Wireless Power Coil Unit Post Layout for Magnetic Flux Flow
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Solution Overview
Problem
Existing coil units in wireless power transfer systems lack sufficient structural strength while maintaining power transfer performance, and random arrangement of support posts can impede magnetic flux flow.
Innovation Solution
The coil unit design includes post structures arranged along the magnetic flux direction, separated around the central axis, to enhance structural strength while allowing uninterrupted magnetic flux flow, using a housing with casings and support posts that penetrate through the magnetic-material plate and coil board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If support posts are arranged to improve the strength of the housing, then the structural strength is improved, but the power transfer performance decreases due to impeded magnetic flux flow
Solution Approach 1:
The support posts are segmented and arranged at specific locations around the central axis rather than being randomly distributed. This segmentation allows the housing to gain structural strength while the gaps between posts permit magnetic flux to flow through the magnetic-material plate, resolving the contradiction between strength improvement and power transfer performance maintenance.
2Ease of manufacture
If random arrangement of support posts is used to simplify manufacturing, then the ease of manufacture is improved, but the power transfer performance decreases due to magnetic flux impediment
Solution Approach 1:
The support posts are positioned at specific locations with local quality considerations - arranged along the magnetic flux direction but separated around the central axis. This localized arrangement strategy enables the housing to gain strength where needed while preserving magnetic flux flow paths, achieving both manufacturing feasibility and power transfer performance.
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
This design improves the structural strength of the coil unit while maintaining efficient power transfer performance by ensuring magnetic flux flow through regions between the post structures, preventing impediment and magnetic saturation.
Implementation Method 1
a coil for transmission or reception of AC power... to be induced by the coil at the transmission or reception of the AC power from the outer edge of the magnetic-material plate toward the central axis through the magnetic-material plate
Data Source
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AI summary
A coil unit (10) includes a ferrite plate (13) and a coil board (14) to which a coil (112) for transmission or reception of AC power is mounted. The ferrite plate is mounted on the ferrite plate. The coil unit includes a housing that houses the ferrite plate and the coil board therein while being stacked in a predetermined stacking direction. The coil unit includes post structures (21, 22, 23, 24) for ensuring a space in the housing in the stacking direction. Each of the post structures includes at least one through hole (41, 42) formed through the ferrite and the coil board, and at least one support post (31, 32) received in the at least one through hole. Each of the post structures is arranged along a corresponding respective flow direction of magnetic flux to be induced by the coil at the transmission or reception of the AC power from the outer edge of the ferrite toward the central axis of the coil unit through the ferrite plate. The post structures are separated from one another around the central axis as viewed in the stacking direction.