Coil Wire Support Element for Inductive Power Transfer
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Solution Overview
Problem
Conventional coil wire support elements in inductive power transfer couplers increase the distance between coils, leading to poor inductive power transmission efficiency and electromagnetic shielding effects, which hinder efficient wireless power transmission.
Innovation Solution
A coil wire support element with a reduced front wall height, allowing coil wire layers to be coiled in closer proximity, utilizing a support member with a front and back wall or an additional intermediate wall for lateral support, and optionally a removable segment to further minimize the front wall height, enabling closer coil placement without compromising structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coil wire support elements with front and back walls are used, then structural support and protection during manufacturing are improved, but the distance between interacting coils increases and electromagnetic shielding occurs, reducing inductive power transmission efficiency
Solution Approach 1:
The patent removes the front wall from the coil wire support element, extracting the harmful component that caused electromagnetic shielding and increased coil distance. The back wall is retained to maintain necessary structural support during manufacturing and operation. This selective removal resolves the contradiction by eliminating the source of energy loss while preserving structural reliability.
Solution Approach 2:
The patent applies different structural qualities to different parts of the support element: the front wall is completely removed or reduced to minimal thickness where it would cause shielding, while the back wall maintains sufficient thickness for structural support. This local differentiation allows the structure to simultaneously achieve low electromagnetic interference and high mechanical reliability.
2Loss of energy
If the front wall height is reduced to improve inductive power transmission efficiency, then the space between interacting coils is reduced, but structural support during coiling and protection from damage may be compromised
Solution Approach 1:
The front wall is segmented into a removable segment and a remaining segment. The removable segment is taken away after the coiling process to achieve minimal front wall height for optimal inductive power transmission. During manufacturing, the complete front wall provides necessary structural support, and its removal afterward resolves the structural integrity issue while maintaining efficiency benefits.
Solution Approach 2:
The front wall is designed with a predetermined breaking point or removable segment that allows it to be removed after coiling. This preliminary design enables the structure to provide full support during the critical coiling phase, then be modified to achieve the optimal low-height configuration for power transmission efficiency.
3Loss of energy
If multiple coil wire layers are coiled on the support member, then inductive power transfer efficiency is improved through increased loop number, but the height of the coil wire section increases requiring taller support structures
Solution Approach 1:
The patent uses a mandrel as a temporary copying structure during the coiling process. The mandrel provides the necessary support geometry for coiling multiple layers, then is removed to leave the coil with minimal support structure height. This allows multiple layers to be formed with the support of a temporary structure that doesn't contribute to the final height.
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 enhances inductive power transfer efficiency by reducing the space between interacting coils and minimizing electromagnetic interference, thereby improving the overall performance of inductive power transfer systems.
Implementation Method 1
The coiled wire enables to inductively transfer power between inductive power transfer couplers of same or similar kind
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
The invention relates to coil wire support elements, to manufacturing methods thereof, and to inductive power transfer couplers incorporating same. Such a coil wire support element comprises a support member for supporting a coil wire, a coil wire section formed of coil wire that is coiled on the support member in one or more coil wire layers, and a front and one back wall arranged at the respective ends of the support member and protruding from the support member in a radial direction for providing lateral support to parts of the at least one coil wire layer in one coil wire section, wherein the height of the at least one coil wire layer, coiled in said one coil wire section on the support member, is larger in the radial direction than the height of the segment of the front wall protruding in said radial direction from the support member.