Foreign Object Detection Coil Substrate With Through-Hole Component Spaces
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Solution Overview
Problem
Existing foreign object detection systems in wireless power transfer configurations face challenges in accommodating circuit components and wires without increasing the substrate size or affecting detection accuracy, as the through holes for ribs occupy space that could be used for these components.
Innovation Solution
A foreign object detection device with a detection coil unit featuring a substrate with through holes and component spaces within the coils' openings, allowing for a concentrated coil arrangement, high detection accuracy, and maintaining a small substrate area, using rectangular or elliptical through holes aligned with the vehicle's movement direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If circuit components and wires are disposed between the ring-shaped coils, then the detection accuracy is improved, but the interval between the coils increases which adversely affects detection performance
Solution Approach 1:
The patent transitions from a planar substrate layout to a three-dimensional configuration by utilizing through-holes that extend vertically through the substrate. Circuit components are disposed within these through-holes, effectively moving them from the horizontal plane to the vertical dimension. This allows the coils to maintain close horizontal spacing while providing adequate space for components and wires in the vertical direction, thus preserving detection accuracy without increasing coil interval.
Solution Approach 2:
The patent embeds circuit components and wires within the through-holes of the substrate, creating a nested structure where components are contained inside the substrate thickness. This nesting approach allows efficient use of vertical space, enabling components to be positioned without occupying horizontal space between coils, thereby maintaining tight coil spacing for optimal detection performance.
2Ease of manufacture
If circuit components and wires are disposed on both of the outer sides of the ring-shaped coils, then the components are accommodated, but the substrate size increases
Solution Approach 1:
The patent utilizes the vertical dimension by creating through-holes that extend through the substrate thickness. Circuit components and wires are positioned within these vertical channels rather than spreading out horizontally. This dimensional transition allows all necessary components to be accommodated within the substrate's vertical space, eliminating the need to expand the substrate's horizontal footprint.
Solution Approach 2:
The substrate is designed with a porous structure containing multiple through-holes distributed throughout its area. These through-holes provide dedicated spaces for housing circuit components and routing wires. The porous configuration allows efficient packing of components within the substrate volume without requiring additional horizontal area, as each through-hole serves as an independent compartment for component placement.
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 configuration ensures high accuracy in foreign object detection while keeping the substrate area small, improving the performance and efficiency of the detection system.
Implementation Method 1
a detector connected to the coils to detect the existence of a foreign object on the basis of a vibration signal output when each of the coils is excited
Data Source
AI summary
A foreign object detection device includes a detection coil unit including a detection coil substrate (220) and a plurality of coils (242), which are mounted on a surface of the detection coil substrate (220) and each include a conductive pattern turned around the Z axis, and a detector (26) connected to the coils (242) to detect the existence of a foreign object on the basis of a vibration signal output when each of the coils (242) is excited. The coils (242) each define an opening. The detection coil substrate (220) has a through hole (228) extending through the detection coil substrate (220), and a component space for accommodating a switch (248) or a wiring pattern (250), within each of the openings of the coils (242) as seen in the Z-axis direction.