Core Contactless LLC Charger with Matrix Core Set
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Solution Overview
Problem
Magnetic-inductive power transfer and wireless power transfer technologies face efficiency decreases when operating outside of resonant frequency, leading to ineffective power transfer in electric vehicle charging applications.
Innovation Solution
A core contactless LLC charger with a removable and separable matrix core set (MCS) in the transmitter-receiver transformer, which increases resonant magnetic-induction coupling area and decreases core loss, enabling non-contact power transmission through primary-side resonance without the need for secondary-side resonance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If series or parallel resonance with both-side resonances is used for power transfer, then power transfer can be achieved, but transfer effectiveness decreases quickly if the converter operates outside of the resonant frequency
Solution Approach 1:
The patent divides the traditional single transformer structure into a matrix core set comprising multiple independent magnetic cores (e.g., 3x3=9 cores). Each core can be independently controlled and optimized, allowing the system to segment the resonant frequency management across multiple units. This segmentation enables the converter to maintain effective power transfer across a wider frequency range by selectively activating or adjusting individual cores.
Solution Approach 2:
The patent implements dynamic frequency adjustment capability through the matrix core structure, where the resonant frequency can be dynamically tuned by changing the number of active cores or their configuration. This dynamic adaptability allows the system to respond to varying operating conditions and maintain optimal transfer effectiveness without being constrained to a single fixed resonant frequency.
2Ease of manufacture
If a fixed transformer structure is used, then manufacturing is simpler, but the resonant magnetic-induction coupling area is limited and core loss is higher
Solution Approach 1:
The transformer is segmented into multiple discrete magnetic cores arranged in a matrix, where each core is a standard, easily manufacturable unit. This segmentation allows for simplified manufacturing of individual cores while achieving a larger total magnetic coupling area when combined. The modular nature also facilitates easier assembly and replacement.
Solution Approach 2:
Multiple individual magnetic cores are merged into a unified matrix core set that functions as a single transformer system. By combining the magnetic fields of multiple cores, the system achieves a larger effective resonant magnetic-induction coupling area, which reduces core loss and improves power transfer efficiency while maintaining the simplicity of individual core manufacturing.
3Reliability
If both primary-side and secondary-side resonance are required, then power transfer can be maintained, but the system complexity increases
Solution Approach 1:
The patent extracts the secondary-side resonance requirement from the system, designing a configuration where only primary-side resonance is needed for effective power transfer. The matrix core structure on the primary side is designed to provide sufficient magnetic coupling and frequency stability without requiring active resonance control on the secondary side, thereby reducing system complexity.
Solution Approach 2:
The matrix core set acts as an intermediary that enhances magnetic coupling between primary and secondary sides, providing the necessary frequency stability and power transfer reliability through its structured arrangement of magnetic cores. This intermediary structure eliminates the need for complex secondary-side resonance control while maintaining stable power transfer.
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 LLC charger achieves efficient contactless power transfer with a wide frequency response capability, maintaining charging even when deviations occur, and automatically regulates charging current to ensure safe and efficient battery charging.
Implementation Method 1
charges a battery pack with a non-contact power transmission via a resonant magnetic-induction coupling (RMIC) between the TX-MCS and the RX-MCS
Implementation Method 2
Magnetic-inductive power transfer (MIPT) and wireless power transfer (WPT) are modern contactless ways to transfer power particularly for use in electric vehicles. Either MIPT or WPT that uses series or parallel resonance with both-side resonances for power transfer
Data Source
AI summary
The configurations of LLC charger and controlling methods thereof are provided. The proposed charger includes a transmitter-receiver (TX-RX) transformer including a TX-matrix core set (TX-MCS) and an RX-MCS, an LLC power stage electrically connected to the TX-MCS, and a rectifier electrically connected to the RX-MCS so as to charge a battery pack with a non-contact power transmission.