved side of the transmitting coil away from the receiving coil. According to the coupler, the flexible nanocrystalline magnetic core can be tightly attached to the curved surface, the transmission efficiency is improved, installation is simple, magnetic flux leakage is avoided, and the weight of the coupler is reduced.

Description

Technical Field

[0001] The present disclosure relates to the technical field of inductive wireless transmission, and in particular to a coupler and an electrical device. Background Art

[0002] In an inductive wireless power transmission system, a coupler is usually used to convert and transmit signals. In the related art, ferrite cores are usually used on both sides of the coil of the coupler to increase the coupling coefficient and improve the transmission efficiency. However, in some electrical equipment, such as an underwater autonomous vehicle, which has an arc-shaped shell, the coupler is applied to the underwater autonomous vehicle. In order to adapt to its shell design, the coupler also has an arc-shaped surface, and the coil of the coupler (such as a double D-shaped coil) also has an arc-shaped surface. Therefore, the ferrite core also needs to be set to the arc shape that adapts to the shell design.

[0003] In related technologies, such as Figure 1 As shown, the ferrite core 1' is usually made into a square block with rounded corners 11'. The ferrite core 1' needs to be spliced ​​together, and its bending performance is poor. It cannot fit the curved surface tightly, which affects the transmission efficiency and is cumbersome to install. The rounded corners 11' of the ferrite core 1' are formed by a mold, which may cause air gaps and thus magnetic flux leakage. In addition, the magnetic saturation capacity of the ferrite core 1' is low, and the required thickness is larger, which increases the weight and volume of the coupler.

[0004] The above information disclosed in this Background section is only for enhancement of understanding of the background of the present disclosure and therefore it may contain information that does not constitute the prior art that is already known to one of ordinary skill in the art. Summary of the invention

[0005] The embodiments of the present disclosure provide a coupler and an electrical device, wherein the flexible nanocrystalline magnetic core can fit tightly with a curved surface, thereby improving transmission efficiency, simplifying installation, avoiding magnetic flux leakage, and reducing the weight of the coupler.

[0006] The disclosed embodiment provides a coupler, including a receiving end, a transmitting end and at least one flexible nanocrystalline magnetic core. The receiving end is provided with a receiving coil having a curved surface; the transmitting end is provided with a transmitting coil having a curved surface. When wireless transmission is performed between the transmitting end and the receiving end, the transmitting end is located on one side of the receiving end in the vertical direction and has a spacing with the receiving end, and the transmitting coil corresponds to the receiving coil in the vertical direction; at least one flexible nanocrystalline magnetic core is attached to at least one of the curved surface side of the receiving coil away from the transmitting coil and the curved surface side of the transmitting coil away from the receiving coil.

[0007] In some embodiments of the present disclosure, there are multiple flexible nanocrystalline magnetic cores, a portion of the multiple flexible nanocrystalline magnetic cores are attached to the curved side of the receiving coil away from the transmitting coil, and another portion of the multiple flexible nanocrystalline magnetic cores are attached to the curved side of the transmitting coil away from the receiving coil.

[0008] In some embodiments of the present disclosure, the multiple flexible nanocrystalline magnetic cores located on the curved surface side of the receiving coil and the multiple flexible nanocrystalline magnetic cores located on the curved surface side of the transmitting coil are respectively arranged in parallel and at intervals.

[0009] In some embodiments of the present disclosure, the flexible nanocrystalline magnetic core includes multiple layers of stacked nanocrystalline ribbons, and the multiple layers of nanocrystalline ribbons are bonded by an adhesive.

[0010] In some embodiments of the present disclosure, the thickness of each layer of the nanocrystalline ribbon is 14 μm to 25 μm, and the thickness of the flexible nanocrystalline magnetic core is 0.5 mm to 2 mm.

[0011] In some embodiments of the present disclosure, the stacking factor of the flexible nanocrystalline magnetic core is 0.65-0.88.

[0012] In some embodiments of the present disclosure, the nanocrystalline ribbon is a broken nanocrystalline ribbon processed by an extrusion process.

[0013] In some embodiments of the present disclosure, the magnetic permeability of the flexible nanocrystalline magnetic core is 800-3000.

[0014] In some embodiments of the present disclosure, the flexible nanocrystalline magnetic core is attached to the curved side of the receiving coil away from the transmitting coil, and the ferrite magnetic core is attached to the curved side of the transmitting coil away from the receiving coil; or, the ferrite magnetic core is attached to the curved side of the receiving coil away from the transmitting coil, and the flexible nanocrystalline magnetic core is attached to the curved side of the transmitting coil away from the receiving coil.

[0015] An embodiment of the present disclosure also provides an electrical device, comprising the coupler described in any of the above embodiments.

[0016] Compared with the prior art, the coupler of the embodiment of the present disclosure has at least the following beneficial effects:

[0017] In the coupler of the disclosed embodiment, at least one flexible nanocrystalline magnetic core is attached to at least one of the curved side of the receiving coil away from the transmitting coil and the curved side of the transmitting coil away from the receiving coil. Since the nanocrystalline magnetic core is flexible, it can better fit the curved surface, improve the transmission efficiency, and avoid magnetic flux leakage. The nanocrystalline magnetic core is a whole and does not need to be spliced, so the installation is simpler. In addition, since the nanocrystalline magnetic core has a higher magnetic saturation capacity and requires a smaller thickness, it can reduce the volume and weight, thereby reducing the weight of the coupler. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the embodiments of the present disclosure or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present disclosure. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0019] Figure 1 is a schematic diagram of a ferrite core in the related art;

[0020] Figure 2 A schematic diagram of the structure of a coupler provided in an embodiment of the present disclosure in a wireless transmission state;

[0021] Figure 3 Another structural schematic diagram of the coupler provided by the embodiment of the present disclosure in a wireless transmission state;

[0022] Figure 4 A simplified schematic diagram of a cross section of an underwater vehicle provided with a coupler according to an embodiment of the present disclosure;

[0023] Figure 5 A schematic diagram of the unfolding of the flexible nanocrystalline magnetic core provided by an embodiment of the present disclosure;

[0024] Figure 6 A schematic diagram of the bending of a flexible nanocrystalline magnetic core provided in an embodiment of the present disclosure;

[0025] Figure 7 A schematic diagram of stacking multiple layers of nanocrystalline ribbons of a flexible nanocrystalline magnetic core provided by an embodiment of the present disclosure;

[0026] Figure 8 A test diagram of transmission efficiency using magnetic cores with different magnetic permeabilities at different output powers provided by an embodiment of the present disclosure;

[0027] Figure 9a to Figure 9d Thermal distribution test diagram of flexible nanocrystalline magnetic cores with different magnetic permeabilities provided by the embodiments of the present disclosure;

[0028] Figure 10a to Figure 10cThe temperature rise test diagram of the magnetic cores with different magnetic permeabilities under different output powers provided by the embodiment of the present disclosure, wherein: Fig.10a The output power is 500W. Fig.10b The output power is 700W. Fig.10c The output power is 1000W;

[0029] Figure 11a to Figure 11b The temperature distribution test diagram of the nanocrystalline magnetic core with a magnetic permeability of 800 at the receiving end and the transmitting end under different output powers provided in the embodiment of the present disclosure, wherein: Fig.11a For the receiving end, Fig.11b For the transmitter;

[0030] Fig.12 A weight distribution diagram of a coupler provided for an embodiment of the present disclosure;

[0031] Fig.13 A schematic diagram of an underwater vehicle provided for an embodiment of the present disclosure (partial components removed to expose the coupler).

[0032] Description of reference numerals:

[0033] Related technologies: 1', ferrite core; 11', rounded corners.

[0034] The present disclosure: 100, coupler; 1, receiving end; 11, receiving coil; 12, first support plate; 2, transmitting end; 21, transmitting coil; 22, second support plate; 3, flexible nanocrystalline magnetic core; 31, nanocrystalline ribbon; 32, adhesive; 200, electrical equipment; 201, shell; X, first direction; Y, second direction; Z, vertical direction; r, radius of the coupler; θ, bending angle of the coupler. DETAILED DESCRIPTION

[0035] Example embodiments will now be described more fully with reference to the accompanying drawings. However, example embodiments can be implemented in a variety of forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be comprehensive and complete and will fully convey the concepts of the example embodiments to those skilled in the art. The same reference numerals in the figures represent the same or similar structures, and thus their detailed description will be omitted.

[0036] In the following description of different exemplary embodiments of the present disclosure, reference is made to the accompanying drawings, which form a part of the present disclosure and in which different exemplary structures that can implement multiple aspects of the present disclosure are shown by way of example. It should be understood that other specific schemes of components, structures, exemplary devices, systems and steps can be used, and structural and functional modifications can be made without departing from the scope of the present disclosure. Moreover, although the terms "above", "between", "within", etc. may be used in this specification to describe different exemplary features and elements of the present disclosure, these terms are used herein only for convenience, such as according to the direction of the examples in the accompanying drawings. Nothing in this specification should be construed as requiring a specific three-dimensional direction of the structure to fall within the scope of the present disclosure. In addition, the terms "first", "second", etc. in the claims are used only as marks and are not numerical limitations on their objects.

[0037] The flowcharts shown in the accompanying drawings are only exemplary and do not necessarily include all the contents and operations / steps, nor must they be executed in the order described. For example, some operations / steps can be decomposed, and some operations / steps can be combined or partially combined, so the actual execution order may change according to actual conditions.

[0038] In addition, in the description of the present disclosure, “plurality” means at least two, for example, two, three, etc., unless otherwise clearly and specifically defined.

[0039] In an inductive radio transmission system, a coupler is used for signal conversion and transmission. The coupler of the embodiment of the present disclosure is a coupler with a curved surface, for example, a coupler for an underwater autonomous vehicle. In order to adapt to the arc-shaped shell design of the underwater autonomous vehicle, the coupler also needs to have a curved surface.

[0040] like Figure 2 As shown, the coupler 100 of the embodiment of the present disclosure includes a receiving end 1, a transmitting end 2 and at least one flexible nanocrystalline magnetic core 3. It should be noted that: Figure 2 The structural relationship between the receiving end 1 and the transmitting end 2 when they are in a wireless transmission state is shown in . The coupler used in underwater autonomous vehicles has a receiving end 1 located inside the vehicle's shell, and a transmitting end 2 fixed at a predetermined position on the bottom of the water (similar to a charging pile). When the vehicle needs to be wirelessly charged, the vehicle stops above the transmitting end 2, so that the receiving end 1 is located directly above the transmitting end 2 in the vertical direction Z, facilitating wireless transmission between the two. That is, the positional relationship between the receiving end 1 and the transmitting end 2 is not fixed, and the receiving end 1 and the transmitting end 2 may not be a one-to-one correspondence. For example, one transmitting end 2 can correspond to the receiving end 1 of multiple vehicles, as long as wireless transmission between the two can be achieved, and no special limitation is made here.

[0041] It should also be noted that Figure 2 The receiving end 1 and the transmitting end 2 of the coupler 100 are fixedly connected (for example, by threaded connection) to facilitate the study of the wireless transmission performance between the two, which can also be understood as Figure 2 The coupler 100 shown in FIG. 1 is a research model of a coupler. In actual use, the two are not necessarily fixedly connected.

[0042] like Figure 2 and Figure 3 As shown, the receiving end 1 is provided with a curved receiving coil 11, that is, because the coupler 100 has a curved surface, the receiving coil 11 is provided at the receiving end 1 in a curved form, as shown in FIG. Figure 4 As shown, for example, the receiving end 1 has an arc-shaped surface, and the receiving coil 11 is attached to the arc-shaped surface. Therefore, the receiving coil 11 is bent and thus has a curved surface. Figure 4 The circle in represents the shell of the electric device 200 (eg, an underwater vehicle), and the receiving coil 11 can be attached to the inner surface of the shell.

[0043] The transmitting end 2 is provided with a transmitting coil 21 having a curved surface. When wireless transmission is performed between the transmitting end 2 and the receiving end 1, the transmitting end 2 is located on one side of the receiving end 1 in the vertical direction Z and has a spacing with the receiving end 1. The transmitting coil 21 corresponds to the receiving coil 11 in the vertical direction Z. The vertical direction Z can be understood as a direction perpendicular to the ground when the coupler 100 is placed on the ground.

[0044] like Figure 2 As shown, the transmitting end 2 is provided with a curved transmitting coil 21, that is, because the coupler 100 has a curved surface, the transmitting coil 21 is provided at the transmitting end 2 in a curved form, as shown in FIG. Figure 4 As shown, for example, the transmitting end 2 has an arc-shaped surface, and the transmitting coil 21 is attached to the arc-shaped surface. Therefore, the transmitting coil 21 is bent and has a curved surface.

[0045] The transmitting coil 21 corresponds to the receiving coil 11 in the vertical direction Z, that is, in the vertical direction Z, the projection area of ​​the receiving coil 11 and the projection area of ​​the transmitting coil 21 can at least partially overlap, so that the signal of the transmitting coil 21 can be transmitted to the receiving coil 11. In some embodiments, when wireless transmission is performed between the receiving end 1 and the transmitting end 2, the receiving coil 11 completely corresponds to the transmitting coil 21 in the vertical direction Z, so that the signal of the transmitting coil 21 can be transmitted to the receiving coil 11 to the greatest extent.

[0046] like Figure 2 and Figure 3 As shown, the receiving coil 11 and the transmitting coil 21 can both be double-D coils. The coils are sheet-shaped and have two spaced hollow portions, similar to two parallel D-shaped coils.

[0047] In some embodiments, continue to refer to Figure 2 and Figure 3 The coupler 100 may further include a first support plate 12 and a second support plate 22. The first support plate 12 is provided at the receiving end 1, and the first support plate 12 has a receiving curved surface, and the receiving coil 11 is attached to the receiving curved surface. The second support plate 22 is provided at the transmitting end 2, and the second support plate 22 has a transmitting curved surface, and the transmitting coil 21 is attached to the transmitting curved surface. The transmitting curved surface may be the bottom surface of the second support plate 22 (the side facing away from the receiving end 1), and may be the curved surface of the second support plate 22 facing the first support plate 12.

[0048] like Figure 4 As shown, alternating current is supplied to the transmitting coil 21 , and the transmitting coil 21 generates an alternating magnetic field, which points to the receiving coil 11 . The receiving coil 11 induces an alternating current in the alternating magnetic field, thereby realizing wireless transmission between the transmitting coil 21 and the receiving coil 11 . Figure 4 The arrow in represents the signal transmitted from the transmitting coil 21 to the receiving coil 11. The signal includes an alternating magnetic field. The transmission distance of the signal can be 45 mm, and the operating frequency is 85 kHz. Figure 4 In the embodiment, the radius r of the coupler 100 may be 0.2 m, which may also be the radius of the shell of the underwater vehicle. The bending angle θ of the coupler 100 may be 72°. Of course, different couplers 100 have different radii r and bending angles θ, which are not limited here.

[0049] like Figure 2 As shown, at least one flexible nanocrystalline magnetic core 3 is attached to at least one of the curved surface side of the receiving coil 11 away from the transmitting coil 21 and the curved surface side of the transmitting coil 21 away from the receiving coil 11 .

[0050] Since the flexible nanocrystalline magnetic core 3 has the functions of magnetic concentration and magnetic shielding, it can improve the transmission efficiency between the transmitting coil 21 and the receiving coil 11. However, it is precisely for this reason that the flexible nanocrystalline magnetic core 3 cannot be arranged between the transmitting coil 21 and the receiving coil 11, otherwise magnetic shielding may be generated between the two coils, affecting the transmission between the two. Therefore, the flexible nanocrystalline magnetic core 3 is attached to the curved side of the receiving coil 11 away from the transmitting coil 21 and / or attached to the curved side of the transmitting coil 21 away from the receiving coil 11.

[0051] like Figure 5 and Figure 6 As shown, the flexible nanocrystalline magnetic core 3 can be in a strip shape and can be bent at will, so the flexible nanocrystalline magnetic core 3 can be more closely attached to the curved surface. The flexible nanocrystalline magnetic core 3 has a metal material. In the embodiment of the present disclosure, the material of the flexible nanocrystalline magnetic core 3 can be an iron-based material, such as a Fe-Si-B-Nb-Cu material.

[0052] In some embodiments, a flexible nanocrystalline magnetic core 3 may be provided, and the flexible nanocrystalline magnetic core 3 may be attached to the side of the receiving coil 11 away from the transmitting coil 21, or the flexible nanocrystalline magnetic core 3 may be attached to the side of the transmitting coil 21 away from the receiving coil 11. Since the transmission efficiency between the transmitting coil 21 and the receiving coil 11 can be improved by adding the flexible nanocrystalline magnetic core 3, the flexible nanocrystalline magnetic core 3 may be attached to only one of the two coils, and the signal transmission efficiency between the two coils can also be improved.

[0053] In some embodiments, a plurality of flexible nanocrystalline magnetic cores 3 may be provided, a portion of the plurality of flexible nanocrystalline magnetic cores 3 being attached to the curved surface side of the receiving coil 11 away from the transmitting coil 21 , and another portion of the plurality of flexible nanocrystalline magnetic cores 3 being attached to the curved surface side of the transmitting coil 21 away from the receiving coil 11 .

[0054] That is to say, the flexible nanocrystalline magnetic core 3 is attached to both sides of the receiving coil 11 and the transmitting coil 21 which are away from each other.

[0055] In some embodiments, a flexible nanocrystalline magnetic core 3 is attached to the side of the receiving coil 11 and the side of the transmitting coil 21, respectively. The flexible nanocrystalline magnetic core 3 can completely cover the receiving coil 11 or the transmitting coil 21, or can cover part of the receiving coil 11 or the transmitting coil 21. The area of ​​the flexible nanocrystalline magnetic core 3 can be cut according to demand. In other embodiments, a flexible nanocrystalline magnetic core 3 can be attached to the side of the receiving coil 11, and multiple flexible nanocrystalline magnetic cores 3 can be attached to the side of the transmitting coil 21, or a flexible nanocrystalline magnetic core 3 can be attached to the side of the transmitting coil 21, and multiple flexible nanocrystalline magnetic cores 3 can be attached to the side of the receiving coil 11, or multiple flexible nanocrystalline magnetic cores 3 are attached to the side of the transmitting coil 21 and the side of the receiving coil 11. Those skilled in the art can set it according to the actual situation, and no special limitation is made here.

[0056] like Figure 2 As shown, the receiving coil 11 is attached to the upper surface of the first support plate 11, and the flexible nanocrystalline magnetic core 3 is attached to the upper surface of the receiving coil 11, as shown in FIG. Figure 3 As shown, the transmitting coil 21 is attached to the bottom surface of the second support plate 22 , and the flexible nanocrystalline magnetic core 3 is attached to the surface of the transmitting coil 21 away from the receiving coil 11 , that is, the flexible nanocrystalline magnetic core 3 is located on opposite sides of the receiving coil 11 and the transmitting coil 21 .

[0057] In some embodiments, Figure 2 As shown, the multiple flexible nanocrystalline magnetic cores 3 located on the curved surface side of the receiving coil 11 and the multiple flexible nanocrystalline magnetic cores 3 located on the curved surface side of the transmitting coil 21 are respectively arranged in parallel and at intervals.

[0058] Continue to refer Figure 2 The flexible nanocrystalline magnetic core 3 may be in a strip shape and may be arranged in parallel and spaced relation at the receiving coil 11 side and the transmitting coil 21 side along a first direction X. The first direction X is perpendicular to the vertical direction Z, and the first direction X is parallel to the extending direction of the receiving coil 11. Figure 2 In some embodiments, the flexible nanocrystalline magnetic cores 3 may also be arranged in parallel and spaced apart in the second direction Y. The second direction Y is Figure 2 The extension direction of the flexible nanocrystalline magnetic core 3 is the extension direction of the arc edge of the curved surface. The first direction X, the second direction Y and the vertical direction Z are perpendicular to each other.

[0059] In some embodiments, the plurality of flexible nanocrystalline magnetic cores 3 may also be tilted and spaced apart on the receiving coil 11 side and / or the transmitting coil 21 side, that is, the extension direction of the flexible nanocrystalline magnetic core 3 has an angle with both the first direction X and the second direction Y.

[0060] The plurality of flexible nanocrystalline magnetic cores 3 may be arranged at equal intervals or at unequal intervals. The widths of the flexible nanocrystalline magnetic cores 3 (eg Figure 2 The dimensions along the first direction X) may be the same or different.

[0061] In some embodiments, the flexible nanocrystalline magnetic core 3 located on the transmitting coil 21 side or the receiving coil 11 side can be in the shape of a strip, having 4 to 16 strips. Specifically, in addition to the above two end values, it can also be 5, 8, 10, 12, 14 or 15 strips. Those skilled in the art can set it according to actual needs, and no special limitation is made here.

[0062] In some embodiments, in the extension direction of the flexible nanocrystalline magnetic core 3 , the flexible nanocrystalline magnetic core 3 may have multiple segments. For example, in the second direction Y, each flexible nanocrystalline magnetic core 3 may have two, three, four or more segments spaced apart.

[0063] In some embodiments, the number and arrangement of the flexible nanocrystalline magnetic cores 3 located on the transmitting coil 21 side and the receiving coil 11 side are the same, and when wireless transmission is performed between the transmitting coil 21 and the receiving coil 11, in the vertical direction Z, the projections of the flexible nanocrystalline magnetic cores 3 located on the two coil sides overlap, which can better improve the signal transmission efficiency.

[0064] Since each or each section of the flexible nanocrystalline magnetic core 3 is complete and does not have gaps such as fillets, magnetic flux leakage can be avoided, and the flexible nanocrystalline magnetic core 3 can be directly attached to a curved surface, making installation easier.

[0065] In some embodiments, Figure 7As shown, the flexible nanocrystalline magnetic core 3 includes multiple layers of stacked nanocrystalline ribbons 31 , and the multiple layers of nanocrystalline ribbons 31 are bonded by an adhesive 32 .

[0066] Since the nanocrystalline core of the flexible nanocrystalline magnetic core 3 is made of metal material, eddy current loss will be generated in the high-frequency magnetic field, reducing the transmission efficiency. However, by stacking multiple layers of nanocrystalline ribbons 31, such eddy current loss can be effectively reduced and the signal transmission efficiency can be improved.

[0067] In some embodiments, the thickness of each layer of nanocrystalline ribbon 31 is 14μm to 25μm. Specifically, in addition to the above two end values, it can also be 15μm, 16μm, 18μm, 20μm, 22μm or 23μm. The thickness of the flexible nanocrystalline magnetic core 3 is 0.5mm to 2mm. Specifically, in addition to the above two end values, it can also be 0.6mm, 0.8mm, 1mm, 1.5mm, 1.8mm. Those skilled in the art can choose according to actual conditions, and no special limitation is made here. The required number of layers of nanocrystalline ribbon 31 can be obtained based on the thickness of a single layer of nanocrystalline ribbon 31 and the overall thickness of the flexible nanocrystalline magnetic core 3. For example, the number of layers of nanocrystalline ribbon 31 can be 17 layers.

[0068] The selection of the thickness of the flexible nanocrystalline magnetic core 3 mainly considers three factors, namely, coupling degree, transmission power and bending performance. Within the above range, the thicker the flexible nanocrystalline magnetic core 3, the more it can enhance the coupling degree between the transmitting coil 21 and the receiving coil 11, and improve the transmission efficiency. The thicker the flexible nanocrystalline magnetic core 3 has, the larger the cross-sectional area, so under the same magnetic field strength, the magnetic flux density passing through the flexible nanocrystalline magnetic core 3 is smaller, the core loss will also be smaller, and the temperature rise is smaller, that is, the greater the thickness of the magnetic core, the greater the transmission power. In addition, when the thickness of the flexible nanocrystalline magnetic core 3 exceeds the upper limit of the above range, its flexibility is reduced and bending is hindered, so the thickness is preferably controlled within the above range.

[0069] Therefore, setting the thickness of the flexible nanocrystalline magnetic core 3 within the above range can not only improve the signal transmission efficiency through the flexible nanocrystalline magnetic core 3 , but also maintain the flexibility of the nanocrystalline magnetic core to ensure a closer fit with the curved surface.

[0070] Two adjacent layers of nanocrystalline ribbons 31 are bonded by adhesive 32, and the adhesive 32 may be a pressure-sensitive adhesive (PSA). The thickness of the adhesive 32 between two adjacent layers of nanocrystalline ribbons 31 may be 3 to 5 μm. The stacking direction of the nanocrystalline ribbons 31 of the embodiment of the present disclosure is the same as the direction of the induced magnetic field.

[0071] In some embodiments, the stacking coefficient of the flexible nanocrystalline magnetic core 3 is 0.65 to 0.88. The stacking coefficient refers to the proportion of the total thickness of the stacked nanocrystalline ribbons 31 (excluding the thickness occupied by adhesives, air, etc.) in the thickness of the flexible nanocrystalline magnetic core 3. Specifically, in addition to the above two end values, the stacking coefficient can also be 0.66, 0.68, 0.7, 0.72, 0.75, 0.78, 0.8 or 0.85.

[0072] In some embodiments, the nanocrystalline ribbon 31 is a broken nanocrystalline ribbon 31 that has been processed by an extrusion process. Specifically, the nanocrystalline ribbon 31 is extruded by a roller, and the inside of the nanocrystalline ribbon 31 is squeezed into a plurality of smaller fragments, so that the current path in the nanocrystalline ribbon 31 can be reduced and the eddy current loss can be reduced. By adjusting the size and type of the roller and the force applied during rolling, the degree of fragmentation of the nanocrystalline ribbon 31 can be controlled. By controlling the degree of fragmentation of the nanocrystalline ribbon 31, the magnetic permeability of the nanocrystalline ribbon 31 can be controlled.

[0073] The magnetic permeability of the traditional nanocrystalline ribbon 31 (i.e., the unbroken nanocrystalline ribbon) is 15000-30000. The eddy current in the nanocrystalline ribbon 31 is relatively large, thus generating relatively large eddy current losses. Reducing the magnetic permeability of the nanocrystalline ribbon 31 can reduce the eddy current losses. Crushing the nanocrystalline ribbon 31 can significantly reduce its magnetic permeability, for example, it can be reduced to below 3000. The magnetic permeability is related to the degree of crushing of the nanocrystalline ribbon 31. The greater the degree of crushing, that is, the smaller the fragments, the smaller the magnetic permeability. Therefore, by extruding and crushing the nanocrystalline ribbon 31, the eddy current losses of the flexible nanocrystalline magnetic core 3 can be further reduced, thereby improving the transmission efficiency.

[0074] In some embodiments, the magnetic permeability of the flexible nanocrystalline magnetic core 3 is 800-3000, specifically, in addition to the above two end values, it can also be 1500, 2000, 2500. The magnetic permeability can be controlled by controlling the degree of fragmentation of the nanocrystalline ribbon 31 .

[0075] Since the magnetic saturation capacity of the flexible nanocrystalline core 3 is as high as 1.25T, while the magnetic saturation capacity of the ferrite core is only 0.45T, under the same magnetic field strength, the thickness of the flexible nanocrystalline core 3 is much smaller than that of the ferrite core, and therefore the weight and volume of the flexible nanocrystalline core 3 are much smaller than those of the ferrite core, thereby reducing the weight of the coupler 100 and the volume occupied by the coupler 100.

[0076] In addition, the present disclosure also tests various performances of the coupler 100 having the ferrite core and the flexible nanocrystalline core 3 .

[0077] refer to Figure 8, shows a test diagram of the transmission efficiency of the coupler 100 with magnetic cores of different magnetic permeabilities under different output powers. In this test, six kinds of magnetic cores are selected, namely NiZn magnetic core (a kind of ferrite magnetic core), flexible nanocrystalline magnetic core 3 without breaking, and flexible nanocrystalline magnetic core 3 with broken magnetic permeabilities (μ) of 800, 1500, 2000 and 3000 respectively. The horizontal axis represents the output power of the coupler 100, and the vertical axis represents the transmission efficiency of the coupler 100. It can be concluded from the figure that with the increase of output power, the transmission efficiency shows a slow climbing trend. Among them, the transmission efficiency of the coupler 100 with NiZn magnetic core is the lowest, indicating that the transmission efficiency of the flexible nanocrystalline magnetic core 3 is higher than that of the ferrite magnetic core, and the transmission efficiency of the flexible nanocrystalline magnetic core 3 with a magnetic permeability of 800 is the highest, indicating that breaking can reduce eddy current loss, and even if the magnetic permeability decreases, the transmission efficiency can be improved.

[0078] refer to Figure 9a to Figure 9d , which shows the thermal distribution of the flexible nanocrystalline core captured by a thermal imager (such as the FLIR E6-XT infrared thermal imager). Figure 9a The magnetic permeability of the flexible nanocrystalline core 3 is 800. Figure 9b The magnetic permeability of the flexible nanocrystalline core 3 is 1500. Fig.9c The magnetic permeability of the flexible nanocrystalline core 3 is 2000. Figure 9d The magnetic permeability of the flexible nanocrystalline magnetic core 3 is 3000. As can be seen from the figure, the heat is mainly concentrated in the central concave area of ​​the inner core of the flexible nanocrystalline magnetic core 3. The reason for this phenomenon is that the word density of the central part of the double D-shaped coil is higher, so more heat is generated in this part.

[0079] refer to Figures 10a to 10c , Temperature rise test diagram of using magnetic cores with different magnetic permeabilities at different output powers. Figure 9a to Figure 9d The heat distribution in the flexible nanocrystalline magnetic core is selected as the test point, and the temperature change is tested with a thermocouple for 15 minutes. Fig.10a The output power is 500W. Fig.10b The output power is 700W. Fig.10cThe output power is 1000W. In this test, a total of six types of cores were selected, namely NiZn core (a kind of ferrite core), unbroken flexible nanocrystalline core 3, and broken flexible nanocrystalline core 3 with magnetic permeability (μ) of 800, 1500, 2000 and 3000 respectively. The horizontal axis represents the test time, and the vertical axis represents the temperature. It can be concluded from the figure that the temperature after stabilization increases with the increase of magnetic permeability, which further proves that the crushing process reduces the eddy current loss of the flexible nanocrystalline core 3. In addition, compared with the flexible nanocrystalline core 3 with a magnetic permeability lower than 3000, the temperature of the NiZn core is higher, while the temperature of the flexible nanocrystalline core 3 is lower, the heat generation is reduced, and its temperature performance is better than that of the NiZn core.

[0080] At an output power of 700W, Fig.10b As shown in FIG. 1 , the maximum temperature of the unbroken flexible nanocrystalline magnetic core 3 is 90.2°C, and the maximum temperature of the NiZn magnetic core is 82.1°C. Therefore, in order to avoid overheating and burning of the material, Fig.10c At the 1000W output power, these two materials were not used. Fig.10c As shown in the figure, the temperature variation trend of the four groups of broken flexible nanocrystalline magnetic cores 3 is similar to that of Fig.10a , Fig.10b The temperature variation trends at the output powers of 500 W and 700 W are the same. It can also be concluded from the figure that in the flexible nanocrystalline magnetic core 3, the greater the degree of fragmentation, the smaller the magnetic permeability and the lower the temperature rise.

[0081] Through the above test, it can be concluded that the flexible nanocrystalline magnetic core 3 with a magnetic permeability of 800 has better performance, such as small temperature rise, high transmission efficiency, etc. Therefore, the flexible nanocrystalline magnetic core 3 with a magnetic permeability of 800 can be preferably used in the coupler 100 .

[0082] refer to Figure 11a to Figure 11b , shows the temperature distribution test diagram of the nanocrystalline core with a magnetic permeability of 800 at the receiving end 1 and the transmitting end 2 under different output powers, where: Fig.11a For receiving end 1, Fig.11b It is the transmitting end 2. As can be seen from the figure, the temperature of the flexible nanocrystalline magnetic core 3 of the transmitting end 2 is higher than that of the receiving end 1. The reason for this situation may be that the primary current is large, which produces a strong magnetic density in the surrounding space, resulting in high eddy current loss of the flexible nanocrystalline magnetic core 3 of the transmitting end 2. In addition, Fig.11a The temperature shown in Figure 10a to Figure 10c The temperature difference of the flexible nanocrystalline magnetic core 3 in the example is not large, indicating that changing the flexible nanocrystalline magnetic core 3 at the transmitting end 2 will not affect the temperature distribution of the nanocrystalline magnetic core at the receiving end 1.

[0083] In addition, from Figure 11a to Figure 11bIt can be concluded that when the output power is 1000W, the maximum temperature of the flexible nanocrystalline core 3 with a magnetic permeability of 800 is 54.1℃, and according to Fig.10b It can be seen that the maximum temperature of the nickel-zinc core under 700W working conditions is 82.1℃, and the temperature rise of the nickel-zinc core is higher, which further proves that the flexible nanocrystalline core 3 with a magnetic permeability of 800 generates less heat and has better temperature performance than the nickel core.

[0084] refer to Fig.12 , a weight distribution diagram of the coupler 100 is shown. Taking a coupler 100 as an example, the total weight of the coupler 100 is 6240g (grams), of which about 26.51% is a resin model for installing the coil, and the resin includes 13% (811g) of the resin of the receiving end 1 and 13.51% (843g) of the resin of the transmitting end 2 in the figure. The Litz wire used on both sides of the transmitting end 2 and the receiving end 1 accounts for 68.85% of the total weight, such as 34.28% (2139g) of the coil of the receiving end 1 and 34.57% (2157g) of the coil of the transmitting end 2 in the figure. The 12 flexible nanocrystalline magnetic cores 3 only account for 4.56% (290g) of the weight of the coupler 100. Therefore, the weight of the flexible nanocrystalline magnetic core 3 in the present disclosure is very light, which can reduce the weight of the coupler 100, and the thickness of the flexible nanocrystalline magnetic core 3 can be 0.5mm, which can occupy less space in the coupler 100 and further reduce the volume of the coupler 100.

[0085] It can be seen from the above tests that the flexible nanocrystalline magnetic core 3 with a magnetic permeability of 800 is sufficient to meet the requirements of the coupler 100 with an output power of 1000 W and will not produce other effects.

[0086] In some embodiments, the flexible nanocrystalline magnetic core 3 can also be used in combination with the ferrite magnetic core in the coupler 100. For example, the flexible nanocrystalline magnetic core 3 is attached to the curved surface side of the receiving coil 11 away from the transmitting coil 21, and the ferrite magnetic core is attached to the curved surface side of the transmitting coil 21 away from the receiving coil 11; or, the ferrite magnetic core is attached to the curved surface side of the receiving coil 11 away from the transmitting coil 21, and the flexible nanocrystalline magnetic core 3 is attached to the curved surface side of the transmitting coil 21 away from the receiving coil 11.

[0087] That is to say, according to the actual situation (for example, considering material limitations, cost, etc.), the coupler 100 may also use a ferrite core in combination with the flexible nanocrystalline core 3. Those skilled in the art may choose according to the actual situation, and no special limitation is made here.

[0088] In summary, the coupler 100 of the embodiment of the present disclosure has at least one flexible nanocrystalline magnetic core 3 attached to at least one of the curved side of the receiving coil 11 away from the transmitting coil 21 and the curved side of the transmitting coil 21 away from the receiving coil 11. Since the nanocrystalline magnetic core is flexible, it can better fit the curved surface, improve the transmission efficiency, and avoid magnetic flux leakage. The nanocrystalline magnetic core is a whole and does not need to be spliced, so the installation is simpler. In addition, since the nanocrystalline magnetic core has a higher magnetic saturation capacity and a smaller required thickness, it can reduce the volume and weight, thereby reducing the volume and weight of the coupler 100 and providing compactness of the coupler.

[0089] The disclosed embodiment also provides an electric device 200, which can be an underwater vehicle or a curved screen. The electric device 200 includes the coupler 100 described in any of the above embodiments. The receiving end 1 of the coupler 100 is placed in a housing 201, and the transmitting end 2 can be placed at a predetermined position on the bottom of the water. When the vehicle needs to be charged, it can stop above the transmitting end 2, so that wireless transmission is performed between the transmitting end 2 and the receiving end 1 in the housing 201. Figure 4 , the transmitting coil 21 of the transmitting end 2 and the flexible nanocrystalline magnetic core 3 can be placed on a supporting platform. Fig.13 As shown, taking an underwater vehicle as an example, it has an arc-shaped shell 201 to reduce resistance in water. In order to be able to show the coupler 100, Fig.13 The underwater vehicle in the embodiment omits part of the housing and some components in the housing. For the specific structure of the coupler 100, reference can be made to the description of the above embodiment, which will not be repeated here. The curvature of the receiving coil 11 of the coupler 100 is the same as that of the housing 201, so that it can be easily arranged on the housing 201.

[0090] By providing the above-mentioned coupler 100, the transmission efficiency can be improved, the weight and volume of the electrical device 200 can be reduced, and the operation thereof can be more stable.

[0091] It should be understood that the present disclosure does not limit its application to the detailed structure and arrangement of the components proposed in this specification. The present disclosure can have other embodiments and can be implemented and executed in a variety of ways. The aforementioned variations and modifications fall within the scope of the present disclosure. It should be understood that the present disclosure disclosed and defined in this specification extends to all alternative combinations of two or more individual features mentioned or evident in the text and / or the drawings. All these different combinations constitute multiple alternative aspects of the present disclosure. The embodiments described in this specification illustrate the best mode known for implementing the present disclosure and will enable those skilled in the art to utilize the present disclosure.

Claims

1. A coupler, characterized in that: include: A receiving end is provided with a receiving coil having a curved surface; The transmitting end is provided with a transmitting coil having a curved surface; When wireless transmission is performed between the transmitting end and the receiving end, the transmitting end is located on one side of the receiving end in a vertical direction and has a spacing with the receiving end, and the transmitting coil corresponds to the receiving coil in the vertical direction; At least one flexible nanocrystalline magnetic core is attached to at least one of the curved surface side of the receiving coil away from the transmitting coil and the curved surface side of the transmitting coil away from the receiving coil.

2. The coupler according to claim 1, characterized in that There are multiple flexible nanocrystalline magnetic cores, a part of which is attached to the curved side of the receiving coil away from the transmitting coil, and another part of which is attached to the curved side of the transmitting coil away from the receiving coil.

3. The coupler according to claim 2, characterized in that: The multiple flexible nanocrystalline magnetic cores located on the curved surface side of the receiving coil and the multiple flexible nanocrystalline magnetic cores located on the curved surface side of the transmitting coil are respectively arranged in parallel and at intervals.

4. The coupler according to claim 1, characterized in that The flexible nanocrystalline magnetic core includes multiple layers of stacked nanocrystalline ribbons, and the multiple layers of nanocrystalline ribbons are bonded by an adhesive.

5. The coupler according to claim 4, characterized in that The thickness of each layer of the nanocrystalline ribbon is 14 μm to 25 μm, and the thickness of the flexible nanocrystalline magnetic core is 0.5 mm to 2 mm.

6. The coupler according to claim 4, characterized in that The stacking coefficient of the flexible nanocrystalline magnetic core is 0.65-0.

88.

7. The coupler according to claim 4, characterized in that: The nanocrystalline ribbon is a broken nanocrystalline ribbon processed by an extrusion process.

8. The coupler according to claim 7, characterized in that The magnetic permeability of the flexible nanocrystalline magnetic core is 800-3000.

9. The coupler according to claim 1, characterized in that: The flexible nanocrystalline magnetic core is attached to the curved surface side of the receiving coil away from the transmitting coil, and the ferrite magnetic core is attached to the curved surface side of the transmitting coil away from the receiving coil; or, The ferrite core is attached to the curved surface side of the receiving coil away from the transmitting coil, and the flexible nanocrystalline core is attached to the curved surface side of the transmitting coil away from the receiving coil.

10. An electrical device, characterized in that: Comprising a coupler as claimed in any one of claims 1 to 9.

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