Non-Contact Power Supply Coil Parallel Hybrid Winding
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Solution Overview
Problem
Conventional non-contact power supply coils for electric vehicles face challenges in maintaining shape retention, handleability, and reducing alternating-current resistance while conforming to predetermined dimensions and electrical characteristics, leading to increased manufacturing and transportation costs due to line length differences and phase differences caused by varying wire lengths.
Innovation Solution
A coil design where two Litz wires are wound side by side with ends connected using crimp terminals, forming regions of abutting and separating sections, allowing for parallel hybrid winding that adjusts line lengths and reduces phase differences, enabling shape retention without external spacers and improving electrical characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a single wire rod is divided into two and wound apart in parallel to reduce alternating-current resistance, then the alternating-current resistance is reduced, but the line lengths become different causing phase differences and increased manufacturing complexity
Solution Approach 1:
The wire rod is divided into two separate wires, each wound independently in parallel. This segmentation allows each wire to be optimized for equal length while maintaining the low alternating-current resistance benefit of parallel winding, thereby resolving the contradiction between reduced energy loss and manufacturing complexity.
2Loss of energy
If spacers are used to provide gap between turns of the wire, then the alternating-current resistance is reduced, but the manufacturing cost and device complexity increase
Solution Approach 1:
The spacer component is extracted and replaced by the natural gap created between adjacent turns of the two parallel-wound wires. This eliminates the need for additional spacer parts, reducing manufacturing cost and device complexity while maintaining the gap necessary for reduced alternating-current resistance.
3Reliability
If the coil shape is standardized to certain sizes for secure power transmission, then the power transmission reliability is improved, but the coil thickness cannot be reduced below certain limits
Solution Approach 1:
The coil structure transitions from a single-layer planar winding to a multi-layer stacked configuration. By arranging multiple thin winding layers in the thickness direction, the coil achieves the required outer dimensions for reliable power transmission while minimizing thickness through efficient vertical stacking, thus resolving the contradiction between reliability and volume.
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 coil design achieves predetermined dimensions and electrical characteristics, reduces manufacturing costs, and enhances handleability by minimizing line length differences and phase effects, while maintaining efficient power transmission.
Implementation Method 1
a loss caused by a proximity effect and a skin effect which vary depending on a frequency, a twist configuration of a wire rod
Implementation Method 2
a loss caused by a proximity effect and a skin effect which vary depending on a frequency, a twist configuration of a wire rod
Implementation Method 3
supplying power to the electric vehicle by wirelessly transmitting power while facing a planar coil (ground-side coil) for power transmission (primary side)
Data Source
AI summary
A coil according to one embodiment of the present invention is a coil in which a first electric wire on an inner peripheral side and a second electric wire on an outer peripheral side are wound side by side to connect ends of the electric wires with each other, and the coil includes a first region where the first electric wire abuts on the second electric wire of another adjacent turn and separates from the second electric wire of a same turn.