Segmented Amorphous Iron Alloy Stack for Inductive Energy Transmission
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Solution Overview
Problem
Existing coil arrangements for inductive energy transmission, particularly in electric vehicles, face challenges with high mass, brittleness, and complex production processes, as well as inefficiencies in magnetic field transmission due to the use of ferrite materials.
Innovation Solution
A coil arrangement featuring a flat winding with a stack of thin, nanocrystalline amorphous iron alloy layers separated by polyethylene or polyimide films, which reduces mass and brittleness, enhances magnetic permeability, and allows for flexible adaptation to carrier parts, while simplifying production and enabling effective magnetic field guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If ferrite materials are used for the coil core, then magnetic field transmission is effective, but the mass increases and brittleness occurs
Solution Approach 1:
The patent divides the solid ferrite coil core into multiple thin layers (each less than 1mm thick) separated by non-magnetic spacing. This segmentation reduces the overall mass while maintaining magnetic field transmission effectiveness through the layered structure, directly resolving the contradiction between mass reduction and magnetic efficiency.
Solution Approach 2:
The patent creates a composite structure combining thin ferrite layers with non-magnetic spacing materials. This composite approach allows the system to achieve both low mass (through thin layers) and effective magnetic field transmission (through the composite's optimized magnetic properties), resolving the mass-efficiency contradiction.
2Loss of energy
If solid ferrite material is used, then magnetic field transmission is effective, but the structure becomes brittle and difficult to produce
Solution Approach 1:
By segmenting the solid ferrite into thin layers, the patent improves manufacturability through simpler production processes while maintaining magnetic efficiency. The layered structure is easier to produce and assemble than solid ferrite, resolving the contradiction between manufacturing ease and magnetic performance.
Solution Approach 2:
The patent changes the physical parameters of the magnetic material by reducing layer thickness to less than 1mm and introducing spacing between layers. These parameter changes transform the material from brittle solid ferrite to a flexible layered structure that is easier to manufacture while preserving magnetic field transmission.
3Weight of moving object
If thin layers with spacing are used, then mass is reduced and flexibility increases, but magnetic field transmission must be optimized
Solution Approach 1:
The patent optimizes magnetic field transmission in the thin-layered structure by carefully controlling layer thickness (less than 1mm) and spacing dimensions. These parameter optimizations ensure that despite the reduced mass and increased flexibility, the magnetic field transmission efficiency is maintained or improved through reduced magnetic reluctance in the optimized path.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves improved effectiveness in inductive energy transmission by reducing material mass, increasing flexibility, and simplifying manufacturing, while maintaining high magnetic field strength and efficiency, with the ability to be mounted on vibrating surfaces and adapt to various geometries.
Implementation Method 1
the relative magnetic permeability of the material exceeds the value of 30,000, in particular has a value between 50,000 and 200,000
Implementation Method 2
A coil arrangement featuring a flat winding with a stack of thin, nanocrystalline amorphous iron alloy layers
Data Source
Figure 1
AI summary
Coil arrangement for a system for inductive energy transmission, wherein the coil arrangement has a winding and a stack, wherein the winding axis is oriented parallel to the stack direction, in particular wherein the winding is a flat winding and/or a concentric winding, in particular a ring winding.