An assembled wireless charging road magnetically permeable surface layer unit and a construction method thereof

Abstract

An assembled wireless charging road magnetic guide surface layer unit and a construction method thereof, which relate to the technical fields of wireless charging roads and assembled pavement structures. The unit is used for solving the problems of magnetic shielding, difficult implementation of discrete partition construction on site, and low integration of wireless charging modules and road surface layer structures in the prior art. The magnetic guide surface layer unit comprises an electromagnetic module and a prefabricated asphalt concrete surface layer plate. The electromagnetic module comprises a GFRP bottom support, an electromagnetic shielding plate, a transmitting coil, a local pouring seal layer and a GFRP top plate. The prefabricated asphalt concrete surface layer plate comprises a magnetic guide asphalt mixture area and a common asphalt mixture area. The construction method comprises the steps of prefabrication of an assembled composite functional unit, layout of a roadside power supply system, setting of a power supply line channel, civil preparation of a road functional area, installation of the functional unit, electrical connection, joint treatment and system debugging and detection. The unit is used for wireless charging roads for electric vehicles.

Description

Technical Field

[0001] This invention relates to the fields of road engineering, wireless power transmission and prefabricated pavement structure technology, and specifically to a prefabricated wireless charging road magnetic surface layer unit and its construction method. Background Technology

[0002] With the development of electric vehicles and intelligent transportation infrastructure, wireless charging roads, as a type of road infrastructure that enables wireless power replenishment during vehicle movement or parking, have attracted widespread attention. In wireless charging roads, the road structure not only bears the vehicle load and environmental impact, but also serves as the functional carrier in the wireless power transmission process. In particular, the road surface layer located between the transmitting and receiving coils directly affects the magnetic field distribution, coil coupling degree, and system charging efficiency through its material properties and structural form.

[0003] In existing technologies, when ordinary asphalt mixtures are used as conventional road surface materials for wireless charging roads, they can easily adversely affect the effective magnetic flux linkage between the transceiver coils, leading to a decrease in system transmission power and efficiency. To address this issue, existing technologies propose deploying magnetically conductive asphalt mixtures in localized areas of the road surface layer to enhance the convergence and transmission capabilities of the main magnetic flux, thereby improving the coupling performance and charging effect of the wireless charging system.

[0004] However, existing magnetically conductive surface layers still present significant structural and construction challenges in engineering implementation. Firstly, while laying the magnetically conductive asphalt mixture continuously along the wireless charging functional section conforms to the conventional asphalt pavement construction organization of being continuous, regular, and with fewer joints, the continuous magnetic coverage above the closed transmitting coil easily creates significant magnetic shielding in the area directly above the coil conductor, thus weakening the system's coupling performance. Secondly, if discrete zoning construction is carried out on-site entirely according to the laboratory-optimized zoning method, it will lead to frequent material switching, complex zoning boundaries, low construction efficiency, and difficulties in quality control, hindering engineering implementation.

[0005] Furthermore, in existing wireless charging road construction, the electromagnetic module and the road surface layer are usually constructed separately. The lack of integrated design between module packaging, surface layer paving, and on-site installation results in low structural integration, which is detrimental to factory prefabrication, on-site assembly, and subsequent maintenance and replacement. Therefore, it is still necessary to provide a prefabricated implementation scheme for the magnetic conductive surface layer of wireless charging roads that balances charging performance and construction feasibility. Summary of the Invention

[0006] The purpose of this invention is to address the problems in existing technologies, such as magnetic shielding issues arising from continuous laying of the magnetically conductive surface layer, difficulties in implementing discrete zoning construction on-site, and low integration of the wireless charging module with the road surface structure. Therefore, this invention provides a prefabricated wireless charging road magnetically conductive surface layer unit and its construction method.

[0007] The technical solution of this invention is:

[0008] The present invention provides a prefabricated wireless charging road magnetic surface layer unit, comprising an electromagnetic module encapsulated by glass fiber reinforced composite material and a precast asphalt concrete surface layer plate located on top of the electromagnetic module. The electromagnetic module includes a GFRP base, an electromagnetic shielding plate disposed within the GFRP base, a transmitting coil, a partial potting layer, and a GFRP top plate; The GFRP base is provided with a mounting groove for mounting the electromagnetic shielding plate and the transmitting coil, and an outlet for leading out the tail wire of the transmitting coil. The transmitting coil is disposed above the electromagnetic shielding plate, and the tail wire of the transmitting coil is connected to the main feed cable through the lead-out opening; The local potting layer is disposed around the transmitting coil and the electromagnetic shielding plate; The GFRP top plate and the GFRP bottom support cooperate to form a closed electromagnetic module encapsulation shell; The precast asphalt concrete surface slab includes a magnetic asphalt mixture zone and a regular asphalt mixture zone; The magnetically conductive asphalt mixture area is located above the effective coupling area of ​​the transmitting coil, while the ordinary asphalt mixture area is located directly above and around the coil conductor to reduce the adverse magnetic shielding effect caused by continuous magnetic coverage.

[0009] Furthermore, the GFRP base is a groove-shaped structure with a planar dimension of 700 mm × 700 mm to 850 mm × 850 mm, a groove depth of 8 mm to 10 mm, a base plate thickness of 2 mm to 4 mm, and a side wall thickness of 2 mm to 4 mm.

[0010] Furthermore, the transmitting coil is a planar rectangular coil or a planar circular coil, wound with 300 to 1000 strands of Litz wire with a single strand diameter of 0.1 mm, the outer diameter of the coil bundle is 2 mm to 4 mm, and it is wound with 25 to 40 turns;

[0011] When the transmitting coil is a planar rectangular coil, its outer dimensions are 500 mm × 500 mm to 650 mm × 650 mm;

[0012] When the transmitting coil is a planar circular coil, its outer diameter is 500mm~650mm.

[0013] Furthermore, the electromagnetic shielding plate is a magnetic shielding component made of a high-permeability shielding material, and its planar dimensions are larger than the outer dimensions of the transmitting coil; When the transmitting coil is a planar rectangular coil, the width of the edge of the electromagnetic shielding plate extending beyond the outer edge of the transmitting coil is 20mm on each side;

[0014] When the transmitting coil is a planar circular coil, the electromagnetic shielding plate extends outward by 20mm along the outer edge of the transmitting coil in the circumferential direction; the thickness of the electromagnetic shielding plate is 2mm~5mm.

[0015] Furthermore, both the transmitting coil and the electromagnetic shielding plate are located at the geometric center of the GFRP base;

[0016] The lead-out opening of the transmitting coil tail wire is located on the side of the GFRP base near the roadside power supply, and a sealing structure is provided at the lead-out opening.

[0017] Furthermore, the local potting layer is disposed at one or more locations among the corner of the transmitting coil, the tail wire lead-out location, and the surrounding area where relative displacement is likely to occur; the local potting layer is made of thermally conductive and insulating epoxy potting resin, thermally conductive and insulating silicone resin, or potting material with insulating and thermally conductive properties.

[0018] Furthermore, the interface reinforcement structure on the upper surface of the GFRP top plate includes one or more of the following: roughened surface, mechanical interlocking texture, shallow groove, and limiting rib; the precast asphalt concrete surface plate and the electromagnetic module adopt a composite connection method with mechanical interlocking as the main component and adhesive bonding as the auxiliary component.

[0019] Furthermore, the magnetically conductive asphalt mixture zone is composed of asphalt binder, aggregate, and magnetic material, wherein the coarse aggregate, fine aggregate, or filler in the aggregate is replaced by magnetic material in an equal volume manner, and the replacement amount of the magnetic material is 5% to 40% of the total volume of the aggregate; the thickness of the precast asphalt concrete surface layer slab is consistent with the design thickness of the surface layer on the road, which is 4cm to 6cm.

[0020] The present invention also provides a construction method for a prefabricated wireless charging road magnetic surface layer unit, comprising the following steps:

[0021] Step 1: Prefabricate the assembled wireless charging road magnetic surface layer units in the factory;

[0022] Step 2: Install a roadside power supply system in the road median, shoulder, or reserved space on the roadside, and lead the main power supply cable to the wireless charging road functional area;

[0023] Step 3: Set up a line channel in the road structure to lay the main power supply cable and connect it to the tail wire interface of the prefabricated wireless charging road magnetic surface layer unit.

[0024] Step 4: Carry out civil engineering preparation for the road functional area, and form installation slots or reserve installation positions in the existing or newly built roads for installing the prefabricated wireless charging road magnetic surface layer unit;

[0025] Step 5: Install the prefabricated assembled wireless charging road magnetic surface layer unit into the mounting slot or reserved mounting position to complete the positioning, leveling and fixing;

[0026] Step 6: Electrically connect the tail wire of the transmitting coil of the prefabricated wireless charging road magnetic surface layer unit to the main feeder cable, and connect it to the roadside power supply node;

[0027] Step 7: Seal and waterproof the lateral joints between the prefabricated wireless charging road magnetic surface layer unit and the conventional road surface, as well as the inter-plate joints between adjacent prefabricated wireless charging road magnetic surface layer units.

[0028] Step 8: Conduct system debugging and testing, including continuity testing, insulation testing, and parameter verification of the roadside power supply system, electrical connection interfaces, and transmitting coil circuit.

[0029] Furthermore, the cable channel in step three includes one or more of the following: a horizontal conduit, a vertical cable channel, a cable trench, or a reserved cable cavity; In step four, the installation groove is arranged along the centerline of the target lane. The planar dimensions of the installation groove are 730 mm × 730 mm to 880 mm × 880 mm, and the groove depth is 60 mm to 90 mm. A leveling layer with a thickness of 10 mm to 30 mm is set at the bottom of the installation groove. In step five, the assembled wireless charging road magnetic surface layer unit is arranged along the centerline of the target lane, and multiple units can be set at intervals along the longitudinal direction of the lane. The electrical connection in step six adopts a sealed connection structure and is located in a position that is easy to maintain and avoids direct wheel load. The joint width in step seven is 10 mm to 30 mm, and flexible caulking and sealing material is used for sealing and waterproofing. The parameter verification in step eight includes inductance parameter detection, and the debugging and testing also includes one or more of the following: power supply node output detection and functional area power-on trial operation detection.

[0030] Compared with the prior art, the present invention has the following advantages:

[0031] 1. The present invention sets up a magnetically conductive asphalt mixture area and an ordinary asphalt mixture area in the precast asphalt concrete surface slab. The magnetically conductive asphalt mixture area is arranged above the effective coupling area of ​​the transmitting coil, and the ordinary asphalt mixture area is arranged in the area directly above the coil and the surrounding area. The above structure can enhance the main magnetic flux convergence and transmission while reducing the adverse magnetic shielding effect caused by continuous magnetic coverage, thereby improving the coupling performance of the wireless charging system.

[0032] 2. This invention employs a GFRP-encapsulated electromagnetic module, integrating the transmitting coil and electromagnetic shielding plate into a structural unit that combines insulation, waterproofing, positioning, and basic support functions. A closed electromagnetic module enclosure is formed through the combination of a GFRP base, a GFRP top plate, and a partial potting layer. This structure improves the structural integration between the wireless charging module and the road surface layer, and enhances its environmental adaptability in road service environments.

[0033] 3. This invention transforms the complex on-site zoning construction of the magnetically conductive surface layer into the factory prefabrication and on-site installation of prefabricated wireless charging road magnetically conductive surface layer units. This is achieved through a prefabricated construction method involving factory prefabrication, on-site hoisting, joint treatment, and electrical connections. This method reduces the frequency of material switching and the difficulty of boundary control, improves the regularity of construction organization and implementation efficiency, and helps to shorten the construction cycle and reduce traffic disruption.

[0034] 4. This invention includes a civil engineering preparation step for road functional areas in its construction method. For existing road reconstruction, installation grooves are formed in the existing road surface. For new road construction, installation positions and wiring channels are reserved during the construction of the base and lower layers. This invention is applicable to both existing road reconstruction and new road construction. Furthermore, the prefabricated wireless charging road magnetic surface layer unit is easy to disassemble, replace, and maintain, making it highly suitable for the engineering implementation of wireless charging road magnetic surface layers. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the overall structure of the assembled wireless charging road magnetic surface layer unit of the present invention. Figure 2 This is a schematic diagram of the structure of the GFRP-encapsulated electromagnetic module of the present invention.

[0036] Figure 3 This is a schematic diagram showing the partitioning of the magnetic asphalt mixture zone and the ordinary asphalt mixture zone in the precast asphalt concrete surface slab of the present invention. Figure 4 This is a schematic diagram of the implementation process of the present invention.

[0037] The components include: 1. Electromagnetic module; 2. Precast asphalt concrete surface slab; 3. GFRP base; 4. Electromagnetic shielding plate; 5. Transmitting coil; 6. GFRP top plate; 7. Lead-out opening; 8. Magnetic asphalt mixture area; 9. Ordinary asphalt mixture area. Detailed Implementation

[0038] Specific implementation method one: Combining Figures 1 to 3 This embodiment describes an electromagnetic module 1 encapsulated by glass fiber reinforced composite material and a precast asphalt concrete surface plate 2 located on top of the electromagnetic module 1. The electromagnetic module 1 includes a GFRP base 3, an electromagnetic shielding plate 4 disposed within the GFRP base 3, a transmitting coil 5, a partial potting layer, and a GFRP top plate 6; The GFRP base 3 is provided with a mounting groove for mounting the electromagnetic shielding plate 4 and the transmitting coil 5, and an outlet opening 7 for leading out the tail wire of the transmitting coil 5. The transmitting coil 5 is disposed above the electromagnetic shielding plate 4, and the tail wire of the transmitting coil 5 is connected to the main feed cable through the lead-out opening 7. The local potting layer is disposed around the transmitting coil 5 and the electromagnetic shielding plate 4; The GFRP top plate 6 and the GFRP bottom support 3 cooperate to form a closed electromagnetic module encapsulation shell; The precast asphalt concrete surface slab 2 includes a magnetically conductive asphalt mixture zone 8 and an ordinary asphalt mixture zone 9; The magnetically conductive asphalt mixture area 8 is located above the effective coupling area of ​​the transmitting coil 5, and the ordinary asphalt mixture area 9 is located directly above and around the coil conductor to reduce the adverse magnetic shielding effect caused by continuous magnetic coverage.

[0039] This embodiment uses a GFRP base, an electromagnetic shielding plate, a transmitting coil, a partial potting layer, and a GFRP top plate to form a closed electromagnetic module, integrating and encapsulating the wireless charging components to improve structural integration and environmental adaptability. At the same time, the precast asphalt concrete surface plate is divided into a magnetically conductive asphalt mixture area and a regular asphalt mixture area. The magnetically conductive area corresponds to the area above the effective coupling region of the transmitting coil to enhance the convergence of the main magnetic flux, while the regular area corresponds to the area directly above and around the coil conductor to reduce the magnetic shielding effect caused by continuous magnetic coverage.

[0040] Specific Implementation Method Two: Combining Figure 2 This embodiment describes a GFRP base 3 with a groove-shaped structure. Its planar dimensions are 700 mm × 700 mm to 850 mm × 850 mm, the groove depth is 8 mm to 10 mm, the base plate thickness is 2 mm to 4 mm, and the side wall thickness is 2 mm to 4 mm.

[0041] This embodiment uses a planar dimension of 700mm×700mm to 850mm×850mm to accommodate the outer dimensions of the transmitting coil of common passenger vehicle wireless charging systems (500mm×650mm) and leave installation margin to ensure that the electromagnetic shielding plate and transmitting coil can be smoothly installed inside the base. The groove depth of 8mm~10mm can accommodate the electromagnetic shielding plate with a thickness of 2mm~5mm and the transmitting coil with an outer diameter of 2mm~4mm. The total thickness of the two stacked together is about 4mm~9mm. After adding the local potting layer, it just fills the groove depth, which avoids the module shaking due to excessive gaps and prevents the coil from being damaged by the top plate due to insufficient groove depth. The thickness of the bottom plate and the side wall are both controlled at 2mm~4mm. On the one hand, this ensures that the base has sufficient structural strength to withstand the pressure transmitted by the upper asphalt surface layer and vehicle load. On the other hand, it avoids the increase in module weight and material cost due to excessive wall thickness.

[0042] Specific implementation method three: Combining Figure 2 In this embodiment, the transmitting coil 5 is a planar rectangular coil or a planar circular coil, wound with 300 to 1000 strands of Litz wire with a single strand diameter of 0.1 mm, the outer diameter of the coil bundle is 2 mm to 4 mm, and it is wound with 25 to 40 turns.

[0043] When the transmitting coil 5 is a planar rectangular coil, its outer dimensions are 500 mm × 500 mm to 650 mm × 650 mm;

[0044] When the transmitting coil 5 is a planar circular coil, its outer diameter is 500mm~650mm.

[0045] This embodiment uses 300-1000 strands of Litz wire with a single strand diameter of 0.1 mm. This is because the skin effect is significant under high-frequency current, and the insulation of multiple thin strands effectively reduces AC resistance and coil self-heating. The outer diameter of the wire harness is controlled at 2mm-4mm, with 25-40 turns. This ensures sufficient ampere-turns to generate a strong magnetic field without making the coil too thick or having too many turns, which would affect the packaging. Both planar rectangular and circular shapes can be used to adapt to the receiving coil layout of different vehicle models. Rectangular coils have stronger directionality, while circular coils have better alignment tolerance. The outer dimensions or outer diameter are 500mm-650mm, matching the receiving coil dimensions of common passenger car chassis, ensuring an effective coupling area between the transmitting and receiving coils, while not exceeding the mounting groove size of the GFRP base, facilitating overall packaging.

[0046] Specific implementation method four: Combination Figure 2 In this embodiment, the electromagnetic shielding plate 4 is a magnetic shielding component made of a high permeability shielding material, and its planar dimensions are larger than the outer dimensions of the transmitting coil 5. When the transmitting coil 5 is a planar rectangular coil, the width of the edge of the electromagnetic shielding plate 4 extending beyond the outer edge of the transmitting coil 5 is 20mm on each side;

[0047] When the transmitting coil 5 is a planar circular coil, the electromagnetic shielding plate 4 extends outward by 20mm along the outer edge of the transmitting coil 5. The thickness of the electromagnetic shielding plate 4 is 2mm to 5mm.

[0048] The electromagnetic shielding plate in this embodiment serves to physically constrain the direction of the magnetic field generated by the transmitting coil. Preferably, a high-permeability material is used to fabricate the shielding plate, which is placed close to the coil below. This provides a low-resistivity path for the magnetic field lines, guiding the magnetic field primarily upwards (towards the receiving coil) while minimizing downward leakage. This prevents the magnetic field from penetrating into the road structure or underground spaces, where it can generate heat due to eddy currents. The shielding plate's planar dimensions extend 20mm beyond the coil's outer contour on each side to include the magnetic field lines at the coil's edges within the constrained area, preventing lateral escape. The thickness is controlled between 2mm and 5mm because high-permeability materials within this thickness range already provide sufficient magnetic flux pathways; further increasing the thickness would offer limited improvement in shielding effectiveness and would instead increase the overall module thickness and material cost.

[0049] Specific Implementation Method Five: Combining Figure 2 In this embodiment, both the transmitting coil 5 and the electromagnetic shielding plate 4 are located at the geometric center of the GFRP base 3.

[0050] The lead-out opening 7 of the tail wire of the transmitting coil 5 is located on the side of the GFRP base 3 near the roadside power supply, and a sealing structure is provided at the lead-out opening 7.

[0051] In this embodiment, both the transmitting coil and the electromagnetic shielding plate are located at the geometric center of the GFRP base. This ensures that the center of the magnetic field generated by the coil is aligned with the center of the charging area on the road, allowing the chassis receiving coil to be precisely aligned with the area of ​​strongest magnetic field when a vehicle enters, reducing efficiency loss caused by offset. The tail wire lead-out opening is located on the side of the base closer to the roadside power supply to shorten the distance between the tail wire and the main roadside feeder cable, reducing cable laying length and signal attenuation. A sealed structure is provided at the opening because the base is buried inside the road surface, and groundwater, rainwater, snowmelt, or road seepage water may enter the module through the tail wire channel. The sealed structure prevents moisture intrusion that could cause coil short circuits or a decrease in insulation performance.

[0052] Specific Implementation Method Six: Combination Figure 2In this embodiment, the local potting layer is disposed at one or more locations, including the corner of the transmitting coil 5, the tail wire lead-out location, and the surrounding area where relative displacement is likely to occur; the local potting layer is made of thermally conductive and insulating epoxy potting resin, thermally conductive and insulating silicone resin, or potting material with insulating and thermally conductive properties.

[0053] In this embodiment, the local potting layer is only applied to key areas such as coil corners and tail wire exits, rather than potting the entire module. The coil generates heat when energized. Corners are areas where the Litz wire bends and stress concentrates, and the tail wire exit is the connection point between the coil and external cables. These two locations are most prone to relative displacement under repeated vibrations from vehicle loads. Potting only these localized areas not only fixes the weakest points and prevents fatigue fracture but also leaves gaps in the rest of the module to facilitate heat dissipation during coil operation. Thermally conductive and insulating resin or silicone resin is chosen as the potting material because these materials can conduct the heat generated by the coil to the top plate and bottom support for dissipation while ensuring electrical insulation between the coil and the surrounding structure, preventing leakage.

[0054] Specific implementation method seven: Combination Figure 2 In this embodiment, the interface reinforcement structure on the upper surface of the GFRP top plate 6 includes one or more of the following: roughened surface, mechanical interlocking texture, shallow groove, and limiting rib; the precast asphalt concrete surface plate 2 and the electromagnetic module 1 adopt a composite connection method with mechanical interlocking as the main component and adhesive bonding as the auxiliary component.

[0055] In this embodiment, the upper surface of the GFRP top slab is roughened, with mechanical interlocking textures, shallow grooves, or limiting ribs to enhance the interfacial interlocking force between the top slab and the upper asphalt concrete surface layer. During prefabrication, the asphalt concrete surface layer is laid on top of the top slab. After compaction, the asphalt mixture embeds into these textures or shallow grooves, forming a mechanical interlock after curing.

[0056] The preferred mechanical interlocking method involves setting raised ribs or tooth-like structures on the upper surface of the top slab, and creating dovetail or trapezoidal grooves, with matching grooves formed on the bottom surface of the precast asphalt concrete surface layer slab. This composite connection method, primarily mechanical interlocking and supplemented by adhesive, is chosen because adhesives alone are prone to aging and detachment under varying road surface temperatures and repeated vehicle loads. Mechanical interlocking structures are more reliable over long-term service, and the addition of a small amount of adhesive fills tiny gaps at the contact interface, preventing moisture penetration.

[0057] Specific implementation method eight: Combination Figure 3This embodiment describes a magnetically conductive asphalt mixture zone 8 composed of asphalt binder, aggregates, and magnetic materials. The coarse aggregates, fine aggregates, or fillers in the aggregates are replaced by magnetic materials in equal volume, with the replacement amount of the magnetic materials being 5% to 40% of the total aggregate volume. The thickness of the precast asphalt concrete surface layer 2 is consistent with the design thickness of the road surface layer, which is 4cm to 6cm.

[0058] The magnetically conductive asphalt mixture of this embodiment is made by replacing a portion of the coarse aggregate, fine aggregate, or filler with magnetic material by an equal volume in a mixture based on ordinary asphalt mixture. The replacement ratio is adjusted according to the type of magnetic material and the object being replaced, and is usually controlled between 5% and 40% of the total aggregate volume. When the replacement ratio is too low, the improvement in magnetic permeability is limited; while when the replacement ratio is too high, it may weaken the aggregate skeleton structure, leading to a decrease in high-temperature stability. Equal volume replacement is used instead of equal weight replacement because the density of magnetic materials is usually different from that of ordinary aggregates. Equal volume replacement can maintain the volume stability of the mixture, and the thickness and porosity after paving and compaction are basically the same as ordinary asphalt mixtures, without the occurrence of local bulges or depressions. The thickness of the precast surface layer slab is 4cm to 6cm, consistent with the design thickness of the surface layer on conventional roads, so that the upper surface can be flush with the adjacent road surface after installation, without the need for additional leveling or adjustment.

[0059] Specific Implementation Method Nine: Combining Figures 1 to 4 This embodiment, and its construction method, includes the following steps:

[0060] Step 1: Prefabricate the assembled wireless charging road magnetic surface layer units in the factory;

[0061] Step 2: Install a roadside power supply system in the road median, shoulder, or reserved space on the roadside, and lead the main power supply cable to the wireless charging road functional area;

[0062] Step 3: Set up a line channel in the road structure to lay the main power supply cable and connect it to the tail wire interface of the prefabricated wireless charging road magnetic surface layer unit.

[0063] Step 4: Carry out civil engineering preparation for the road functional area, and form installation slots or reserve installation positions in the existing or newly built roads for installing the prefabricated wireless charging road magnetic surface layer unit;

[0064] Step 5: Install the prefabricated assembled wireless charging road magnetic surface layer unit into the mounting slot or reserved mounting position to complete the positioning, leveling and fixing;

[0065] Step 6: Electrically connect the transmitting coil 5 tail wire of the prefabricated wireless charging road magnetic surface layer unit to the main feeder cable and connect it to the roadside power supply node;

[0066] Step 7: Seal and waterproof the lateral joints between the prefabricated wireless charging road magnetic surface layer unit and the conventional road surface, as well as the inter-plate joints between adjacent prefabricated wireless charging road magnetic surface layer units.

[0067] Step 8: Conduct system debugging and testing, including continuity testing, insulation testing, and parameter verification of the roadside power supply system, electrical connection interfaces, and five-circuit transmitting coil.

[0068] This implementation method transfers all processes that originally needed to be completed on-site, such as the zonal paving of the magnetic asphalt mixture, the installation of electromagnetic modules, and the surface layer paving, to the factory. On-site work only involves excavating the installation trench, hoisting the units, treating the joints, and making electrical connections. Prefabrication in the factory in step one ensures the boundary accuracy between the magnetic zone and the ordinary zone, avoiding the problems of frequent material switching and boundary control difficulties during on-site zonal construction. Steps two through four involve pre-laying the roadside power supply system and cable channels to ensure the cables are in place before unit installation, preventing damage to already installed units or the road surface during subsequent wiring. Step five, positioning, leveling, and fixing, ensures that the upper surface of each unit is flush with the adjacent road surface, preventing bumps during vehicle movement. Step six, electrical connections, are performed after unit installation, with the tail wire connected to the main cable after exiting the lead-out opening. Step seven involves sealing and waterproofing the joints to prevent road surface water from seeping into the electromagnetic modules along the joints. Step eight involves continuity testing, insulation testing, and parameter verification. Only after confirming that all coil circuits and power supply nodes are working properly can the unit be put into operation, thus avoiding the need to dismantle and rework the unit if a fault is found after power-on.

[0069] Specific Implementation Method Ten: Combining Figures 1 to 4 This embodiment describes a wiring channel in step three that includes one or more of the following: a horizontal conduit, a vertical cable channel, a cable trench, or a reserved cable cavity. In step four, the installation groove is arranged along the centerline of the target lane. The planar dimensions of the installation groove are 730 mm × 730 mm to 880 mm × 880 mm, and the groove depth is 60 mm to 90 mm. A leveling layer with a thickness of 10 mm to 30 mm is set at the bottom of the installation groove. In step five, the assembled wireless charging road magnetic surface layer unit is arranged along the centerline of the target lane, and multiple units can be set at intervals along the longitudinal direction of the lane. The electrical connection in step six adopts a sealed connection structure and is located in a position that is easy to maintain and avoids direct wheel load. The joint width in step seven is 10 mm to 30 mm, and flexible caulking and sealing material is used for sealing and waterproofing. The parameter verification in step eight includes inductance parameter detection, and the debugging and testing also includes one or more of the following: power supply node output detection and functional area power-on trial operation detection.

[0070] This implementation utilizes various methods for the wiring channel, including conduit, cable trenches, and pre-reserved cavities, to adapt to both existing road reconstruction and new road construction. During reconstruction, the channel is formed by trenching and burying pipes; during new construction, it is pre-reserved during the base layer construction. The installation trench is arranged along the lane centerline and is 15mm wider on each side than the surface layer unit. The trench depth is 60mm-90mm, plus a 10mm-30mm leveling layer at the bottom. After the unit is placed, its upper surface is flush with the road surface. The leveling layer also compensates for unevenness at the bottom of the trench, preventing the unit from cracking due to unsupported pressure. Multiple units are arranged longitudinally along the lane at intervals because actual wireless charging does not require continuous installation; charging points only need to be set up in specific parking or driving areas. The electrical connection uses a sealed structure and is located away from wheel loads to prevent joint loosening or water ingress and short circuits caused by repeated vehicle traffic. A 10mm-30mm width is left at the joints and sealed with flexible sealant because asphalt pavement expands and contracts with temperature changes; the flexible material can expand and contract accordingly without cracking, while also preventing surface water from seeping down the joints. During commissioning, inductance parameters and power supply node outputs are checked and a power-on test run is conducted. The purpose is to confirm that the resonant frequency and coupling performance of each transmitting coil meet the design requirements, and to avoid opening the road to traffic before local coil faults are detected.

[0071] Combination Figures 1 to 4 Description of embodiments of the present invention:

[0072] Example 1: This example provides a prefabrication method for a modular composite functional unit, wherein the modular wireless charging road magnetic surface layer is applied to the wireless charging road functional area of ​​ordinary passenger vehicles. The modular composite functional unit includes a lower GFRP encapsulated electromagnetic module and an upper prefabricated asphalt concrete surface slab, wherein the prefabricated asphalt concrete surface slab is 4cm thick and has an overall planar dimension of 770 mm × 770 mm. The specific prefabrication steps include the following:

[0073] 1) Fabrication of GFRP base. A groove-shaped GFRP base is fabricated using fiberglass cloth and high-temperature resistant resin. The GFRP base has a square groove structure with a planar dimension of 770 mm × 770 mm, a groove depth of 6 mm, a base plate thickness of 3 mm, and a side wall thickness of 3 mm. An installation groove for mounting the electromagnetic shielding plate and the transmitting coil is formed in the middle of the GFRP base, and an opening for the tail wire lead-out is reserved on the side near the roadside power supply.

[0074] 2) Laying the electromagnetic shielding plate and transmitting coil. The electromagnetic shielding plate is laid on the bottom of the GFRP base tray, and then the transmitting coil is installed on top of the electromagnetic shielding plate. The electromagnetic shielding plate is a magnetic shielding component made of high-permeability shielding material, with a planar dimension of 570 mm × 570 mm and a thickness of 2 mm. The transmitting coil is a planar rectangular coil, wound with 600 strands of Litz wire with a single strand diameter of 0.1 mm, a wire bundle outer diameter of 3 mm, and 35 turns, with an outer dimension of 550 mm × 550 mm. The edge of the electromagnetic shielding plate extends 20 mm beyond the outer edge of the transmitting coil on each side.

[0075] 3) Local potting and pressing of the top plate. The corner areas of the transmitting coil and the tail wire lead-out areas are locally potted, and then the GFRP top plate is pressed to form a closed GFRP-encapsulated electromagnetic module. The local potting layer uses thermally conductive and insulating epoxy potting resin, with a local potting thickness of 6 mm; the GFRP top plate is 3 mm thick, and the GFRP top plate and GFRP base are connected by bonding and hot-pressing composite methods.

[0076] 4) Perform interface strengthening treatment on the top slab. The upper surface of the GFRP top slab undergoes interface strengthening treatment to improve its interfacial synergy with the upper precast asphalt concrete surface layer. The top slab surface is roughened and shallow grooves are formed. The grooves are 2 mm deep and 8 mm to 12 mm wide.

[0077] 5) Precast asphalt concrete surface slabs are laid in zones. The ordinary asphalt mixture is AC-13 dense-graded asphalt mixture, including asphalt binder, coarse aggregate, fine aggregate, and filler. The magnetic asphalt mixture is formed by replacing part of the aggregate with magnetic material in equal volume on the basis of the ordinary asphalt mixture, wherein the magnetic material replacement ratio is 20% of the total aggregate volume. The magnetic asphalt mixture and the ordinary asphalt mixture are arranged in predetermined zones above the GFRP top plate. The magnetic asphalt mixture zone has a planar dimension of 360 mm × 360 mm and is located above the effective coupling area of ​​the transmitting coil. The ordinary asphalt mixture zone is located directly above the coil conductor and outside the magnetic zone. Then, a precast asphalt concrete surface slab with a thickness of 4 cm is formed by molding and compaction.

[0078] 6) Assemble and verify the prefabricated composite functional unit. Assemble the precast asphalt concrete surface slab with the lower GFRP-encapsulated electromagnetic module to form the prefabricated composite functional unit, and verify its dimensions, elevation, inductance parameters, and appearance integrity. The flatness deviation of the upper surface of the prefabricated composite functional unit is controlled within ±2 mm.

[0079] In other embodiments, the transmitting coil may also be a planar circular coil, wound with 600 strands of Litz wire with a single strand diameter of 0.1 mm, the outer diameter of the coil bundle is 3 mm, and it is wound with 35 turns, resulting in an outer diameter of 550 mm. Correspondingly, the electromagnetic shielding plate is a circular or near-circular magnetic shielding component adapted to the transmitting coil, with an outer diameter 40 mm larger than the outer diameter of the transmitting coil and a thickness of 2 mm. The magnetically conductive asphalt mixture area is located above the effective coupling area of ​​the transmitting coil, and its planar shape is circular or near-circular.

[0080] Example 2: This example provides a construction method for a prefabricated wireless charging road magnetic conductive surface layer under the condition of existing road reconstruction. The prefabricated wireless charging road magnetic conductive surface layer is deployed in the functional area of ​​a regular passenger vehicle wireless charging road. The prefabricated composite functional units are arranged along the centerline of the target lane. The specific construction steps include the following:

[0081] 1) Prefabricated composite functional unit. The prefabricated composite functional unit is manufactured in a factory according to the method of Example 1. The overall planar dimensions of the prefabricated composite functional unit are 770 mm × 770 mm, and the thickness of the prefabricated asphalt concrete surface slab is 4 cm.

[0082] 2) Deployment of the roadside power supply system. Roadside power supply nodes are installed in the road median, shoulder, or reserved space on the roadside, and the main feeder cable is led to the wireless charging road functional area. The roadside power supply node includes a power supply interface, a power conversion device, a compensation network, and a control unit; in this embodiment, the spacing between roadside power supply nodes is 30 m, and each roadside power supply node corresponds to 2 prefabricated composite functional units. The main feeder cable uses weather-resistant insulated cable with an outer diameter of 25 mm.

[0083] 3) Forming a power supply line channel. A power supply line channel is formed in the existing road structure to introduce the main feeder cable into the wireless charging road functional area. The power supply line channel includes a transverse conduit and a partial cable trench; in this embodiment, the transverse conduit has an inner diameter of 80 mm and a burial depth of 200 mm, and the cable trench has a width of 100 mm and a depth of 100 mm.

[0084] 4) Prepare the civil engineering for the road functional area. Form installation grooves in the existing road surface according to the design location, and level and load-bearing the bottom of the grooves. The installation grooves are arranged along the centerline of the target lane; in this embodiment, the planar dimensions of a single installation groove are 810 mm × 810 mm, and the groove depth is 100 mm; a leveling layer with a thickness of 10 mm is provided at the bottom of the installation groove.

[0085] 5) Install the prefabricated composite functional units. Transport the prefabricated composite functional units to the construction site, hoist them into the installation slots, and complete positioning, leveling, and fixing. The prefabricated composite functional units are arranged along the centerline of the target lane and spaced longitudinally along the lane; in this embodiment, the longitudinal spacing between two adjacent prefabricated composite functional units is 100 mm.

[0086] 6) Complete the electrical connection. Connect the tail wire of the transmitting coil of the prefabricated composite functional unit to the main feeder cable and connect it to the roadside power supply node. The electrical connection adopts a sealed connection structure, and the connection point is located in a position that is easy to maintain and avoids direct wheel load.

[0087] 7) Perform pavement connection and joint treatment. Treat the lateral joints between the prefabricated composite functional units and the conventional pavement, as well as the inter-slab joints between adjacent functional units, and complete the waterproof sealing. The joint width is 20 mm; the sealing and waterproofing treatment uses a flexible caulking sealant, preferably asphalt grout.

[0088] 8) Perform system debugging and testing.

[0089] The roadside power supply system, electrical connection interfaces, and each transmitting coil circuit are subjected to continuity testing, insulation testing, and parameter verification. After confirming that the connections are normal, power-on debugging and trial operation are carried out. In this embodiment, parameter verification includes inductance parameter testing, and debugging and testing also include power supply node output testing and functional area power-on trial operation testing.

[0090] Example 3: This example provides a construction method for a prefabricated wireless charging road magnetic conductive surface layer under new road construction conditions. The prefabricated wireless charging road magnetic conductive surface layer is deployed in the functional area of ​​a regular passenger vehicle wireless charging road. The prefabricated composite functional units are arranged along the centerline of the target lane. The specific construction steps include the following:

[0091] 1) Deploy a roadside power supply system. Roadside power supply nodes are installed in the road median, shoulder, or reserved space along the roadside, and main feeder cables are laid. Each roadside power supply node includes a power supply interface, power conversion device, compensation network, and control unit. In this embodiment, the spacing between roadside power supply nodes is 30 m, and the main feeder cables are arranged longitudinally along the road.

[0092] 2) Pre-embed wiring channels and reserve installation positions. During the construction of the base layer and the middle and lower layers, wiring channels are pre-embedded simultaneously, and installation positions for prefabricated composite functional units are reserved. The wiring channels include horizontal conduits and vertical cable channels; in this embodiment, the inner diameter of the horizontal conduit is 80 mm, the reserved installation position plane size is 810 mm × 810 mm, and the reserved depth is 100 mm.

[0093] 3) Prefabricated composite functional unit. Following the method in Example 1, the prefabricated composite functional unit is completed in the factory. The overall planar dimensions of the prefabricated composite functional unit are 770 mm × 770 mm, and the thickness of the prefabricated asphalt concrete surface slab is 4 cm.

[0094] 4) Install the prefabricated composite functional units. Transport the prefabricated composite functional units to the construction site and install them in the road functional area according to the preset positions. The prefabricated composite functional units are arranged along the centerline of the target lane and spaced longitudinally along the lane; in this embodiment, the longitudinal spacing between two adjacent prefabricated composite functional units is 100mm.

[0095] 5) Complete electrical connections and elevation adjustments. Connect the transmitting coil tail wire to the main feeder cable and adjust the installation elevation of the prefabricated composite functional unit. The electrical connection adopts a sealed connection structure; in this embodiment, after adjustment, the upper surface of the prefabricated composite functional unit is basically flush with the upper surface of the adjacent conventional road surface, and the height difference is controlled within ±2 mm.

[0096] 6) Joint treatment and pavement connection. Seal and waterproof the joints between slabs and the lateral joints between the prefabricated composite functional units and the conventional pavement, forming a partially functional road surface layer together with the conventional pavement on both sides. The joint width is 20 mm; the sealing and waterproofing treatment uses a flexible caulking sealant, preferably asphalt sealant.

[0097] 7) Conduct system debugging and testing. Perform continuity testing, insulation testing, and parameter verification on the roadside power supply system, electrical connection interfaces, and each transmitting coil circuit. After confirming that the connection is normal, conduct power-on debugging and trial operation.

[0098] Through the above-described implementation methods, this invention constructs a complete engineering implementation path encompassing factory prefabrication, roadside power supply, line introduction, on-site installation, joint waterproofing, and system commissioning. This transforms the traditional complex, zonal on-site construction mode for the magnetically conductive surface layer of wireless charging roads into a standardized, prefabricated, and assembled installation mode for functional units. On the one hand, this solution retains the gain effect of the magnetically conductive asphalt mixture on magnetic flux convergence and transmission within the effective coupling area of ​​the transmitting coil, while mitigating the adverse magnetic shielding effect caused by continuous magnetic coverage. On the other hand, the integrated construction of the GFRP-encapsulated electromagnetic module and the prefabricated asphalt concrete surface layer improves the structural integration between the wireless charging module and the road surface layer, enhancing its insulation, waterproofing, and environmental adaptability in road service environments. Furthermore, this invention is applicable to both existing road reconstruction and new road construction, facilitating construction organization, subsequent replacement, and maintenance, thereby improving the engineering feasibility and application potential of the magnetically conductive surface layer for wireless charging roads.

[0099] While the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the invention. Those skilled in the art can make other changes within the spirit of the invention and apply it to fields not mentioned in the invention. Of course, all such changes made in accordance with the spirit of the invention should be included within the scope of protection claimed by the invention.

Claims

1. A prefabricated wireless charging road magnetic surface layer unit, characterized in that: It includes an electromagnetic module (1) encapsulated by glass fiber reinforced composite material and a precast asphalt concrete surface plate (2) located on top of the electromagnetic module (1). The electromagnetic module (1) includes a GFRP base (3), an electromagnetic shielding plate (4) disposed in the GFRP base (3), a transmitting coil (5), a local potting layer and a GFRP top plate (6). The GFRP base (3) is provided with a mounting groove for mounting the electromagnetic shielding plate (4) and the transmitting coil (5), and a lead-out opening (7) for leading out the tail wire of the transmitting coil (5). The transmitting coil (5) is positioned above the electromagnetic shielding plate (4), and the tail wire of the transmitting coil (5) is connected to the main feed cable through the lead-out opening (7). The local potting layer is disposed around the transmitting coil (5) and the electromagnetic shielding plate (4); The GFRP top plate (6) and the GFRP bottom support (3) cooperate to form a closed electromagnetic module encapsulation shell; The precast asphalt concrete surface slab (2) includes a magnetic asphalt mixture area (8) and a regular asphalt mixture area (9). The magnetically conductive asphalt mixture area (8) is located above the effective coupling area of ​​the transmitting coil (5), and the ordinary asphalt mixture area (9) is located above the coil conductor and in the surrounding area to reduce the adverse magnetic shielding effect caused by continuous magnetic coverage.

2. The assembled wireless charging road magnetically permeable surface layer unit according to claim 1, characterized in that: The GFRP base (3) is a groove structure with a plane size of 700 mm × 700 mm ~ 850 mm × 850 mm, a groove depth of 8 mm ~ 10 mm, a base plate thickness of 2 mm ~ 4 mm, and a side wall thickness of 2 mm ~ 4 mm.

3. The assembled wireless charging road magnetic surface layer unit according to claim 1, characterized in that: The transmitting coil (5) is a planar rectangular coil or a planar circular coil, wound with 300~1000 strands of Litz wire with a single strand diameter of 0.1 mm, and the outer diameter of the coil bundle is 2mm~4mm, with 25~40 turns wound. When the transmitting coil (5) is a planar rectangular coil, its outer dimensions are 500 mm × 500 mm ~ 650 mm × 650 mm; When the transmitting coil (5) is a planar circular coil, its outer diameter is 500mm~650mm.

4. The assembled wireless charging road magnetic surface layer unit according to claim 3, characterized in that: The electromagnetic shielding plate (4) is a magnetic shielding component made of a high permeability shielding material, and its planar dimensions are larger than the outer dimensions of the transmitting coil (5); When the transmitting coil (5) is a planar rectangular coil, the width of the edge of the electromagnetic shielding plate (4) extending beyond the outer edge of the transmitting coil (5) is 20mm on each side; When the transmitting coil (5) is a planar circular coil, the electromagnetic shielding plate (4) extends outward by 20mm along the outer edge of the transmitting coil (5) in the circumferential direction; The thickness of the electromagnetic shielding plate (4) is 2mm~5mm.

5. The assembled wireless charging road magnetic surface layer unit according to claim 1, characterized in that: The transmitting coil (5) and the electromagnetic shielding plate (4) are both located at the geometric center of the GFRP base (3); The lead-out opening (7) of the tail wire of the transmitting coil (5) is located on the side of the GFRP base (3) near the roadside power supply, and a sealing structure is provided at the lead-out opening (7).

6. The assembled wireless charging road magnetic surface layer unit according to claim 1, characterized in that: The local potting layer is set at one or more of the following locations: the corner of the transmitting coil (5), the tail wire lead-out location, and the surrounding area where relative displacement is likely to occur; the local potting layer is made of thermally conductive and insulating epoxy potting resin, thermally conductive and insulating silicone resin, or potting material with insulating and thermally conductive properties.

7. The prefabricated wireless charging road magnetic surface layer unit according to claim 1, characterized in that: The interface reinforcement structure on the upper surface of the GFRP top plate (6) includes one or more of the following: roughened surface, mechanical interlocking texture, shallow groove, and limiting rib; the precast asphalt concrete surface plate (2) and the electromagnetic module (1) adopt a composite connection method with mechanical interlocking as the main component and bonding as the auxiliary component.

8. The assembled wireless charging road magnetic surface layer unit according to claim 1, characterized in that: The magnetic asphalt mixture zone (8) is composed of asphalt binder, aggregate and magnetic material, wherein the coarse aggregate, fine aggregate or filler in the aggregate is replaced by magnetic material in an equal volume manner, and the replacement amount of the magnetic material is 5% to 40% of the total volume of the aggregate; The thickness of the precast asphalt concrete surface layer 2 is consistent with the design thickness of the road surface layer, which is 4cm to 6cm.

9. A construction method for the prefabricated wireless charging road magnetic surface layer unit according to any one of claims 1 to 8, characterized in that: Includes the following steps: Step 1: Prefabricate the assembled wireless charging road magnetic surface layer units in the factory; Step 2: Install a roadside power supply system in the road median, shoulder, or reserved space on the roadside, and lead the main power supply cable to the wireless charging road functional area; Step 3: Set up a line channel in the road structure to lay the main power supply cable and connect it to the tail wire interface of the prefabricated wireless charging road magnetic surface layer unit. Step 4: Carry out civil engineering preparation for the road functional area, and form installation slots or reserve installation positions in the existing or newly built roads for installing the prefabricated wireless charging road magnetic surface layer unit; Step 5: Install the prefabricated assembled wireless charging road magnetic surface layer unit into the mounting slot or reserved mounting position to complete the positioning, leveling and fixing; Step 6: Electrically connect the tail wire of the transmitting coil (5) of the assembled wireless charging road magnetic surface layer unit to the main feeder cable and connect it to the roadside power supply node; Step 7: Seal and waterproof the lateral joints between the prefabricated wireless charging road magnetic surface layer unit and the conventional road surface, as well as the inter-plate joints between adjacent prefabricated wireless charging road magnetic surface layer units. Step 8: Conduct system debugging and testing, including continuity testing, insulation testing and parameter verification of the roadside power supply system, electrical connection interface and transmitting coil (5) circuit.

10. The construction method according to claim 9, characterized in that: The cable channel in step three includes one or more of the following: horizontal conduit, vertical cable channel, cable trench, or reserved cable cavity; In step four, the installation groove is arranged along the centerline of the target lane. The planar dimensions of the installation groove are 730 mm × 730 mm to 880 mm × 880 mm, and the groove depth is 60 mm to 90 mm. A leveling layer with a thickness of 10 mm to 30 mm is set at the bottom of the installation groove. In step five, the assembled wireless charging road magnetic surface layer unit is arranged along the centerline of the target lane, and multiple units can be set at intervals along the longitudinal direction of the lane. The electrical connection in step six adopts a sealed connection structure and is located in a position that is easy to maintain and avoids direct wheel load. The joint width in step seven is 10 mm to 30 mm, and flexible caulking and sealing material is used for sealing and waterproofing. The parameter verification in step eight includes inductance parameter detection, and the debugging and testing also includes one or more of the following: power supply node output detection and functional area power-on trial operation detection.

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